Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 143

1D-98 Engine Mechanical: For J20 Engine

Camshaft journal

Wear of Tappet and Shim
Check tappet and shim 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
clearance exceeds limit, replace tappet or cylinder head.

Cylinder head bore and tappet outside diameter

Oil Relief Valve
Check oil relief valve for clogging and ball for being
stuck.

Item

Standard

Camshaft journal bore
diameter. (IN & EX) [A]

26.000 – 26.033 mm
(1.0236 – 1.0249 in.)

Camshaft journal O.D. (IN &
EX) [B]

25.959 – 25.980 mm
(1.0221 – 1.0228 in.)

I5JB0A142036-01

I2RH0B140085-01

Item

Standard

Limit

Tappet outside
diameter [A]

32.456 – 32.472 mm

(1.2778 – 1.2784 in.)

—

Cylinder head bore
[B]

32.500 – 32.525 mm

(1.2795 – 1.2805 in.)

—

Cylinder head to
tappet clearance

0.028 – 0.069 mm

(0.0011 – 0.0027 in.)

0.15 mm

(0.0059 in.)

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Engine Mechanical: For J20 Engine 1D-99

Valves and Cylinder Head Components

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1. Cylinder block

7. Valve stem seal

13. Cylinder head bolt (M6)

: Be sure to tighten cylinder head bolt (M8) after securing
cylinder head bolt (M10).

2. Cylinder head

8. Valve spring

14. Knock pin

3. Cylinder head gasket

: Identification number provided on gasket comes
to crankshaft pully side, facing up.

9. Valve spring retainer

: Tighten 52 N

⋅m (5.2 kgf-m, 38.0 lb-ft), 82 N⋅m (8.2 kgf-m, 59.5

lb-ft), 0 N

⋅m (0 kgf-m, 0 lb-ft), 52 N⋅m (5.2 kgf-m, 38.0 lb-ft)

and 103 N

⋅m (10.3 kgf-m, 74.5 lb-ft) by the specified

procedure.

4. Intake valve

10. Valve cotter

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

5. Exhaust valve

11. Valve guide

: Do not reuse.

6. Valve spring seat

12. Cylinder head bolt (M10)

: Apply engine oil to sliding surface of each part.

1D-100 Engine Mechanical: For J20 Engine

Valves and Cylinder Head Removal and
Installation

S6JB0A1426025

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 timing chain cover. Refer to “Timing Chain

Cover Removal and Installation: For J20 Engine” for
removal.

5) Remove 2nd timing chain and 1st timing chain. Refer

to “2nd Timing Chain and Chain Tensioner Removal
and Installation: For J20 Engine” and “1st Timing
Chain and Chain Tensioner Removal and
Installation: For J20 Engine” for removal.

6) Remove camshafts, tappets and shims. Refer to

“Camshafts, Tappet and Shim Removal and
Installation: For J20 Engine” for removal.

7) Loosen cylinder head bolts (M10) in such order as

numbered in figure and remove them.

NOTE
Don’t forget to remove cylinder head bolt
(M6) (3) as shown in figure.

8) Check all around cylinder head for any other parts

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

9) Remove cylinder head with intake manifold, exhaust

manifold and water outlet cap. Use lifting device, if
necessary.

Installation

1) Match match mark (1) on crank timing sprocket and

mating surface (2) of cylinder block and lower
crankcase.

2) Clean mating surface of cylinder head and cylinder

block (2). Remove oil, old gasket and dust from
mating surface.

3) Install knock pins (3) to cylinder block.
4) Install new cylinder head gasket (1) to cylinder block.

Identification number (6) provided on gasket comes
to crankshaft pulley side (4), facing up (toward
cylinder head side).

1. Crankshaft pulley side

2. Flywheel side

“5”

“4”

“8”

“10”

“6”

“2”

3, “1”

“9”

“11”

“7”

“3”

1

2

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5. Flywheel side

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I5JB0A142041-01

Engine Mechanical: For J20 Engine 1D-101

5) Install cylinder head to cylinder block.

Apply engine oil to cylinder head bolts and tighten
them gradually as follows.
a) Tighten cylinder head bolts (M10) to 52 N

⋅m (5.2

kgf-m, 38.0 lb-ft) according to numerical order in
figure.

b) In the same manner as in step a), retighten

cylinder head bolts (M10) to 82 N

⋅m (8.2 kgf-m,

59.5 lb-ft).

c) Loosen cylinder head bolts (M10) until tightening

torque is reduced to 0 according to numerical
order in figure.

d) Tighten cylinder head bolts (M10) to 52 N

⋅m (5.2

kgf-m, 38.0 lb-ft) according to numerical order in
figure.

e) In the same manner as in step b), retighten

cylinder head bolts (M10) to 103 N

⋅m (10.3 kgf-

m, 74.5 lb-ft).

f) Tighten cylinder head bolt (M6) to specified

torque.

Tightening torque
Cylinder head bolt (M10) (a): Tighten 52 N

⋅m

(5.2 kgf-m, 38.0 lb-ft), 82 N

⋅m (8.2 kgf-m, 59.5

lb-ft), 0 N

⋅m (0 kgf-m, 0 lb-ft), 52 N⋅m (5.2 kgf-

m, 38.0 lb-ft) and 103 N

⋅m (10.3 kgf-m, 74.5 lb-

ft) by the specified procedure.
Cylinder head bolt (M6) (b): 11 N·m (1.1 kgf-
m, 8.0 lb-ft)

6) Install camshafts and tappets and shims. Refer to

“Camshafts, Tappet and Shim Removal and
Installation: For J20 Engine” for installation.

7) Install 1st timing chain. Refer to “1st Timing Chain

and Chain Tensioner Removal and Installation: For
J20 Engine” for installation.

8) Install 2nd timing chain. Refer to “2nd Timing Chain

and Chain Tensioner Removal and Installation: For
J20 Engine” for installation.

9) Install timing chain cover. Refer to “Timing Chain

Cover Removal and Installation: For J20 Engine” for
installation.

10) Check intake and exhaust valve lashes referring to

“Valve Lash (Clearance) Inspection: For J20
Engine”.

11) Install cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For J20
Engine”.

12) Install oil pan referring to “Oil Pan and Oil Pump

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

13) Install engine assembly to vehicle referring to

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

1. Crankshaft pulley side

2. Flywheel side

1. Crankshaft pulley side

2. Flywheel side

“7”

“9”

“4”

“2”

“6”

“8”

“5”

“1”

“3”

“10”

1

2

I5JB0A142042-01

“4”

“3”

“7”

“9”

“5”

“1”

“8”

“10”

“6”

“2”

1

2

I5JB0A142043-01

1. Crankshaft pulley side

2. Flywheel side

“7”, (a)

“9”, (a) 3, “11”, (b) “4”, (a)

“2”, (a)

“6”, (a)

“8”, (a)

“5”, (a)

“1”, (a)

“3”, (a)

“10”, (a)

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