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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
   - Mechanical part of the J20 engine
      + General description
      - Routine maintenance
         Compression check
         Check of depression of the engine
         Check of pressure of oil
         Filtering element of the air filter
         Case of butterfly valves and inlet collector
         Collector of an exhaust system
         Cover of a head of the cylinder
         Oil pan and grid of the oil pump
         Oil pump
         Cover of a chain of synchronization
         Second chain of synchronization and natyazhitel of a chain
         First chain of synchronization and natyazhitel of a chain
         Cam-shafts and regulators of a klapanny 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 moment of an inhaling
   + 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


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Valves and head of the block of the cylinder

Components

"And" — put hermetic (SUZUKI BOND No. 1215, 99000-31110) on a carving
1 — the cylinder block
2 — a cylinder head
3 — laying of a head of the cylinder
4 — the inlet valve
5 — the final valve
6 — a cup of a klapanny spring
7 — consolidation of a core of the valve
8 — a valve spring (external)
9 — a valve spring (internal)

10 — the holder of a spring of the valve
11 — the valve check
12 — a hydraulic regulator of a klapanny gap
13 — the directing plug of the valve
14 — a water exhaust pipe
15 — a cover of a final branch pipe
16 — a bolt of a head of the cylinder
17 — a bolt of a head of the cylinder (М6)
18 — a bolt of a water exhaust pipe


Put fixing hermetic 99000-31110 on a bolt carving.

The rotating moment of an inhaling.

Not to use repeatedly.

Grease with engine oil sliding surfaces of each part.

Removal

 PERFORMANCE ORDER

  1. Dump pressure of oil.
  2. Disconnect a negative cable from the accumulator.
  3. Merge engine oil.
  4. Merge antifreeze.
  1. Remove a cross-section basic rack.
  1. Remove a final hose of the air filter.
  1. Disconnect the following electric wire conclusions:
    • The socket of the valve of system of a retsirkulyatsiya of the fulfilled gases
    • Socket of the valve of control of idling
    • 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
    • The 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
  1. Disconnect a rope of an accelerator and a cable of a drive of butterfly valves And/t (for vehicles with And/t) from the case of butterfly valves.
  1. 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
  1. Remove a back element of rigidity of an inlet collector.
  2. Disconnect a water pipe from an inlet collector.
  3. Uncover cylinder heads, an oil pan, a cover of a chain of the synchronization, the second and first chains of synchronization, cam-shafts and regulators of klapanny gaps, having addressed to the Section Cam-shafts and regulators of a klapanny gap in this Chapter.
  1. Disconnect an exhaust pipe No. 1 (1) from a collector of an exhaust system (2).
  1. Remove an element of rigidity of a collector of an exhaust system (1) (if that is available).
  1. Untwist bolts of a head of the cylinder, and take out them.

Do not forget to take out a bolt (М6).


1 — the party of a pulley of the crankshaft
2 — the flywheel party
3 — a bolt (М6)
  1. Check everything round a cylinder head, whether there are no other details which are necessary for removing or disconnecting, and remove or disconnect everything that is necessary.
  2. Take out a cylinder head with an inlet collector, a collector of an exhaust system and a water exhaust pipe. Use the elevating device if it is necessary.

Dismantling

 PERFORMANCE ORDER

  1. At maintenance of a head of the cylinder remove an inlet collector, injectors, a collector of an exhaust system, a water exhaust pipe and a cover of a final branch pipe from a cylinder head.
  1. By means of special tools compress klapanny springs and then remove valve (1) checks.
  • Special tool
    • (А): 09916-14510
    • (В): 09916-14910
    • (С): 09919-28610
    • (D): 09916-84511
  1. Release the special tool and remove holders of a spring and klapanny springs.
  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: (А): 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

With the help a micromeasure and a calliper take readings of diameters of cores of valves and directing to check a gap between cores and directing. 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

5.965-5.980 mm (0.2349 – 0.2354 inches)

Release

5.940-5.955 mm (0.2339 – 0.2344 inches)

Internal diameter of the directing plug of the valve

Admission

6.000-6.012 mm (0.2363 – 0.2366 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)

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

Position

Norm

Limit

On an admission

1.0 mm (0.039 inches)

0.6 mm (0.023 inches)

On release

1.2 mm (0.047 inches)

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.
  1. Check each valve on existence of radial wear by means of the tsiferblatny 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).

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). 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 and 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 is ground to readiness by grinding in.
    • 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 valve cup: 1.1-1.3 mm (0.0433 – 0.0511 inches).
    • Cup of the inlet valve: use mills of a cup of the valve 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 is necessary for using to receive necessary width of a cup. Width of a cup 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 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.
And — inlet
In — final

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.
  2. By means of a kalibromer check a planshetnost condensed 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.
  1. 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.

