1987 SUZUKI GRAND VITARA Service Repair Manual

2) Next, check bearing cap bore diameter with-
out bearing.
On mating surface of cylinder block, five
alphabets are stamped as shown in Fig.
3-5-46.
Three kinds of alphabets (“A”, “B” and
“C”) represent following cap bore diameters.
The first, second, third, fourth and fifth (left
to right) stamped alphabets indicate the cap
bore diameter of bearing caps “l”, “2”, “3”,
“4” and “5” respectively.
For example, in Fig. 3-5-46, the first (leftmost)
alphabet “B” indicates that the cap bore dia. of
bearing cap @ is within 49.006 - 49.012 mm,
and the fifth (rightmost) alphabet “A” indicates
that the cap bore dia. of cap @ is within 49.000
- 49.006 mm.
Fig. 3-5-46 Stamped alphabets on cylinder
block
3) There are five kinds of standard bearings
differing in thickness. To distinguish them,
they are painted in following colors at the
position indicated in Fig. 3-5-47.
Each color indicates the following thicknesses
at center of bearing.
IBlack1.999 - 2.003 mm
(0.0787 - 0.0788 in.)I
I
Colorless2.002 - 2.006 mm
(no paint)(0.0788 - 0.0789 in.)I9
Yellow2.005 - 2.009 mm
(0.0789 - 0.0790 in.)
IBlue2.008 - 2.012 mm
(0.0790 - 0.0791 in.)I
1. Paint
Fig. 3-5-47 Paint on standard bearing
4) From the numeral stamped on crank webs of
No. 2 and No. 3 cylinders and the alphabets
stamped on mating surface of cylinder block,
determine new standard bearing to be install-
ed to the journal, by referring to the table
shown below.
For example, if numeral stamped on crank
web is “1” and alphabet stamped on mating
surface is “B”,install new standard bearing
painted in “Black” to its journal.
3-32

Numerals stamped on crank
webs (Journals diameter)
123
Alphabets AGreenBlackColorless
stamped Bon matingBlackColorlessYellow
surfacecColorlessYellowBlue
New standard bearing to be installed.
5) Using gaging plastic, check bearing clearance
with new standard bearing selected.
If clearance still exceeds its limit, use next
thicker bearing and recheck clearance.
6) When replacing crankshaft or cylinder block.
due to any reason, select new standard
bearings to be installed by referring to the
numerals stamped on new crankshaft or the
alphabets stamped on the mating surface of
new cylinder block.
UNDERSIZE BEARING (0.25 mm):
l 0.25 mm undersize bearing is available in 5
kinds differing in thickness.
To distinguish them, each bearing is painted
in following colors at position indicated in
Fig. 3-5-48.
Each color indicates following thickness at
center of bearing.
Color paintedBearing thicknessI
Green & Red2.121 - 2.125 mm
(0.0835 - 0.0836 in. )III
Black & Red2.124 - 2.128 mm
(0.0836 - 0.0837 in.)
Red only2.127 - 2.131 mm
(0.0837 - 0.0838 in.)I
Yellow & Red2.130 - 2.134 mm
(0.0838 - 0.0839 in.)
Blue & Red2.133 - 2.137 mm
(0.0839 - 0.0840 in.)I
11. Paint
Fig. 3-5-48 Faints on undersize bearing
l If crankshaft journal is necessary to be
reground to undersize, regrind the journal and
select undersize bearing to be used as follows.
1) Regrind journal to following finished dia-
meter.
IFinished diameter44.732 -44.750 mm
(1.7612 - 1.7618 in.)I
2) Using micrometer, measure reground journal
diameter. Measurement should be carried out
in two directions perpendicular to each other
in order to check for out-of-round.
3) From the journal diameter measured above
and the alphabets stamped on mating surface
of cylinder block, select the undersize bearing
to be installed by referring to the table
shown below.
Check bearing clearance with undersize
bearing selected.
3-33

