Suzuki Vitara, Grand Vitara, XL7 2000-06

Camshaft, Bearings & Lifters

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Inspection



1.6L Engine
Cam Height
  1. Using a micrometer, measured height of cam. If measured height is below 1.4206 inch. (36.084 mm), replace camshaft.
  2.  
  3. Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
    NOTE
    Valve lifters are not used on this engine.

  4.  

Runout
  1. Hold camshaft between two -V- blocks, and measure runout by using a dial gauge. If runout exceeds the limit, 0.0039 inch. (0.10 mm) replace camshaft.
    NOTE
    If any malcondition is found, replace camshaft or cylinder head with housing.


    NOTE
    Never replace cylinder head without replacing housing.


    NOTE
    Valve lifters are not used on this engine.

  2.  

2.0L, 2.5L, 2.7L Engines
Cam Height
  1. Using a micrometer, measure cam height. If measured height is below 1.5828 inch. (40.202 mm) for intake and 1.5638 inch. (39.721 mm) for exhaust replace camshaft.
  2.  
  3. Intake cam height standard reading 1.5906-1.5969 inch. (40.402-40.562 mm).
  4.  
  5. Exhaust cam height standard reading 1.5717-1.5780 inch. (39.921-40.081 mm).
  6.  
  7. Exhaust cam height standard reading for 2.7L is 1.5906-1.5969 (40.402-40.562 mm).
  8.  

Runout
  1. Set camshaft between two -V- blocks, and measure its runout by using a dial gauge. If measured runout exceeds 0.0039 inch. (0.10 mm ), replace camshaft.
  2.  
  3. Check valve lash adjuster for pitting, scratches, or damage. If any malcondition is found, replace.
  4.  
  5. Measure cylinder head bore and adjuster outside diameter to determine cylinder head-to-adjuster clearance. If clearance exceeds limit, replace adjuster or cylinder head.
  6.  

Valve Lash Adjusters

NOTE
Valve lash adjusters are used on these engines.

  1. Valve lash adjuster O.D standard reading 1.2189-1.2195 inch. (30.959-30.975 mm).
  2.  
  3. Cylinder head bore standard reading 1.2205-1.2215 inch. (31.000-31.025 mm).
  4.  
  5. Cylinder head to adjuster clearance 0.0010-0.0026 inch. (0.025-0.066 mm).
  6.  
  7. Cylinder head adjuster clearance limit 0.0059 inch. (0.15 mm).
  8.  
  9. If case of the following, valve lash adjuster noise may be caused by air trapped into valve lash adjusters:

    Vehicle is left for 24 hours or more.
     
    Engine oil is changed.
     
    Hydraulic lash adjuster is replaced or reinstalled.
     
    Engine is overhauled.
     
    If noise from valve lash adjusters is suspected, perform the following checks.
     
    Check engine oil for the followings.
     
    Oil level in oil pan. If oil level is low, add oil up to full level hole on oil level gauge.
     
    Oil quality. If oil is discolored, or deteriorated, change it.
     
    Oil leaks - If leak is found, repair it.
     
    Oil pressure. If defective pressure is found, repair it.
     

  10.  
  11. Run engine for about half an hour at about 2000 to 3000 rpm, and then air will be purge and tapping sound will cease.
  12.  
  13. Should tapping sound not cease, it is possible that hydraulic valve lash adjuster is defective.
  14.  
  15. Replace it if defective. If defective adjuster can-t be located by hearing among 16 of them. check as follows.
    1. Stop engine and remove cylinder head cover.
    2.  
    3. Push adjuster downward hard (with less than 44 ft. lbs. force) when cam crest is not on adjuster check if clearance exists between cam and adjuster. If it does, adjuster is defective and needs replacement.
    4.  

  16.  

Removal & Installation



1.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Radiator
     
    Accessory drive belts
     
    Crankshaft pulley
     
    Front cover
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Camshaft sprocket
     
    Valve cover
     
    Distributor and case, if equipped
     
    Camshaft Position (CMP) sensor and case, if equipped
     

  6.  
  7. Loosen the rocker arm locknuts and back the valve adjusters off until all rocker arms move freely with no tension.
  8.  
  9. Remove or disconnect the following:

    Camshaft bearing caps. Loosen the bolts in reverse of the tightening sequence.
     
    Camshaft

    Click image to see an enlarged view

    Fig. Camshaft housing torque sequence-1.6L engine



    Click image to see an enlarged view

    Fig. Exploded view of the valve train components-1.6L engine

     

  10.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft bearing caps. Tighten the bolts in sequence to 96 inch lbs. (11 Nm).
     
