Suzuki Grand Vitara JB627. Manual - part 12

 

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Suzuki Grand Vitara JB627. Manual - part 12

 

 

1-iv Table of Contents

Engine Block Heater (If Equipped) Inspection ..1D-21
Timing Chain Cover Removal and Installation ..1D-21
Timing Chain Cover Inspection .........................1D-23
LH (No.1) Bank 2nd Timing Chain and Chain 

Tensioner Components...................................1D-23

LH (No.1) Bank 2nd Timing Chain and Chain 

Tensioner Removal and Installation................1D-24

LH (No.1) Bank 2nd Timing Chain and Chain 

Tensioner Inspection.......................................1D-28

1st Timing Chain and Chain Tensioner 

Components....................................................1D-29

1st Timing Chain and Chain Tensioner 

Removal and Installation.................................1D-30

1st Timing Chain and Chain Tensioner 

Inspection........................................................1D-34

RH (No.2) Bank 2nd Timing Chain and Chain 

Tensioner Components...................................1D-35

RH (No.2) Bank 2nd Timing Chain and Chain 

Tensioner Removal and Installation................1D-36

RH (No.2) Bank 2nd Timing Chain and Chain 

Tensioner Inspection.......................................1D-38

Camshafts, Tappets and Shims Components...1D-39
Camshafts, Tappets and Shims Removal and 

Installation.......................................................1D-40

Camshafts and Camshaft Housings 

Inspection........................................................1D-42

Tappets and Shims Inspection..........................1D-43
Valves and Cylinder Heads Components .........1D-44
Valves and Cylinder Heads Removal and 

Installation.......................................................1D-45

Valves and Cylinder Heads Disassembly and 

Reassembly ....................................................1D-47

Valves and Valve Guides Inspection.................1D-49
Cylinder Head Inspection ..................................1D-51
Valve Springs Inspection...................................1D-52
Pistons, Piston Rings, Connecting Rods and 

Cylinders Components....................................1D-53

Pistons, Piston Rings, Connecting Rods and 

Cylinders Removal and Installation.................1D-54

Pistons, Piston Rings, Connecting Rods and 

Cylinders Disassembly and Reassembly ........1D-55

Cylinders, Pistons and Piston Rings 

Inspection........................................................1D-58

Piston Pins and Connecting Rods Inspection ...1D-59
Crank Pins and Connecting Rod Bearings 

Inspection........................................................1D-60

Main Bearings, Crankshaft and Cylinder 

Block Components..........................................1D-64

Main Bearings, Crankshaft and Cylinder 

Block Removal and Installation .......................1D-65

Crankshaft Inspection .......................................1D-68
Main Bearings Inspection..................................1D-69
Rear Oil Seal and Flywheel Inspection .............1D-73
Cylinder Block Inspection..................................1D-73

Specifications.....................................................1D-74

Tightening Torque Specifications......................1D-74

Special Tools and Equipment ...........................1D-75

Recommended Service Material .......................1D-75
Special Tool ......................................................1D-75

Engine Lubrication System .................... 1E-1

General Description .............................................1E-1

Engine Lubrication Description ...........................1E-1

Diagnostic Information and Procedures ............1E-2

Oil Pressure Check .............................................1E-2

Repair Instructions ..............................................1E-3

Oil Pan and Oil Pump Strainer Components.......1E-3
Oil Pan and Oil Pump Strainer Removal and 

Installation .........................................................1E-4

Oil Pan and Oil Pump Strainer Cleaning.............1E-6
Oil Pump and Oil Pump Chain Components.......1E-6
Oil Pump and Oil Pump Chain Removal and 

Installation .........................................................1E-7

Oil Pump and Oil Pump Chain Inspection...........1E-8
Oil Pump Disassembly and Reassembly ............1E-8
Oil Pump Inspection ............................................1E-9

Specifications .....................................................1E-10

Tightening Torque Specifications......................1E-10

Special Tools and Equipment ...........................1E-10

Recommended Service Material .......................1E-10
Special Tool ......................................................1E-10

Engine Cooling System ...........................1F-1

General Description ............................................. 1F-1

Cooling System Description ................................ 1F-1
Coolant Description............................................. 1F-1

