Suzuki Vitara, Grand Vitara, XL7 2000-06

Valve Lash (Clearance) Adjustment

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1.6L Engine




NOTE
Measure valve clearance with the engine cold.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the valve cover.
  4.  
  5. Set the engine to Top Dead Center (TDC) of the compression stroke for the cylinder to be adjusted.
  6.  
  7. Check the valve clearance. The valve clearance specifications are as follows:

    Intake valves: 0.005-0.007 inches (0.13-0.17mm)
     
    Exhaust valves: 0.005-0.007 inches (0.13-0.17mm)
     

  8.  
  9. After adjustment, tighten the locknuts to 11-14 ft. lbs. (15-19 Nm).
  10.  
  11. Repeat for each valve to be adjusted.
  12.  


NOTE
Measure valve clearance with the engine cold.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the valve cover.
  4.  
  5. Set the engine to Top Dead Center (TDC) of the compression stroke for the cylinder to be adjusted.
  6.  
  7. Check the valve clearance. The valve clearance specifications are as follows:

    Intake valves: 0.005-0.007 inches (0.13-0.17mm)
     
    Exhaust valves: 0.005-0.007 inches (0.13-0.17mm)
     

  8.  
  9. After adjustment, tighten the locknuts to 11-14 ft. lbs. (15-19 Nm).
  10.  
  11. Repeat for each valve to be adjusted.
  12.  

1.8L, 2.0L & 2.5L Engines



The 1.8L, 2.0L and 2.5L engines utilize automatic hydraulic lash adjusters to maintain proper valve lash at all times. Periodic valve lash inspection and adjustment is not necessary or possible.

2.0L, 2.5L, 2.7L Engines



2.0L, 2.5L and 2.7L engines utilize automatic hydraulic lash adjusters to maintain proper valve lash at all times. Periodic valve lash inspection and adjustment is not necessary or possible.

2.7L Engines



  1. Disconnect the negative battery cable.
  2.  
  3. Remove cylinder head covers.
  4.  
  5. Using 19 mm wrench, turn crankshaft pulley clockwise until timing mark -O- position of cylinder block and index of crankshaft pulley are aligned.
  6.  
  7. Check whether cam position of No.1 cylinder is at the specified position [A] as shown in figure.
  8.  
  9. If cam position is [B], locate cam position to [A] by turning crankshaft one rotation.
  10.  
  11. Check valve lashes with thickness gauge according to the following procedure.
    1. Check valve lashes of cylinder No.1.
    2.  
    3. Turn crankshaft pulley by 120° clockwise.
    4.  
    5. Check valve lashes of cylinder No.6.
    6.  
    7. In the same manner as (b)-(c), check valve lashes of cylinder No.5, cylinder No.4, cylinder No.3 then cylinder No.2.
    8.  

  12.  
  13. If valve lash is out of specification, record valve lash and adjust it to specification by replacing shim.
  14.  
  15. Cold engine intake valve clearance specification 0.007-0.008 inch. (0.18-0.22 mm).
  16.  
  17. Hot engine intake valve clearance specification 0.008-0.011 inch. (0.21-0.27 mm).
  18.  
  19. Cold engine exhaust valve clearance specification 0.011-0.012 inch. (0.28-0.32 mm).
  20.  
  21. Hot engine exhaust valve clearance specification 0.012-0.014 inch. (0.30-0.36 mm).

    Click image to see an enlarged view

    Fig. Checking valve lash 2.7L-2006

  22.  
  23. Close the valve whose shim is to be replaced by turning crankshaft, then turn tappet till its cut section faces inside.
  24.  
  25. Lift down the valve by turning crankshaft to 360°.
  26.  
  27. Hold tappet at that position using special tool (A): 09916-66510 as follows.
    1. Remove its housing bolts.
    2.  
    3. Check housing No. and select special tool corresponding to housing No.
    4.  
    5. Numbers on camshaft housing are marked for intake and exhaust. Select corresponding tool for intake or exhaust.

      Click image to see an enlarged view

      Fig. Tool (A): 09916-66510

    6.  

  28.  
  29. Hold down the tappet so as not to contact the shim by installing special tool on camshaft housing with housing bolt tighten housing bolts to 7 ft. lbs. (11 Nm).

    Click image to see an enlarged view

    Fig. Tool (A): 09916-66510 installation

  30.  
  31. Turn camshaft by approximately 90° clockwise and remove shim.

    Click image to see an enlarged view

    Fig. Shim removal shown

  32.  
  33. Using a micrometer, measure the thickness of the removed shim, and determine replacement shim by calculating the thickness of new shim with the following formula and table.
    NOTE
    For example of intake side: When thickness of removed shim is 0.094 inch. (2.400 mm), and measured valve clearance is 0.018 inch. (0.450 mm). A = 0.094 inch. (2.400 mm) + 0.018 inch. (0.450 mm)-0.008 inch. (0.200 mm) = 0.104 inch. (2.650 mm) Calculated thickness of new shim = 0.104 inch. (2.650 mm)



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

  34.  
  35. Select new shim No. (1) with a thickness as close as possible to calculated value.

    Click image to see an enlarged view

    Fig. Valve lash shim chart 2.7L-2006

  36.  
  37. Install new shim facing shim No. side with tappet.
  38.  
  39. Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step and remove special tool.
  40.  
  41. Install camshaft housing and tighten bolts to 8 ft. lbs. (11 Nm).
  42.  
  43. Turn crankshaft pulley more than 4 rotations.
  44.  
  45. Check valve clearance again after adjusting it.
  46.  
  47. After checking and adjusting all valves.
  48.  
  49. Install cylinder head covers.
  50.  
  51. Connect the negative battery cable.
  52.  

 
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