Suzuki Grand Vitara SQ416/SQ420/420WD

since 1998 of release

Repair and car operation



Suzuki Grandee of Wetar
+ General information
+ Maintenance and greasing
+ 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
         Compression check
         Check of depression of the engine
         Check of pressure of oil
         Klapanny gap
         Filtering element of the air filter
         Cover of a head of cylinders
         Case of butterfly valves and inlet collector
         Collector of the fulfilled gases
         Belt of a 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 moment of an inhaling
   + Mechanical part of the J20 engine
   + engine Cooling
+ Fuel system
+ ignition System
+ start System
+ release System
+ Transmissions
+ Coupling
+ Transfer
+ Forward and back differentials
+ Windows, mirrors, locks and security measures. Immobilizer
+ Electric equipment





Valves and head of the block of cylinders

1 — valve checks
2 — the holder of a spring of the valve
3 — a valve spring
4 — consolidation of a core of the valve
5 — a cup of a klapanny spring
6 — the exhaust valve

7 — the inlet valve
8 — a head bolt цилиндра*
9 — a head цилиндра*
10 — a pin
11 — an oil nozzle
12 — the directing plug of the valve


*8) Address to item of 3 procedures of installation.

*9) The mark "Top" specified on laying, goes from a crankshaft pulley the face up.

The rotating moment of an inhaling

Not to use repeatedly.

Grease with engine oil a sliding surface of each part.

Removal

 PERFORMANCE ORDER

  1. Dump pressure of fuel.
  2. Disconnect a negative cable from the accumulator.
  3. Drain cooling system.
  • Be convinced of that temperature of antifreeze of the engine low before to remove any parts of system of cooling.
  • Also make sure that the negative cable is disconnected from the accumulator before removing any parts.

  1. Remove an element of rigidity of an inlet collector (1).
  1. Remove an airintaking sleeve.
      • Disconnect the following electric wires, and then release plaits of wires from clips.
      • Sensor of provision of a butterfly valve
      • The regulating pneumovalve of idling
      • The 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 a retsirkulyatsiya of the fulfilled gases
      • Sensor of pressure of differential of a collector
      • The gate for production of not condensing gases
      • Nozzle wires at the coupling
      • Sensor of heating of oxygen-1
  1. 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
      • Hose of antifreeze of the engine (the target 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
  1. Disconnect a rope of an accelerator and a cable of a drive of butterfly valves And/t (if that is available) from the case of butterfly valves.
  1. Uncover cylinder heads, having addressed to the Section the Cover of a head of cylinders in this Chapter.
  1. Completely unscrew all screws regulating a klapanny gap.
  1. Remove a belt of a drive of the gas-distributing mechanism and a cam-shaft, having addressed to Sections the Belt of a drive of the gas-distributing mechanism and the tension device for a belt and a valve Yoke, an axis of yokes and a cam-shaft in this Chapter.
  1. Remove regulating lever of the generator from an inlet collector.
  2. Remove regulating lever of the compressor for air conditioning from a cylinder head (if that is available).
  1. 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.
  1. Untwist bolts of a head of the cylinder in an order specified in drawing below, and take out them.
«1» — the party of a pulley of a cam-shaft
«2» — the party of the distributor of ignition
  1. Check everything round a cylinder head, whether there are still any details which are necessary for removing or disconnecting, remove or disconnect, all that is necessary.
  2. Remove a cylinder head with an inlet collector and a collector of the fulfilled gases by means of the elevating device.

Removal

 PERFORMANCE ORDER

  1. 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.
  2. Remove yokes and an axis of yokes, having addressed to the Section a valve Yoke, an axis of yokes and a cam-shaft in this Chapter.
  1. By means of the special tool (the valve lift) compress klapanny springs and then remove valve (1) checks, using the special tool (nippers).
Special tool
  • (А): 09916-14510
  • (В): 09916-14910
  • (С): 09916-84511
  1. Release (open) the special tool and remove the holder of a spring and a klapanny spring.
  2. Remove the valve from the combustion chamber.
  1. Remove oil consolidation of a core of the valve (1) from the directing plug of the valve and then a cup of a klapanny spring (2).

Do not use oil consolidation repeatedly after dismantle. At assembly surely use new oil consolidation.


  1. By means of the special tool (a stripper of the directing plug of the valve) shift directing plug of the valve from the combustion chamber on the party of a klapanny spring. Special tool (And): 09916-44910.

Do not use directing plug of the valve repeatedly after dismantle. Surely use the new directing plug of the valve (the working size) at assembly.

  1. Combine the disassembled parts, except for consolidation of a core of the valve and the directing plug of the valve, one after another, so that it was possible to establish them on their initial places.

Check

Directing plugs of the valve

 PERFORMANCE ORDER

  1. With the help a micromeasure and a kruglomer take readings of diameters of cores of valves and directing to check a gap between cores and directing.
  1. Do not forget to take readings from several places on all length of each core and directing. If the gap falls outside the limits norm, replace the valve and directing plug of the valve.