Measured journal diameter
44.744 - 44.750 mm44.738 - 44.744 mm44.732 - 44.738 mm
(1.7616 - 1.7618 in.)(1.7614 - 1.7616 in.)(1.7612 - 1.7614 in.)
Alphabets stamped I AGreen & RedBlack & RedRed only
on mating surfaceBBlack & RedRed onlyYellow & Red
of cylinder blockCRed onlyYellow & RedBlue & Red
Undersize bearing to be installed.
Rear Oil Seal
Carefully inspect oil seal for wear or damage. If
its lip is worn or damaged, replace oil seal.
1. Rear oil seal
Fig. 3-5-49 Rear oil sealOil Pump
Flywheel
l If ring gear is damaged, cracked or worn,
replace flywheel.
l If surface contacting clutch disc is damaged,
or excessibly worn, replace flywheel.
l Check flywheel for face runout with a dial
wge.
If runout is out of limit, replace flywheel.
Limit on runout0.2 mm (0.0078 in.)
Fig. 3-5-50 Measuring runou t
1) Inspect oil seal lip for fault or other damage.
Replace as necessary.
2) Inspect outer and inner rotors, rotor plate,
and oil pump case for excessive wear or
damage.
l Radial clearance:
Check radial clearance between outer rotor
and case, using thickness gauge.
If clearance exceeds its limit, replace outer
rotor or case.
Outer rotor and case0.310 mm (0.0122 in.)
3-34

3-6. ENGINE REASSEMBLY
NOTE:
l All parts to be used in reassembly must be
perfectly clean.
l Oil sliding and rubbing surfaces of engine
parts just before using them in reassembly.
Use engine oil (Refer to page l-8).
l Have liquid packing ready for use. SUZUKI
BOND NO. 1215 is specified for it. Use it
wherever its use is specified in order to
ensure leak-free (oil and water) workmanship
of reassembly.
l There are many running clearances. During
the course of engine reassembly, be sure to
check these clearances, one after another,
as they form.
l Gaskets, “0” rings and similar sealing mem-
bers must be in perfect condition. For these
members, use replacement parts in stock.
l Tightening torque is specified for impor-
tant fasteners - mainly bolts and nuts -of
the engine and other components. Use torque
wrenches and constantly refer to the specified
values given on p. 3-58.
l Do not disregard match marks provided on
parts. Some of them are those given at the
time of disassembly.
l There are many sets of parts. Crankshaft
bearings, connecting rods, pistons, etc., are
in combination sets. Do not disturb such
combinations and make sure that each part
goes back to where it came from.
Engine reassembly is the reverse of engine disas-
sembly as far as sequence is concerned, but
there are many reassembling steps that involve
measures necessary for restoring engine as close
to factory-assembled condition as possible. Only
those steps will be dealt with here.
Fig. 3-5-51 Radial clearances
l Side clearance:
Using straight edge and thickness gauge,
measure side clearance.
Limit on side
clearance0.15 mm (0.0059 in.)
Fig. 3-5-52 Side clearance measurement
Timing Belt end Tensioner
l Inspect timing belt for wear or crack. Replace
it as necessary.
l Inspect tensioner for smooth rotation.
3-35

Crankshaft
1) Install main bearings to cylinder block.
NOTE:
If main bearing replacement is necessary, select
such bearing as to allow proper clearance as
described on p. 3-30 and install it in place.
Between two halves of main bearing, one
side has oil groove. Install this half with oil
groove to cylinder block, and another half
without oil groove to bearing cap.
Make sure that two halves are painted with
same color.
1. Cylinder block
2. Upper half of bearing
3. Oil groove
3) Install thrust bearings to cylinder block
between No. 2 and No. 3 cylinders. Face oil
groove sides to crank webs.
r21. Thrust bearing2. Oi I groove
Fig. 3-6-3 Ins tatting thrust bearing
4) Install crankshaft to cylinder block.
5) Oil crankshaft journals.
6) When fitting bearing caps to journals after
setting crankshaft in place, be sure to point
arrow mark (on each cap) to crankshaft
pulley side. Fit them sequentially in ascend-
ing order, 1, 2, 3, 4 and 5, starting from
pulley side.
Fig. 3-6- 1Installing bearing half with oil grooveTightening torque50-57 N-m
for main bearing5.0-5.7 kg-m
cap bolts36.5-41 .O lb-ft
2) Be sure to oil crankshaft journal bearings as
shown.Gradual and uniform tightening is important for
bearing cap bolts. Make sure that five caps
become tight equally and uniformly specified
torque.
NOTE:
After tightening cap bolts, check to be sure that
crankshaft rotates smoothly when turned by
hand.
Fig. 3-6-2
3-36

