1987 SUZUKI GRAND VITARA Service Repair Manual

2-14. SPEEDOMETER
IConditionIPossible causeICorrection
Faulty indication1. Damaged speedometer drive or driven gear
2. Defective drive cable
3. Drive cable incompletely or imporperly
tied into the meter
4. Defective speedometer
Replace
Replace
Set right
Replace
Speedometer noise1. Inadequately lubricated or defective cable
2. Not enough oil in transfer
Lubricate or replace
Replenish
2-15. WATER TEMPERATURE METER
Condition
Faulty indication
No indication
Possible cause
1. Incomplete metal-to-metal contact in
terminal connections
2. Receiver gauge defective (due to burnt
point or deformed bimetal element)
3. Defective temperature gauge
1. Open-circuit
2. Defective receiver gauge (open-circuited
heat wire, deformed bimetal element or
pointer)
Repair
Replace
3. Defective temperature gaugeReplace
Correction
Repair and tighten
Replace
Replace
2-19

3-1.
3-2.
3-3.
3-5.
3-6.
3-7.
3-8.
3-9.
SECTION 3
ENGINE
CONTENTS
GENERAL DESCRIPTION.................................... 3-2
ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL...... 3-5
ENGINE REMOVAL.......................................3-6
ENGINE DISASSEMBLY.................................. 3-9
INSPECTION OF ENGINE COMPONENTS....................3-17
ENGINE REASSEMBLY...................................3-35
ENGINE INSTALLATION.................................3-53
ENGINE MAINTENANCE SERVICE.........................3-53
RECOMMENDED TORQUE SPECIFICATIONS.................3-58
3-4.
3-1
3

3-1. GENERAL DESCRIPTION
1) Engine
The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its S.O.H.C (Single
overhead camshaft) valve mechanism arranged for “V’‘-type valve configuration.
This single overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through
timing belt, and no push rods are provided in the valve train system.
Fig. 3- I- 1
3-2

2) Engine Lubrication
The oil pump is of a trochoid type, and mounted on the crankshaft at the crankshaft pulley side.
Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
In one path, oil reaches the crankshaft journal bearings.
Oil from the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersect-
ing passages drilled in the crankshaft, and then injected from a small hole provided on the big end of
connecting rod to lubricate piston, rings, and cylinder wall.
In another path, oil goes up to the cylinder head and lubricates rocker arms, valves and camshaft, etc.,
after passing through the internal oilway of rocker arm shafts.
An oil relief valve is provided on the oil pump. This valve starts relieving oil pressure when the pressure
comes over about 3.0 kg/cm2 (42.7 psi, 300 kPa). Relieved oil drains back to the oil pan.
Fig. 3- 1-2
3-3

3) Cylinder Head and Valve Train
The cylinder head is made of cast aluminum alloy and has four combustion chambers arranged in-line.
Each combustion chamber has an intake and an exhaust ports.
Moreover, as shown in Figure 3-l-3, the air induction nozzle is provided near each intake valve. During
intake stroke of the engine, air/fuel mixture enters into the combustion chamber from carburetor through
intake manifold and intake valve. At the same time, air flows to the air induction nozzle through carbure-
tor and air induction passage in the intake manifold, and jets into the combustion chamber.
The air jetted into the combustion chamber accelerates the mixture swirl to improve the combustion
efficiency.
A single overhead camshaft driven by the crankshaft through the timing belt is mounted on the cylinder
head. The camshaft has eight cams, and each cam operates the intake or exhaust valve through rocker arm.
The valve lash can be adjusted by turning the adjusting screw on the rocker arm after loosening the lock
nut.
2-
1.Intake valve2.Exhaust valve
3.Rocker arms
4.Camshaft
6.Air induction nozzle
6.Air induction passage
7.Intake manifold
a.Carburetor
-. - _- - ._ . . . . .Fig. 3- 7-3 Cylinder head and valve train
4) Cylinder Block
The cylinder block is made of cast aluminum alloy and has 4 cylinders arranged “In-Line”. A cylindrical
cast iron sleeve is installed in each cylinder.
5) Crankshaft and Main Bearings
A monoblock casting crankshaft is supported by 5 main bearings which are of precision insert type. Four
crank pins on the crankshaft are positioned 180” apart.
6) Pistons, Rings, Piston Pins and Connecting Rods
The piston is cast aluminum alloy, and has two compression rings and one oil ring.
Among two compression rings (top and 2nd rings), the top ring is plated with hard chromium for improve-
ment in abrasion resistance.
The oil ring consists of two rails and one spacer.
The piston pin is offset. 0.5 mm towards the major thrust side. This allows a gradual change in thrust
pressure against the cylinder wall as the piston travels its path. Pins are chromium steel and have a floating
fit in the pistons. They are retained in the connecting rods by a press fit. The connecting rods are made of
forged steel, and the rod bearings are of precision insert type.
3-4

