Suzuki Grand Vitara JB627. Manual - part 81

1D-5 Engine Mechanical: 

Valve Lash (Clearance) Inspection

S6JB0B1404003

1) Remove negative (–) cable at battery.
2) Remove cylinder head covers referring to “Cylinder 

Head Covers Removal and Installation”.

3) Using 19 mm wrench, turn crankshaft pulley (1) 

clockwise until timing mark “O” position (2) of 
cylinder block and index (3) of crankshaft pulley (1) 
are aligned.

4) Check whether cam position (4) 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 (1) 

according to the following procedure.
a) Check valve lashes of cylinder No.1.
b) Turn crankshaft pulley by 120

° clockwise.

c) Check valve lashes of cylinder No.6.
d) In the same manner as b) – c), check valve 

lashes of cylinder No.5, cylinder No.4, cylinder 
No.3 then cylinder No.2.

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 – 

77 

°F)):

• Intake: 0.18 – 0.22 mm(0.007 – 0.008 in.)
• Exhaust: 0.28 – 0.32 mm(0.011 – 0.012 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.)

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

5. LH (No.1) bank

[B]: TDC in exhaust for No.1 cylinder

3

2

1

4

4

[A]

[B]

5

I6JB01140002-01

1

I6JB01140003-01

Engine Mechanical:  1D-6

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 figure.

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. as below 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, 

7.5 lb-ft) by the specified procedure

4) Turn camshaft by approximately 90

° clockwise and 

remove shim (3).

WARNING

!

 

Never put in the hand between camshaft and 
tappet.

 

No. on camshaft housing

Embossed mark on 

special tool

I2 

⋅ I3 ⋅ I4

IN

E2 

⋅ E3 ⋅ E4

EX

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

C: Pointing to timing chain side

3

1

2

I6JB01140004-01

I5JB0A142066-01

1. Special tool

2. Magnet

1, (a)

(A)

I6JB01140005-01

1

2

3

I6JB01140006-01

1D-7 Engine Mechanical: 

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 – 0.200 mm (0.008 in.)
Exhaust side:
A = B + C – 0.300 mm (0.012 in.)
A: Thickness of new shim
B: Thickness of removed shim
C: Measured valve clearance

For example of intake side:
When thickness of removed shim is 2.400 mm 
(0.094 in.), and measured valve clearance is 0.450 
mm (0.018 in.).
A = 2.400 mm (0.094 in.) + 0.450 mm (0.018 in.) – 
0.200 mm (0.008 in.) = 2.650 mm (0.104 in.)
Calculated thickness of new shim = 2.650 mm 
(0.104 in.)

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

possible to calculated value.

Available new shim No.

7) Install new shim facing shim No. side (1) 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

I2RH0B140014-01

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

1. Tappet

2. Camshaft

I6JB01140007-01

(A)

2

1

I6JB01140008-02

Engine Mechanical:  1D-8

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 covers referring to “Cylinder 

Head Covers Removal and Installation”.

Repair Instructions

Air Intake System Components

S6JB0B1406001

1

(a)

I6JB01140009-01

1

6

9

4

3

2

8

7

10

5

5

5

(a)

(b)

(a)

(a)

I6JB01140010-02

1. Air cleaner assembly

4. Air cleaner outlet hose

7. Air cleaner suction pipe

10. MAF and IAT sensor screw

2. Resonator No.2

5. Clamp

8. Clip

: 2.0 N

⋅m (0.2 kgf-m, 1.5 lb-ft)

3. Air intake pipe

6. Resonator No.1

9. MAF and IAT sensor

: 1.6 N

⋅m (0.16 kgf-m, 1.2 lb-ft)