n
U
1. Crankshaft pulley side2. Arrow mark
Fig. 3-6-4 Ins tailing main bearing caps
Oil Seal Housing
Install oil seal housing and its gasket.
Install new gasket. Do not reuse gasket removed
in disassembly. Apply oil to oil seal lip before
installing. Tighten housing bolts to specifi-
cation.
After installing oil seal housing, gasket edges
might bulge out; if so, cut off edges to flush
with cylinder block and oil seal housing.
Tightening torque
for housing bolts
lo- 13 N-m
l.O- 1.3 kg-m
7.5 - 9.0 lb-ft
Oil Pump
NOTE:
Reassemble components of oil pump assembly
according to following procedure, if disassem-
bled.
a) Wash, clean and then dry all disassembled
parts.
b) Apply thin coat of engine oil to inner and
outer rotors, oil seal lip portion, and inside
surfaces of oil pump case and plate.
c) Install outer and inner rotors to pump case.
d) Install gear plate. Tighten 5 screws securely.
e) After installing plate, check to be sure that
gears turn smoothly by hand.
1) Install two oil pump pins and oil pump gasket
to cylinder block. Use new gasket.
2) To prevent oil seal lip from being damaged or
upturned when installing oil pump to crank-
shaft, fit oil seal guide (special tool) to
crankshaft, and apply engine oil to it.
1. Crankshaft2. Oil seal guide (Vinyl resin) (Special tool09926-18210)
3. Oil pump pin
Fig. 3-6-6 Special tool (Oil seal guide)
ins talla tion
Fig. 3-6-5 Cutting off edges of gasket
3-37

3) Install oil pump to crankshaft and cylinder
block. install No. 1 and No. 2 bolts as shown
in Fig. 3-6-7, and tighten them to specified
torque.
After installing oil pump, check to be sure
that oil seal lip is not upturned, and then
remove special tool.
-
2
2
Fig. 3-6-7
1. NO. 1 bolts (short)
2. No. 2 bolts (long)
Piston, Connecting Rod and Piston Rings
NOTE:
Two sizes of piston are available as standard size
spare part so as to ensure proper piston-to-
cylinder clearance. When installing a standard
size piston, make sure to match piston with
cylinder as follows.
a) Each piston has a stamped number 1 or 2 as
shown depending on its outer diameter.
or 2
Piston
Fig. 3-6-9
b) There are also stamped numbers of 1 and 2
on cylinder block as shown below. First
number indicates inner diameter of No. 1
cylinder, second number of No. 2 cylinder,
third number of No. 3 cylinder and fourth
number of No. 4 cylinder.
4) Edge of oil pump gasket might bulge out: if
it does, cut bulge off with a sharp knife,
making edge smooth and flush with end
faces of the pump case and cylinder block.
Crank
No. 1 CylinderNo. 2 CylinderNo. 3 CylinderNo. 4 Cylinder
Cylinder block
Fig. 3-6- 10
Fig. 3-6-8 Cutting the edge of gaske t
3-38

clUse a number 2 stamped piston for installa-
tion if cylinder is identified with number 2
and a number 1 piston for cylinder with
number 1.
Fig. 3-6- 11
PistonCylinderPiston-to-cylinderNumbera;$;r$p Outside diameterNWtlberck?arancE
(mar kbBore diameter
173.96 - 73.99mm’74.01 74.02mm0.02 - 0.04mm
(2.9126 - 2.9130in.)(2.9138 - 2.9142in.l~0.0009 -0.0016in.)
273.97 - 73.96mm74.00 - 74.01 mm0.02 - 0.04mm
2(2.9134 - 2.9138in.l(0.0008 -0.0016in.l
Also, a letter A, 6, C etc., is stamped on piston
head but ordinarily it is not necessary to dis-
criminate each piston by this number.
1) Install connecting rod to piston.
@ After applying engine oil to piston pin holes
in piston and connecting rod, fit connecting
rod to piston as prescribed in Fig. 3-6-12.
Crankshaft pulley side
1. Piston2. Arrow mark
3. Connecting rod4. Oil hole
(Oil hole should come on
intake side)
Fig. 3-6- 12 Fitting connecting rod to piston
@ Place piston on piston pin remover and
installer (special tool) as indicated in Fig.
3-6-13, and press piston pin into piston and
connecting rod (Fig. 3-6-14).
2. Arrow mark
3. Piston pin remover and installer(Special tool 0991 O-3821 0)
Fig. 3-6- 13 Fitting piston to special tool
3-39
(2.9122-