1987 SUZUKI GRAND VITARA Service Repair Manual

32) Lower vehicle and remove 4 bolts securing
right and left engine mounting brackets(body side).
Fig. 3-3-10
Fig. 3-3-8
CAUTION:Before lifting engine and transmission,
recheck to ascertain all hoses, electric wires
and cables are disconnected from engine
and transmission.
34) Remove clutch lower plate.
35) Separate transmission from engine.
Throughout this MANUAL, 4 cylinders ofengine are identified by numbers: No. 1, No. 2, No. 3 and No. 4 as counted from front end.
33) Take down engine by operating a hoisting
means.
Fig. 3-3-11
Fig. 3-3-9
3-8

3-4. ENGINE DISASSEMBLY
NOTE:
3) Remove distributor assembly.
l Observe critically before starting to remove a
component or part by loosening bolts, nuts
and the like. What you may find before and
during disassembly is valuable information
necessary for sucessful reassembly.
l Be careful in .handling aluminum-alloy parts.
They are softer than steel or cast-iron parts
and their finished surfaces more easily- take
scratch marks.
l Have trays and pans ready for setting aside
disassembled parts in an orderly manner.
Place parts in trays and pans in such a way_.
that they can be readily identified. Put matchFig. 3-4-3
marks or tags on them, as necessary, so that
they will go back to where they came from.
4) Remove the fuel pump and rod.
Carry out engine disassembly in the following
NOTE:
sequence :When removing pump and distributor gear case,
1) Loosen drain plug and drain out engine oil.place waste or receiver under gear casa.
Fig. 3-4-4Fig. 3-4- 1
2) Remove clutch cover and clutch disc. 5) Take down distributor case.
Fig. 3-4-2 (A) Flywheel holder (Special tool09924-
17810) Fig. 3-4-5

6) Take down alternator and water pump
pulley.
Fig. 3-4,9 (A) Flywheel holder (Special tool
09924-17810)
Fig. 3-4-6
8) Remove outside cover on timing belt.
Fig. 3-4-7
7) Remove crankshaft pulley by removing 49) Loosen tensioner bolt and stud, and remove
pulley bolts, with special tool (A) hitched tobelt from crank timing belt pulley and cam-
flywheel so that crankshaft will not turn.shaft pulley after pushing up tensioner
The crank timing belt pulley bolt at theplate fully by finger as shown in Figure
center needs not to be loosened.3-4-l 1.
1.Crankshaft pulley
Fig. 3-4-8
2. Crankshaft pulley bolt
3.Crank timing belt pulley bolt
Fig. 3-4- 10
1.Timing belt2.Tensioner plate
3.Tensioner boltFig.3-4-114.Tensioner stud
3-10

10) Remove timing belt tensioner, tensioner
plate, and tensioner spring.
11) Remove camshaft timing belt pulley by lock-
ing camshaft (insert general rod into the cam-
shaft hole) as shown below.
13) Remove crankshaft timing belt pulley key.
14) Remove timing belt inside cover.
Fig. 3-4- 14
15) Remove water pump.
1.Wrench2.Camshaft timing belt pulley
3. Timing belt inside cover4.Generalrod
Fig.3412
12) Using flywheel holder (A) (Special tool),
remove crankshaft timing belt pulley bolt,
pulley and timing belt guide with crank-
shaft locked.
Fig. 3-4- 15
16) Remove exhaust manifold cover.
17) Take off exhaust manifold and its gasket.
Fig. 3-4-13
1.Crankshaft timing belt pulley2. Pulley bolt3. Timing belt guide
Fig. 3-4- 16
3-11

18) Using special tool (C), remove oil filter.
NOTE:
Be careful not to spill oil when removing filter.
22) Remove water inlet pipe.
Fig. 3-4- 17 (C) Oil filter wrench (099 15-473 10)
19) Draw water hoses off water pump inlet pipe.
Fig. 3-4-2 1
Fig. 3-4- 18
20) Disconnect PCV (Positive crankcase venti-
lation valve) hose from cylinder head cover.
21) Take down intake manifold with carburetor.
Fig. 3-4120
23) Take off cylinder head cover.
24) Loosen 8 valve adjusting screws fully. Leave
screws in place.
Fig. 3-4-22
3-12

25) Loosen rocker arm shaft securing screws
(10 PCS).
Fig. 3-4-23
26) While drawing out rocker arm shaft, separate
valve rocker arms and rocker arm springs.
Fig. 3-4-24
27) Draw camshaft out toward rear end (trans-
mission case side).
28) Remove cylinder head.
____Fig. 3-4-26
a) Use valve lifter (D), (E) to compress valve
spring in order to free valve cotter pieces
for removal. In this way, remove valve
spring and valves.
(D) Valve lifter(Special tool 09916-14510)
(El Valve lifter attachment
Fig. 3-4-27(Special tool 0991648210)
Fig. 3-4-25
3-13

b) Remove valve stem oil seal from valve guide,
and then valve spring seat.
NOTE:
Do not reuse oil seal once disassembled. Besure to use new oil seal when assembling.
1. Valve stem oil seal
2. Blade screw driver
Fig. 3-4-283. Valve spring seat
c) Using special tool (F), drive valve guide out from combustion chamber side to valve
spring side (Figure 3-4-29).
NOTE:
Do not reuse valve guide once disassembled.
Be sure to use new valve guide (Oversize) when
assembling.
NOTE:
Place disassembled parts except valve stem seal
and valve guide in order, so that they can be
installed in their original positions.
29) Remove flywheel, using special tool (A)
as shown.
Fig. 3-4-30 (A) Flywheel holder (Special tool
09924- 17810)
30) Remove oil level gauge guide from oil pump.
Fig. 3-4-3 1 (F)
Valve guide remover (Special tool
09916-44511)
Fig. 3-4-29
3-14

31) Take down oil pan.Fig. 3-4-32
32) Remove oil pump strainer.
Fig. 3-4-33
33) Remove connecting rod bearing caps. 34) Install guide hose over threads of rod bolts.
This is to prevent damage to bearing journal
and cylinder wall when removing connecting
rod.
Fig. 3-4-35
1. Guide hoses
35) Decarbon top of cylinder bore, before removing piston from cylinder.
36) Push piston and connecting rod assembly out through the top of cylinder bore.
CAUTION:
l Before pulling piston out, scribe cylinder
number on its crown.
l Be sure to identify each bearing cap for
its connecting rod by using cylinder
number. Set cap and rod aside in combi-
nation.
1
a) Using piston ring expander, remove two
compression rings (Top and 2nd) and oilring from piston.
b) Remove piston pin from connecting rod.
Fit piston and connecting rod assembly to
special tool (Fig.
3-4-36), and then press
piston pin out of connecting rod by using
arbor press (Fig. 3-4-37).
Fig. 3-4-34
3-15