1987 SUZUKI GRAND VITARA Service Repair Manual

I
Generator (Pickup
coil) resistance130 - 190 ohmsI
1
1. White wire2. Red wire
Fig. 8-14
5. After checking, connect red and white wires
to ignitor as shown in Figure 8-15, and then
install dust cover.
NOTE:
NEVER connect red and white wires reversely.
Reverse connection may cause damage to
generator and ignitor.
1. White wire2. Red wire
3. lgnitor
4. Generator
Fig. 8-15
6. After generator has been assembled on
distributor, make sure to adjust air gap and
install ignitor.
7. Install distributor referring to page 8-11.
[ Ignitorl
1. Disconnect negative cable at battery. Remove
distributor, and then ignitor and generator.
2. Remove dust cover from ignitor.
3. Disconnect red and white wires from ignitor.
4. Connect an ohmmeter, a bulb and 12 voltage
battery to ignitor as shown in Figure 8-16.
Set ohmmeter at 1 ohm to 10 ohm range.
Then bring ohmmeter negative @ prod to
touch red wire terminal of ignitor, and
positive @ prod to touch white wire terminal.
If bulb is illuminated, it indicates that ignitor
is satisfactory. If not, replace ignitor.
NOTE:
l Never connect battery positive and negative
wires reversely. Reverse connection may cause
damage to ignitior.
l Under no circumstances should ohmmeter be
connected reversely.
l Be sure to perform this ohmmeter check
within a short time (two to three seconds).
1
1. lgnitor5.Negative prod9.Black/Whitewire
2. Bulb6.Red wire terminal10.Brown wire
3. Ohmmeter7.Positive prod11.Earth
4. Battery (12V)8.White wire terminal
Fig. 8-16
c---------~
Bulb
T_-.
ITester (+) PIUSL------------
Fig. 8-17
8-7

5. After checking, connect red and white wires
of generator to ignitor and install dust cover
on ignitor.
Refer to Fig. 8-15 for proper connection of
red and white wires.
6. After the generator and ignitor have been
assembled on the distributor, make sure to
adjust the air gap.
7. Install distributor referring to page 8-11.
[Distributor driven gear]
Inspect gear teeth for wear, and see if the
backlash is normal or not. Excessive backlash
can be told by turning the shaft back and forth,
with its driven gear in mesh with driving gear.
Maladjusted ignition timing is often due to
excessive tooth wear in this gearing and, in such
a case, can be corrected by replacing driven gear.
Fig. 8-18
To replace driven gear, grind off both caulk-
ed ends of driven gear set pin with grinder and
drive it off. After fitting new gear, make sure to
use a new pin and caulk its both ends.
Fig. 8- 191. Driven gear set pin
8-8

Ignition Timing
Ignition timing10” BTDC at
800 * 50 r/min
1 Ignition orderIl-3-4-2I
When checking and adjusting ignition timing,
be sure to use timing light (09900-27301 or
09900-27311).
NOTE:
Prior to check and adjustment of ignition timing,
make sure that head lights, heater fan, rear
defogger (if equipped), and air conditioner (if
equipped) are “OFF”. If any one of these
systems is “ON”,idle up system operates and
engine idle speed will be out of the specification.
[Checking]
1. Remove rubber plug from timing check
window on the transmission case.
2. Start engine and warm it up to normal operat-
ing temperature.
3. After warming up, check to be sure that idle
speed is within specification. If idle speed is
out of specification, adjust it by turning
idle speed adjusting screw of carburetor.
4. Connect timing light to high tension cord of
No. 1 cylinder.
5. With engine running at specified idle speed,
direct the timing light to timing check win-
dow. If 10” BTDC timing mark@on flywheel
appears aligned to timing match mark @ ,
ignition is properly timed.
Fig. 8-20
[Adjusting]
lf ignition timing is out of specification, adjust
it.
Loosen distributor flange bolt and turn distri-
butor housing in place to advance or retard
timing.
Turning housing counterclockwise advances
timing, and vice versa. After adjustment, tighten
flange bolt and recheck timing.
Fig. 8-21
1. Distributor flange bolt
2. Timing is retarded
3. Timing is advanced
Be sure to re-install check window rubber plug
after making above check and adjustment.
WARNING:
When engine is warmed up, exhaust mani-
fold cover and other parts are hot as well.
Be careful not to touch them when remov-
ing and reinstalling rubber plug.
[Checking centrifugal advancer]
After removing distributor cap, turn rotor
clockwise by finger and release it
Check that rotor returns smoothly counterclock-
wise by spring force.
If defective, replace distributor.
Fig. 8-22
8-9