    CMP sensor and case, if equipped
     
    Distributor and case, if equipped
     
    Camshaft sprocket. Tighten the bolt to 44 ft. lbs. (60 Nm).
     
    Timing belt and adjust the valve clearance
     
    Valve cover
     
    Front cover
     
    Crankshaft pulley. Tighten the bolts to 12 ft. lbs. (16 Nm).
     
    Accessory drive belts
     
    Radiator
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Radiator
     
    Accessory drive belts
     
    Crankshaft pulley
     
    Front cover
     
    Timing belt
     
    Camshaft sprocket
     
    Valve cover
     
    Distributor and case, if equipped
     
    Camshaft Position (CMP) sensor and case, if equipped
     

  6.  
  7. Loosen the rocker arm locknuts and back the valve adjusters off until all rocker arms move freely with no tension.
  8.  
  9. Remove or disconnect the following:

    Camshaft bearing caps. Loosen the bolts in reverse of the tightening sequence.
     
    Camshaft

    Click image to see an enlarged view

    Fig. Camshaft housing torque sequence-1.6L engine



    Click image to see an enlarged view

    Fig. Exploded view of the valve train components-1.6L engine

     

  10.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft bearing caps. Tighten the bolts in sequence to 96 inch lbs. (11 Nm).
     
    CMP sensor and case, if equipped
     
    Distributor and case, if equipped
     
    Camshaft sprocket. Tighten the bolt to 44 ft. lbs. (60 Nm).
     
    Timing belt and adjust the valve clearance
     
    Valve cover
     
    Front cover
     
    Crankshaft pulley. Tighten the bolts to 12 ft. lbs. (16 Nm).
     
    Accessory drive belts
     
    Radiator
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

1.8L And 2.0L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for installation.



    Negative battery cable
     
    Oil pan
     
    Valve cover
     
    Accessory drive belts
     
    Crankshaft pulley
     
    Front cover
     
    Secondary timing chain
     
    Camshaft Position (CMP) sensor
     



    Camshaft bearing caps. Loosen the bolts in several steps in reverse of the tightening sequence.
     
    Camshafts
     
    Hydraulic lash adjusters

    Click image to see an enlarged view

    Fig. Camshaft housing torque sequence-1.8L and 2.0L engines

     

  8.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Camshafts
     
    Camshaft bearing caps in their original positions. Tighten the bolts in several steps in sequence to 96 inch lbs. (11 Nm).
     
    CMP sensor
     
    Secondary timing chain
     
    Front cover
     
    Crankshaft pulley. Tighten the bolt to 109 ft. lbs. (148 Nm).
     
    Accessory drive belts
     
    Valve cover
     
    Oil pan
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
    WARNING
    Wait 1 / 2 hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in interference between the valves and pistons.

  8.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for installation.



    Negative battery cable
     
    Oil pan
     
    Valve cover
     
    Accessory drive belts
     
    Crankshaft pulley
     
    Front cover
     
    Secondary timing chain
     
    Camshaft Position (CMP) sensor
     



    Camshaft bearing caps. Loosen the bolts in several steps in reverse of the tightening sequence.
     
    Camshafts
     
    Hydraulic lash adjusters

    Click image to see an enlarged view

    Fig. Camshaft housing torque sequence-2.0L engines

     

  8.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Camshafts
     
    Camshaft bearing caps in their original positions. Tighten the bolts in several steps in sequence to 96 inch lbs. (11 Nm).
     
    CMP sensor
     
    Secondary timing chain
     
    Front cover
     
    Crankshaft pulley. Tighten the bolt to 109 ft. lbs. (148 Nm).
     
    Accessory drive belts
     
    Valve cover
     
    Oil pan
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
    WARNING
    Wait 1 / 2 hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in interference between the valves and pistons.

  8.  

2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Oil pan
     
    Accessory drive belts
     
    Water pump pulley
     
    Crankshaft pulley
     
    Timing chain cover
     

  8.  
  9. Align the timing marks as shown.
    WARNING
    Do not allow the crankshaft or camshafts to rotate once the timing chains have been removed. Valve or piston damage could result.



    Click image to see an enlarged view

    Fig. Timing mark alignment-2.5L engine

  10.  
  11. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Left bank secondary timing chain
     
    Primary timing chain
     
    Valve covers
     



    Right bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown.
     
    Right bank secondary timing chain, exhaust and intake camshafts as an assembly
     
    Camshaft Position (CMP) sensor
     
    Left bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown.
     