Schematic and Routing Diagram ........................ 1F-2

Coolant Circulation.............................................. 1F-2

Diagnostic Information and Procedures ............ 1F-3

Engine Cooling Symptom Diagnosis................... 1F-3

Repair Instructions .............................................. 1F-4

Cooling System Components.............................. 1F-4
Coolant Level Check ........................................... 1F-5
Engine Cooling System Inspection and 

Cleaning ............................................................ 1F-5

Cooling System Draining..................................... 1F-6
Cooling System Flush and Refill ......................... 1F-6
Cooling Water Pipes or Hoses Removal and 

Installation ......................................................... 1F-7

Thermostat Removal and Installation.................. 1F-7
Thermostat Inspection......................................... 1F-7
Radiator Cooling Fan Motor On-Vehicle 

Inspection.......................................................... 1F-8

Radiator Cooling Fan Relay Inspection............... 1F-8
Radiator Cooling Fan Assembly Removal and 

Installation ......................................................... 1F-9

Radiator On-Vehicle Inspection and Cleaning .... 1F-9
Radiator Removal and Installation ...................... 1F-9
Water Pump Removal and Installation.............. 1F-10
Water Pump Inspection..................................... 1F-10

Specifications ..................................................... 1F-11

Tightening Torque Specifications...................... 1F-11

Fuel System ............................................. 1G-1

Precautions.......................................................... 1G-1

Precautions on Fuel System Service ................. 1G-1

General Description ............................................ 1G-1

Fuel System Description .................................... 1G-1

Table of Contents 1-v

Fuel Delivery System Description .......................1G-1
Fuel Pump Description........................................1G-2

Schematic and Routing Diagram........................1G-2

Fuel Delivery System Diagram............................1G-2

Diagnostic Information and Procedures............1G-3

Fuel Pressure Inspection ....................................1G-3
Fuel Cut Operation Inspection ............................1G-4

Repair Instructions ..............................................1G-5

Fuel System Components...................................1G-5
Fuel Hose Disconnecting and Reconnecting ......1G-6
Fuel Pressure Relief Procedure ..........................1G-8
Fuel Leakage Check Procedure .........................1G-8
Fuel Lines On-Vehicle Inspection .......................1G-8
Fuel Pipe Removal and Installation ....................1G-9
Fuel Injector On-Vehicle Inspection ..................1G-10
Fuel Injector Removal and Installation..............1G-10
Fuel Injector Inspection.....................................1G-11
Fuel Pressure Regulator Removal and 

Installation.......................................................1G-12

Fuel Pressure Regulator Inspection..................1G-13
Fuel Filler Cap Inspection .................................1G-13
Fuel Tank Inlet Valve Removal and 

Installation.......................................................1G-13

Fuel Tank Inlet Valve Inspection.......................1G-14
Fuel Tank Removal and Installation..................1G-15
Fuel Tank Inspection.........................................1G-16
Fuel Tank Purging Procedure ...........................1G-17
Fuel Pump On-Vehicle Inspection ....................1G-17
Fuel Pump Assembly Removal and 

Installation.......................................................1G-18

Main Fuel Level Gauge Removal and 

Installation.......................................................1G-19

Fuel Pump Inspection .......................................1G-19
Sub Fuel Level Gauge Removal and 

Installation.......................................................1G-19

Sub Fuel Level Gauge Inspection.....................1G-20

Specifications.....................................................1G-20

Tightening Torque Specifications......................1G-20

Special Tools and Equipment ...........................1G-21

Recommended Service Material.......................1G-21
Special Tool ......................................................1G-21

Ignition System........................................ 1H-1

General Description .............................................1H-1

Ignition System Construction ..............................1H-1

Schematic and Routing Diagram........................1H-2

Ignition System Wiring Circuit Diagram...............1H-2

Component Location ...........................................1H-3

Ignition System Components Location ...............1H-3

Diagnostic Information and Procedures............1H-3

Ignition System Symptom Diagnosis...................1H-3
Ignition System Check ........................................1H-4
Ignition Spark Check...........................................1H-5