Technical characteristics of the valve and the directing plug of the valve

Position

Norm

Limit

Diameter of a core of the valve

Admission

5.465-5.480 mm (0.2152 – 0.2157 inches)

Release

5.440-5.455 mm (0.2142 – 0.2147 inches)

Internal diameter of the directing plug of the valve

Admission

5.500-5.512 mm (0.2166 – 0.2170 inches)

Release

Gap between a core and directing

Admission

0.020-0.047 mm (0.0008 – 0.0018 inches)

0.07 mm (0.0027 inches)

Release

0.045-0.072 mm (0.0018 – 0.0028 inches)

0.09 mm (0.0035 inches)


  1. If there is no kruglomer available, instead check deformation of the end of a core of the valve by means of the tsiferblatny indicator. Move the core end in the directions (1) and (2) to measure end deformation. If deformation falls outside the limits norms, replace a core of the valve and directing plug of the valve.
    • 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)

Valves

 PERFORMANCE ORDER

  1. Remove all deposit from valves.
  2. Check each valve on wear existence, прожога or deformations on a forward surface and a core and if it is necessary, replace it.
  3. Measure thickness of a head of the valve. If the measured thickness falls outside the limits norms, replace the valve.

Thickness of a head of the valve

 

Norm

Limit

On an admission

0.8-1.2 mm (0.032 – 0.047 inches)

0.6 mm (0.023 inches)

On release

0.7 mm (0.027 inches)


1 — thickness of a head of the valve
2 — 45 °
  1. Check an end face of a core of the valve about 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 that not сошлифовывать its chamber. If it is worn-out so strongly that its chamber is erased, replace the valve.

Width of contact of a prileganiye

  1. Create drawing of an arrangement of contacts on each valve habitually, i.e., having put a standard covering with a marking mix on a valve cup, and a rotary motion пристукнув a valve cup with a valve head. It is necessary to use the klapanny pritirochny machine (the tool used for grinding in of valves).
  1. The drawing printed on a contact surface of the valve should represent a continuous ring without any breaks, and the width of drawing should be in the specified limits. The standard width of contact formed by means of drawing of an arrangement of contacts on an obverse surface of the valve: on an admission on release — 1.1 – 1.3 mm (0.0433 – 0.0511 inches).

Repair of a cup of the valve

  1. The cup of the valve not creating complete contact to the valve or showing width of contact of a prileganiye, leaving for the specified range, should be repaired by a repolishing or cutting way and repolishings, and is ground to readiness by grinding in.
  1. 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 is necessary for using to receive necessary width of a cup. Width of a cup for a cup of the exhaust valve: 1.1-1.3 mm (0.0433 – 0.0511 inches).
  1. CUP of the INLET VALVE: Sequence of a cut just the same, as for cups of the exhaust valve. Width of a cup for a cup of the inlet valve: 1.1-1.3 mm (0.0433 – 0.0511 inches).
  1. GRINDING IN of VALVES: Grind in the valve to a cup (1) in two steps: at first by means of rough structure of a mix of grinding in of an obverse surface, and then by means of small structure of the mix, each time using the machine for grinding in of nests of valves according to a standard method of grinding in.

Cylinder head

 PERFORMANCE ORDER

  1. Remove all deposit from combustion chambers.

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 also to treat and valves, and cups of valves.

  1. Check a cylinder head about cracks in inlet and final channels, combustion chambers, and on a head surface.

Planshetnost of the condensed surface:

  1. By means of a kalibromer check a surface in 6 places. If the norm of deformation specified below, is exceeded, correct the condensed surface by means of a razmetochny plate and abrasive paper #400 (water-proof abrasive paper on the basis of silicon carbide): put paper on a razmetochny plate, and rub the condensed surface about paper, in order that сошлифовать high places. If it does not help to lower the indication of a kalibromer to norm limits, replace a cylinder head. Leakage of the working gases formed by products of combustion, from this condensed connection often occurs because of deformation of the condensed surface: such leak grows out of decrease in the made capacity.

Limits of deformation of the condensed surface of a head of the cylinder: 0.05 mm (0.002 inches).

Deformation of surfaces of a prileganiye of a collector:

  1. Check surfaces of a prileganiye of a head of the cylinder and collectors by means of a kalibromer, whether to define 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).

Klapannye of a spring

 PERFORMANCE ORDER

  1. Being based on the data provided below, be convinced that each spring is in a good condition, without breakage or easing certificates. Remember that the weakened klapanny springs can cause jingle, not to mention possible decrease in the made capacity because of the leakage of gas caused by pressure decrease of a prileganiye.
Length of a klapanny spring in a free condition:
  • norm: 36.83 mm (1.4500 inches)
  • limit: 35.67 mm (1.4043 inches)

Preliminary loading of a klapanny 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)

Perpendicularity of a spring:

  1. Use a square and a razmetochny plate to check each spring on perpendicularity from the point of view of a gap between the end of a klapanny spring and a square. If the gap is more than the limit specified below, klapanny springs should be replaced. Limit of perpendicularity of klapanny springs: 2.0 mm (0.079 inches).

