Suzuka Grandee Vitara
The general information
Maintenance service and greasing
Heater, ventilation and the conditioner
Steering
Suspension bracket
Wheels and tyres
Forward приводной a shaft shaft/bearing. An oil epiploon
Kardannye shaft
Brake system
- Engines
   - Mechanical part of engine G16
       The general description
      - Routine maintenance
         Compression check
         Check of depression of the engine
         Check of pressure of oil
         Klapannyj backlash
         Filtering element of the air filter
         Cover of a head of cylinders
         The case throttle заслонок and an inlet collector
         Collector of the fulfilled gases
         Drive belt газораспределительного the mechanism and the tension device for a belt
         Маслосборник and a grid of the oil pump
         The oil pump
         Коромысло the valve, an axis коромысел and a cam-shaft
         Valves and head of the block of cylinders
       Piston rod, piston rings, rods and cylinders
      The special tool
      Necessary service materials
      Technical characteristics of the rotating moment of an inhaling
    Mechanical part of engine J20
    Engine cooling
Fuel system
Ignition system
Start system
Release system
Transmissions
Coupling
Transfer
Forward and back differentials
Windows, mirrors, locks and security measures. An immobilizer
Electric equipment





Valves and head of the block of cylinders

1 — valve checks
2 — the holder of a spring of the valve
3 — a valve spring
4 — consolidation of a core of the valve
5 — a cup клапанной springs
6 — the exhaust valve

7 — the inlet valve
8 — a head bolt цилиндра*
9 — a head цилиндра*
10 — a pin
11 — an oil nozzle
12 — the directing plug of the valve


*8) Address to item 3 of procedure of installation.

*9) the Mark "Top" specified on a lining, goes from outside a pulley коленвала a face sheet upwards.

The rotating moment of an inhaling

Not to use repeatedly.

Grease with engine oil a sliding surface of each part.

Removal

 PERFORMANCE ORDER

  1. Dump pressure of fuel.
  2. Disconnect a negative cable from the accumulator.
  3. Drain cooling system.
  • Be convinced of that temperature of antifreeze of the engine low before to remove any parts of system of cooling.
  • Also make sure that the negative cable is disconnected from the accumulator before to remove any parts.

  1. Remove an element of rigidity of an inlet collector (1).
  1. Remove воздухозаборный a sleeve.
      • Disconnect following electric wires, and then release plaits of wires from clips.
      • The gauge of position throttle заслонки
      • The regulating pneumovalve of idling
      • The gauge of temperature of a cooling liquid of the engine
      • The gauge of position of a cam-shaft
      • Wires of grounding from an inlet collector
      • The system valve рециркуляции the fulfilled gases
      • The gauge of pressure of differential of a collector
      • The gate for release of not condensing gases
      • Wires of an atomizer at муфты
      • The gauge of heating of oxygen-1
  1. Disconnect following hoses:
      • Hose for release of not condensing gases from the gate for release of not condensing gases
      • Hose of the amplifier of brakes from an inlet collector
      • Hose of antifreeze of the engine (the target party) from the case throttle заслонок
      • Inlet hose of a radiator from a thermostat cover
      • Inlet hose of a heater from a pipe
      • Hose of giving of fuel and returnable hose from each pipe
      • Vacuum hose from an inlet collector
  1. Disconnect a rope of an accelerator and a cable of a drive throttle заслонок А/Т (if that is available) from the case throttle заслонок.
  1. Uncover cylinder heads, having addressed to Section the Cover of a head of cylinders in this Chapter.
  1. Completely unscrew all screws regulating клапанный a backlash.
  1. Remove a drive belt газораспределительного the mechanism and a cam-shaft, having addressed to Sections a drive Belt газораспределительного the mechanism and the tension device for a belt and Koromyslo of the valve, an axis коромысел and a cam-shaft in this Chapter.
  1. Remove regulating lever of the generator from an inlet collector.
  2. Remove regulating lever of the compressor for an air conditioning from a cylinder head (if that is available).
  1. Disconnect an exhaust pipe №1 (1) from a collector of the fulfilled gases (2) and remove an element of rigidity of a collector of the fulfilled gases (3) or a bolt of an arm of an exhaust pipe.
  1. Untwist bolts of a head of the cylinder in an order specified in drawing more low, and take out them.
1 — the party of a pulley of a cam-shaft
2 — the party of the distributor of ignition
  1. Check up all round a cylinder head, whether there are still any details which are necessary for removing or disconnecting, remove or disconnect, all that is necessary.
  2. Remove a head of the cylinder with an inlet collector and a collector of the fulfilled gases by means of the elevating device.

