Suzuki Grand Vitara JB416 / JB420. Manual - part 90

1D-28 Engine Mechanical: For M16A Engine with VVT

4) Loosen camshaft housing bolts in such order as 

indicated in the figure and remove them.

5) Remove camshaft housings.
6) Remove intake and exhaust camshafts.
7) Remove camshaft bearing (1).

8) Remove tappets (2) with shims (1).

Installation

1) Install tappets and shims to cylinder head.

Apply engine oil around tappet and then install it to 
cylinder head.

NOTE
When installing shim, make sure to direct 
shim No. side toward tappet.

 

2) Install camshaft bearing (1) to cylinder head.

CAUTION

!

 

Do not apply engine oil to camshaft bearing 
back.
Only a upper half bearing of intake camshaft 
bearing No.1 has some holes. Other 
bearings.

 

“12” “13” “20” “21” “16” “17” “8” “9”

“2”

“5”

“3”

“4”

“1”

“10” “11” “18” “19” “14” “15” “6” “7”

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Engine Mechanical: For M16A Engine with VVT 1D-29

3) Install intake camshaft (1) and exhaust camshaft (2).

Align knock pin (3) and match mark (4) with notches 
(5) as shown in the figure.

NOTE
Before installing camshafts, turn crankshaft 
until key position faces upward.
Refer to “Timing Chain and Chain Tensioner 
Removal and Installation: For M16A Engine 
with VVT”.

 

4) Apply engine oil to sliding surface of each camshaft 

and camshaft journal then install them as shown in 
the figure.

5) Install camshaft housing pins (1) as shown in the 

figure.

6) Check position of camshaft housings.

Embossed marks are provided on each camshaft 
housing, indicating position and direction for 
installation. Install housings as indicated by these 
marks.

7) After applying engine oil to housing bolts, tighten 

them temporarily first. Then tighten them by the 
numerical order in the figure. Tighten a little at a time 
and evenly among bolts and repeat tightening 
sequence two or three times before they are 
tightened to specified torque.

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

8) With hexagonal section (1) of intake camshaft (2) 

held stationary with spanner or the like, tighten bolt 
of intake cam timing sprocket assembly (3) to 
specification.

Tightening torque
Intake cam timing sprocket bolt (a):  60 N·m (6.0 
kgf-m, 43.5 lb-ft)

“a”: Approx. 30

°

1

2

3

4

5

“a”

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

C: Pointing to timing chain side

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“10” “9”

“2” “1”,(a) “6”

“5”

“14” “13”

“20”

“17”

“19”

“18”

“21”

“12” “11” “4”

“3”

“8”

“7”

“16” “15”

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1

2

3

(a)

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1D-30 Engine Mechanical: For M16A Engine with VVT

9) Install timing chain with crankshaft sprocket referring 

to “Timing Chain and Chain Tensioner Removal and 
Installation: For M16A Engine with VVT”.

10) Install timing chain cover referring to “Timing Chain 

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

11) Check valve lashes referring to “Valve Lash 

(Clearance) Inspection: For M16A Engine with VVT”.

12) Perform Steps 3) to 8) of “Installation” of “Timing 

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

Camshaft, Tappet and Shim Inspection

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Intake Cam Timing Sprocket Assembly
Fit intake cam timing sprocket assembly to camshaft (2) 
and hold hexagonal section of camshaft by using 
spanner or the like.
Check if sprocket (1) is not turned by hand.
If moved, replace intake cam timing sprocket assembly.

Cam Wear
Using a micrometer, measure cam height “a”. If 
measured height underruns its limit, replace camshaft.

Cam height “a”

Camshaft Runout
Set camshaft between two “V” blocks, and measure its 
runout by using a dial gauge.
If measured runout exceeds limit, replace camshaft.

Camshaft runout limit
0.10 mm (0.0039 in.)

Camshaft Journal Wear
Check camshaft journals and camshaft housings for 
pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder 
head with housing. Never replace cylinder head without 
replacing housings.

Cam height

Standard

Limit

Intake cam

44.929 – 45.089 mm 

(1.769 – 1.775 in.)

44.80 mm 
(1.764 in.)

Exhaust cam

44.399 – 44.559 mm 

(1.748 – 1.754 in.)

44.28 mm 
(1.743 in.)

2

1

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Engine Mechanical: For M16A Engine with VVT 1D-31

Check clearance by using gauging plastic. Checking 
procedure is as follows.

1) Clean housings and camshaft journals.
2) Remove all tappets with shims.
3) Install camshafts to cylinder head.
4) Place a piece of gauging plastic to full width of 

journal of camshaft (parallel to camshaft).

5) Install camshaft housing.
6) Tighten camshaft housing bolts in such order as 

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

NOTE
Do not rotate camshaft while gauging plastic 
is installed.

 

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

7) Remove housing, and using scale (2) on gauging 

plastic envelop, measure gauging plastic (1) width at 
its widest point.

Camshaft journal clearance

If measured camshaft journal clearance exceeds 
limit, measure journal (housing) bore and outside 
diameter of camshaft journal. Replace camshaft or 
cylinder head assembly whichever the difference 
from specification is greater.

Camshaft journal diameter [A]

Camshaft journal bearing bore [B]

Standard

Limit

Intake side 

No.1 housing

0.020 – 0.072 mm

(0.0008 – 0.0028 in.)

0.10 mm

(0.0039 in.)

Others

0.045 – 0.087 mm

(0.0018 – 0.0034 in.)

0.12 mm

(0.0047 in.)

“10” “9”

“2” “1”,(a) “6”

“5”

“14” “13”

“20”

“17”

“19”

“18”

“21”

“12” “11” “4”

“3”

“8”

“7”

“16” “15”

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Item

Standard

Intake side No.1 housing

26.940 – 26.955 mm
(1.0606 – 1.0612 in.)

Exhaust side No.1 housing

26.934 – 26.955 mm
(1.0604 – 1.0612 in.)

Others

22.934 – 22.955 mm
(0.9029 – 0.9037 in.)

Item

Standard

Intake side No.1 housing

—

Exhaust side No.1 housing

27.000 – 27.021 mm 
(1.0630 – 1.0638 in.)

Others

23.000 – 23.021 mm 
(0.9055 – 0.9063 in.)

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