Suzuki Grand Vitara JB627. Manual - part 85

1D-21 Engine Mechanical: 

• Use new exhaust manifold gasket.
• Tighten exhaust manifold mounting bolts and nuts to 

specified torque referring to “Exhaust Manifold 
Removal and Installation in Section 1K”.

• Refill coolant referring to “Cooling System Flush and 

Refill in Section 1F”.

• Finally, start engine and check for engine coolant 

leaks and exhaust gas leakage.

Engine Block Heater (If Equipped) Inspection

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• Check continuity between terminal “a” and “c”. If there 

is no continuity, replace it.

• Check that there is no continuity between terminal “a” 

or “b” and “c”. If there is continuity, replace it.

• Check continuity between terminal “c” and engine 

block heater body. If there is no continuity, replace it.

Timing Chain Cover Removal and Installation

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Removal

1) Remove engine assembly from vehicle. Refer to 

“Engine Assembly Removal and Installation”.

2) Remove electric throttle body assembly with intake 

collector and intake manifold. Refer to “Intake 
Collector and Intake Manifold Removal and 
Installation” and “Electric Throttle Body Assembly 
Removal and Installation”.

3) Remove cylinder head covers. Refer to “Cylinder 

Head Covers Removal and Installation”.

4) Remove P/S pump and A/C compressor (if 

equipped) drive belt referring to “P/S Pump and A/C 
Compressor (If Equipped) Drive Belt Removal and 
Installation in Section 6C”.

5) Remove water pump and generator drive belt. Refer 

to “Water Pump and Generator Drive Belt Removal 
and Installation in Section 1J”.

6) Remove water pump pulley.
7) Remove thermostat cap. Refer to “Thermostat 

Removal and Installation in Section 1F”.

8) Remove P/S pump bracket. Refer to “P/S Hose / 

Pipe Components in Section 6C”.

9) Remove oil pans. Refer to “Oil Pan and Oil Pump 

Strainer Removal and Installation in Section 1E”.

10) Remove crankshaft pulley bolt (1). To lock crankshaft 

pulley, use special tool (camshaft pulley holder) as 
shown in figure.

Special tool
(A):  09917–68221

NOTE
Be sure to use the following bolt for fixing 
special tool to crankshaft pulley.
Bolt size: M8, P1.25 L=45 mm
Strength: 7T

 

11) Remove crankshaft pulley (1).

If it is hard to remove, use special tools (Steering 
wheel remover, Bearing puller attachment) as shown 
in figure.
If bolts of steering wheel remover are too long, 
replace them with those of suitable length.

Special tool
(A):  09944–36011
(B):  09926–58010

12) Remove timing chain cover.

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2. Bolt

3. Wrench

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Engine Mechanical:  1D-22

Installation
Reverse removal sequence to install timing chain cover 
noting the following points.
• Clean sealing surface on timing chain cover, 

crankcase, cylinder block and cylinder heads.
Remove oil, old sealant, and dust from sealing 
surface.

• Apply sealant “A” to timing chain cover sealing 

surface area as shown in figure.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

• Apply sealant “B” to mating surfaces of cylinder head 

and cylinder block as shown in figure.

“B”:  Water tight sealant 99000–31140 (SUZUKI 
Bond No.1207B)

• Apply engine oil to new oil seal lip and water pump O-

ring. Using special tool (bearing installer), install new 
oil seal (2) with its surface is flash with edge of timing 
chain cover (1).

Special tool
(D):  09913–75510

• Install timing chain cover.

Tightening torque
Timing chain cover bolt:  11 N·m (1.1 kgf-m, 8.0 lb-
ft)

• Install CMP sensor to timing chain cover referring to 

“Camshaft Position (CMP) Sensor Removal and 
Installation in Section 1C”.

• Install crankshaft pulley (1).

To lock crankshaft pulley, use special tool (camshaft 
pulley holder) with it at shown in figure.

Special tool
(A):  09917–68221

Tightening torque
Crankshaft pulley bolt (a):  150 N·m (15 kgf-m, 
108.5 lb-ft)

“a”: 2 mm (0.08 in.)

1. Timing chain cover

“b”: 3 mm (0.11 in)

2. Sealant “A”

[A]: View A

“a”: 7 mm (0.28 in.)

1. Cylinder head

“b”: 67 mm (2.64 in.)

2. Cylinder block

“c”: 17 mm (0.67 in.)

3. Cylinder head gasket

“d”: 18 mm (0.71 in.)

4. Rub into

“e”: 10 mm (0.39 in.)

5. Jig

“f”: 34 mm (1.34 in.)

“g”: 50 mm (1.97 in)

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"a"

"b"

"d"

"f"

"e"

"c"

"a"

"g"

2

"B"

1

1

A

A

A

[A]

"B"

1

3

2

4

5

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2. Bolt

3. Wrench

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1D-23 Engine Mechanical: 

NOTE
Be sure to use the following bolt for fixing 
special tool to crank pulley.
Bolt size: M8, P1.25 L=45 mm
Strength: 7T

 

Timing Chain Cover Inspection

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Check oil seal lip for damage or deterioration. Replace 
as necessary.

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

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1. LH (No.1) bank 2nd timing chain

6. Timing chain guide No.4

11. Timing chain guide No. 4 bolt

2. Timing chain tensioner adjuster No.3

7. Timing chain guide No.5

: Apply engine oil to sliding surface of 

each point.

3. LH (No.1) bank intake camshaft 

sprocket

8. Idler sprocket No.2

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

4. LH (No.1) bank exhaust camshaft 

sprocket

9. Timing chain tensioner adjuster No. 3 bolt

: Tighten 45 N

⋅m (4.5 kgf-m, 32.5 lb-ft) by 

the specified procedure.

5. Camshaft sprocket bolt

10. Timing chain tensioner adjuster No. 3 nut

: Tighten 80 N

⋅m (8.0 kgf-m, 58.0 lb-ft) by 

the specified procedure.

Engine Mechanical:  1D-24

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

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Removal

1) Remove engine assembly from vehicle. Refer to 

“Engine Assembly Removal and Installation”.

2) Remove timing chain cover. Refer to “Timing Chain 

Cover Removal and Installation”.

3) Turn crankshaft to meet the following condition.

• Key (1) on crankshaft positions as shown.
• Mark on idler sprocket No.2 (2) points the center 

of crankshaft.

• The marks on sprockets (3) match with marks on 

cylinder head.

4) Remove timing chain tensioner adjuster No.3 (1).

To remove it, slacken LH (No.1) bank 2nd timing 
chain by turning intake camshaft (2) 
counterclockwise a little while pushing back pad.

5) Remove LH (No.1) bank intake and exhaust 

camshaft sprocket bolts.
To remove it, fit a spanner to hexagonal part (3) at 
the center of camshaft to hold it stationary.

6) Remove LH (No.1) bank exhaust camshaft sprocket 

(1).

CAUTION

!

 

Removing sprocket (1) from camshaft (2) may 
cause cam to turn, resulting in damage to 
valve and piston. To prevent this, when 
removing sprocket, hold camshaft stationary 
by using a spanner at its hexagonal part.

 

7) Remove LH (No.1) bank intake camshaft sprocket.
8) Remove LH (No.1) bank 2nd timing chain.

1

2

3

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1. LH (No.1) bank intake camshaft sprocket
2. LH (No.1) bank exhaust camshaft sprocket

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