Suzuki Grand Vitara
+ General information
+ Maintenance and lubricant
+ Heater, ventilation and conditioner
+ Steering
+ Suspension bracket
+ Wheels and tires
+ Forward driving shaft / bearing of a shaft. Oil epiploon
+ Driveshafts
+ Brake system
- Engines
- Mechanical part of the G16 engine
+ General description
- Routine maintenance
Check of a compression
Check of depression of the engine
Check of pressure of oil
Valvate gap
The filtering element of the air filter
Cover of a head of cylinders
Case of butterfly valves and inlet collector
The collector of the fulfilled gases
Belt of the drive of the gas-distributing mechanism and the tension device for a belt
Oil pan and grid of the oil pump
Oil pump
Valve yoke, axis of yokes and cam-shaft
Valves and head of the block of cylinders
+ Piston rod, piston rings, rods and cylinders
Special tool
Necessary service materials
Technical characteristics of the rotating inhaling moment
+ Mechanical part of the J20 engine
+ Cooling of the engine
+ Fuel system
+ System of ignition
+ System of start
+ System of release
+ Transmissions
+ Coupling
+ Transfer
+ Forward and back differentials
+ Windows, mirrors, locks and security measures. Immobilizer
+ Electric equipment
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Valves and head of the block of cylinders
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* 8) Address item 3 of the procedure of installation. |
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* 9) The mark "Top" specified on laying goes from a crankshaft pulley face up. |
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The rotating inhaling moment |
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Oil engine the sliding surface of each part. |
Removal
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Dump fuel pressure.
Disconnect a negative cable from the accumulator.
Drain the cooling system.
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- Make sure that engine antifreeze temperature low before to remove any parts of the cooling system.
- Also make sure that the negative cable is disconnected from the accumulator before removing any parts.
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Remove an element of rigidity of an inlet collector (1).
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Remove an airintaking sleeve.
Disconnect the following electric wires, and then exempt plaits of wires from clips.
Sensor of provision of a butterfly valve
The regulating idling pneumatic valve
Sensor of temperature of cooling liquid of the engine
Sensor of provision of a cam-shaft
Grounding wires from an inlet collector
The valve of system of recirculation of the fulfilled gases
Collector differential pressure sensor
The gate for production of not condensing gases
Nozzle wires at the coupling
Oxygen-1 heating sensor
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Disconnect the following hoses:
Hose for production of not condensing gases from the gate for production of not condensing gases
Hose of the amplifier of brakes from an inlet collector
Engine antifreeze hose (the output party) from the case of butterfly valves
Inlet hose of a radiator from a thermostat cover
Inlet hose of a heater from a pipe
Hose of supply of fuel and returnable hose from each pipe
Vacuum hose from an inlet collector
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Disconnect a rope of an accelerator and a cable of the drive of butterfly valves And/T (if that is available) from the case of butterfly valves.
Completely unscrew all screws regulating a valvate gap.
Remove the regulating generator lever from an inlet collector.
Remove the regulating compressor lever for air conditioning from a cylinder head (if that is available).
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Disconnect an exhaust pipe No. 1 (1) from a collector of the fulfilled gases (2) and remove an element of rigidity of a collector of the fulfilled gases (3) or a bolt of an arm of an exhaust pipe.
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Untwist cylinder head bolts in the order provided in the drawing below and take out them.
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"1" — the party of a pulley of a cam-shaft
"2" — the party of the distributor of ignition |
Check everything around a cylinder head whether there are still any details which need to be removed or disconnected, remove or disconnect, everything that is necessary.
Remove a cylinder head with an inlet collector and a collector of the fulfilled gases by means of the lifting device.
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Removal
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To simplify service of a head of cylinders, remove an inlet collector with the case of butterfly valves and a collector of the fulfilled gases from a head of cylinders.
Remove yokes and an axis of yokes, having addressed the Section Valve Yoke, an axis of yokes and a cam-shaft in this Chapter.
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By means of the special tool (the valve elevator) squeeze valvate springs and then remove checks of the valve (1), using the special tool (nippers).
