1987 SUZUKI GRAND VITARA Service Repair Manual

NOTE:1kerns 1, 5,6, 7 and 6 are inspecial tad (09910-36210).
1.Driver handle
2.Piston pin3.Piston
4.Connecting rod5. Piston pin guide
6.Guide spring
7.Spring retainer8.Base
9.Support
Fig. 3-G 14Ins tatting piston pin
@ Press piston pin until line marked on driver
handle is flush with flat surface of piston
(Fig. 3-6-l 5).
1. Driver handle
2. Line3. Piston
4. Piston pin
Fig. 3-6- 15 Line marked on driver handle
2) Install piston rings to piston.
l As indicated in Fig. 3-6-16, 1st and 2nd
rings have “R” or “T” mark. Installing these
piston rings to piston with marked side of
each ring faced foward top of piston.
l 1st ring differs from 2nd ring in thickness,
shape and color of the surface contacting
cylinder wall.
Distinguish 1st ring from 2nd ring by refer-
ring to Fig. 3-6-16.
l When installing oil ring, install spacer first
and then two rails.
“R” or” T”
1. 1st ring (“A” 1.2 mm)
2. 2nd ring (“6” 1.5 mm)3. Oil ring
Fig. 3-6- 16 Piston rings installation
l After installing 3 rings (lst, 2nd and oil
rings), distribute their end gaps as shown
in Fig. 3-6-l 7.
5
1.Arrow mark
I\,
6
2.1 st ring end gap
3.2nd ring end gap
4.Oil ring rail gaps
5.lnta ke side
6.Exhaust side7.450
8.Oil ring spacer gap
Fig. 3-6- 17 Piston ring end gaps positions
3-40

3) install piston and connecting rod assembly
into cylinder bore.
@Apply engine oil to pistons, rings, cylinder
walls, connecting rod bearings and crank-
pins.
@Put guide hoses over connecting rod bolts as
shown in Fig. 3-6-18. These guide hoses
protect crankpin and thread of rod bolt
from damage during installation of connect-
ing rod and piston assembly.
1. Guide hoses
Fig. 3-6- 18 Guide hoses installation
@When installing piston and connecting rod
assembly into cylinder bore, point arrow
mark on each piston head to crankshaft
pulley side.
1. Crankshaft pulley side
2. Flywheel side
Fig. 3-6- 19 Direction of arrow mark on
piston head
@ Use piston ring compressor (Special tool) to
compress rings. Guide connecting rod into
place on the crankshaft.
Using a hammer handle, tap piston head to
install piston into bore. Hold ring compres-
sor firmly against cylinder block until all
piston rings have entered cylinder bore.
1. Piston ring compressor
(Special tool 09916-77310)
Fig. 3-6-20 Installing piston to cylinder
4) Install connecting rod bearing cap.
When installing cap to rod, point arrow mark
on cap to crankshaft pulley side.
Tighten cap nuts to specification.
Tightening torque33-37 N-m
for rod bearing3.3-3.7 kg-m
cap nuts24.0-26.5 lb-ft
1. Bearing cap
2. Arrow mark3. Crankshaft pulley side
4. Cap nut
Fig. 3-6-21Ins tailing bearing cap
3-41

Oil Pump Strainer
Install seal in the position shown in Fig. 3-6-22.
Tighten strainer bolt first and bracket bolt to
specified torque.
Tighteningtorque9-12 N.m
0.9-for bolts1.2 kg-m
6.5 -8.5 lb-ft
Fig. 3-6-22 Installing seal1. Seal
2. Strainer
3. Bracket
Oil Pan
1) Clean mating surfaces of oil pan and cylinder
block. Remove oil, old sealant, and dusts
from mating surfaces.
After cleaning, apply silicon type sealant to
oil pan mating surface continuously as
shown in Fig. 3-6-23.
Sealant MOOO-31150)
Fig. 3-6-23 Applying sealant to oil pan
2) Install oil pan to cylinder block.
After fitting oil pan to block, run in secur-
ing bolts and start tightening at the center:
move wrench outward, tightening one bolt
at a time.
Tighten bolts to specified torque.
Tighteningtorque9-12 N-m
-for oil panbolts0.91.2 kg-m
7.0 -8.5 lb-ft
3) Install gasket and drain plug to oil pan.
Tighten drain plug to specified torque.
Tightening torque
for drain plug
30-40 N.m
3.0-4.0 kg-m
22.0-28.5 lb-ft
4) Install guide seal to pump case and then oil
level gauge guide.
1. Oil pump2. Oil level gauge guide
3. Guide bolt
4. Guide seal
Fig. 3-6-24 Oil level gauge guide
Flywheel
Install flywheel to crankshaft.
Using special tool, lock flywheel, and tighten
flywheel bolts to specification.
Tightening torque
for flywheel bolts
57 65 N-m-
5.7 6.5 kg-m-
41.5 - 47 lb-ft
3-42

