1987 SUZUKI GRAND VITARA Service Repair Manual

Timing Belt Inside Cover, Belt Pulleys,
Tensioner, Timing Belt and Outside Cover
1) install timing belt inside cover to cylinder
head.
2) Install crankshaft timing belt guide, key and
pulley.
Refer to Fig. 3-6-42 for proper installation
of these parts.
Install timing belt guide in such a way that
its concave side faces oil pump.
Tighten crankshaft timing belt pulley bolt to
specified torque by using flywheel holder
A (Special tool).
1.
2.3.
Timing belt guide
KeyCrank timing belt pulley4. Pulley bolt
(A) Flywheel holder
(09924-I 7810)
Fig. 3-6-42 Installing guide, key and pulley
3) Install camshaft timing belt pulley.
Fit pulley pin on camshaft into slot in
camshaft pulley. Tighten pulley bolt to
specified torque with general rod applied as
shown in Fig. 3-6-44.
inside cover2. Camshaft pulley:
3. Pulley pin4. Slot5. Pulley bolt
Fig. 3-6-43 Pulley pin, slot and pulley bolt
1. Wrench
2. Camshaft timing belt pulley3. Timing belt inside cover
4. General rod
Fig. 3- 6-44
Tightening torque N-mkg-mlb-ft
for pulley bolt56 - 645.6 - 6.4 41.0-46.0
3-48

4) Install timing belt tensioner plate to tensio-
ner.
Insert lug of tensioner plate into hole of
tensioner.
3w1. Tensioner plate42. Tensioner
3. Lug4. Hole
Fig. 3-645 Lug and hole
5) Install timing belt tensioner, tensioner plate
and spring.
Do not tighten tensioner bolt and stud with
wrench yet.
Hand tighten only at this time.
Be sure that plate movement in arrow
direction as shown in Fig. 3-6-46 causes the
same directional movement of tensioner.
If no associated movement between plate
and tensioner occurs, remove tensioner and
plate again and reinsert plate lug into tensio-
ner hole.
1. bolt
2. Tensioner stud3. Tensioner plate
4. Tensioner
5. Spring6. Spring damper
Fig. 3-646 Tensioner installation
6) Before installing timing belt to camshaft
pulley and crankshaft timing belt pulley,
loosen all valve adjusting screws of intake
and exhaust rocker arms fully, or check to
ensure they are loose.
This is to permit free rotation of camshaft
for the following reason; when installing
timing belt to both pulleys, belt should be
correctly tensed by tensioner spring force.
If camshaft does not rotate freely, belt will
not be correctly tensed by tensioner.
1. Valve adjusting screw
2. Locknut
Fig. 3-6-47Valve adjusting screw and lock nut
7) After loosening all valve adjusting screws all
the way, turn camshaft pulley clockwise and
align timing mark on camshaft pulley with
“V” mark on belt inside cover as shown in
Fig. 3-6-48.
1. Camshaft timing pulley
2. Timing mark
3.“V” mark4. Belt inside cover
Fig. 3-648 Timing marks
3-49
Tensioner

8) Turn crankshaft clockwise, fitting 17 mm
wrench to crankshaft timing belt pulley
bolt, and align punch mark on timing belt
pulley with arrow mark on oil pump as
shown in Fig. 3-6-49.
1. Crankshaft timing belt pulley bolt2. Punch mark3. Arrow mark
4. Crankshaft timing belt pulley
Fig. 3-6-49 Timing marks
9) With 4 marks aligned, install timing belt on
two pulleys in such a way that drive side of
belt is free from any slack, and with tensio-
ner plate pushed up by finger.
NOTE:
In this state, No.4 piston is at top dead center
of compression stroke.
NOTE:
When installing timing belt, match arrow mark
(+I on timing belt with rotating direction of
crankshaft.
10)To allow belt to be free of any slack, turn
crankshaft clockwise fully twice after install-
ing belt. After removing belt slack, tighten
tensioner stud first and then tensioner bolt
to 24 - 30 N.m (2.4 - 3.0 kg-m, 17,5 -
21.5 lb-ft).
Then confirm again that 4 marks are match-
ed.9-12 N-m
3. Tensioner plate
Fig. 3-6-51Tensioner bolt and nut
11) Install timing belt outside cover.
Tightening torque
for outside coverN.mkmlb-ft
bolts and nuts9- 120.9 - 1.27.0 - 8.5
Crankshaft Pulley, Water Pump Pulley and
Alternator
1) Install crankshaft pulley.
Fit keyway on pulley to key of crankshaft
timing belt pulley, and tighten 4 bolts to
specification, with flywheel holder (special
tool 09924-17810) hitched to flywheel so
that crankshaft will not turn.
Tightening torque N.mkg-mlb-ft
for pulley boltslo- 13 1.3 7.5-9.0*
Direction of crankshaft1. Drive side of belt
Fig. 3-6-50 Installing timing belt
3-50

