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Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 136

1D-70 Engine Mechanical: For J20 Engine

10) Crank engine with fully charged battery, and read the

highest pressure on compression gauge.

NOTE

• For measuring compression pressure,

crank engine at least 250 rpm by using
fully charged battery.

• If measuring compression pressure is

lower than limit value, check installation
condition of special tool. If it is properly.

Compression pressure
Standard: 1400 kPa (14.0 kg/cm

, 199.0 psi)

Limit: 1100 kPa (11.0 kg/cm

, 158.0 psi)

Max. difference between any two cylinders: 100
kPa (1.0 kg/cm

, 14.2 psi)

11) Carry out Steps 8) through 10) on each cylinder to

obtain 4 readings.

12) After checking, install spark plugs (2) and ignition

coils (1).

13) Install ignition coil couplers.
14) Connect injector wire harness at coupler.
15) Install engine cover.

Engine Vacuum Check

S6JB0A1424002

The engine vacuum that develops in the intake line is a
good indicator of the condition of the engine. The
vacuum checking procedure is as follows:

1) Warm up engine to normal operating temperature

and make sure that engine idle speed is within
specification.

NOTE
After warming up engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake and block drive wheels.

2) Stop engine and remove engine cover.
3) Disconnect vacuum hose (1) from vacuum pipe.
4) Connect special tools (vacuum gauge and hose

joint) to vacuum hose of intake manifold side.

Special tool
(A): 09915–67311
(B): 09918–08210
(C): 09355–35754–600 Hose, SUZUKI GENUINE
PARTS
(D): 09367–04002 3-way joint, SUZUKI GENUINE
PARTS

5) Start engine and run engine at specified idle speed,

and read vacuum gauge. Vacuum should be within
specification.

Vacuum specification
52.6 – 65.8 kPa (40 – 50 cmHg, 15.7 – 19.7 in.Hg)
at specified idle speed

6) After checking, remove special tools.
7) Connect vacuum hose to vacuum pipe.
8) Install engine cover.

I2RH01140002-01

(C)

(D)

(B)

(A)

I5JB0A142002-01

Engine Mechanical: For J20 Engine 1D-71

Valve Lash (Clearance) Inspection

S6JB0A1424003

1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For J20
Engine”.

3) Using 17 mm wrench, turn crankshaft pulley (1)

clockwise until index (2) of cylinder block and index
(3) of crankshaft pulley (1) are aligned.

4) Check whether cam position (1) of No.1 cylinder is at

the specified position [A] as shown in figure.
If cam position is [B], locate cam position to [A] by
turning crankshaft one rotation.

5) Check valve lashes with thickness gauge (4)

according to the following procedure.
a) Check valve lashes of cylinder No.1.
b) Turn crankshaft pulley by 180

° clockwise.

c) Check valve lashes of cylinder No.3.
d) In the same manner as b) – c), check valve

lashes of cylinder No.4 then cylinder No.3.

If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.

Valve clearance specification
When cold (Coolant temperature is 15 – 25

°C (59 –

°F)):

• Intake: 0.18 – 0.22 mm (0.007 – 0.009 in.)
• Exhaust: 0.28 – 0.32 mm (0.011 – 0.013 in.)

When hot (Coolant temperature is 60 – 68

°C (140 –

154

°F)):

• Intake: 0.21 – 0.27 mm (0.008 – 0.011 in.)
• Exhaust: 0.30 – 0.36 mm (0.012 – 0.014 in.)

Replacement of Shim

1) Close the valve whose shim (2) is to be replaced by

turning crankshaft, then turn tappet (3) till its cut
section (1) faces inside as shown in the figure.

[A]: TDC in compression for No.1 cylinder
[B]: TDC in exhaust for No.1 cylinder

[A]

[B]

I5JB0A142064-01

I5JB0A142065-01

I2RH0B140006-01

1D-72 Engine Mechanical: For J20 Engine

2) Lift down the valve by turning crankshaft to 360

°.

3) Hold tappet at that position using special tool as

follows.
a) Remove its housing bolts.
b) Check housing No. and select special tool

corresponding to housing No., referring to
“Special tool selection table”.

Special tool selection table

c) Hold down the tappet so as not to contact the

shim by installing special tool on camshaft
housing with housing bolt (1) tighten housing
bolts to specified torque.

Special tool
(A): 09916–66510

Tightening torque
Camshaft housing bolts (a): 11 N

⋅m (1.1 kgf-

m, 8.0 lb-ft) for tightening of special tool

4) Turn camshaft by approximately 90

° clockwise and

remove shim (3).

WARNING

Never put in the hand between camshaft and
tappet.

5) Using a micrometer (2), measure the thickness of

the removed shim (1), and determine replacement
shim by calculating the thickness of new shim with
the following formula and table.

Shim thickness specification
Intake side:
A = B + C – 0.20 mm (0.008 in.)
Exhaust side:
A = B + C – 0.30 mm (0.012 in.)
A: Thickness of new shim
B: Thickness of removed shim
C: Measured valve clearance

No. on camshaft

housing

Embossed mark on

special tool

I2, I3, I4, I5

E2, E3, E4, E5

A: I: Intake side or E: Exhaust side
B: Position from timing chain side

C: Pointing to timing chain side

I5JB0A142066-01

I3RM0A140005-01

1. Special tool

2. Magnet

I2RH0B140013-01

I2RH0B140014-01

Engine Mechanical: For J20 Engine 1D-73

For example of intake side:
When thickness of removed shim is 2.40 mm (0.094
in.), and measured valve clearance is 0.45 mm
(0.018 in.).
A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20
mm (0.008 in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104
in.)

6) Select new shim No. (1) with a thickness as close as

possible to calculated value.

Available new shims No.

7) Install new shim facing shim No. side with tappet.

8) Lift valve by turning crankshaft counterclockwise (in

opposite direction against above Step 4)) and
remove special tool.

Special tool
(A): 09916–66510

9) Install camshaft housing (1) and tighten bolts to

specified torque.

Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)

10) Turn crankshaft pulley more than 4 rotations.

11) Check valve clearance again after adjusting it.

12) After checking and adjusting all valves.
13) Install cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For J20
Engine”.

Thickness

mm (in.)

Shim No.

Thickness

mm (in.)

Shim No.

2.175 (0.0856)

218

2.600 (0.1024)

260

2.200 (0.0866)

220

2.625 (0.1033)

263

2.225 (0.0876)

223

2.650 (0.1043)

265

2.250 (0.0886)

225

2.675 (0.1053)

268

2.275 (0.0896)

228

2.700 (0.1063)

270

2.300 (0.0906)

230

2.725 (0.1073)

273

2.325 (0.0915)

233

2.750 (0.1083)

275

2.350 (0.0925)

235

2.775 (0.1093)

278

2.375 (0.0935)

238

2.800 (0.1102)

280

2.400 (0.0945)

240

2.825 (0.1112)

283

2.425 (0.0955)

243

2.850 (0.1122)

285

2.450 (0.0965)

245

2.875 (0.1132)

288

2.475 (0.0974)

248

2.900 (0.1142)

290

2.500 (0.0984)

250

2.925 (0.1152)

293

2.525 (0.0994)

253

2.950 (0.1161)

295

2.550 (0.1004)

255

2.975 (0.1171)

298

2.575 (0.1014)

258

3.000 (0.1181)

300

I2RH0B140015-01

1. Tappet

2. Camshaft

(A)

I3RM0A140006-01

I2RH0B140149-01

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