Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 120

1D-6 Engine Mechanical: For M16A Engine with VVT

4) Connect special tool (Vacuum gauge) to PCV hose

(1).

Special tool
(A): 09915–67311

5) Blind PCV valve (2) using tape or the like.

6) Run engine at specified idle speed and read vacuum

gauge. Vacuum should be within specification.

Vacuum specification (at sea level)
59 – 73 kPa (45 – 55 cmHg, 17.7 – 21.6 in.Hg) at
specified idle speed

7) After checking, disconnect special tool (Vacuum

gauge) from PCV hose.

8) Detach blind cap from PCV valve.
9) Connect PCV hose to PCV valve.

Valve Lash (Clearance) Inspection

S6JB0A1414003

1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For M16A
Engine with VVT”.

3) Using 17 mm wrench, turn crankshaft pulley (1)

clockwise until cam lobes (2) become perpendicular
to shim faces (3) at valves “1” and “7” as shown in
the figure.

4) Check valve lashes with thickness gauge (4)

according to the following procedure.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90

° (by turning crankshaft

with wrench).

c) Make sure that cam lobes are perpendicular to

shim faces at valves to be checked (in this case,
“3” and “8”), if not, adjust it by turning crankshaft.
Check valve lashes.

d) In the same manner as b) – c), check valve

lashes at valves “4” and “6”.

e) In the same manner as b) – c) again, check

valve lashes at valves “2” and “5”.

If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.

Valve clearance specification
When cold (Coolant temperature is 15 – 25

°C (59 –

77

°F)):

• Intake: 0.18 – 0.22 mm (0.007 – 0.009 in.)

• Exhaust: 0.28 – 0.32 mm (0.011 – 0.013 in.)

When hot (Coolant temperature is 60 – 68

°C (140 –

154

°F)):

• Intake: 0.21 – 0.27 mm (0.008 – 0.011 in.)
• Exhaust: 0.30 – 0.36 mm (0.012 – 0.014 in.)

Replacement of Shim

1) Close the valve whose shim (2) is to be replaced by

turning crankshaft, then turn tappet (3) till its cut
section (1) faces inside as shown in the figure.

(A)

1

2

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I3RM0A140004-01

I2RH0B140006-01

Engine Mechanical: For M16A Engine with VVT 1D-7

2) Lift down the valve by turning crankshaft to 360

°.

3) Hold tappet at that position using special tool as

follows.
a) Remove its housing bolts.
b) Check housing No. and select special tool

corresponding to housing No., referring to
“Special tool selection table”.

Special tool selection table

c) Hold down the tappet so as not to contact the

shim by installing special tool on camshaft
housing with housing bolt (1) tighten housing
bolts to specified torque.

Special tool
(A): 09916–67020
(A): 09916–67021

Tightening torque
Camshaft housing bolts (a): 8 N

⋅m (0.8 kgf-

m, 6.0 lb-ft) for tightening of special tool

4) Turn camshaft by approximately 90

° clockwise and

remove shim (3).

WARNING

!

Never put in the hand between camshaft and
tappet.

5) Using a micrometer (2), measure the thickness of

the removed shim (1), and determine replacement
shim by calculating the thickness of new shim with
the following formula and table.

Shim thickness specification
Intake side:
A = B + C – 0.20 mm (0.008 in.)
Exhaust side:
A = B + C – 0.30 mm (0.012 in.)
A: Thickness of new shim
B: Thickness of removed shim
C: Measured valve clearance

No. on camshaft

housing

Embossed mark on

special tool

I2

IN2

I3, I4, I5

IN345

E2

EX2

E3, E4, E5

EX345

A: I: Intake side or E: Exhaust side
B: Position from timing chain side

C: Pointing to timing chain side

I2RH0B140011-01

I3RM0A140005-01

1. Special tool

2. Magnet

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1D-8 Engine Mechanical: For M16A Engine with VVT

For example of intake side:
When thickness of removed shim is 2.40 mm (0.094
in.), and measured valve clearance is 0.45 mm
(0.018 in.).
A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20
mm (0.008 in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104
in.)

6) Select new shim No. (1) with a thickness as close as

possible to calculated value.

Available new shims No.

7) Install new shim facing shim No. side with tappet.

8) Lift valve by turning crankshaft counterclockwise (in

opposite direction against above Step 4)) and
remove special tool.

Special tool
(A): 09916–67020
(A): 09916–67021

9) Install camshaft housing (1) and tighten bolts to

specified torque.

Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)

10) Check valve clearance again after adjusting it.

11) After checking and adjusting all valves.

12) Install cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For M16A
Engine with VVT”.

Thickness mm

(in.)

Shim No.

Thickness mm

(in.)

Shim No.

2.175 (0.0856)

218

2.600 (0.1024)

260

2.200 (0.0866)

220

2.625 (0.1033)

263

2.225 (0.0876)

223

2.650 (0.1043)

265

2.250 (0.0886)

225

2.675 (0.1053)

268

2.275 (0.0896)

228

2.700 (0.1063)

270

2.300 (0.0906)

230

2.725 (0.1073)

273

2.325 (0.0915)

233

2.750 (0.1083)

275

2.350 (0.0925)

235

2.775 (0.1093)

278

2.375 (0.0935)

238

2.800 (0.1102)

280

2.400 (0.0945)

240

2.825 (0.1112)

283

2.425 (0.0955)

243

2.850 (0.1122)

285

2.450 (0.0965)

245

2.875 (0.1132)

288

2.475 (0.0974)

248

2.900 (0.1142)

290

2.500 (0.0984)

250

2.925 (0.1152)

293

2.525 (0.0994)

253

2.950 (0.1161)

295

2.550 (0.1004)

255

2.975 (0.1171)

298

2.575 (0.1014)

258

3.000 (0.1181)

300

I2RH0B140015-01

1. Tappet

2. Camshaft

(A)

2

1

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Engine Mechanical: For M16A Engine with VVT 1D-9

Repair Instructions

Air Cleaner Filter Removal and Installation

S6JB0A1416001

Removal

1) Open air cleaner case (1) by unhooking its clamps

(2).

2) Remove air cleaner filter from case.

Installation
Reverse removal procedure for installation.

Air Cleaner Filter Inspection and Cleaning

S6JB0A1416002

Inspection
Check air cleaner filter for dirt. Replace excessive dirty
filter.

Cleaning
Blow off dust by compressed air from air outlet side of
element.

Cylinder Head Cover Removal and Installation

S6JB0A1416003

Removal

1) Disconnect negative cable at battery.
2) Disconnect MAF sensor coupler (1).
3) Remove air cleaner case (2).

4) Remove cylinder head upper cover.
5) Disconnect ignition coil couplers (1).
6) Remove ignition coil assemblies (2) with high-

tension cord (3).

7) Remove wire harness clamp from cylinder head

cover.

8) Remove oil level gauge (1).
9) Disconnect PCV hose (2) from PCV valve (3) and

disconnect breather hose (4) from cylinder head
cover.

10) Remove cylinder head cover mounting bolts in such

order as indicated in the figure.

1

2

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I2RH0B140150-01

2

1

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I2RH0B140032-01

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