Technical characteristics of a klapanny spring

Position

Norm

Limit

Free length of a klapanny spring

The internal

36.08 mm (1.4204 inches)

35.00 mm (1.3779 inches)

The external

40.44 mm (1.5921 inches)

39.22 mm (1.5440 inches)

Preliminary loading of a klapanny spring

The internal

6.9-7.9 kg for 27.5 mm (15.2 – 17.4 pound on 1.08 inches)

6.2 kg for 27.5 mm (13.6 pound on 1.08 inches)

The external

15.4-17.8 kg for 31.7 mm (33.9 – 39.2 pound on 1.25 inch)

13.8 kg for 31.7 mm (30.4 pound on 1.25 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 into an opening by means of special tools. 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 from a cylinder head.
    • Special tool
      • (А): 09916-58210
      • (В): 09917-87810

  • 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 inlet and final valves 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) — 13.5 mm (0.53 inches).

  1. Expand internal diameter of the directing plug of the valve by means of the special tool (a 6.0-millimetric dilator). After expansion clear a trunk.
    • Special tool
      • (А): 09916-34542
      • (В): 09916-37810
  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 klapanny 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 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. 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): 09919-28610
      • (D): 09916-84511
  1. Establish an inlet collector, injectors, a collector of an exhaust system, a water taking-away pipe (2) and a cover of a water taking-away pipe on a cylinder (1) head.

At installation of a water taking-away pipe put hermetic on a bolt carving. "And": hermetic 99000-31110.

Installation

 PERFORMANCE ORDER

  1. Clean the interfaced surface of a head of the cylinder and the cylinder block. Remove oil, old laying and a dust from the interfaced surfaces.
  2. Establish pins (3) on the cylinder (2) block.
  3. Establish new laying of a head of cylinders (1) on the cylinder block. The mark "Top" on laying goes to the party of a pulley of the crankshaft (4) an obverse surface up (to the party of a head of the cylinder).
1 — laying of a head of cylinders
2 — the cylinder block
3 — pins
4 — a crankshaft pulley
5 — flywheel cторона
  1. Establish a cylinder head on the cylinder block. Grease with engine oil 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 specified in drawing below.
    • Just as in (1), twirl them on 84 N • m (8.4 kg-m, 61.0 pound on foot).
1 — cторона of a pulley of the crankshaft
2 — flywheel cторона
    • Release all bolts until the rotating moment of an inhaling will not decrease to 0 in the illustrated order.
1 — cторона of a pulley of the crankshaft
2 — flywheel cторона
    • Fasten all bolts on 53 N • m (5.3 kg-m, 38.5 pound on foot) according to digital order in drawing.
    • Just as in (4) again, twirl them the every rotating moment.
    • The rotating moment of an inhaling:
      • Bolt of a head of the cylinder (and) — 105 N • m (10.5 kg-m, 76.0 pounds on foot)
      • Bolt of a head of the cylinder (М6) (b) — 11 N • m (1.1 kg-m, 8.0 pound on foot)

Do not forget to fasten bolt М6 (3) after fix other bolts.


1 — the party of a pulley of the crankshaft
2 — the flywheel party
3 — a bolt
  1. Be convinced of that the key (2) on the crankshaft is leveled with a mark of synchronization (1).
  1. Repeat dismantle procedure upside-down for the purpose of installation.
  2. Adjust a tension of a belt of the cooling fan, having addressed to the Section Regulation and check of a tension of a belt of the cooling fan in Head engine Cooling.
  3. Adjust люфт a rope of an accelerator and люфт a cable of a drive of butterfly valves And/t (for vehicles with And/t).
  4. Check, whether everything the removed parts are put into place. Repeatedly establish any necessary parts which were not earlier established.
  5. Fill in engine oil in the engine, having addressed to the Section Engine oil and the filter in Head Maintenance and greasing.
  6. Back fill cooling system, having addressed to the Section Washing and filling of system of cooling in Head engine Cooling.
  7. Fill in a case of forward differential with transmission oil, having addressed to the Section Service out of a workshop in Head Forward differential.
  8. Fill in steering system with strengthening by special liquid, having addressed to the Section power steering Liquid in Head power steering System.
  9. Connect a negative cable to the accumulator.
  10. Check, whether there is no leakage of fuel, antifreeze, oil and exhaust gas on each connection.
  11. Be convinced of that installation of a corner of an advancing of ignition or injection of fuel corresponds to technical requirements, having addressed to the Section Check and adjustment of time of an advancing of ignition in Head ignition System for the J20 engine.