Removal

 PERFORMANCE ORDER

  1. To simplify service of a head of cylinders, remove an inlet collector with the case throttle заслонок and a collector of the fulfilled gases from a head of cylinders.
  2. Remove коромысла and an axis коромысел, having addressed to Razdelu Koromyslo of the valve, an axis коромысел and a cam-shaft in this Chapter.
  1. By means of the special tool (the valve lift) compress клапанные springs and then remove checks of the valve (1), using the special tool (nippers).
The special tool
  • (): 09916-14510
  • (): 09916-14910
  • (): 09916-84511
  1. Release (open) the special tool and remove the holder of a spring and клапанную a spring.
  2. Remove the valve from outside combustion chambers.
  1. Remove oil consolidation of a core of the valve (1) from the directing plug of the valve and then a cup клапанной springs (2).

Do not use oil consolidation repeatedly after dismantle. At assemblage necessarily use new oil consolidation.


  1. By means of the special tool (a stripper of the directing plug of the valve) shift directing plug of the valve from outside combustion chambers on the party клапанной springs. The special tool (): 09916-44910.

Do not use directing plug of the valve repeatedly after dismantle. Necessarily use the new directing plug of the valve (the working size) at assemblage.

  1. Combine the disassembled parts, except for consolidation of a core of the valve and the directing plug of the valve, one after another, so that they could be established on their initial places.

Check

Directing plugs of the valve

 PERFORMANCE ORDER

  1. With the help a micromeasure and кругломера take readings of diameters of cores of valves and directing to check up a backlash between cores and directing.
  1. Do not forget to take readings from several places on all length of each core and directing. If the backlash falls outside the limits norm, replace the valve and directing plug of the valve.

Technical characteristics of the valve and the directing plug of the valve

Position

Norm

Limit

Diameter of a core of the valve

Admission

5.465 – 5.480 mm (0.2152 – 0.2157 inches)

Release

5.440 – 5.455 mm (0.2142 – 0.2147 inches)

Internal diameter of the directing plug of the valve

Admission

5.500 – 5.512 mm (0.2166 – 0.2170 inches)

Release

Backlash between a core and directing

Admission

0.020 – 0.047 mm (0.0008 – 0.0018 inches)

0.07 mm (0.0027 inches)

Release

0.045 – 0.072 mm (0.0018 – 0.0028 inches)

0.09 mm (0.0035 inches)


  1. If is not present кругломера available, instead check up deformation of the end of a core of the valve with the help циферблатного the indicator. Move the core end in directions (1) and (2) to measure end deformation. If deformation falls outside the limits norms, replace a core of the valve and directing plug of the valve.
    • Limit of deformation of the end of a core of the valve:
      • On an admission: 0.14 mm (0.005 inches)
      • On release: 0.18 mm (0.007 inches)

Valves

 PERFORMANCE ORDER

  1. Remove all deposit from valves.
  2. Check up each valve on deterioration presence, прожога or deformations on a forward surface and a core and if it is necessary, replace it.
  3. Measure a thickness of a head of the valve. If the measured thickness falls outside the limits norms, replace the valve.

Thickness of a head of the valve

 

Norm

Limit

On an admission

0.8 – 1.2 mm (0.032 – 0.047 inches)

0.6 mm (0.023 inches)

On release

0.7 mm (0.027 inches)


1 — a thickness of a head of the valve
2 — 45
  1. Check up an end face of a core of the valve on a subject изъязвления and deterioration. If deterioration or изъязвление is found out, the end face of a core of the valve can be cleared repeatedly, but is not strong, so that not сошлифовывать its chamber. If it is worn out so strongly that its chamber is erased, replace the valve.

Width of contact прилегания

  1. Create drawing of an arrangement of contacts on each valve in the habitual image, i.e., having put a standard covering a marking mix on a valve cup, and a rotary motion пристукнув a cup of the valve with a valve head. It is necessary to use клапанный притирочный the machine tool (the tool used for grinding in of valves).
  1. The drawing printed on a contact surface of the valve should represent a continuous ring without any breaks, and the width of drawing should be in the specified limits. The standard width of contact formed by means of drawing of an arrangement of contacts on an obverse surface of the valve: on an admission on release — 1.1 – 1.3 mm (0.0433 – 0.0511 inches).

