Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 140

1D-86 Engine Mechanical: For J20 Engine

10) Install crankshaft pulley. To lock crankshaft pulley 

(1), use special tool (camshaft pulley holder) as 
shown in figure.

Special tool
(A):  09917–68221

NOTE
Be sure to use the following bolts instead of 
pins in order to fix crank pulley by special 
tool.
Bolt size: M8, P1.25 L = 25 mm (0.98 in.)
Strength: 7T

 

Tightening torque
Crankshaft pulley bolt (a):  150 N·m (15.0 kgf-m, 
108.5 lb-ft)

11) Install engine assembly to vehicle referring to 

“Engine Assembly Removal and Installation: For J20 
Engine”.

Timing Chain Cover Cleaning and Inspection

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Clean
Clean sealing surface on timing chain cover, crank case, 
cylinder block and cylinder head.
Remove oil, old sealant, and dust from sealing surface.

Inspection
Check oil seal lip for fault or other damage. Replace as 
necessary.

2nd Timing Chain and Chain Tensioner Components

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2. Bolt

3. Wrench

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10

4

9

5

1

9

OIL

2

OIL

3

8

(a)

7

(c)

6

(b)

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 1. 2nd timing chain

: Apply engine oil

6. Camshaft timing sprocket bolt

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

 2. Timing chain tensioner adjuster No.2

: Apply engine oil to sliding surface.

7. Timing chain tensioner adjuster No.2 nut

: 80 N

⋅m (8.0 kgf-m, 58.0 lb-ft)

3. Tensioner adjuster No.2 gasket

8. Timing chain tensioner adjuster No.2 bolt

: 45 N

⋅m (4.5 kgf-m, 32.5 lb-ft)

Engine Mechanical: For J20 Engine 1D-87

2nd Timing Chain and Chain Tensioner 
Removal and Installation

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CAUTION

!

 

After 2nd timing chain is removed, never turn 
intake camshaft, exhaust camshaft and 
crankshaft independently more than such an 
extent as shown. If turned, interference may 
occur between piston and valves and valves 
themselves, and parts related to piston and 
valves may be damaged.

 

Removal

1) Remove engine assembly from vehicle referring to 

“Engine Assembly Removal and Installation: For J20 
Engine”.

2) Remove oil pan. Refer to “Oil Pan and Oil Pump 

Strainer Removal and Installation: For J20 Engine in 
Section 1E” for removal.

3) Remove cylinder head cover. Refer to “Cylinder 

Head Cover Removal and Installation: For J20 
Engine” for removal.

4) Remove timing chain cover. Refer to “Timing Chain 

Cover Removal and Installation: For J20 Engine” for 
removal.

5) Turn crankshaft clockwise to meet the following 

conditions.
• Key on crankshaft match with mark on cylinder 

block (I).

• Arrow mark on idler sprocket points upward (II).
• Marks on cam sprockets match with marks on 

cylinder head (III).

• Mark on crank sprocket match with mark on lower 

crankcase (IV).

4. Intake camshaft timing sprocket

9. Pin

: Do not reuse.

5. Exhaust camshaft timing sprocket

10. Oil relief valve

1. Knock pin of intake camshaft
2. Knock pin of exhaust camshaft
3. Timing mark of intake side
4. Timing mark of exhaust side
5. Match mark on crank timing sprocket
6. Timing mark on lower crankcase

“a”: Camshafts (IN & EX) allowable turning range..... Within 20

° on both 

right and left

“b”: Crankshaft allowable turning range..... Within 90

° on both right and left

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1. Timing marks of intake camshaft timing sprocket
2. Timing marks of exhaust camshaft timing sprocket
3. Arrow mark on idler sprocket
4. Key on crankshaft
5. Timing mark of crankshaft timing sprocket

2, (III)

1, (III)

3, (II)

4, (I)

5, (IV)

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1D-88 Engine Mechanical: For J20 Engine

6) Remove timing chain tensioner adjuster No.2 (1) and 

gasket. To remove them, slacken 2nd timing chain 
by turning intake camshaft counterclockwise a little 
while pushing back pad.

7) Remove intake and exhaust camshaft timing 

sprocket bolts (1). To remove them, fit a spanner (4) 
to hexagonal part (3) at the center of camshaft to 
hold it stationary.

8) Remove camshaft timing sprockets and 2nd timing 

chain (2).

Installation

1) Check that match mark (1) on crank timing sprocket 

is in match with timing mark (2) on lower crankcase 
as shown in figure.

2) Check that arrow mark (1) on idler sprocket faces 

upward as shown in figure.

3) Check that knock pins of intake (2) and exhaust (3) 

camshafts are aligned with timing marks on cylinder 
head as shown in figure.

4) Install 2nd timing chain by aligning yellow plate (1) of 

2nd timing chain and match marks on idler sprocket.

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4. Timing mark of intake side
5. Timing mark of exhaust side

2. Match mark of 2nd timing chain (Arrow mark)

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Engine Mechanical: For J20 Engine 1D-89

5) Install sprockets to intake and exhaust camshafts by 

aligning dark blue plate of 2nd timing chain, match 
marks on intake sprocket and exhaust sprocket 
respectively.

CAUTION

!

 

Do not turn more than allowable turning 
range.
If turned excessively, valve and piston may 
be damaged.

 

NOTE
As an arrow mark is provided on both sides, 
camshaft timing sprocket has no specific 
installation direction.

 

6) Tighten intake and exhaust camshaft timing sprocket 

bolts (1) to specified torque. To tighten it, fit a 
spanner (2) to hexagonal part (3) at the center of 
camshaft to hold it stationary.

Tightening torque
Camshaft timing sprocket bolt (a):  80 N·m (8.0 
kgf-m, 57.5 lb-ft)

7) Push back plunger (1) into tensioner body (2), and 

hold it at the position by inserting stopper (3) into 
body.

8) Install timing chain tensioner adjuster No.2 (1) with 

new gasket.

Tightening torque
Timing chain tensioner adjuster No.2 bolt (a):  11 
N·m (1.1 kgf-m, 8.0 lb-ft)
Timing chain tensioner adjuster No.2 nut (b):  45 
N·m (4.5 kgf-m, 33.0 lb-ft)

9) Pull out stopper (2) from timing chain tensioner 

adjuster No.2.

1. Dark blue
2. Arrow mark on intake camshaft timing sprocket
3. Arrow mark on exhaust camshaft timing sprocket

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