-1. Key
‘32. Crankshaft pulley3. Pulley bolt
Fig. 3-6-52 Installing crankshaft pulley
2) Install alternator assembly.
Tighten alternator ass’y securing bolts (3pcs)
only to the extent to allow alternator to be
moved by hand. Don’t torque them tight.
NOTE:
Adjust water pump belt tension to specification
upon completion of installing engine ass’y to
body and then cooling fan and water pump
pulley. Make sure to refer to p. 1-5 of this
manual for adjusting procedure.
Distributor Case
1) Install distributor case O-ring to cylinder
head.
2) Install distributor case.
3) Tighten bolts to specified torque.
Tightening torque N.mkg-mlb-ft
forcasebolts8-120.8-1.26.0-8.5
Fig. 3-6-53
Fuel Pump
Install fuel pump rod, gasket and fuel pump to
cylinder head.
Apply engine oil to rod @ before installation.
Use new gasket.
Fig. 3-6-54 Fuel pump rod installation
case with about 3Occ (1.02/1.05 US/Imp
3-51

Clutch Disc and Cover?
Install clutch disc and cover.
For installation, refer to p. 11-7 of SECTION 11
CLUTCH in this manual and torque each bolt to
specification.
Transmission Assembly
1) Check to make sure that 2 pins @ are
fitted to cylinder block.
Fig. 3-6-55
2) Attach transmission assembly to engine
cylinder block and tighten bolts and nuts to
specified torque.
Tightening torque ~.mkg-mI b-ftfor transmission,.aSe bolts an,-j nutS22 - 352.2 - 3.5 16.0-25.0
Distributor
1) Install distributor to case.
For installation, besure to refer to SECTION
8 IGNITION SYSTEM in this manual.
Valve Lash (Clearance) Adjustment
Adjust valve lash of all intake and exhaust
valves to specification, referring to description
on valve lash on p. 3-53 of this manual.
Cylinder Head Cover
Install cover to cylinder head and tighten
bolts to specified torque.
NOTE:
Check and adjust ignition timing with engine
installed to car body and after installing and
connecting all necessary parts. For procedure,
refer to p. 8-9 of SECTION 8 IGNITION SYS-
TEM in this manual.
3-52

3-7. ENGINE INSTALLATION
1) Lower engine with transmission into vehicle,
but do not remove lifting device.
2) Tighten engine mounting bracket bolts
(right and left) and transmission mounting
bolts to specification. Refer to p. 3-58.
3) Remove lifting device.
4) Reverse removal procedures for installation
of remainder.
5) Adjust accelerator cable play and clutch
cable play.
6) Connect vacuum hoses securely. Refer to
section 5 “EMISSION CONTROL SYSTEM”
for correct connection.
7) Connect wire harnesses and couplers secure-
IY.
8) Tighten bolts and nuts to specified torque.
For individual specification, refer to each
section.
9) Fill specified amount of specified trans-
mission oil and engine oil. For the detail,
refer to SECTION 1 PERIODIC MAINTE-
NANCE SERVICE of this manual.
10) After adjusting water pump belt tension to
specification, fill specified amount of engine
cooling water.
11) Before starting engine, check again to ensure
that all parts once disassembled or discon-
nected are back in place securely.
12)Start engine and check ignition timing. If
it is not to specified timing, adjust it, referr-
ing to SECTION 8 of this manual.
13) After engine is started, check for oil leak,
abnormal noise and other malcondition.
Also, check each part for operation.
3-8. ENGINE MAINTENANCE SERVICE
Fan Belt
Adjust belt tension as outlined in SECTION 6
ENGINE COOLING SYSTEM (p. 6-10).
Ignition Timing
Refer to IGNITION TIMING, Page 8-9.
Carburetor
fidjustments to be made are detailed in SEC-
TION 4 (p. 4-19).
Valve Lash (Clearance)
Valve lash specifications:
Valve lash refers to gap between rocker arm
adjusting screw and valve stem. Use a thickness
gauge to measure this gap @.
When coldWhen hot(Coolant tempe-(Coolant tempa-
Valve lashrature is 15 - 25%rature is 60 - 66’C
(gap A)or 69 - 77’F)or 140 - 154’F)
specif i-0.13 - 0.17 mm0.23 - 0.27 mmcationIntake(0.0051 - 0.0067 in) (0.009 - 0.011 in)
Exhaust0.16 -0.20 mm0.26 - 0.30 mm(0.0063 - 0.0079 in) (0.0102 - 0.0116 in)
Screw lock nut 15 - 19 N.m(1.5 - 1.9 kg-m, 11 .O - 13.5 lb-ft)
Adjusting screw
8
Valve stem
Fig. 3-8-l
Checking and adjusting procedures:
NOTE:
l Refer to Fig. 3-3-11 of SECTION 3 for
cylinder numbers (No. 1, No. 2, No. 3 and
No. 4) mentioned in this section.
l When adjustment becomes necessary in step
4), loosen adjusting screw lock nut and then
make adjustment by turning adjusting screw.
After adjustment, tighten lock nut to specifi-
ed torque while holding adjusting screw
stationary with straight headed screwdriver,
and then make sure again that gap @ is
within specification.
3-53