Repair of a cup of the valve

  1. The cup of the valve not creating full contact to the valve or showing width of contact прилегания, leaving for the specified range, should be repaired by repolishing or cutting and repolishing, and is ground to readiness by grinding in.
  1. CUP of the EXHAUST VALVE: Use a mill of a cup of the valve (1) to make two cuts. It is necessary to use two mills: the first to make a corner in 15 , and the second to make a corner in 45 . The second mill is necessary for using to receive necessary width of a cup. Width of a cup for a cup of the exhaust valve: 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
  1. CUP of the INLET VALVE: Sequence of a cut precisely same, as for cups of the exhaust valve. Width of a cup for a cup of the inlet valve: 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
  1. GRINDING in of VALVES: Grind in the valve to a cup (1) in two steps: at first by means of rough structure of a mix of grinding in of an obverse surface, and then by means of small structure of a mix, each time using the machine tool for grinding in of nests of valves according to a standard method of grinding in.

Cylinder head

 PERFORMANCE ORDER

  1. Remove all deposit from combustion chambers.

Do not use the sharp tool for соскребания a deposit. Be cautious not to make the tease or a groove on metal surfaces at соскребании a deposit. It also to concern and valves, and cups of valves.

  1. Check up a head of the cylinder about cracks in inlet and final channels, combustion chambers, and on a head surface.

Планшетность the condensed surface:

  1. With the help калибромера check up a surface in 6 places. If the norm of deformation specified more low, is exceeded, correct the condensed surface with the help разметочной a plate and an abrasive paper #400 (a water-proof abrasive paper on the basis of silicon carbide): put a paper on разметочную a plate, and потрите the condensed surface about a paper, that сошлифовать high places. If it does not help to lower the indication калибромера to norm limits, replace a cylinder head. Leak of the working gases formed by products of combustion, from this condensed connection often occurs because of deformation of the condensed surface: such leak grows out of decrease in made capacity.

Limits of deformation of the condensed surface of a head of the cylinder: 0.05 mm (0.002 inches).

Deformation of surfaces прилегания a collector:

  1. Check up surfaces прилегания heads of the cylinder and collectors with the help калибромера, whether to define there is a necessity to correct these surfaces or to replace a cylinder head.

Limits of deformation of surfaces прилегания a collector: 0.10 mm (0.004 inches).

Klapannye springs

 PERFORMANCE ORDER

  1. Being based on the data given more low, be convinced that each spring is in a good condition, without breakage or easing certificates. Remember that weakened клапанные springs can cause jingle, not to mention possible decrease in made capacity because of the leak of gas caused by pressure decrease прилегания.
Length клапанной springs in a free condition:
  • Norm: 36.83 mm (1.4500 inches)
  • Limit: 35.67 mm (1.4043 inches)

Preliminary loading клапанной springs:

  • Norm: 10.7 – 12.5 kg for 31.5 mm (23.6 – 27.5 pounds on 1.24 inches)
  • Limit: 9.3 kg for 31.5 mm (20.5 pounds on 1.24 inches)

Perpendicularity of a spring:

  1. Use a square and разметочную a plate to check up each spring on perpendicularity from the point of view of a backlash between the end клапанной springs and a square. If the backlash is more than the limit specified more low, клапанные springs should be replaced. A perpendicularity limit клапанных springs: 2.0 mm (0.079 inches).

Assemblage

 PERFORMANCE ORDER

  1. Before to establish directing plug of the valve in a cylinder head, expand directing aperture by means of the special tool (a 11-millimetric dilator) to remove teases and to make its really round.
    • The special tool:
      • (): 09916-34542
      • (): 09916-38210
  1. Establish directing plug of the valve on a cylinder head. In regular intervals heat up a head of the cylinder to temperature 80 – 100С (176 – 212F) not to deform a head, and enter the new directing plug of the valve until the special tool (the adaptation for installation of the directing plug of the valve) will not concern cylinder heads. After installation check up height of ledges of the directing plug of the valve (1) from a cylinder head.
    • The special tool
      • (): 09916-56011
      • (D): 09916-58210

  • Do not use the disassembled directing plug of the valve repeatedly. Establish the new directing plug of the valve (the repair size).
  • Directing plugs of the valve on an admission and on release the identical.
  • The repair size of the directing plug of the valve: 0.03 mm (0.0012 inches).
  • Ledge of the directing plug of the valve (on an admission and on release): 11.5 mm (0.45 inches).

