Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 139

1D-82 Engine Mechanical: For J20 Engine

Installation

1) Install clutch cover and clutch disk referring to

“Clutch Cover, Clutch Disc and Flywheel Removal
and Installation in Section 5C”, if removed.

2) Install engine with engine front mounting bracket to

engine front mounting. For tightening torque,
referring to “Engine Mountings Components: For J20
Engine”, if removed.

3) Connect transmission from engine referring to

“Manual Transmission Assembly Dismounting and
Remounting: For Petrol Engine Model in Section 5B”
or “Automatic Transmission Unit Components in
Section 5A”, if removed.

4) Lift engine with transmission, front suspension frame

and engine rear mounting member into engine
compartment with jack.

CAUTION

!

Before lifting engine, to avoid damage to A/C
compressor and P/S pump, make clearance
by rising them.

5) Tighten engine rear mounting member bolt referring

to “Engine Mountings Components: For J20 Engine”.

6) Carry out Step 5) to 19) of “Installation” under “Front

Suspension Frame, Stabilizer Bar and/or Bushings
Removal and Installation in Section 2B” in order to lift
engine with front suspension frame.

7) Remove engine jack.
8) Install front and rear propeller shafts referring to

“Propeller Shaft Removal and Installation in Section
3D”.

9) Install exhaust No.1, No.2 and center pipes referring

to “Exhaust System Components: For Petrol Engine
Model in Section 1K”.

10) Install A/C compressor to its bracket (if equipped)

referring to “Compressor Assembly Removal and
Installation for J20 Engine Model in Section 7B”.

11) Install P/S pump to its bracket referring to “P/S Pump

Removal and Installation (J20A Engine Model) in
Section 6C”.

12) Return disconnected hoses, cables and electric wire

noting the followings.
• Tighten nuts to specified torque.

Tightening torque
Starting motor terminal nut: 11 N·m (1.1 kgf-m,
8.0 lb-ft)
Generator terminal nut: 7 N·m (0.7 kgf-m, 5.0 lb-
ft)

13) Install water pump and generator drive belt referring

to “Water Pump and Generator Drive Belt Removal
and Installation (For J20 Engine): For Petrol Engine
Model in Section 1J”.

14) Adjust water pump and generator drive belt tension

referring to “Water Pump and Generator Drive Belt
On-Vehicle Inspection (For J20 Engine): For Petrol
Engine Model in Section 1J”.

15) Install air cleaner assembly referring to “Air Cleaner

Assembly Removal and Installation: For J20
Engine”.

16) Check all removed parts are back in place.
17) For A/T model, adjust select cable referring to

“Select Cable Adjustment in Section 5A”.

18) Refill cooling system with coolant referring to

“Cooling System Flush and Refill: For Petrol Engine
Model in Section 1F”.

19) Refill engine with engine oil referring to “Engine Oil

and Filter Change (Petrol Engine Model) in Section
0B”.

20) Bleed air from clutch system referring to “Air

Bleeding of Clutch System in Section 5C” for air
bleeding procedure.

21) Install engine hood after disconnecting windshield

washer hose.

22) Connect negative cable at battery.
23) With engine OFF, turn ignition switch to ON position

and check for fuel leakage.

24) Start engine and check coolant, oil and exhaust gas

leakage at each connection.

Engine Mechanical: For J20 Engine 1D-83

Timing Chain Cover Components

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Timing Chain Cover Removal and Installation

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Removal

1) Remove engine assembly from vehicle referring to

“Engine Assembly Removal and Installation: For J20
Engine”.

2) Remove oil pan referring to “Oil Pan and Oil Pump

Strainer Removal and Installation: For J20 Engine in
Section 1E”.

3) Remove cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For J20
Engine”.

4) Remove crankshaft pulley bolt.

To lock crankshaft pulley (1), use special tool
(camshaft pulley holder) as shown in figure.

Special tool
(a): 09917–68221

NOTE
Be sure to use the following bolts instead of
pins in order to fix crankshaft pulley by
special tool.
Bolt size: M8, P1.25 L = 25 mm (0.98 in.)
Strength: 7T

2

9

(d)

6

(b)

3

5

1207B

1207F

4

1

(a)

7

8

10

(c)

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1. Crankshaft pulley bolt

6. Timing chain cover bolt and nut

: 150 N

⋅m (15.0 kgf-m, 108.5 lb-ft)

2. Crankshaft pulley

7. Idler pulley

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

3. Oil seal

: Apply engine oil to oil seal lip.

8. Idler pulley nut

: 42 N

⋅m (4.2 kgf-m, 30.5 lb-ft)

4. Timing chain cover

: See “A”
: See “B”

9. Generator belt tensioner bolt

: 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

5. Belt tensioner

10. Pin

: Do not reuse.

“A”: Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.
“B”: Apply sealant 99000-31250 to the mating surface of timing chain cover referring to the figure of Step 3) in “Timing Chain Cover Removal and

Installation: For J20 Engine”.

2. Bolt

3. Wrench

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1D-84 Engine Mechanical: For J20 Engine

5) Remove crankshaft pulley (1).

To remove crankshaft pulley, use special tools
(Steering wheel remover, Bearing puller attachment)
with it as shown in figure.

Special tool
(A): 09944–36011
(B): 09926–58010

6) Remove idler pulley (1), water pump pulley (2) and

belt tensioner (3).

7) Remove timing chain cover (1) bolts (3) and nut (2).

Installation

1) Clean sealing surfaces on timing chain cover,

cylinder block and cylinder head.
Remove oil, oil sealant and dust from sealing
surface.

2) Install new oil seal (2) to timing chain cover using

special tool, if removed.

NOTE
When installing new oil seal (2), drive it until
its surface is flash with edge of timing chain
cover (1).

Special tool
(A): 09913–75510

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Engine Mechanical: For J20 Engine 1D-85

3) Apply sealant “A” and “B” to specific area as shown

in figure.

“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
“B”: Water tight sealant 99000–31140 (SUZUKI
Bond No.1207B)

Sealant amount for timing chain cover
“a”: 3 mm (0.12 in.)
“b”: 2 mm (0.08 in.)
“c”: 6 mm (0.24 in.)
“d”: 16 mm (0.63 in.)
“e”: 14 mm (0.55 in.)
“f”: 65 mm (2.56 in.)
“g”: 73 mm (2.87 in.)
“h”: 4 mm (0.16 in.)

4) Apply engine oil to oil seal lip, then install timing

chain cover (1). Tighten bolts and nut to specified
torque.

NOTE
Before installing timing chain cover, check
that pin is securely fitted.

Tightening torque
Timing chain cover bolt and nut (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)

5) Install belt idler pulley (1). Tighten nut to specified

torque.

Tightening torque
Idler pulley nut (a): 42 N·m (4.2 kgf-m, 30.5 lb-ft)

6) Install belt tensioner (2). Tighten bolts to specified

torque.

Tightening torque
Generator belt tensioner bolt (b): 25 N·m (2.5
kgf-m, 18.5 lb-ft)

7) Install water pump pulley (3).

8) Install cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For J20
Engine”.

9) Install oil pan. Refer to “Oil Pan and Oil Pump

Strainer Removal and Installation: For J20 Engine in
Section 1E” for installation.

2. Cylinder head

5. Rub into

3. Cylinder head gasket

6. Jig

4. Cylinder block

[C]: View C

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