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
- Mechanical part of engine J20
The general description
- Routine maintenance
Compression check
Check of depression of the engine
Check of pressure of oil
Filtering element of the air filter
The case throttle заслонок and an inlet collector
Exhaust system collector
Cover of a head of the cylinder
Маслосборник and a grid of the oil pump
The oil pump
Cover of a chain of synchronisation
The second chain of synchronisation and натяжитель chains
The first chain of synchronisation and натяжитель chains
Cam-shafts and regulators клапанного a backlash
Valves and head of the block of the cylinder
Pistons, piston rings, rods and cylinders
Assembly armature of the engine
The special tool
Necessary service materials
Technical characteristics of the rotating moment of an inhaling
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
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Valves and head of the block of the cylinder
Components
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Put fixing hermetic 99000-31110 on a bolt carving. |
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The rotating moment of an inhaling. |
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Grease with engine oil sliding surfaces of each part. |
Removal
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Dump pressure of oil.
Disconnect a negative cable from the accumulator.
Merge engine oil.
Merge antifreeze.
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Remove a cross-section basic rack.
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Remove a final hose of the air filter.
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Disconnect following electric wire conclusions:
Socket of the valve of system рециркуляции the fulfilled gases
Socket of the valve of the control of idling
Socket of the gauge of position of the case throttle заслонок
Socket of the gauge of absolute pressure in an inlet collector
Clip of grounding from an inlet collector
Socket of the gauge 1 and-or 2 heatings of oxygen
Socket of the gauge of position of a cam-shaft
Socket of the gauge of temperature of a cooling liquid of the engine
Socket of fastening of wires of an atomizer
Wire of grounding at муфты
Муфты ignition coils
Clips of plaits of wires
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Disconnect a rope of an accelerator and a cable of a drive throttle заслонок А/Т (for vehicles with А/Т) from the case throttle заслонок.
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Disconnect following hoses:
Hose of the amplifier of brakes from an inlet collector
Vacuum hose from an inlet collector
Hose for release of gases from the gauge of absolute pressure in an inlet collector
Water hose from a bypass pipe
Hose of giving of fuel and returnable hose from each pipe
Hose of a heater from a heater exhaust pipe
Inlet hose of a radiator from a water exhaust pipe
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Remove a back element of rigidity of an inlet collector.
Disconnect a water pipe from an inlet collector.
Uncover cylinder heads, маслосборник, a cover of a chain of the synchronisation, the second and first chains of synchronisation, cam-shafts and regulators клапанных backlashes, having addressed to Section Cam-shafts and regulators клапанного a backlash in this Chapter.
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Disconnect an exhaust pipe №1 (1) from a collector of an exhaust system (2).
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Remove an element of rigidity of a collector of an exhaust system (1) (if that is available).
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Untwist bolts of a head of the cylinder, and take out them.
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Do not forget to take out a bolt (М6). |
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1 — the pulley party коленвала
2 — the flywheel party
3 — a bolt (М6) |
Check up all round a cylinder head, whether there are no other details which are necessary for removing or disconnecting, and remove or disconnect everything that is necessary.
Take out a head of the cylinder with an inlet collector, a collector of an exhaust system and a water exhaust pipe. Use the elevating device if it is necessary.
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Dismantling
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At maintenance service of a head of the cylinder remove an inlet collector, injectors, an exhaust system collector, a water exhaust pipe and a cover of a final branch pipe from a cylinder head.
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By means of special tools compress клапанные springs and then remove checks of the valve (1).
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The special tool
(): 09916-14510
(): 09916-14910
(): 09919-28610
(D): 09916-84511
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Release the special tool and remove holders of a spring and клапанные springs.
Remove the valve from outside combustion chambers.
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Remove oil consolidation of a core of the valve (1) from the directing plug of the valve, and then a cup клапанной springs (2).
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Do not use oil consolidation repeatedly after dismantle. At assemblage necessarily use new oil consolidation. |
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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.
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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. |
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.
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Check
Directing plugs of the valve
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With the help a micromeasure and a calliper take readings of diameters of cores of valves and directing to check up a backlash between cores and directing. 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
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Position
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Norm
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Limit
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Diameter of a core of the valve
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Admission
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5.965 – 5.980 mm (0.2349 – 0.2354 inches)
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—
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Release
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5.940 – 5.955 mm (0.2339 – 0.2344 inches)
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—
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Internal diameter of the directing plug of the valve
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Admission
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6.000 – 6.012 mm (0.2363 – 0.2366 inches)
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—
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Release
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Backlash between a core and directing
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Admission
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0.020 – 0.047 mm (0.0008 – 0.0018 inches)
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0.07 mm (0.0027 inches)
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Release
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0.045 – 0.072 mm (0.0018 – 0.0028 inches)
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0.09 mm (0.0035 inches)
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Valves
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Remove all deposit from valves.
Check up each valve on deterioration presence, прожога or deformations on a forward surface and a core and if it is necessary, replace it.
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
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Position
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Norm
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Limit
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On an admission
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1.0 mm (0.039 inches)
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0.6 mm (0.023 inches)
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On release
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1.2 mm (0.047 inches)
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0.7 mm (0.027 inches)
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1 — a thickness of a head of the valve
2 — 45 |
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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.
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Check up each valve on presence of radial deterioration with the help циферблатного the indicator and the V-shaped block. Slowly rotate the valve to check up deterioration. If deterioration exceeds norm limits, replace the valve. A limit of radial deterioration of a head of the valve: 0.08 mm (0.003 inches).
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Width of contact прилегания
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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). 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 and release — 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
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Repair of a cup of the valve
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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 is ground to readiness by grinding in.
