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
- Mechanical part of the J20 engine
+ General description
- Routine maintenance
Check of a compression
Check of depression of the engine
Check of pressure of oil
The filtering element of the air filter
Case of butterfly valves and inlet collector
Collector of the exhaust system
Cylinder head cover
Oil pan and grid of the oil pump
Oil pump
Synchronization chain cover
Second chain of synchronization and natyazhitel of a chain
First chain of synchronization and natyazhitel of a chain
Cam-shafts and regulators of a valvate gap
Valves and head of the block of the cylinder
Pistons, piston rings, rods and cylinders
+ Assembly fittings of the engine
Special tool
Necessary service materials
Technical characteristics of the rotating inhaling moment
+ 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 the cylinder
Components
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Apply the fixing sealant 99000-31110 on a bolt carving. |
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The rotating inhaling moment. |
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Oil engine the sliding surfaces of each part. |
Removal
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Dump oil pressure.
Disconnect a negative cable from the accumulator.
Merge engine oil.
Merge antifreeze.
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Remove a cross basic rack.
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Remove a final hose of the air filter.
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Disconnect the following electric wire conclusions:
The socket of the valve of system of recirculation of the fulfilled gases
Idling control valve socket
Socket of the sensor of position of the case of butterfly valves
The socket of the sensor of absolute pressure in an inlet collector
Grounding clip from an inlet collector
Socket of the sensor 1 and/or 2 of heating of oxygen
Socket of the sensor of provision of a cam-shaft
Socket of the sensor of temperature of cooling liquid of the engine
Socket of fastening of wires of a nozzle
Grounding wire at the coupling
Couplings of coils of ignition
Clips of plaits of wires
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Disconnect a rope of an accelerator and a cable of the drive of butterfly valves And/T (for vehicles with And/T) from the case of butterfly valves.
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Disconnect the following hoses:
Hose of the amplifier of brakes from an inlet collector
Vacuum hose from an inlet collector
Hose for production of gases from the sensor of absolute pressure in an inlet collector
Water hose from a bypass pipe
Hose of supply of fuel and returnable hose from each pipe
Heater hose from an exhaust pipe of a heater
Inlet hose of a radiator from a water exhaust pipe
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Remove a back element of rigidity of an inlet collector.
Disconnect a water pipe from an inlet collector.
Uncover cylinder heads, an oil pan, a synchronization chain cover, the second and first chains of synchronization, cam-shafts and regulators of valvate gaps, having addressed the Section Cam-shafts and regulators of a valvate gap in this Chapter.
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Disconnect an exhaust pipe No. 1 (1) from a collector of the exhaust system (2).
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Remove an element of rigidity of a collector of the exhaust system (1) (if that is available).
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Untwist cylinder head bolts, and take out them.
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Do not forget to take out a bolt (M6). |
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1 — the party of a pulley of the crankshaft
2 — the party of a flywheel
3 — a bolt (M6) |
Check everything around a cylinder head whether there are no other details which need to be removed or disconnected, and remove or disconnect everything that is necessary.
Take out a cylinder head with an inlet collector, a collector of the exhaust system and a water exhaust pipe. Use the lifting device if it is necessary.
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Dismantling
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At maintenance of a head of the cylinder remove an inlet collector, injectors, a collector of the exhaust system, a water exhaust pipe and a cover of a final branch pipe from a cylinder head.
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By means of special tools squeeze valvate springs and then remove checks of the valve (1).
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Special tool
(A): 09916-14510
(C): 09916-14910
(C): 09919-28610
(D): 09916-84511
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Release the special tool and remove holders of a spring and valvate springs.
Remove the valve from the combustion chamber.
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Remove oil consolidation of a core of the valve (1) from the directing valve plug, 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 caliper take readings of diameters of cores of valves and guides to check a gap between cores and guides. 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. |
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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5.965 – 5.980 mm (0.2349 – 0.2354 inches)
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—
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Release
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5.940 – 5.955 mm (0.2339 – 0.2344 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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6.000 – 6.012 mm (0.2363 – 0.2366 inches)
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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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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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Position
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Norm
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Limit
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On an admission
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1.0 mm (0.039 inches)
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0.6 mm (0.023 inches)
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On release
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1.2 mm (0.047 inches)
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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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Check each valve for existence of radial wear by means of the dial indicator and the V-shaped block. Slowly rotate the valve to check wear. If wear exceeds norm limits, replace the valve. Limit of radial wear of a head of the valve: 0.08 mm (0.003 inches).
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Width of contact of a prileganiye
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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). 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 and release — 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
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Repair of a cup of the valve
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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 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 valve cup: 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
Cup of the inlet valve: use valve cup mills to make three cuts. It is necessary to use three mills: the first to make a corner in 15 °, and the second to make a corner in 60 °, and a third to make a corner in 45 °. The third mill needs to be used to receive the necessary width of a cup. Cup width for a cup of the inlet valve: 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
Grinding in of valves: grind in the valve to a cup 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. |
Check a cylinder head regarding cracks in inlet and final canals, combustion chambers, and for head surfaces.