  1. Expand internal diameter of the directing plug of the valve by means of the special tool (a 5.5-millimetric dilator). After expansion clear a trunk.
    • The special tool
      • (): 09916-34542
      • (): 09916-34550
  1. Establish a cup клапанной springs on a cylinder head.
  1. Put new consolidation of a core of the valve (1) on directing plug of the valve. Having greased with engine oil consolidation and a core of the special tool (the handle of the tool for an establishment of the directing plug of the valve), place oil consolidation on a core, and then establish consolidation on directing plug of the valve, having pressed the special tool a hand. After installation be convinced that consolidation is correctly fixed to directing valve plugs.
    • The special tool
      • (): 09917-98221
      • (): 09916-58210

  • Do not use consolidation repeatedly after dismantle. Do not forget to put new consolidation.
  • At installation never knock or do not beat on the special tool a hammer or something. Establish consolidation on directing only pressing the special tool a hand. Постукивание or the accent on the special tool can damage consolidation.

  1. Establish the valve (1) on directing plug of the valve. Before to establish the valve on directing plug of the valve, grease with engine oil core consolidation, internal diameter of the directing plug of the valve and a valve core.
  1. Establish клапанную a spring and the holder of a spring. Each spring has the top end (the end with the big step of a spring (1)) and the bottom end (the end with small step of a spring (2)). Do not forget to establish a spring into place the bottom end (the party of the holder клапанной a spring (3)) to a bottom (the cup party клапанной a spring (4)).
1 — the end with the big step of a spring
2 — the end with small step of a spring
3 — the party of the holder клапанной springs
4 — the cup party клапанной springs
  1. By means of the special tool (the valve lift) compress клапанную a spring and insert two checks of the valve (1) into a groove in a valve core.
    • The special tool
      • (): 09916-14510
      • (): 09916-14910
      • (): 09916-84511
  1. Establish коромысла, springs and an axis коромысел, having addressed to Razdelu Koromyslo of the valve, an axis коромысел and a cam-shaft in this Chapter.
  2. Establish an inlet collector and a collector of the fulfilled gases.

Installation

 PERFORMANCE ORDER

  1. Remove an old lining and oil on the interfaced surfaces, and establish pins (4) and a new lining of a head of cylinders (1), i.e. the mark "Top" on a lining goes to the pulley party коленвала (2) obverse surface to the party of a head of the cylinder.
1 — a lining of a head of cylinders
2 — a pulley коленвала
3 — the flywheel party
4 — pins
  1. Be convinced of that the oil nozzle (a nozzle of Venturi) (1) is established and if it is established be convinced that it is not clamped.
  2. Grease with engine oil bolts of a head of the cylinder and twirl them gradually as follows:
    • Twirl all bolts on 35 Н•м (3.5 kg th. 25.0 pound on foot) in a digital order as it is specified in drawing.
    • Just as in (1), twirl them on 55 Н•м (5.5 kg th, 40.0 pound on foot).
    • Release all bolts until the rotating moment of an inhaling will not decrease to 0 upside-down inhalings.
    • Just as in (1), twirl them on 35 Н•м (3.5 kg th, 25.0 pound on foot).
    • Just as in (1) again, twirl them by the specified rotating moment. The rotating moment of an inhaling: a bolt of a head of the cylinder () — 68 Н•м (6.8 kg th, 49.5 pounds on foot).
1 — the party of a pulley of a cam-shaft
  1. Repeat dismantle procedure upside-down for the purpose of installation.
  2. Adjust a tension of a belt of a drive of the water pump, having addressed to Section Regulation and check of a tension of a belt of the cooling fan in the Head engine Cooling.
  3. Adjust a tension of a belt of the pump of the hydraulic booster of a steering or a tension of a belt of compressor A/T if that is available. Address to Section the Engine in the Head Maintenance service and greasing.
  4. Adjust backlashes of inlet and exhaust valves, having addressed to Razdelu Klapannyj a backlash in this Chapter.
  5. Adjust люфт a rope of an accelerator and люфт a cable of a drive throttle заслонок А/Т.
  6. Check up, whether all removed parts are put into place. Repeatedly establish any necessary parts which have not been earlier established.
  7. Back fill cooling system, having addressed to Section Washing and filling of system of cooling in the Head engine Cooling.
  8. Connect a negative cable to the accumulator.
  9. Check up, whether there is no leak of fuel, antifreeze and exhaust gas on each connection.
  10. Be convinced of that installation of a corner of an advancing of ignition or fuel injection corresponds to technical requirements, having addressed to the Head ignition System.