Assembly

 PERFORMANCE ORDER

  1. Before establishing directing plug of the valve in a cylinder head, expand directing opening by means of the special tool (a 11-millimetric dilator) to remove teases and to make it really round.
    • Special tool:
      • (А): 09916-34542
      • (В): 09916-38210
  1. Establish directing plug of the valve on a cylinder head. Evenly heat up a cylinder head to temperature 80 – 100°С (176 – 212°F) not to deform a head, and enter the new directing plug of the valve until the special tool (the adaptation for installation of the directing plug of the valve) will 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
      • (С): 09916-56011
      • (D): 09916-58210

  • Do not use the disassembled directing plug of the valve repeatedly. Establish the new directing plug of the valve (the repair size).
  • Directing plugs of the valve on an admission and on release the identical.
  • The repair size of the directing plug of the valve: 0.03 mm (0.0012 inches).
  • Ledge of the directing plug of the valve (on an admission and on release): 11.5 mm (0.45 inches).

  1. Expand internal diameter of the directing plug of the valve by means of the special tool (a 5.5-millimetric dilator). After expansion clear a trunk.
    • Special tool
      • (А): 09916-34542
      • (В): 09916-34550
  1. Establish a cup of a klapanny spring on a cylinder head.
  1. Put new consolidation of a core of the valve (1) on directing plug of the valve. Having greased with engine oil consolidation and a core of the special tool (the tool handle for establishment of the directing plug of the valve), place oil consolidation on a core, and then establish consolidation on directing plug of the valve, having pressed the special tool a hand. After installation be convinced that consolidation is correctly fixed to directing valve plugs.
    • Special tool
      • (А): 09917-98221
      • (В): 09916-58210

  • Do not use consolidation repeatedly after dismantle. Do not forget to put new consolidation.
  • At installation never knock or do not beat on the special tool a hammer or something. Establish consolidation on directing only in pressing the special tool a hand. Postukivaniye or an accent on the special tool can damage consolidation.

  1. Establish the valve (1) on directing plug of the valve. Before establishing the valve on directing plug of the valve, grease with engine oil core consolidation, internal diameter of the directing plug of the valve and a valve core.
  1. Establish a klapanny 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 bottom end (the end with a small step of a spring (2)). Do not forget to establish a spring into place the bottom end (the party of the holder of a klapanny spring (3)) to a bottom (the party of a cup of a klapanny spring (4)).
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 klapanny spring
4 — the party of a cup of a klapanny spring
  1. By means of the special tool (the valve lift) compress a klapanny spring and insert two checks of the valve (1) into a groove in a valve core.
    • Special tool
      • (А): 09916-14510
      • (В): 09916-14910
      • (С): 09916-84511
  1. Establish yokes, springs and an axis of yokes, having addressed to the Section a valve Yoke, an axis of yokes and a cam-shaft in this Chapter.
  2. Establish an inlet collector and a collector of the fulfilled gases.

Installation

 PERFORMANCE ORDER

  1. 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" on laying goes to the party of a pulley of the crankshaft (2) an obverse surface to the party of a head of the cylinder.
1 — laying of a head of cylinders
2 — a crankshaft pulley
3 — the flywheel party
4 — pins
  1. Be convinced of that the oil nozzle (Venturi's nozzle) (1) is established and if it is established, be convinced that it is not clamped.
  2. Grease with engine oil 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 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 will not decrease to 0 upside-down inhalings.
    • 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 moment of an inhaling: a bolt of a head of the cylinder (and) — 68 N • m (6.8 kg-m, 49.5 pounds on foot).
«1» — the party of a pulley of a cam-shaft
  1. Repeat dismantle procedure upside-down for the purpose of installation.
  2. Adjust a tension of a belt of a drive of the water pump, having addressed to the Section Regulation and check of a tension of a belt of the cooling fan in Head engine Cooling.
  3. Adjust a tension of a belt of the pump of the hydraulic booster of a steering or a tension of a belt of the And/t compressor if that is available. Address to the Section Engine in Head Maintenance and greasing.
  4. Adjust gaps of inlet and exhaust valves, having addressed to Razdelu Klapanny a gap in this Chapter.
  5. Adjust люфт a rope of an accelerator and люфт a cable of a drive of butterfly valves And/t.
  6. Check, whether everything the removed parts are put into place. Repeatedly establish any necessary parts which were not earlier established.
  7. Back fill cooling system, having addressed to the Section Washing and filling of system of cooling in Head engine Cooling.
  8. Connect a negative cable to the accumulator.
  9. Check, whether there is no leakage of fuel, antifreeze and exhaust gas on each connection.
  10. Be convinced of that installation of a corner of an advancing of ignition or injection of fuel corresponds to technical requirements, having addressed to Head ignition System.