By means of a kalibromer check a planshetnost condensed 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.
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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. 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. 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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Technical characteristics of a valvate spring
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Position
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Norm
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Limit
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Free length of a valvate spring
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Internal
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36.08 mm (1.4204 inches)
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35.00 mm (1.3779 inches)
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External
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40.44 mm (1.5921 inches)
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39.22 mm (1.5440 inches)
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Preliminary loading of a valvate spring
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Internal
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6.9 – 7.9 kg for 27.5 mm (15.2 – 17.4 pound on 1:08 inches)
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6.2 kg for 27.5 mm (13.6 pound on 1:08 inches)
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External
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15.4 – 17.8 kg for 31.7 mm (33.9 – 39.2 pound on 1:25 inch)
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13.8 kg for 31.7 mm (30.4 pound on 1:25 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 into an opening by means of special tools. 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 valve plug from a cylinder head.
Special tool
(A): 09916-58210
(C): 09917-87810
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- Do not reuse the disassembled directing valve plug. Install the new directing valve plug (the repair size).
- Identical directing plugs of inlet and final valves.
- 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) — 13.5 mm (0.53 inches).
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Expand the internal diameter of the directing valve plug by means of the special tool (a 6.0-millimeter dilator). After expansion clear a trunk.
Special tool
(A): 09916-34542
(C): 09916-37810
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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 valvate springs (internal and external springs) 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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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): 09919-28610
(D): 09916-84511
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Establish an inlet collector, injectors, a collector of the exhaust system, the water taking-away pipe (2) and a cover of the water taking-away pipe on a head of the cylinder (1).
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At installation of the water taking-away pipe apply sealant on a bolt carving. "And": sealant 99000-31110. |
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Installation
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Clean the interfaced surface of a head of the cylinder and block of the cylinder. Remove oil, old laying and dust from the interfaced surfaces.
Install pins (3) on the block of the cylinder (2).
Install new laying of a head of cylinders (1) on the cylinder block. The mark "Top" in laying goes to the party of a pulley of the crankshaft (4) a front surface up (to the party of a head of the cylinder).
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1 — laying of a head of cylinders
2 — the cylinder block
3 — pins
4 — a crankshaft pulley
5 — the party of a flywheel |
Install a cylinder head on the cylinder block. Oil engine bolts of a head of the cylinder and twirl them gradually as follows.
Twirl all bolts on 53 N • m (5.3 kg-m 38.5 pound on foot) in a digital order as it is provided in the drawing below.
Just as in (1), twirl them on 84 N • m (8.4 kg-m, 61.0 pound on foot).
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1 — the party of a pulley of the crankshaft
2 — the party of a flywheel |
Release all bolts until the rotating moment of an inhaling does not decrease to 0 in the illustrated order.
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1 — the party of a pulley of the crankshaft
2 — the party of a flywheel |
Fasten all bolts on 53 N • m (5.3 kg-m, 38.5 pound on foot) according to a digital order in the drawing.
Just as in (4) again, twirl them with the specified rotating moment.
The rotating inhaling moment:
Bolt of a head of the cylinder (a) — 105 N • m (10.5 kg-m, 76.0 pounds on foot)
Bolt of a head of the cylinder (M6) (b) — 11 N • m (1.1 kg-m, 8.0 pound on foot)
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Do not forget to fasten a bolt of M6 (3) after fix other bolts. |
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1 — the party of a pulley of the crankshaft
2 — the party of a flywheel
3 — a bolt |
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Make sure that the key (2) on the crankshaft is leveled with a mark of synchronization (1).
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Repeat the procedure of dismantle upside-down for the purpose of installation.
Adjust a tension of a belt of the cooling fan, 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 side play of a rope of an accelerator and a side play of a cable of the drive of butterfly valves And/T (for vehicles with And/T).
Check whether everything the removed parts are put into place. Repeatedly establish any necessary parts which were not earlier established.
Fill in engine oil in the engine, having addressed the Section Engine oil and the filter in the Head Maintenance and lubricant.
Back fill the cooling system, having addressed the Section Washing and filling of the cooling system in the Head Okhlazhdeniye of the engine.
Fill in a case of forward differential with gearbox oil, having addressed the Section Service out of a workshop in the Head Forward differential.
Fill in system of steering with strengthening by special liquid, having addressed the Section Power Steering Liquid in the Head Sistema of the power steering.
Connect a negative cable to the accumulator.
Check whether there is no leak of fuel, antifreeze, oil 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 Section Check and adjustment of time of an advancing of ignition in the Head Sistema of ignition for the J20 engine.
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