Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 161

1D-170 Engine Mechanical: For F9Q Engine

Camshaft and Tappet Inspection

S6JB0A1436023

Camshaft
• Check journals and cam faces for wear or damage.

If any malcondition is found, replace camshaft.

Camshaft thrust play

1) Remove all tappets from cylinder head.
2) Install camshaft to cylinder head.
3) Install camshaft housing referring to “Installation”

under “Camshaft and Tappet Removal and
Installation: For F9Q Engine”.

4) Measure camshaft thrust play using special tool and

dial gauge (1) as shown in figure.If measured thrust
play is out of specification, replace camshaft and/or
cylinder head.

Camshaft thrust play
0.045 – 0.135 mm (0.00178 – 0.00531 in.)

Cam Wear
Using a micrometer, measure cam height “a”. If
measured height underruns its limit, replace camshaft.

Camshaft Journal Wear
Check camshaft journals and camshaft housings for
pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder
head with housing. Never replace cylinder head without
replacing housings.

Wear of Tappet
Check tappet for pitting, scratches, or damage.
If any malcondition is found, replace.

Measure cylinder head bore and tappet outside diameter
to determine cylinder head-to-tappet clearance. If
measured clearance is out of specification, replace
tappet and/or cylinder head.

Cylinder head to tappet clearance
0.015 – 0.074 mm (0.00059 – 0.00291 in.)

Tappet outside diameter [A]
34.965 – 34.985 mm (1.37658 – 1.37736 in.)

Cylinder head tappet bore [B]
35.000 – 35.039 mm (1.37796 – 1.37948 in.)

I5JB0B140073-01

I5JB0B140074-01

I5JB0B140075-01

I5JB0B140133-01

I2RH0B140086-01

Engine Mechanical: For F9Q Engine 1D-171

Valve and Cylinder Head Assembly Components

S6JB0A1436024

12

12

10

1

2

3

4

8

11

5

9

(a)

7

6

I5JB0B140076-01

1. Valve cotter

6. Intake valve

11. Cylinder head gasket

2. Valve spring retainer

7. Exhaust valve

12. Dowel pin

3. Valve spring

8. Valve guide

: Tighten 30 N

⋅m (3.0 kgf-m, 22.0 lb-ft), 100°, 0 N⋅m

(0.0 kgf-m, 0.0 lb-ft), 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

and 213

° by the specified procedure.

4. Valve stem seat

9. Cylinder head bolt

: Do not reuse.

5. Valve stem seal

: Do not lubricate valve stem seal before fitting.

10. Cylinder head

: Apply engine oil to sliding surface of each part.

1D-172 Engine Mechanical: For F9Q Engine

Valve and Cylinder Head Assembly Removal
and Installation

S6JB0A1436062

Removal

1) Remove engine assembly referring to “Engine

Assembly Removal and Installation: For F9Q
Engine”.

2) Remove timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation: For F9Q
Engine”.

3) Remove turbocharger referring to “Turbocharger

Assembly Removal and Installation: For F9Q
Engine”.

4) Remove EGR cooler referring to “EGR Pipe and

EGR Cooler Removal and Installation: For F9Q
Engine”.

5) Remove oil separator referring to “Oil Separator

Removal and Installation: For F9Q Engine”.

6) Remove EGR valve referring to “EGR Valve

Removal and Installation: For F9Q Engine”.

7) Remove ventilation pipe No.2 referring to “Oil

Separator Components: For F9Q Engine”.

8) Remove injection pump rear bracket referring to

“Injection Pump Removal and Installation: For Diesel
Engine Model in Section 1G”, if necessary.

9) Loosen cylinder head bolts in numerical order (“1”

through “10”) as shown in figure, and remove them.

CAUTION

!

Never reuse cylinder head bolts once
removed it due to plastic deformation
tightening. Be sure to use new cylinder head
bolts when installing.

10) Check all around cylinder head for any other parts

required to be removed or disconnected, and
remove or disconnect whatever necessary.

11) Remove cylinder head and cylinder head gasket

from cylinder block.

12) Remove dowel pins, if necessary.
13) Remove vacuum pump referring to “Vacuum Pump

Removal and Installation: For F9Q Engine”, if
necessary.

14) Remove thermostat assembly referring to

“Thermostat Assembly Removal and Installation: For
Diesel Engine Model in Section 1F”, if necessary.