1.Flywheel holder (Special tool 09924-l 7810)
2. Flywheel bolts
3.Input shaft end bearing
4. Locating pin
Fig. 3-6-25
Cylinder Head
NOTE:
l Do not reuse valve guide once disassembled.
Install new valve guide (Oversize).
l Intake and exhaust valve guides are identical.
1) Install new valve guide into cylinder head.
a) Before installing new valve guide into
cylinder head, ream guide hole with 12 mm
reamer (Special tool) to remove burrs, mak-
ing sure that guide hole diameter after
reaming comes within specified range.
Valve guide hole12.030 - 12.048 mm
Dia. (In & Ex)(0.4736 - 0.4743 in.)
b) Install valve guide to cylinder head.
Heat cylinder head uniformly at a tempe-
rature of 80 to 100°C (176 to 212”F),
using care not to distort head, and drive new
valve guide into hole with special tools.
Refer to Fig. 3-6-27.
Drive in new valve guide until valve guide
installer(Special tool) contacts cylinder head.
After installation, make sure that valve
guide protrudes by 14 mm from cylinder
head (Fig. 3-6-27).
1. Valve guide installer attachment (Special tool 09917-88210)
2. Valve guide installer handle (Special tool 09916-57321)
3. Valve guide protrusion (14 mm)
Fig. 3-6-27 Valve guide installation
clReam valve guide bore with 7 mm reamer
(Special tool).
After reaming, clean bore.
1. Valve guide
2.7 mm reamer (Special tool 09916-34520)
Fig. 3-6-28 Reaming valve guide bore
1.12 mm reamer (Special tool 09916-37310)
Fig. 3-6-26 Reaming guide hole
3-43

2) Install valve spring seat to cylinder head.
3) Install new valve stem seal to valve guide.
After applying engine oil to seal and spindle
of valve stem seal installer (special tool), fit
oil seal to spindle, and then install seal to
valve guide by pushing special tool by hand.
After installation, check to be sure that
seal is properly fixed to valve guide.
NOTE:
l Do not reuse oil seal disassembled. Be sure to
install new oil seal.
l When installing, never tap or hit special tool
with a hammer or else. Install seal to guide
only by bushing special tool with hand.
Tapping or hitting special tool may cause
damage on seal.
7 i
1.Valve stem seal installer (Special tool 09917-98210)
2. Valve stem seal
Fig. 3-6-29 Valve stem seal installation
4) Install valve to valve guide.
Before installing valve to valve guide, apply
engine oil to stem seal, valve guide bore,
and valve stem.
Fig. 3-6-30 Valve installation
5) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch
end) and bottom end (small-pitch end)
Be sure to position spring in place with its
bottom end (small-pitch end) down to valve
spring seat side.
41. Large-pitch2. Small-pitch
3.Valve spring retainer side
4. Valve spring seat side
Fig. 3-6-3 1Valve spring installation
3-44