Repair Instructions ..............................................1H-6

Ignition Timing Inspection ...................................1H-6
Ignition Coil Assembly (Igniter and Ignition 

Coil) Removal and Installation ..........................1H-7

Ignition Coil Assembly (Igniter and Ignition 

Coil) Inspection .................................................1H-7

Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-7

Specifications.......................................................1H-8

Tightening Torque Specifications........................1H-8

Special Tools and Equipment .............................1H-8

Special Tool ........................................................1H-8

Starting System .........................................1I-1

General Description .............................................. 1I-1

Cranking Circuit Introduction................................ 1I-1
Starting Motor Circuit Description ........................ 1I-1

Diagnostic Information and Procedures............. 1I-2

Cranking System Symptom Diagnosis................. 1I-2
Starting Motor Performance Test ......................... 1I-4

Repair Instructions ............................................... 1I-5

Starting Motor Components ................................. 1I-5
Starting Motor Dismounting and Remounting ...... 1I-6
Starting Motor Disassembly and Assembly.......... 1I-6
Starting Motor Inspection ................................... 1I-10

Specifications...................................................... 1I-13

Starting Motor Specifications ............................. 1I-13
Tightening Torque Specifications....................... 1I-13

Special Tools and Equipment ............................ 1I-13

Recommended Service Material ........................ 1I-13
Special Tool ....................................................... 1I-13

Charging System ......................................1J-1

General Description ............................................. 1J-1

Battery Description.............................................. 1J-1
Generator Description ......................................... 1J-2

Diagnostic Information and Procedures............ 1J-3

Battery Inspection ............................................... 1J-3
Generator Symptom Diagnosis ........................... 1J-4
Generator Test (Undercharged Battery 

Check)............................................................... 1J-5

Generator Test (Overcharged Battery Check) .... 1J-5

Repair Instructions .............................................. 1J-6

Jump Starting in Case of Emergency.................. 1J-6
Battery Dismounting and Remounting ................ 1J-7
Generator Dismounting and Remounting............ 1J-7
Generator Components....................................... 1J-8
Generator Disassembly and Assembly ............... 1J-9
Generator Inspection......................................... 1J-12
Water Pump and Generator Drive Belt 

Inspection and Adjustment.............................. 1J-13

Water Pump and Generator Drive Belt 

Removal and Installation................................. 1J-14

Specifications..................................................... 1J-15

Charging System Specifications ....................... 1J-15
Tightening Torque Specifications...................... 1J-15

Special Tools and Equipment ........................... 1J-15

Special Tool ...................................................... 1J-15

Exhaust System....................................... 1K-1

Precautions...........................................................1K-1

Exhaust System Caution.....................................1K-1

General Description .............................................1K-1

Exhaust System Description ...............................1K-1

Precautions: 1-1

Engine

Precautions

Precautions

Precautions for Engine

S6JB0B1000001

Air Bag Warning
Refer to “Air Bag Warning in Section 00”.

Precautions on Engine Service
Refer to “Precautions on Engine Service in Section 1A” or “Precautions on Engine Service in Section 1A”.

Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 1A” or “Precautions in Diagnosing Trouble in Section 1A”.

Precautions on Fuel System Service
Refer to “Precautions on Fuel System Service in Section 1G”.

Engine Cooling System Warning
Refer to “Coolant Description in Section 1F”.

Engine Fuel System Service Precautions
Refer to “Precautions on Fuel System Service in Section 1G”.

Exhaust System Caution
Refer to “Exhaust System Caution in Section 1K”.

Precaution for CAN Communication System
Refer to “Precaution for CAN Communication System in Section 00”.

Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter in Section 00”.

Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service in Section 00”.

Precautions of ECM Circuit Inspection
Refer to “Precautions of ECM Circuit Inspection in Section 1A”.

Precautions of Electrical Throttle Body System Calibration
Refer to “Precautions of Electric Throttle Body System Calibration in Section 1A”.

Precaution for DTC Troubleshooting
Refer to “Precautions for DTC Troubleshooting in Section 1A”.

Precaution in Replacing ECM
Refer to “Precaution in Replacing ECM in Section 10C” (if equipped with immobilizer control system).

 

 

 

 

 

 

 

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