[Checking vacuum advancer]
Remove distributor cap.
Disconnect vacuum hose from vacuum hose 3
way joint, and connect vacuum pump gauge
(0991747910) to its hose. Apply vacuum (ab-
out 400 mmHg). And then with pump stopped,
check to ensure that vacuum pump gauge
indicator remains at the same level, and release
it. Check that generator base plate with gene-
rator moves smoothly. If plate does not move
smoothly, replace defective parts.
Fig. 8-24
1. Distributor drive gear
2. Camshaft3. Cylinder head
Fig. 8-23
@I Vacuum pump gauge (a991 7-47910)
1. Generator base plate
2. Vacuum controller
Distributor Drive Gear
NOTE:
When removing distributor gear case from cylin-
der head, engine oil in cylinder head may come
out. So place waste or receiver under gear case
when removing.
Inspect drive gear for wear.
Worn gear is likely to disturb ignition timing
and therefore must be replaced.
Replacing worn-down drive gear is not enough.
Inspect driven gear (a part of the distributor
assembly), too, and replace it if badly worn
down.
[Important reminders for removal and installa-
tion]
Before removing drive gear from camshaft,
scribe a match mark on this shaft to root
center line of drive gear as shown in Fig.
B-25 and, when mounting replacement drive
gear, refer to this mark.
When pressing replacement drive gear onto
camshaft, be sure to position gear angularly
as shown in Fig. B-25. (align mark on Cam-
shaft scribed in removal with root center of
drive gear)
NOTE:
There is no need to discriminate between two
end faces of drive gear.
Distributor side view
1. Drive gear
2. Camshaft
3. Center line of
45mmhole
4. Center line ofroot5. @5mm hole(Provided on pulleyside of camshaft)
6. Scribed matchmark
7. 5O
Fig. 8-25
l About 30 cc(1.01/l .05 US/Imp 02) of
engine oil must be fed into distributor gear
case after servicing this case, that is, removing
and putting it back. Be sure to add this much
oil before starting engine for the first time
after servicing.
8-11

8-3. IMPORTANT REMINDERS FOR
INSTALLATIONDistributor
When re-installing distributor, be sure to insertit into distributor gear case in the following
sequence:
1. Turn over crankshaft in normal direction (clockwise as viewed from crankshaft pulley
side) until specified timing mark @on flywheel aligns with timing match mark
0.
CAUTION :
After aligning two marks, remove cylinder
head cover to visually confirm that rocker
arms are not riding on camshaft cams at
No. 1 cylinder. If arms are found to be
riding on cams, turn over crankshaft 360”
to align two marks anew.
lO’(B.T.D.C.1timing mark
mark
Fig.
2. Remove distributor cap, and turn rotor to make center of rotor align with cap clamp
center on distributor housing as shown in
figure.
1. Rotor
Fig. 8-27 3. Center of rotor
2. Housing and clamp
3. Insert distributor into gear case in such a way that center of distributor flange will coincide
with the distributor mounting screw holeprovided in distributor gear case. When distributor is inserted properly, position of
distributor rotor becomes as shown in figure.
Secure distributor in place tentatively by
making mounting screw finger-tight.
Fig. 8-28 1. Distributor flange 3. Rotor
2. Mounting screw
4. Install cap gasket and distributor cap to
distributor. Hook 2 clamps securely.
5. Distribute cords as shown in figure. Securely
connect cords to distributor cap terminals and
spark plugs.
NOTE:
Make sure to clamp high tension cords so that
they do not contact other parts.
1. No. 1 cylinder 3. No. 3 cylinder
2. No. 2 cylinder 4. No. 4 cylinder
Fig. 8-29 High tension cords distribution
6. Connect vacuum hose to vacuum controller,
and coupler of lead wires.
7. Connect negative cable at battery.
8. Start engine and adjust ignition timing by
using timing light as previously outlined.
After adjustment, tighten distributor flange
bolt.
8-11

SECTION 9
CRANKING SYSTEM
GENERAL DESCRIPTION.,.....,...........................,9-2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
LUBRICATION9-5
9-1.
9-2.
9-3.
9-4.
9-5.
REMOVAL AND INSTALLATION.............................9-5
DISASSEMBLY............................................ 9-6
STARTING MOTOR INSPECTION.............................9-7
COMMUTATOR...........................................9-7
FIELD COIL............................................. 9-8
9-7.
9-8.
CONTENTS
BRUSH................................................. 9-8
BRUSH HOLDER AND SPRING............................... 9-9
DRIVE LEVER........................................... 9-9
PINION................................................. 9-9
ARMATURE SHAFT BUSH.................................. 9-9
MAGNETIC SWITCH......................................9-10
PERFORMANCE TEST.....................................9-11
PULL-IN TEST...........................................9-11
HOLD-IN TEST..........................................9-11
PLUNGER RETURN......................................9-11
PERFORMANCE TEST....................................9-11
CLUTCH SWITCH........................................ 9-12
9
9-6.
9-1

9-1. GENERAL DESCRIPTION
To distributorMagnetic switch
Pull in coil
Hold in coil
I I
Magnetic switch contacts
Plungerhclutch. . . ..i+rh
Pin
h n
Pinion 84 Over running
clutchStarting motor
Fig. 9 1 Cranking circuit
CRANKING CIRCUIT
The cranking circuit consists of the battery, starting motor, ignition switch, clutch switch and related
electrical wiring. These components are connected electrically as shown in Fig. 9-l. Only the starting
motor will be covered in this portion.
STARTING MOTOR
The starting motor consists of parts shown in Fig. 9-2 and has field coils mounted in starting motor yoke
(frame).
The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they
will be protected against possible dirt and water splash.
In the circuit shown in Fig. 9-1, the magnetic (motor) switch coils are magnetized when the ignition
switch is closed. The resulting plunger and pinion drive lever movement causes the pinion to engage the
engine flywheel gear and the magnetic switch main contacts to close, and cranking takes place. When the
engine starts, the pinion overrunning clutch protects the armature from excessive speed until the switch
is opened, at which time the return spring causes the pinion to disengage.
9-2

BAa7
1 IId916156
1. Drive housing cover
2.Drive bushing3.Drive housing
4.Armature ring
5. Armature stop ring6.Over-running clutch7. Pinion drive lever
8.Magnetic switch
9. Commutator end cover10.Brush spring11.Brush holder12.Brush
13.Washer
14. Commutator end bushing18.Armature
16. Starting motor yoke
A : Hold-in coilB : Pull-in coil
9-3