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Special tool
(A): 09916-14510
(C): 09916-14910
(C): 09916-84511
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Release (open) the special tool and remove the holder of a spring and a valvate spring.
Remove the valve from the combustion chamber.
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Remove oil consolidation of a core of the valve (1) from the directing plug of the valve and then a cup of a valvate spring (2).
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Do not reuse oil consolidation after dismantle. At assembly surely use new oil consolidation. |
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By means of the special tool (a stripper of the directing valve plug) shift the directing valve plug from the combustion chamber on the party of a valvate spring. Special tool (A): 09916-44910.
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Do not reuse the directing valve plug after dismantle. Surely use the new directing valve plug (the working size) at assembly. |
Put the sorted parts, except for consolidation of a core of the valve and a guide of the plug of the valve, one after another, so that they could be established on their initial places.
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Check
The directing valve plugs
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With the help a micromeasure and a kruglomer take readings of diameters of cores of valves and guides to check a gap between cores and guides.
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Do not forget to take readings from several places on all length of each core and guide. If the gap goes beyond norm, replace the valve and the directing valve plug.
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Technical characteristics of the valve and the directing valve plug
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Position
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Norm
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Limit
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Diameter of a core of the valve
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Admission
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5.465 – 5.480 mm (0.2152 – 0.2157 inches)
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—
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Release
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5.440 – 5.455 mm (0.2142 – 0.2147 inches)
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—
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Internal diameter of the directing valve plug
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Admission
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5.500 – 5.512 mm (0.2166 – 0.2170 inches)
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—
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Release
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Gap between a core and a guide
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Admission
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0.020 – 0.047 mm (0.0008 – 0.0018 inches)
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0.07 mm (0.0027 inches)
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Release
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0.045 – 0.072 mm (0.0018 – 0.0028 inches)
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0.09 mm (0.0035 inches)
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If the kruglomer is unavailable, instead check deformation of the end of a core of the valve by means of the dial indicator. Move the end of a core in the directions (1) and (2) to measure deformation of the end. If deformation goes beyond norms, replace a core of the valve and the directing valve plug.
Limit of deformation of the end of a core of the valve:
on an admission: 0.14 mm (0.005 inches)
on release: 0.18 mm (0.007 inches)
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Valves
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Remove all deposit from valves.
Check each valve for existence of wear, a prozhog or deformation on a forward surface and a core and if it is necessary, replace it.
Measure valve head thickness. If the measured thickness goes beyond norms, replace the valve.
Valve head thickness
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Norm
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Limit
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On an admission
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0.8 – 1.2 mm (0.032 – 0.047 inches)
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0.6 mm (0.023 inches)
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On release
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0.7 mm (0.027 inches)
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1 — valve head thickness
2 — 45 ° |
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Check a valve core end face regarding an ulceration and wear. If wear or an ulceration is found, the end face of a core of the valve can be cleared repeatedly, but is not strong, so not to soshlifovyvat its camera. If it is worn-out so strongly that its camera is erased, replace the valve.
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Width of contact of a prileganiye
Create the drawing of an arrangement of contacts on each valve habitually, i.e., having applied a standard covering with the marking mix on a valve cup, and having killed with rotary motion a valve cup with a valve head. It is necessary to use the valvate pritirochny machine (the tool used for grinding in of valves).
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The drawing printed on the contact surface of the valve has to represent a continuous ring without any breaks, and width of the drawing has to be in the specified limits. The standard width of contact formed by means of the drawing of an arrangement of contacts on the front surface of the valve: on an admission on release — 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
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Repair of a cup of the valve
The valve cup which is not creating full contact with the valve or showing width of contact of a prileganiye going beyond the specified range has to be repaired by regrinding or cutting and regrinding, and is ground to readiness by grinding in.
