Content .. 83 84 85 86 ..

Suzuki Grand Vitara JB416 / JB420. Manual - part 85

1D-8 Engine Mechanical: For M16A Engine with VVT

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): 09916–67020
(A): 09916–67021

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) Check valve clearance again after adjusting it.

11) After checking and adjusting all valves.

12) Install cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For M16A
Engine with VVT”.

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

Engine Mechanical: For M16A Engine with VVT 1D-9

Repair Instructions

Air Cleaner Filter Removal and Installation

S5JB0A1416001

Removal

1) Open air cleaner case (1) by unhooking its clamps

(2).

2) Remove air cleaner filter from case.

Installation
Reverse removal procedure for installation.

Air Cleaner Filter Inspection and Cleaning

S5JB0A1416002

Inspection
Check air cleaner filter for dirt. Replace excessive dirty
filter.

Cleaning
Blow off dust by compressed air from air outlet side of
element.

Cylinder Head Cover Removal and Installation

S5JB0A1416011

Removal

1) Disconnect negative cable at battery.
2) Disconnect MAF sensor coupler (1).
3) Remove air cleaner case (2).

4) Remove cylinder head upper cover.
5) Disconnect ignition coil couplers (1).
6) Remove ignition coil assemblies (2) with high-

tension cord (3).

7) Remove wire harness clamp from cylinder head

cover.

8) Remove oil level gauge (1).
9) Disconnect PCV hose (2) from PCV valve (3) and

disconnect breather hose (4) from cylinder head
cover.

10) Remove cylinder head cover mounting bolts in such

order as indicated in the figure.

I5JB0A141003-02

I2RH0B140150-01

I5JB0A141004-02

I2RH0B140032-01

I5JB0A141006-01

1D-10 Engine Mechanical: For M16A Engine with VVT

11) Remove cylinder head cover (1) with cylinder head

cover gasket (2) and spark plug hole gasket (3).

Installation

1) Install new spark plug hole gaskets (1) and new

cylinder head cover gasket (2) to cylinder head cover
(3) as shown in the figure.

2) Remove oil, old sealant, and dust from sealing

surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface

area (2) as shown.

“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)

• Timing chain cover (1) and cylinder head (2)

mating surface as shown.

“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)

3) Install cylinder head cover to cylinder head.

NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.

4) Tightening bolts in such order as indicated in the

figure a little at a time till they are tightened to
specified torque.

Tightening torque
Cylinder head cover bolt (a): 8 N·m (0.8 kgf-m,
6.0 lb-ft)

5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).

8) Install wire harness clamp to cylinder head cover.
9) Install ignition coil assemblies with high-tension cord.

10) Connect ignition coil couplers and clamp harness

securely.

11) Install cylinder head upper cover.

12) Connect negative cable at battery.

I5RS0D140014-01

I5RS0D140015-01

I2RH0B140036-01

I2RH0B140037-01

I5JB0A141007-01

Engine Mechanical: For M16A Engine with VVT 1D-11

Throttle Body and Intake Manifold Components

S5JB0A1416009

Throttle Body On-Vehicle Inspection

S5JB0A1416005

Check electric throttle body assembly referring to “Throttle Valve Operation Check” and “Electric Throttle Body
Assembly Operation Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”.

I5JB0A141005-05

[A]: Installing location of intake manifold bolt and nut

7. EVAP canister purge valve

14. Intake manifold bolt (short)

1. Intake manifold

8. EVAP canister purge valve hose

15. Intake manifold bolt (long)

2. Gasket

9. MAP sensor bolt

16. To delivery pipe

3. Electrical throttle body

10. To EGR valve

: 5 N

⋅m (0.5 kgf-m, 4.0 lb-ft)

4. EGR pipe

11. To PCV valve

: Do not reuse.

5. MAP sensor

12. To brake booster

6. PCV hose

13. Intake manifold nut

Content .. 83 84 85 86 ..