Suzuki Grand Vitara JB416 / JB420. Manual - part 105

1D-88 Engine Mechanical: For J20 Engine

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).

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.

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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Engine Mechanical: For J20 Engine 1D-89

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.

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.

 

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

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

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

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1D-90 Engine Mechanical: For J20 Engine

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.

10) Turn crankshaft two rotations clockwise, and then 

align timing mark (1) on crankshaft and timing mark 
(2) on cylinder block as shown in figure.
At this time, check timing marks (3, 5 and 7) of 
sprockets are in match with timing marks (4, 6 and 8) 
of cylinder head, cylinder block and lower crank 
case. Also, check arrow mark (9) on idler sprocket 
faces upward as shown in figure.

11) Apply oil to timing chains, tensioner, tensioner 

adjusters, sprockets and guides.

12) Install timing chain cover. Refer to “Timing Chain 

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

13) Install cylinder head cover. Refer to “Cylinder Head 

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

14) Install oil pan. Refer to “Oil Pan and Oil Pump 

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

15) Install engine assembly to vehicle referring to 

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

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3. Timing mark on crank timing sprocket
4. Timing mark on lower crankcase
5. Timing mark on intake camshaft timing sprocket
6. Timing mark of intake camshaft timing sprocket
7. Timing mark on exhaust camshaft timing sprocket
8. Timing mark of exhaust camshaft timing sprocket
9. Arrow mark on idler sprocket point upward

7

8

9

5

6

1

3

4

2

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Engine Mechanical: For J20 Engine 1D-91

2nd Timing Chain and Chain Tensioner 
Inspection

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Timing Chain Guide No.2
Check shoe (2) for wear or damage.

Camshaft Sprocket
Check teeth of sprocket for wear or damage.

Timing Chain
Check timing chain for wear or damage.

Tensioner Adjuster No.2
Check shoe (1) for wear or damage and latch functions 
properly.

1st Timing Chain and Chain Tensioner Components

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1. Timing chain guide No.2

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OIL

(c)

10

(b)

9

(a)

8

4

7

OIL

3

OIL

1

OIL

2

OIL

5

6

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1. 1st timing chain

6. Timing chain tensioner adjuster No.1

: 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

2. Idler sprocket

7. Timing chain guide No.1

: 9 N

⋅m (0.9 kgf-m, 6.5 lb-ft)