Suzuki Grand Vitara JB416 / JB420. Manual — part 90

1D-28 Engine Mechanical: For M16A Engine with VVT

4) Loosen camshaft housing bolts in such order as

indicated in the figure and remove them.

5) Remove camshaft housings.
6) Remove intake and exhaust camshafts.
7) Remove camshaft bearing (1).

8) Remove tappets (2) with shims (1).

Installation

1) Install tappets and shims to cylinder head.

Apply engine oil around tappet and then install it to
cylinder head.

NOTE
When installing shim, make sure to direct
shim No. side toward tappet.

2) Install camshaft bearing (1) to cylinder head.

CAUTION

!

Do not apply engine oil to camshaft bearing
back.
Only a upper half bearing of intake camshaft
bearing No.1 has some holes. Other
bearings.

“12” “13” “20” “21” “16” “17” “8” “9”

“2”

“5”

“3”

“4”

“1”

“10” “11” “18” “19” “14” “15” “6” “7”

I3RM0A140031-01

I4RS0B140019-01

I2RH0B140074-01

I2RH0B140075-01

I5RW0A140033-01

Engine Mechanical: For M16A Engine with VVT 1D-29

3) Install intake camshaft (1) and exhaust camshaft (2).

Align knock pin (3) and match mark (4) with notches
(5) as shown in the figure.

NOTE
Before installing camshafts, turn crankshaft
until key position faces upward.
Refer to “Timing Chain and Chain Tensioner
Removal and Installation: For M16A Engine
with VVT”.

4) Apply engine oil to sliding surface of each camshaft

and camshaft journal then install them as shown in
the figure.

5) Install camshaft housing pins (1) as shown in the

figure.

6) Check position of camshaft housings.

Embossed marks are provided on each camshaft
housing, indicating position and direction for
installation. Install housings as indicated by these
marks.

7) After applying engine oil to housing bolts, tighten

them temporarily first. Then tighten them by the
numerical order in the figure. Tighten a little at a time
and evenly among bolts and repeat tightening
sequence two or three times before they are
tightened to specified torque.

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

8) With hexagonal section (1) of intake camshaft (2)

held stationary with spanner or the like, tighten bolt
of intake cam timing sprocket assembly (3) to
specification.

Tightening torque
Intake cam timing sprocket bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)

“a”: Approx. 30

°

1

2

3

4

5

“a”

I4RS0A140014-01

I3RM0A140033-01

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

C: Pointing to timing chain side

I2RH0B140078-01

“10” “9”

“2” “1”,(a) “6”

“5”

“14” “13”

“20”

“17”

“19”

“18”

“21”

“12” “11” “4”

“3”

“8”

“7”

“16” “15”

I3RH0B140041-01

1

2

3

(a)

I3RH0B140042-01

1D-30 Engine Mechanical: For M16A Engine with VVT

9) Install timing chain with crankshaft sprocket referring

to “Timing Chain and Chain Tensioner Removal and
Installation: For M16A Engine with VVT”.

10) Install timing chain cover referring to “Timing Chain

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

11) Check valve lashes referring to “Valve Lash

(Clearance) Inspection: For M16A Engine with VVT”.

12) Perform Steps 3) to 8) of “Installation” of “Timing

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

Camshaft, Tappet and Shim Inspection

S5JB0A1416022

Intake Cam Timing Sprocket Assembly
Fit intake cam timing sprocket assembly to camshaft (2)
and hold hexagonal section of camshaft by using
spanner or the like.
Check if sprocket (1) is not turned by hand.
If moved, replace intake cam timing sprocket assembly.

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

Cam height “a”

Camshaft Runout
Set camshaft between two “V” blocks, and measure its
runout by using a dial gauge.
If measured runout exceeds limit, replace camshaft.

Camshaft runout limit
0.10 mm (0.0039 in.)

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.

Cam height

Standard

Limit

Intake cam

44.929 – 45.089 mm

(1.769 – 1.775 in.)

44.80 mm
(1.764 in.)

Exhaust cam

44.399 – 44.559 mm

(1.748 – 1.754 in.)

44.28 mm
(1.743 in.)

2

1

I3RH0B140043-01

I2RH0B140080-01

I2RH0B140081-01

I2RH0B140082-01

Engine Mechanical: For M16A Engine with VVT 1D-31

Check clearance by using gauging plastic. Checking
procedure is as follows.

1) Clean housings and camshaft journals.
2) Remove all tappets with shims.
3) Install camshafts to cylinder head.
4) Place a piece of gauging plastic to full width of

journal of camshaft (parallel to camshaft).

5) Install camshaft housing.
6) Tighten camshaft housing bolts in such order as

indicated in the figure a little at a time till they are
tightened to specified torque.

NOTE
Do not rotate camshaft while gauging plastic
is installed.

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

7) Remove housing, and using scale (2) on gauging

plastic envelop, measure gauging plastic (1) width at
its widest point.

Camshaft journal clearance

If measured camshaft journal clearance exceeds
limit, measure journal (housing) bore and outside
diameter of camshaft journal. Replace camshaft or
cylinder head assembly whichever the difference
from specification is greater.

Camshaft journal diameter [A]

Camshaft journal bearing bore [B]

Standard

Limit

Intake side

No.1 housing

0.020 – 0.072 mm

(0.0008 – 0.0028 in.)

0.10 mm

(0.0039 in.)

Others

0.045 – 0.087 mm

(0.0018 – 0.0034 in.)

0.12 mm

(0.0047 in.)

“10” “9”

“2” “1”,(a) “6”

“5”

“14” “13”

“20”

“17”

“19”

“18”

“21”

“12” “11” “4”

“3”

“8”

“7”

“16” “15”

I3RH0B140041-01

I2RH0B140083-01

Item

Standard

Intake side No.1 housing

26.940 – 26.955 mm
(1.0606 – 1.0612 in.)

Exhaust side No.1 housing

26.934 – 26.955 mm
(1.0604 – 1.0612 in.)

Others

22.934 – 22.955 mm
(0.9029 – 0.9037 in.)

Item

Standard

Intake side No.1 housing

—

Exhaust side No.1 housing

27.000 – 27.021 mm
(1.0630 – 1.0638 in.)

Others

23.000 – 23.021 mm
(0.9055 – 0.9063 in.)

I2RH0B140084-01