1) Remove cylinder head cover.
2) Remove ignitiontiming check window
rubber plug from clutch housing of trans-
mission case.
3)Turn crankshaft clockwise (viewing from
crankshaft pulley side) to the extent that
line @above “T” mark punched on fly-
wheel is aligned with match mark @ on
transmission case as shown below, i.e. No. 1
cylinder piston reaches TDC position.
Fig. 3-8-2 1. Match mark2. ‘7” (TDC) mark
4) Remove distributor cap and check that rotor
is positioned as shown in figure. If rotor is
out of place, turn crankshaft clockwise
once (360”). In this state, check valve lashes
at valves @,@I, @and 0. Rotate cran kshaft
exactly one turn, and check the same at
valves 8, @, @ and @I.
Fig. 3-8-3
EX
Fig. 3-8-4-
Fig. 3-8-5 Measuring valve lashes
5) Upon completion of check and adjustment,
install cylinder head cover and torque bolts
to specification.
Tightening torque N.,.,.,
for cylinder head Ib-mlb-ft
cover bolts4-50.4 - 0.53.0 - 3.5*
6) Install distributor cap and connect blow-by
gas hose to cylinder head cover.
Camshaft Timing Belt
For checking procedures of damage, wear and
tension of camshaft timing belt, refer to SEC-
TION 1 (p. 1-5) of this manual.
Engine Oil
Refer to SECTION 1 (p. I-7) of this manual.
Engine Oil Filter
For removal and installation of filter, refer to
SECTION 1 (p. I-7) of this manual.
3-54

Engine Coolant
This subject is covered in SECTION 6 ENGINE
COOLING SYSTEM.
Exhaust Line and Muffler
Inspect each exhaust line connection for tight-
ness, and examine muffler and other parts for
evidence of breakage and leakage of gases.
Repair or replace defective parts, if any.
Compression Pressure Measurement
Check compression pressure on all four cylinders
as follows:
1) Warm up engine.
2) Stop engine after warming up.
3) Remove all spark plugs and disconnect
high tension cord from ignition coil.
4) Install compression gauge (special tool) into
spark plug hole.
5) Disengage clutch (to lighten starting load on
engine), and depress accelerator pedal all
the way to make throttle full-open.
6) Crank engine with fully charged battery, and
read the highest pressure on compression
gauge.
Standard
Limit
Max. difference
between any two
cylinders
Compression pressure
14.0 kg/cm2 (199.0 psi)
400 r/min
12.0 kg/cm2 (170.0 psi)
400 r/min
1 .O kg/cm2 (14.2 psi),
400 r/min
3
7) Carry out steps 4) through 6) on each cylin-
der to obtain four readings.
NOTE:
Compression pressure value is measured by using
compression gauge (Special tool 09915-64510).
Oil Pump Discharge Pressure Measurement
NOTE:
Prior to checking oil pressure, check the follow-
ing.
l Oil level in oil pan.
If level is low, add oil up to Full level hole on
oil level gauge.
0 Oil quality.
If oil is discolored, or deteriorated, change oil.
For particular oil to be used, refer to table on
p l-8 of SECTION 1.
l Oil leak.
If leak is found, repair it
1. Compression gauge (Special tool 09915-64510)
Fig. 3-8-7 Installing compression gauge
3-55