Suzuki Grand Vitara JB419. Service manual — part 42

Engine Mechanical: 1D-14

Installation

1) Confirm that special tool (A) is inserted into TDC pin

hole.
If special tool (A) is removed, insert special tool (A)
referring to Step 5) of “Installation” under “Piston,
Piston Ring and Connecting Rod Removal and
Installation”.

Special tool
(A): 09912–46510

2) Check crankshaft groove (1) is located in middle of

two ribs (2) on gasket holder plate.

3) Check mark (1) of camshaft pulley (2) is aligned with

mark (3) of timing belt inner cover (4).

4) Install crankshaft timing belt pulley (1), if removed.
5) Install timing belt tensioner plate (2), if removed.

Tightening torque
Timing belt tensioner plate bolt (a): 10 N·m (1.0
kgf-m, 7.5 lb-ft)

6) Install timing belt tensioner pulley (3) with positioning

hole (4) to pin (5) of timing belt tensioner plate, and
tighten timing belt tensioner pulley nut by hand
temporarily.

7) Install timing belt (1) with aligning its matching lines

(2) with matching marks (3) of camshaft pulley (4),
injection pump pulley (5) and crankshaft timing belt
pulley (6).

NOTE
Be sure to direct arrow mark (7) of timing belt
clockwise as shown in figure.

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1D-15 Engine Mechanical:

8) Remove special tool (A) from TDC pin hole.
9) Adjust timing belt tension as follows.

a) Tighten crankshaft pulley bolt to crankshaft

temporarily by hand.

b) Install adjusting bolt (1) to timing belt tensioner

plate, and tighten adjusting bolt and timing belt
tensioner pulley nut (2) by hand.

NOTE
Be sure to use adjusting bolt (1) of M6 size
and 1.0 mm (0.039 in.) pitch.

c) Pre-tense timing belt as follows.

Special tool
(E): 09919–76520
(F): 09919–76530

i)

Fit special tools with torque wrench on
crankshaft belt pulley bolt.

ii) Pre-tense timing belt by turning special tools

with torque wrench (1) clockwise to 11 N

⋅m

(1.1kgf-m, 8.0 lb-ft) as shown in figure.

iii) Remove special tool (E) and (F).

d) Measure timing belt tension using special tool as

follows.

Special tool
(G): 09919–76540

i)

Place sensor (2) of special tool (G) on the
center of crankshaft pulley and timing belt
tensioner pulley of timing belt.

NOTE
Be sure to separate sensor (2) from timing
belt by specified distance “a”.

Distance between timing belt and sensor
“a”: 2 - 10 mm (0.08 - 0.40 in.)

ii) Measure timing belt tension flipping timing

belt by finger as shown in figure.
If timing belt tension is out of specification
below, adjust timing belt tension by
tightening / loosening adjusting bolt (1) and
return to Step c).

Timing belt tension (Frequency displayed
on special tool):
87 – 93 Hz

e) Tighten timing belt tensioner pulley nut (3) to 10

N

⋅m (1.0 kgf-m, 7.5 lb-ft) temporarily.

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Engine Mechanical: 1D-16

f) Turn crankshaft two revolutions clockwise until

mark (1) of camshaft pulley (2) matches with
mark (3) of timing belt inner cover (4).

g) Check that special tool (A) can be inserted into

TDC pin hole smoothly.

h) Remove special tool (A).
i)

Pre-tense timing belt in the same manner as
step c).

j)

Measure timing belt tension in the same manner
as step d).
If timing belt tension is out of specification below,
remove timing belt and return to Step 1).

Timing belt tension (Frequency displayed on
special tool):
75 – 85 Hz

k) Tighten timing belt tensioner pulley nut to

specified torque.

Tightening torque
Timing belt tensioner pulley nut: 45 N·m (4.5
kgf-m, 32.5 lb-ft)

l)

Remove adjusting bolt (2).

m) Turn crankshaft four revolutions clockwise until

mark (1) of camshaft pulley (2) matches with
mark (3) of timing belt inner cover (4).

n) Confirm number of timing belt teeth between

mark (1) of camshaft pulley (2) and mark (3) of
injection pump pulley (4) is 29.
If not, remove timing belt and return to Step 1).

10) Install crankshaft pulley as follows.

a) Lock ring gear in the same manner as Step 6) -

a) of “Removal”.

b) Fit crankshaft pulley (1) to crankshaft.
c) Tighten new crankshaft pulley bolt (2) as follows.

i)

Tighten crankshaft pulley bolt to 40 N

⋅m (4.0

kgf-m, 29.0 lb-ft).

ii) Retighten crankshaft pulley bolt by turning

through 110

°.

Tightening torque
Crankshaft pulley bolt (a): Tighten 40
N

⋅m (4.0 kgf-m, 29.0 lb-ft) and 110° by the

specified procedure

iii) Remove special tool (B) or screw driver or

the like.

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1D-17 Engine Mechanical:

11) Apply sealant “A” to thread of TDC pin cap (1), and

tighten TDC pin cap as specified torque.

Tightening torque
TDC pin cap (a): 20 N·m (2.0 kgf-m, 14.5 lb-ft)

“A”: Loctite rhodorseal 5661

® (Loctite

rhodorseal 5661

®)

12) Install timing belt cover No.1 (1) and timing belt

cover No.2 (2).

Tightening torque
Timing belt cover No.2 bolt (a): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)

13) Install accessory drive belt referring to “Accessory

Drive Belt and Idler Pulley Removal and Installation
in Section 1J”.

Timing Belt and Belt Tensioner Inspection

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Timing belt
Inspect timing belt for wear or crack.Replace it as
necessary.

Timing belt tensioner
Inspect timing belt tensioner pulley for smooth rotation.
Replace it as necessary.

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(a)

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1

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