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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 valve cup: 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
Cup of the inlet valve: use mills of a cup of the valve to make three cuts. It is necessary to use three mills: the first to make a corner in 15 , and the second to make a corner in 60 , and third to make a corner in 45 . The third mill is necessary for using to receive necessary width of a cup. Width of a cup for a cup of the inlet valve: 1.1 – 1.3 mm (0.0433 – 0.0511 inches).
Grinding in of valves: grind in the valve to a cup 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.
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Cylinder head
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Remove all deposit from combustion chambers.
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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. |
Check up a head of the cylinder about cracks in inlet and final channels, combustion chambers, and on a head surface.
With the help калибромера check up планшетность condensed 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.
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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).
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Deformation of surfaces прилегания a collector
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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).
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Klapannye springs
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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.
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Technical characteristics клапанной springs
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Position
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Norm
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Limit
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Free length клапанной springs
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The internal
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36.08 mm (1.4204 inches)
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35.00 mm (1.3779 inches)
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The external
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40.44 mm (1.5921 inches)
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39.22 mm (1.5440 inches)
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Preliminary loading клапанной springs
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The internal
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6.9 – 7.9 kg for 27.5 mm (15.2 – 17.4 pound on 1.08 inches)
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6.2 kg for 27.5 mm (13.6 pound on 1.08 inches)
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The external
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15.4 – 17.8 kg for 31.7 mm (33.9 – 39.2 pound on 1.25 inch)
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13.8 kg for 31.7 mm (30.4 pound on 1.25 inches)
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Perpendicularity of a spring
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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).
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Assemblage
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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
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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 into an aperture by means of special tools. 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 from a cylinder head.
The special tool
(): 09916-58210
(): 09917-87810
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- 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 inlet and final valves 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) — 13.5 mm (0.53 inches).
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Expand internal diameter of the directing plug of the valve by means of the special tool (a 6.0-millimetric dilator). After expansion clear a trunk.
The special tool
(): 09916-34542
(): 09916-37810
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Establish a cup клапанной springs on a cylinder head.
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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
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- 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.
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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.
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Establish клапанные springs (internal and external springs) 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)).
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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
(): 09919-28610
(D): 09916-84511
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Establish an inlet collector, injectors, an exhaust system collector, a water taking away pipe (2) and a cover of a water taking away pipe on a head of the cylinder (1).
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At installation of a water taking away pipe put hermetic on a bolt carving. "And": hermetic 99000-31110. |
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Installation
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Clean the interfaced surface of a head of the cylinder and the cylinder block. Remove oil, an old lining and a dust from the interfaced surfaces.
Establish pins (3) on the block of the cylinder (2).
Establish a new lining of a head of cylinders (1) on the cylinder block. The mark "Top" on a lining goes to the pulley party коленвала (4) obverse surface upwards (to the party of a head of the cylinder).
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1 — a lining of a head of cylinders
2 — the cylinder block
3 — pins
4 — a pulley коленвала
5 — cторона a flywheel |
Establish a cylinder head on the cylinder block. Grease with engine oil bolts of a head of the cylinder and twirl them gradually as follows.
Twirl all bolts on 53 Н•м (5.3 kg th. 38.5 pound on foot) in a digital order as it is specified in drawing more low.
Just as in (1), twirl them on 84 Н•м (8.4 kg th, 61.0 pound on foot).
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1 — cторона a pulley коленвала
2 — cторона a flywheel |
Release all bolts until the rotating moment of an inhaling will not decrease to 0 in the illustrated order.
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1 — cторона a pulley коленвала
2 — cторона a flywheel |
Fasten all bolts on 53 Н•м (5.3 kg th, 38.5 pound on foot) according to digital order in drawing.
Just as in (4) again, twirl them with the specified rotating moment.
The rotating moment of an inhaling:
Bolt of a head of the cylinder () — 105 Н•м (10.5 kg th, 76.0 pounds on foot)
Bolt of a head of the cylinder (М6) (b) — 11 Н•м (1.1 kg th, 8.0 pound on foot)
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Do not forget to fasten bolt М6 (3) after fix other bolts. |
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1 — the pulley party коленвала
2 — the flywheel party
3 — a bolt |
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Be convinced of that the key (2) on коленвале is levelled with a mark of synchronisation (1).
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Repeat dismantle procedure upside-down for the purpose of installation.
Adjust a tension of a belt of the cooling fan, having addressed to Section Regulation and check of a tension of a belt of the cooling fan in the Head engine Cooling.
Adjust люфт a rope of an accelerator and люфт a cable of a drive throttle заслонок А/Т (for vehicles with А/Т).
Check up, whether all removed parts are put into place. Repeatedly establish any necessary parts which have not been earlier established.
Fill in engine oil in the engine, having addressed to Section Engine oil and the filter in the Head Maintenance service and greasing.
Back fill cooling system, having addressed to Section Washing and filling of system of cooling in the Head engine Cooling.
Fill in картер forward differential трансмиссионным with oil, having addressed to Section Service out of a workshop in the Head Forward differential.
Fill in system of a steering with strengthening by a special liquid, having addressed to Section the Liquid of the hydraulic booster of a wheel in the Head System of the hydraulic booster of a wheel.
Connect a negative cable to the accumulator.
Check up, whether there is no leak of fuel, antifreeze, oil and exhaust gas on each connection.
Be convinced of that installation of a corner of an advancing of ignition or fuel injection corresponds to technical requirements, having addressed to Section Check and adjustment of time of an advancing of ignition in the Head System of ignition for engine J20.
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