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CUP of the EXHAUST VALVE: Use a mill of a cup of the valve (1) to make two cuts. It is necessary to use two mills: the first to make a corner in 15 °, and the second to make a corner in 45 °. The second mill needs to be used to receive the necessary width of a cup. Cup width for a cup of the exhaust valve: 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
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CUP of the INLET VALVE: The sequence of a cut just the same, as for cups of the exhaust valve. Cup width for a cup of the inlet valve: 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
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GRINDING IN of VALVES: Grind in the valve to a cup (1) in two steps: at first by means of rough composition of mix of grinding in of a front surface, and then by means of small composition of mix, every time using the machine for grinding in of nests of valves according to a standard method of grinding in.
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Cylinder head
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Remove all deposit from combustion chambers.
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Do not use the sharp tool for a deposit soskrebaniye. Be careful not to make the tease or a groove on metal surfaces at a deposit soskrebaniye. It to treat also valves, and cups of valves. |
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Check a cylinder head regarding cracks in inlet and final canals, combustion chambers, and for head surfaces.
Planshetnost of the condensed surface:
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By means of a kalibromer check a surface in 6 places. If the norm of deformation provided below is exceeded, correct the condensed surface by means of a razmetochny plate and abrasive paper #400 (waterproof abrasive paper on the basis of silicon carbide): put paper on a razmetochny plate, and rub the condensed surface about paper to soshlifovat high places. If it does not help to lower indications of a kalibromer to norm limits, replace a cylinder head. Leak of the working gases formed by combustion products from this condensed connection often happens because of deformation of the condensed surface: such leak is result of decrease in the made power.
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Limits of deformation of the condensed cylinder head surface: 0.05 mm (0.002 inches).
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Deformation of surfaces of a prileganiye of a collector:
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Check surfaces of a prileganiye of a head of the cylinder and collectors by means of a kalibromer to define whether there is a need to correct these surfaces or to replace a cylinder head.
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Limits of deformation of surfaces of a prileganiye of a collector: 0.10 mm (0.004 inches).
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Valvate springs
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Based on the data provided below be convinced that each spring is in good shape, without evidence of breakage or easing. Remember that the weakened valvate springs can be the cause of jingle, not to mention possible decrease in the made power because of the leak of gas caused by pressure decrease of a prileganiye.
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Length of a valvate spring in a free state:
norm: 36.83 mm (1.4500 inches)
limit: 35.67 mm (1.4043 inches)
Preliminary loading of a valvate spring:
norm: 10.7 – 12.5 kg for 31.5 mm (23.6 – 27.5 pounds on 1:24 inches)
limit: 9.3 kg for 31.5 mm (20.5 pounds on 1:24 inches)
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Perpendicularity of a spring:
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Use a square and a razmetochny plate to check each spring for perpendicularity from the point of view of a gap between the end of a valvate spring and a square. If the gap is more than limit provided below valvate springs have to be replaced. Limit of perpendicularity of valvate springs: 2.0 mm (0.079 inches).
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Assembly
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Before installing the directing valve plug in a cylinder head, expand the directing opening by means of the special tool (a 11-millimeter dilator) to remove teases and to make it really round.
Special tool:
(A): 09916-34542
(C): 09916-38210
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Install the directing valve plug on a cylinder head. Evenly heat a cylinder head to temperature of 80 - 100 °C (176 – 212 °F) not to deform a head, and you enter the new directing valve plug until the special tool (the device for installation of the directing valve plug) does not concern a cylinder head. After installation check height of ledges of the directing plug of the valve (1) from a cylinder head.
Special tool
(C): 09916-56011
(D): 09916-58210
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Do not reuse the disassembled directing valve plug. Install the new directing valve plug (the repair size).
- The directing valve plugs on an admission and on release identical.
- The repair size of the directing valve plug: 0.03 mm (0.0012 inches).
- Ledge of the directing valve plug (on an admission and on release): 11.5 mm (0.45 inches).
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Expand the internal diameter of the directing valve plug by means of the special tool (a 5.5-millimeter dilator). After expansion clear a trunk.
Special tool
(A): 09916-34542
(C): 09916-34550
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Install a cup of a valvate spring on a cylinder head.