3-2. ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL
The following parts of components do not require engine removal to receive services (replacement, inspec-
tion or adjustment):
Part or ComponentNature of Service1
1. Spark plug
2. Distributor
Replacement or inspection
Replacement, inspection or adjustment
1 3. Exhaust manifold1 Replacement or inspectionI
I 4. Oil filter1 ReplacementI
1 5. Oil pressure unit( Replacement
6. Cylinder head cover1 ReplacementI
I7. Rocker shaft1 Replacement or inspectionI
8. Rocker-arm
9. Rocker-arm spring
Replacement or inspection
Replacement or inspectionI
10. Cam shaft
11 Cylinder head
I12. Radiator
Replacement or inspection (Cylinder head removal required)
Replacement or inspection
Replacement or inspection (Cooling fan and fan shroud
removal required)I
13. Cooling fan
14. Camshaft timing belt pulley
Replacement
Replacement or inspection
I
15. Crankshaft timing belt pulley
16. Timing beltReplacement or inspection (Cooling fan and fan shroud
1 Replacement or inspection
removal required)
17. Fuel pump
18. Carburetor
Replacement
Replacement, inspection or adiustment
19. Intake manifold1 ReplacementI
20. Alternator
21. Starter motor
Replacement or inspection
22. Fan belt
23. Water pump
Replacement, inspection or tension adjustment
Replacement (Cooling fan and fan shroud removal required)
24.Pulleys (crank, generator, fan)Replacement
25. Timing belt cover)Replacement (Cooling fan and fan shroud removal required)
26. Water hose
27. Oil pan, oil strainer, and oil pump
Replacement or inspection
Replacement or inspection
28. Piston and connecting rodReplacement or inspection (Cylinder head and oil pan
removal required)
Replacement or inspection
3-5

3-3. ENGINE REMOVAL
1) Disconnect negative (-) and positive (+)
cords from battery terminals.
‘)From starter motor terminals, disconnect
black/yellow lead wire and positive (+)
battery cord.
Disconnect coupler and white lead wire
from alternator terminals.
Disconnect lead wires from water tempera-
ture gauge and thermal switch. The gauge
and switch are on intake manifold.
Disconnect earth lead wire from intake
manifold.
5) Disconnect couplers of carburetor fuel cut
solenoid valve, vent solenoid valve and
mixture control solenoid valve, and dis-
connect couplers from TWSVS and VSV.
6) Remove warm air hose.
) Disconnect breather hose from air cleaner
case.
,) Remove air intake case from carburetor
body and air inlet hose.
1) Disconnect accelerator cable from carbure-
tor.
10) Disconnect vacuum hoses of TCAC and
canister from intake manifold.
11) Remove fuel tank filler cap to release fuel
vapor pressure in fuel tank. After releasing,
reinstall it. Disconnect fuel feed and return
hoses from fuel pump.
12) Disconnect lead wire from oil pressure unit
terminal and oxygen sensor lead wire at the
coupler.
13) Disconnect lead wires of back-up light
switch and fifth switch at their couplers.
14) Disconnect distributor lead wire at the
coupler.
15) Pull off high-tension cord from ignition coil.
16) Loosen radiator drain plug to drain cooling
water,
17) Disconnect water hoses from thermostat
cap and water inlet pipe. After removing
cooling fan & clutch and fan shroud, remove
radiator.
Fig. 3-3- 1
Fig. 3-3-2
16) Disconnect heater hoses from heater unit
outlet pipe and intake manifold.
Fig. 3-3-3
3)
4)
3-6

19) Disconnect brake booster vacuum hose from
pipe.
20) Disconnect coupler of lead wire (black) from distributor gear case.
21) Remove 4 bolts fastening gear shift lever boot No. 2 and move the boot upward.Fig. 3-3-4
22) Move gear shift lever boot No. 1 to upperside of shift lever.
23) Loosen 3 bolts tightening gear shift lever case cover and take shift lever out of lever
case.
26) Disconnect clutch cable from engine mount- ing bracket and clutch release lever.
27) Loosen drain plug to drain transmission oil.
28) Remove propeller shaft interconnecting transmission case and transfer case.
29) By using a chain block, hold engine so that the engine is kept from falling.
NOTE:
engine at two hooks provided, one on
inlet-
manifold side and the other on exhaust-mani-
fold side.
30) Remove exhaust center pipe mounting bracket and 4 transmission mounting bolts.
Fig. 3-3-6
31) Remove the pipe connected to chassis
under the transmission case.
Fig. 3-3-5
24) Raise vehicle.25) Sever exhaust manifold from muffler by undoing joint.
Fig. 3-3-7
3-7