6) Using special tool (Valve lifter), compress
valve spring and fit two valve totters to
groove provided in valve stem.
1. Valve lifter (Special tool)
2.Forceps (Specialtool13.Valve totters4. Valve spring retainer
Fig. 3-6-32 Valve totters installation
7) Be sure that locating pins @ are in place and
then install new head gasket as shown in
Fig. 3-6-33, namely in such a way that
“TOP” mark provided on the gasket comes
on top side (toward cylinder head side)
and on crankshaft pulley side.
1
4
4
1. Cylinder head gasket2. Crankshaft pulley side
3 Flywheel side4. Locating pin
Fig. 3-6-33 Cylinder head gasket installation
8) Install cylinder head onto cylinder block.
Tighten cylinder head bolts gradually with a
torquewrench,following sequence in
Fig. 3-6-34. Finally tighten bolts to specified
torque.
Tightening torque for63-70 N-m
cylinder head bolts6.3-7.0 kg-m
46.0 -50.5 lb-ft
Fig. 3-6-34 Tightening sequence of cylinder
head bolts
Camshaft
1) Apply engine oil to cams and journals on
camshaft, and oil seal on cylinder head.
2) Install to cylinder head from transmission
case side.
Fig. 3-6-35 Camshaft installation
3-35

Rocker-Arm Shafts
1) Apply engine oil to rocker arms and rocker
arm shafts.
2) install rocker arms, springs and rocker arm
shafts.
The two rocker arm shafts are not identical.
To distinguish between the two, dimensions
of their stepped ends differ as shown in
Fig. 36-36. Install intake rocker arm shaft,
facing its stepped end to camshaft pulley
side, and exhaust rocker arm shaft, facing
its stepped end to distributor side (rear side).
56
b01000
/3
I
3
I
o-
“7
1. Intake rocker arm shaft
2.14 mm (0.55 in)
3. Exhaust rocker arm shaft
4.15 mm (0.59 in)
5. Camshaft pulley side
6.Distributor side
Fig. 3-6-36 Rocker arm shafts installation
3) After installing rocker arms, springs, and
rocker arm shafts as shown in Fig. 3-6-37,
tighten rocker arm shaft screws to specified
torque.
Tightening torque9 -12 N.m
for rocker arm shaft0.9 -1.2 kg-m
screws7.0 -8.5 lb-ft
NOTE:
Valve clearance is adjusted after all parts are
assembled. So it is not adjusted at this point
Leave rocker arm adjusting screw as loose as
can be.
1. Intake side
2. Exhaust side
Fig. 3-6-37
Water Inlet Pipe
Install water inlet pipe to cylinder block.
Make sure to fit seal ring @(O-ring) to inlet
pipe before installation.
Fig. 3-6-38
Intake Manifold and Carburetor
1) Install intake manifold gasket to cylinder
head. Use new gasket.
NOTE:
Clean cylinder head mating surface with gasket
before installation.
2) Install intake manifold with carburetor to
cylinder head.
3) Tighten manifold bolts and nuts to specified
torque.
Tightening torque ~.mkg-mlb-ftfor manifold bolts
and nuts18 - 281.8 - 2.8 13.5-20.0
3-46

Fig. 3-6-39
4) Connect water hoses to water inlet pipe and
clamp each hose.
Oil FilterInstall oil filter.
CAUTION:For oil filter installation, refer to P. 1-7 of
this manual.
Exhaust Manifold and Cover
1) Install exhaust manifold gasket to cylinder
head. Use new gasket.
NOTE:
Clean cylinder head mating surface with gasket
before installation.
2) Install exhaust manifold to cylinder head.
3) Tighten bolts and nuts to specified torque.
Tightening torque
N.mkg-mlb-ft
for bolts and nuts18 - 28 1.8 - 2.8 13.5-20.0 Water pump
1) Install water pump gasket to cylinder block.
Use new gasket.
NOTE:
Clean cylinder block mating surface with gasket
before installation.
2) Install water pump to cylinder block.
3) Tighten bolts and nuts to specified torque.
Tightening torque N.m
for water pumpb-mI b-ft
bolts and nuts
8 - 12 0.9 - 1.2 7.0 - 8.5,
Fig. 3-6-40
4) Install rubber seats 0; one between oil
pump and water pump and the other be-
tween water pump and cylinder head.
4) Install exhaust manifold cover.
Fig. 3-6-4 1
3-47