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In this study, an enhanced numerical manifold method (NMM) simulator is developed to determine the combined impacts of reinforcement range and grouting timing on the effectiveness of grouting reinforcement for preventing the large deformation geo-hazard during the tunnel excavation through a fault rupture zone. To accomplish this objective, the limitations of the current two-dimensional simulation method, which lacks connection to the actual tunnel excavation process, are overcome by proposing a novel softening path function. Using this novel softening path function, each simulation step is given a specific physical meaning, establishing a connection to the actual tunnel excavation process. This improvement enables more accurate and analyzable simulation outcomes. To verify the accuracy of the proposed softening path function, a series of simulations of tunnel excavation are conducted using this softening path function. These results align closely with the results obtained by other reliable numerical methods and previous studies. After validation, several sets of numerical cases are conducted, considering 6 different geo-stress conditions, 10 different grouting reinforcement ranges, and 7 different grouting timings. Based on these simulation results, a critical value for reinforcement range, which equals to the diameter of tunnel face, is identified, and it is founded that delaying the grouting timing can increase the slurry migration range up to 94.6%. Furthermore, delaying the grouting timing can also reduce the convergence displacement of reinforced surrounding rocks after excavation up to 18.2% within a geo-stress range of 10 to 20 MPa. • A novel softening path function with clear physical meanings for tunnel excavation simulations is proposed. • A critical value of the grouting reinforcement range is identified. • Influences of grouting timing on the slurry migration range are revealed. • Influences of grouting timing on the convergence displacement of tunnels are revealed. [ABSTRACT FROM AUTHOR]