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Put new consolidation of a core of the valve (1) on the directing valve plug. Having oiled engine consolidation and a core of the special tool (the tool handle for establishment of the directing valve plug), place oil consolidation on a core, and then install consolidation on the directing valve plug, having pressed the special tool a hand. After installation be convinced that consolidation is correctly fixed to a valve plug guide.
Special tool
(A): 09917-98221
(C): 09916-58210
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Do not reuse consolidation after dismantle. Do not forget to put new consolidation.
- At installation never you knock or do not beat the special tool with the hammer or something. Establish consolidation on a guide only by pressing the special tool a hand. Percussion or an accent on the special tool can damage consolidation.
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Install the valve (1) on the directing valve plug. Before installing the valve on the directing valve plug, oil engine consolidation of a core, internal diameter of the directing plug of the valve and a core of the valve.
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Establish a valvate spring and the holder of a spring. Each spring has the top end (the end with a big step of a spring (1)) and the lower end (the end with a small step of a spring (2)). Do not forget to establish a spring into place by the lower end (the party of the holder of a valvate spring (3)) to a bottom (the party of a cup of a valvate spring (4)).
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1 — the end with a big step of a spring
2 — the end with a small step of a spring
3 — the party of the holder of a valvate spring
4 — the party of a cup of a valvate spring |
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By means of the special tool (the valve elevator) squeeze a valvate spring and insert two checks of the valve (1) into a groove in a valve core.
Special tool
(A): 09916-14510
(C): 09916-14910
(C): 09916-84511
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Establish yokes, springs and an axis of yokes, having addressed the Section Valve Yoke, an axis of yokes and a cam-shaft in this Chapter.
Establish an inlet collector and a collector of the fulfilled gases.
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Installation
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Remove old laying and oil on the interfaced surfaces, and establish pins (4) and new laying of a head of cylinders (1), i.e. the mark "Top" in laying goes to the party of a pulley of the crankshaft (2) a front surface to the party of a head of the cylinder.
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1 — laying of a head of cylinders
2 — a crankshaft pulley
3 — the party of a flywheel
4 — pins |
Make sure that the oil nozzle (Venturi's nozzle) (1) is established and if it is established, then be convinced that it is not clamped.
Oil engine bolts of a head of the cylinder and twirl them gradually as follows:
Twirl all bolts on 35 N • m (3.5 kg-m 25.0 pound on foot) in a digital order as it is specified in the drawing.
Just as in (1), twirl them on 55 N • m (5.5 kg-m, 40.0 pound on foot).
Release all bolts until the rotating moment of an inhaling does not decrease to 0 upside-down of an inhaling.
Just as in (1), twirl them on 35 N • m (3.5 kg-m, 25.0 pound on foot).
Just as in (1) again, twirl them by the specified rotating moment. The rotating inhaling moment: a bolt of a head of the cylinder (a) — 68 N • m (6.8 kg-m, 49.5 pounds on foot).
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"1" — the party of a pulley of a cam-shaft |
Repeat the procedure of dismantle upside-down for the purpose of installation.
Adjust a tension of a belt of the drive of the water pump, having addressed the Section Regulation and check of a tension of a belt of the cooling fan in the Head Okhlazhdeniye of the engine.
Adjust a tension of a belt of the pump of the hydraulic booster of steering or a tension of the And/T compressor belt if that is available. Address the Section Engine in the Head Maintenance and lubricant.
Adjust gaps of inlet and exhaust valves, having addressed the Section the Valvate gap in this Chapter.
Adjust a side play of a rope of an accelerator and a side play of a cable of the drive of butterfly valves And/T.
Check whether everything the removed parts are put into place. Repeatedly establish any necessary parts which were not earlier established.
Back fill the cooling system, having addressed the Section Washing and filling of the cooling system in the Head Okhlazhdeniye of the engine.
Connect a negative cable to the accumulator.
Check whether there is no leak of fuel, antifreeze and exhaust gas on each connection.
Make sure that installation of a corner of an advancing of ignition or injection of fuel conforms to technical requirements, having addressed the Head Sistema of ignition.
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