    Left bank camshafts
     
    Hydraulic lash adjusters

    Click image to see an enlarged view

    Fig. Left bank camshaft housing loosening sequence-2.5L engine



    Click image to see an enlarged view

    Fig. Right bank camshaft housing loosening sequence-2.5L engine

     

  12.  

To install:

  1. Install or connect the following:
    WARNING
    Wait 1 / 2 hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in interference between the valves and pistons.



    Hydraulic lash adjusters in their original positions
     
    Left bank camshafts
     
    Left bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm).
     
    CMP sensor
     
    Right bank secondary timing chain, exhaust and intake camshafts as an assembly
     
    Right bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm).
     



    Valve covers. Tighten the bolts to 90 inch lbs. (10.5 Nm).
     
    Primary timing chain
     
    Left bank secondary timing chain
     
    Timing chain cover
     
    Crankshaft pulley. Tighten the bolt to 109 ft. lbs. (148 Nm).
     
    Water pump pulley
     
    Accessory drive belts
     
    Oil pan
     
    Intake manifold
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

2.5L, 2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Oil pan
     
    Accessory drive belts
     
    Water pump pulley
     
    Crankshaft pulley
     
    Timing chain cover
     

  8.  
  9. Align the timing marks as shown.
    WARNING
    Do not allow the crankshaft or camshafts to rotate once the timing chains have been removed. Valve or piston damage could result.



    Click image to see an enlarged view

    Fig. Timing mark alignment-2.5L engine

  10.  
  11. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Left bank secondary timing chain
     
    Primary timing chain
     
    Valve covers
     



    Right bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown.
     
    Right bank secondary timing chain, exhaust and intake camshafts as an assembly
     
    Camshaft Position (CMP) sensor
     
    Left bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown.
     
    Left bank camshafts
     
    Hydraulic lash adjusters

    Click image to see an enlarged view

    Fig. Left bank camshaft housing loosening sequence-2.5L engine



    Click image to see an enlarged view

    Fig. Right bank camshaft housing loosening sequence-2.5L engine

     

  12.  

To install:

  1. Install or connect the following:
    WARNING
    Wait 1 / 2 hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in interference between the valves and pistons.



    Hydraulic lash adjusters in their original positions
     
    Left bank camshafts
     
    Left bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm).
     
    CMP sensor
     
    Right bank secondary timing chain, exhaust and intake camshafts as an assembly
     
    Right bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm).
     



    Valve covers. Tighten the bolts to 90 inch lbs. (10.5 Nm).
     
    Primary timing chain
     
    Left bank secondary timing chain
     
    Timing chain cover
     
    Crankshaft pulley. Tighten the bolt to 109 ft. lbs. (148 Nm).
     
    Water pump pulley
     
    Accessory drive belts
     
    Oil pan
     
    Intake manifold
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove engine assembly from vehicle.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Ignition coils
     
    Valve covers
     
    Accessory drive belts
     
    Cooling fan and shroud
     
    Water pump pulley
     
    Radiator
     
    Power steering pump and brackets
     
    Oil pan and pickup tube
     
    Crankshaft pulley
     
    Front crankshaft seal
     
    Crankshaft Position (CKP) sensor
     
    Front cover

    Click image to see an enlarged view

    Fig. Timing chain alignment marks-2.7L Engine

     

  10.  
  11. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Left bank secondary timing chain
     
    Primary timing chain
     
    Valve covers
     



    Right bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown.
     
    Right bank secondary timing chain, exhaust and intake camshafts as an assembly
     
    Camshaft Position (CMP) sensor
     
    Left bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown.
     
    Left bank camshafts
     
    Hydraulic lash adjusters

    Click image to see an enlarged view

    Fig. Left bank camshaft housing loosening sequence-2.7L engine



    Click image to see an enlarged view

    Fig. Right bank camshaft housing loosening sequence-2.7L engine

     

  12.  

To install:

  1. Install or connect the following:
    WARNING
    Wait 1 / 2 hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in interference between the valves and pistons.



    Hydraulic lash adjusters in their original positions
     
    Left bank camshafts
     
    Left bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm).
     
    CMP sensor
     
    Right bank secondary timing chain, exhaust and intake camshafts as an assembly
     
    Right bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm).
     



    Valve covers. Tighten the bolts to 90 inch lbs. (10.5 Nm).
     
    Primary timing chain
     
    Left bank secondary timing chain
     
    Timing chain cover
     
    Crankshaft pulley. Tighten the bolt to 109 ft. lbs. (148 Nm).
     
    Water pump pulley
     
    Accessory drive belts
     
    Oil pan
     
    Intake manifold
     

  2.  
  3. Install engine assembly
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Fill the crankcase to the correct level.
  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

 
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