Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 148

1D-118 Engine Mechanical: For J20 Engine

c. There are 5 kinds of standard bearings differing in

thickness. To distinguish them, they are painted in
the following colors at the position as indicated in
the figure.
Each color indicated the following thickness at the
center of bearing.

Standard size of connecting rod bearing
thickness

d. From number stamped on connecting rod and its

cap and alphabet stamped on crank web No. 3
cylinder, determine new standard bearing to be
installed to connecting rod big-end inside, by
referring to the table.
For example, if number stamped on connecting
rod and its cap is “1” and alphabet stamped on
crank web No. 3 cylinder is “B”, install a new
standard bearing painted in “Black” to its
connecting rod big-end inside.

Specifications of new standard connecting rod
bearing size

e. Check bearing clearance with newly selected

standard bearing referring to “Crank pin and
connecting rod bearings: For J20 Engine”.
If clearance still exceeds its limit, use next thicker
bearing and recheck clearance.

• Connecting rod bolt

Measure each thread diameter of connecting rod bolts
(1) at “A” on 28.5 mm (1.12 in.) from bolt mounting
surface and “B” on 42.0 mm (1.65 in.) from bolt
mounting surface by using a micrometer (2).
Calculate difference in diameters (“A” – “B”). If it
exceeds limit, replace connecting rod.

Connecting rod bolt measurement points
“a”: 28.5 mm (1.12 in.)
“b”: 42.0 mm (1.65 in.)

Connecting rod bolt diameter difference
limit (“A” – “B”): 0.1 mm (0.004 in.)

Cleaning
Clean carbon from piston head and ring grooves, using a
suitable tool.

Color painted

Bearing thickness

Green

1.482 – 1.485 mm

(0.05835 – 0.05846 in.)

Black

1.485 – 1.488 mm

(0.05847 – 0.05858 in.)

Colorless

1.488 – 1.491 mm

(0.05859 – 0.05870 in.)

Yellow

1.491 – 1.494 mm

(0.05871 – 0.05881 in.)

Blue

1.494 – 1.497 mm

(0.05882 – 0.05893 in.)

1. Paint

Number stamped on
connecting rod and its cap
(Connecting rod big end inside
diameter)

1

2

3

Alphabet
stamped on
crank web of
No. 3 cylinder
(Crank pin
diameter)

A

Green

Black

Colorless

B

Black

Colorless

Yellow

C Colorless

Yellow

Blue

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1

2

1

‘‘a’’

‘‘b’’

‘‘A’’

‘‘B’’

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Engine Mechanical: For J20 Engine 1D-119

Main Bearings, Crankshaft and Cylinder Block Components

S6JB0A1426034

I5JB0A142056-02

1. Cylinder block

9. Check valve

17. Knock sensor

2. Lower crankcase

: Apply sealant 99000-31250 to mating surface.

10. Flywheel

: Tighten 40 N

⋅m (4.0 kgf-m, 29.0 lb-ft), 0

N

⋅m (0 kgf-m, 0 lb-ft), 40 N⋅m (4.0 kgf-m,

29.0 lb-ft) and 58 N

⋅m (5.8 kgf-m, 42.0

lb-ft) by the specified procedure.

3. Crankshaft

11. Water pump

: Tighten 26 N

⋅m (2.6 kgf-m, 19.0 lb-ft) by

the specified procedure.

4. O-ring

12. Heater outlet pipe

: 70 N

⋅m (7.0 kgf-m, 51.0 lb-ft)

5. Oil pump chain

13. CKP sensor

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

6. Main bearing

: Do not apply engine oil between cylinder block
and bearing, between lower crankcase and
bearing. Upper half of bearing has an oil groove.

14. Crankcase bolt (10 mm thread

diameter)

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

7. Thrust bearing

15. Crankcase bolt (8 mm thread diameter)

: Do not reuse.

8. Rear oil seal

16. Flywheel mounting bolt

: Apply engine oil to inside / sliding

surface.

1D-120 Engine Mechanical: For J20 Engine

Main Bearings, Crankshaft and Cylinder Block
Removal and Installation

S6JB0A1426035

Removal

1) Remove engine assembly from vehicle. Refer to

“Engine Assembly Removal and Installation: For J20
Engine”.

2) Remove clutch and flywheel (drive plate for A/T) by

using special tool.

Special tool
(A): 09924–17810

3) Remove pistons and connecting rods referring to

“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation: For J20 Engine”.

4) Remove CKP sensor (1).

5) Remove water pump (1) and heater outlet pipe.
6) Remove engine front mounting brackets (2).

7) Loosen crankcase bolts, in sequence shown in figure

and remove them.

8) Remove crankshaft from cylinder block.

Installation

NOTE

• All parts to be installed must be perfectly

clean.

• Be sure to oil crankshaft journals, journal

bearings, thrust bearings, crankpins,
connecting rod bearings, pistons, piston
rings and cylinder bores.

• Journal bearings, crankcase (bearings

caps), connecting rods, rod bearings, rod
bearing caps, pistons and piston rings are
in combination sets. Do not disturb
combination and try to see that each part
goes back to where it came from, when
installing.

• Clean mating surface of cylinder block and

lower crankcase, remove oil, old sealant
and dust from mating surface.

1. Flywheel bolt

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1. Lower crankcase
2. Crankcase bolts (10 mm thread diameter)
3. Crankcase bolts (8 mm thread diameter)

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(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

(21)

(22)

1

2

3

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Engine Mechanical: For J20 Engine 1D-121

1) Fit main bearings to cylinder block (1).

One of two halves of main bearing (4) has oil groove
(3).
Install this half with oil groove to cylinder block and
another half without oil groove to lower crankcase.
Make sure that two halves are painted in the same
color.

2) Install new O-ring (2) to cylinder block.
3) Install knock pins (5) to cylinder block.

4) Fit thrust bearings (1) to cylinder block between No.2

and No.3 cylinders. Face oil groove (2) sides to
crank webs.

5) Confirm that dowel pins (3) are installed to cylinder

block.

6) Put crankshaft (1) with oil pump chain to cylinder

block.

7) Apply sealant “A” to lower crankcase (1) mating

surface area as shown in figure.

“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)

Sealant amount for lower crankcase
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)

8) Install lower crankcase (1) to cylinder block.

After applying engine oil to all crankcase bolts ((1) –
(22)), tighten them gradually as follows.
a) Tighten bolts ((1) – (10)) to 30 N

⋅m (3.0 kgf-m,

21.5 lb-ft) according to numerical order as
shown.

b) Tighten bolts ((1) – (10)) to 42 N

⋅m (4.2 kgf-m,

30.5 lb-ft) according to numerical order as
shown.

c) In the same manner as in step a), tighten them to

the specified torque.

d) Tighten bolts ((11) – (22)) to the specified torque

according to numerical order as shown.

Tightening torque
Crankcase bolt with 10 mm thread diameter
((1) – (10)): Tighten 40 N

⋅m (4.0 kgf-m, 29.0

lb-ft), 0 N

⋅m (0 kgf-m, 0 lb-ft), 40 N⋅m (4.0 kgf-

m, 29.0 lb-ft) and 58 N

⋅m (5.8 kgf-m, 42.0 lb-ft)

by the specified procedure.
Crankcase bolt with 8 mm thread diameter
((11) – (22)): Tighten 26 N

⋅m (2.6 kgf-m, 19.0

lb-ft) by the specified procedure.

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I5JB0A142057-01

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2. Bearing

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