15) Remove intake and exhaust manifolds referring to

“Intake Manifold and Exhaust Manifold Removal and
Installation: For F9Q Engine”, if necessary.

16) Remove camshaft and tappets referring to

“Camshaft and Tappet Removal and Installation: For
F9Q Engine”, if necessary.

17) Remove fuel injector referring to “Fuel Injector

Removal and Installation: For Diesel Engine Model
in Section 1G”, if necessary.

18) Remove injection pump referring to “Injection Pump

Removal and Installation: For Diesel Engine Model
in Section 1G”, if necessary.

19) Remove common rail (high pressure fuel injection

rail) referring to “Common Rail (High Pressure Fuel
Injection Rail) Removal and Installation: For Diesel
Engine Model in Section 1G”, if necessary.

I5JB0B140077-02

Engine Mechanical: For F9Q Engine 1D-173

Installation

1) Remove oil, old sealant and dust from bolt holes and

mating surface of cylinder head and cylinder block.

2) Install camshaft and tappets referring to “Camshaft

and Tappet Removal and Installation: For F9Q
Engine”, if removed.

3) Install cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For F9Q
Engine”, if removed.

4) Install injection pump referring to “Injection Pump

Removal and Installation: For Diesel Engine Model
in Section 1G”, if removed.

5) Install common rail (high pressure fuel injection rail)

referring to “Common Rail (High Pressure Fuel
Injection Rail) Removal and Installation: For Diesel
Engine Model in Section 1G”, if removed.

6) Install fuel injector referring to “Fuel Injector Removal

and Installation: For Diesel Engine Model in Section
1G”, if removed.

7) Install high pressure pipes referring to “High

Pressure Pipe Removal and Installation: For Diesel
Engine Model in Section 1G”, if removed.

8) Install intake and exhaust manifolds referring to

“Intake Manifold and Exhaust Manifold Removal and
Installation: For F9Q Engine”, if removed.

9) Install vacuum pump referring to “Vacuum Pump

Removal and Installation: For F9Q Engine”, if
removed.

10) Install thermostat assembly referring to “Thermostat

Assembly Removal and Installation: For Diesel
Engine Model in Section 1F”, if removed.

11) Install dowel pins (1) to cylinder block, if removed.

12) Install new cylinder head gasket (2) to cylinder block.

13) Install cylinder head to cylinder block, and tighten

new cylinder head bolts as follows.
a) Tighten cylinder head bolts to 30 N

⋅m (3.0 kgf-m,

22.0 lb-ft) according to numerical order (“1”
through “10”) as shown in figure.

b) Retighten them by turning through 100

° in same

manner as Step a).

c) Wait 3 minutes for setting time.
d) Loosen cylinder head bolts (“1” and “2”) until they

are completely free, and tighten them to 25 N

⋅m

(2.5 kgf-m, 18.0 lb-ft), then retighten then by
turning through 213

°.

e) Loosen and tighten bolts (“3” and “4”), bolts (“5”

and “6”), bolts (“7” and “8”) then bolt (“9” and
“10”) in the same manner as Step d).

Tightening torque
Cylinder head bolt (a): Tighten 30 N

⋅m (3.0

kgf-m, 22.0 lb-ft), 100

°, 0 N⋅m (0.0 kgf-m, 0.0

lb-ft), 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft) and 213°

by the specified procedure

14) Install injection pump rear bracket referring to

“Injection Pump Removal and Installation: For Diesel
Engine Model in Section 1G”, if necessary.

15) Install EGR valve referring to “EGR Valve Removal

and Installation: For F9Q Engine”.

16) Install oil separator referring to “Oil Separator

Removal and Installation: For F9Q Engine”.

17) Install EGR cooler referring to “EGR Pipe and EGR

Cooler Removal and Installation: For F9Q Engine”.

18) Install turbocharger referring to “Turbocharger

Assembly Removal and Installation: For F9Q
Engine”.

19) Install ventilation pipe No.2 referring to “Oil

Separator Components: For F9Q Engine”.

20) Install timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation: For F9Q
Engine”.

21) Install engine assembly referring to “Engine

Assembly Removal and Installation: For F9Q
Engine”.

I5JB0B140078-01

I5JB0B140079-01