Suzuki Grand Vitara JB419. Manual - part 48

Engine Mechanical:  1D-38

Camshaft and Tappet Inspection

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Camshaft
• Check journals and cam faces for wear or damage.

If any malcondition is found, replace camshaft.

Camshaft thrust play

1) Remove all tappets from cylinder head.
2) Install camshaft to cylinder head.
3) Install camshaft housing referring to “Installation” 

under “Camshaft and Tappet Removal and 
Installation”.

4) Measure camshaft thrust play using special tool and 

dial gauge (1) as shown in figure.If measured thrust 
play is out of specification, replace camshaft and/or 
cylinder head.

Camshaft thrust play
0.045 – 0.135 mm (0.00178 – 0.00531 in.)

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

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.

Wear of Tappet 
Check tappet for pitting, scratches, or damage.
If any malcondition is found, replace.

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1D-39 Engine Mechanical: 

Measure cylinder head bore and tappet outside diameter 
to determine cylinder head-to-tappet clearance. If 
measured clearance is out of specification, replace 
tappet and/or cylinder head.

Cylinder head to tappet clearance
0.015 – 0.074 mm (0.00059 – 0.00291 in.)

Tappet outside diameter [A]
34.965 – 34.985 mm (1.37658 – 1.37736 in.)

Cylinder head tappet bore [B]
35.000 – 35.039 mm (1.37796 – 1.37948 in.)

Valve and Cylinder Head Assembly Components

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12

12

10

1

2

3

4

8

11

5

9

(a)

7

6

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1. Valve cotter

6. Intake valve

11. Cylinder head gasket

2. Valve spring retainer

7. Exhaust valve

12. Dowel pin

Engine Mechanical:  1D-40

Valve and Cylinder Head Assembly Removal 
and Installation

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Removal

1) Remove engine assembly referring to “Engine 

Assembly Removal and Installation”.

2) Remove timing belt referring to “Timing Belt and Belt 

Tensioner Removal and Installation”.

3) Remove turbocharger referring to “Turbocharger 

Assembly Removal and Installation”.

4) Remove EGR cooler referring to “EGR Pipe and 

EGR Cooler Removal and Installation”.

5) Remove oil separator referring to “Oil Separator 

Removal and Installation”.

6) Remove EGR valve referring to “EGR Valve 

Removal and Installation”.

7) Remove ventilation pipe No.2 referring to “Oil 

Separator Components”.

8) Remove injection pump rear bracket referring to 

“Injection Pump Removal and Installation in Section 
1G”, if necessary.

9) Loosen cylinder head bolts in numerical order (“1” 

through “10”) as shown in figure, and remove them.

CAUTION

!

 

Never reuse cylinder head bolts once 
removed it due to plastic deformation 
tightening. Be sure to use new cylinder head 
bolts when installing.

 

10) Check all around cylinder head for any other parts 

required to be removed or disconnected, and 
remove or disconnect whatever necessary.

11) Remove cylinder head and cylinder head gasket 

from cylinder block.

12) Remove dowel pins, if necessary.
13) Remove vacuum pump referring to “Vacuum Pump 

Removal and Installation”, if necessary.

14) Remove thermostat assembly referring to 

“Thermostat Assembly Removal and Installation in 
Section 1F”, if necessary.

15) Remove intake and exhaust manifolds referring to 

“Intake Manifold and Exhaust Manifold Removal and 
Installation”, if necessary.

16) Remove camshaft and tappets referring to 

“Camshaft and Tappet Removal and Installation”, if 
necessary.

17) Remove fuel injector referring to “Fuel Injector 

Removal and Installation in Section 1G”, if 
necessary.

18) Remove injection pump referring to “Injection Pump 

Removal and Installation in Section 1G”, if 
necessary.

19) Remove common rail (high pressure fuel injection 

rail) referring to “Common Rail (High Pressure Fuel 
Injection Rail) Removal and Installation in Section 
1G”, if necessary.

3. Valve spring

8. Valve guide

: Tighten 30 N

⋅m (3.0 kgf-m, 22.0 lb-ft), 100°, 0 N⋅m 

(0.0 kgf-m, 0.0 lb-ft), 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft) 

and 213

° by the specified procedure.

4. Valve stem seat

9. Cylinder head bolt

: Do not reuse.

5. Valve stem seal

: Do not lubricate valve stem seal before fitting.

10. Cylinder head

: Apply engine oil to sliding surface of each part.

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1D-41 Engine Mechanical: 

Installation

1) Remove oil, old sealant and dust from bolt holes and 

mating surface of cylinder head and cylinder block.

2) Install camshaft and tappets referring to “Camshaft 

and Tappet Removal and Installation”, if removed.

3) Install cylinder head cover referring to “Cylinder 

Head Cover Removal and Installation”, if removed.

4) Install injection pump referring to “Injection Pump 

Removal and Installation in Section 1G”, if removed.

5) Install common rail (high pressure fuel injection rail) 

referring to “Common Rail (High Pressure Fuel 
Injection Rail) Removal and Installation in Section 
1G”, if removed.

6) Install fuel injector referring to “Fuel Injector Removal 

and Installation in Section 1G”, if removed.

7) Install high pressure pipes referring to “High 

Pressure Pipe Removal and Installation in Section 
1G”, if removed.

8) Install intake and exhaust manifolds referring to 

“Intake Manifold and Exhaust Manifold Removal and 
Installation”, if removed.

9) Install vacuum pump referring to “Vacuum Pump 

Removal and Installation”, if removed.

10) Install thermostat assembly referring to “Thermostat 

Assembly Removal and Installation in Section 1F”, if 
removed.

11) Install dowel pins (1) to cylinder block, if removed.

12) Install new cylinder head gasket (2) to cylinder block.

13) Install cylinder head to cylinder block, and tighten 

new cylinder head bolts as follows.
a) Tighten cylinder head bolts to 30 N

⋅m (3.0 kgf-m, 

22.0 lb-ft) according to numerical order (“1” 
through “10”) as shown in figure.

b) Retighten them by turning through 100

° in same 

manner as Step a).

c) Wait 3 minutes for setting time.
d) Loosen cylinder head bolts (“1” and “2”) until they 

are completely free, and tighten them to 25 N

⋅m 

(2.5 kgf-m, 18.0 lb-ft), then retighten then by 
turning through 213

°.

e) Loosen and tighten bolts (“3” and “4”), bolts (“5” 

and “6”), bolts (“7” and “8”) then bolt (“9” and 
“10”) in the same manner as Step d).

Tightening torque
Cylinder head bolt  (a):  Tighten 30 N

⋅m (3.0 

kgf-m, 22.0 lb-ft), 100

°, 0 N⋅m (0.0 kgf-m, 0.0 

lb-ft), 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft) and 213° 

by the specified procedure

14) Install injection pump rear bracket referring to 

“Injection Pump Removal and Installation in Section 
1G”, if necessary.

15) Install EGR valve referring to “EGR Valve Removal 

and Installation”.

16) Install oil separator referring to “Oil Separator 

Removal and Installation”.

17) Install EGR cooler referring to “EGR Pipe and EGR 

Cooler Removal and Installation”.

18) Install turbocharger referring to “Turbocharger 

Assembly Removal and Installation”.

19) Install ventilation pipe No.2 referring to “Oil 

Separator Components”.

20) Install timing belt referring to “Timing Belt and Belt 

Tensioner Removal and Installation”.

21) Install engine assembly referring to “Engine 

Assembly Removal and Installation”.

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