Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 130

1D-46 Engine Mechanical: For M16A Engine with VVT

Piston clearance
Standard: 0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Standard (piston with coating (new one)): 0.016 –
0.045 mm (0.0006 – 0.0018 in.)
Limit: 0.161 mm (0.0065 in.)

Ring groove clearance
Before checking, piston grooves must be clean, dry and
free of carbon deposits.
Fit new piston ring (1) into piston groove, and measure
clearance between ring and ring land by using thickness
gauge (2). If clearance is out of specification, replace
piston.

Ring groove clearance

Piston Ring
Piston ring end gap
To measure end gap, insert piston ring (2) into cylinder
bore and then measure the gap by using thickness
gauge (1).
If measured gap exceeds limit, replace ring.

NOTE
Decarbonize and clean top of cylinder bore
before inserting piston ring.

Piston ring end gap

“a”: 19.5 mm (0.77 in.)

Standard

Limit

Top ring

0.03 – 0.07 mm

(0.0012 – 0.0028 in.)

0.12 mm (0.0047 in.)

2nd ring

0.02 – 0.06 mm

(0.0008 – 0.0024 in.)

0.10 mm (0.0039 in.)

Oil ring

0.03 – 0.17 mm

(0.0012 – 0.0067 in.)

—

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Item

Standard

Limit

Top ring

0.20 – 0.35 mm

(0.0079 – 0.0138 in.)

0.7 mm (0.0276 in.)

2nd ring

0.35 – 0.50 mm

(0.0138 – 0.0197 in.)

1.0 mm (0.0394 in.)

Oil ring

0.20 – 0.70 mm

(0.0079 – 0.0276 in.)

1.2 mm (0.0472 in.)

“a”: 120 mm (4.72 in.)

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Engine Mechanical: For M16A Engine with VVT 1D-47

Piston Pins and Connecting Rods Inspection

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Piston Pin
Visual inspection
Check piston pin, connecting rod small end bore and
piston bore for wear or damage, paying particular
attention to condition of small end bore bush. If pin,
connecting rod small end bore or piston bore is badly
worn or damaged, replace pin, connecting rod and/or
piston.

Piston pin clearance
Check piston pin clearance in small end and piston.
Replace connecting rod and/or piston if its small end is
badly worn or damaged or if measured clearance
exceeds limit.

Piston pin clearance in connecting rod small end
Standard: 0.003 – 0.014 mm (0.0001 – 0.0006 in.)
Limit: 0.05 mm (0.00020 in.)

Piston pin clearance in piston
Standard: 0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Limit: 0.05 mm (0.0020 in.)

Small-end bore
20.003 – 20.011 mm (0.7875 – 0.7878 in.)

Piston pin dia.
19.997 – 20.000 mm (0.7873 – 0.7874 in.)

Piston bore
20.006 – 20.014 mm (0.7876 – 0.7880 in.)

Connecting Rod
Big-end side clearance
Check big-end of connecting rod for side clearance, with
rod fitted and connected to its crank pin in the normal
manner. If measured clearance is found to exceed its
limit, replace connecting rod.

Big-end side clearance
Standard: 0.25 – 0.40 mm (0.0098 – 0.0157 in.)
Limit: 0.55 mm (0.0217 in.)

Connecting rod alignment
Mount connecting rod on aligner to check it for bow and
twist. If measured value exceeds the limit, replace it.

Connecting rod alignment
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)

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1D-48 Engine Mechanical: For M16A Engine with VVT

Connecting rod bolt deformation (Plastic
deformation tightening bolt)
Measure each thread diameter of connecting rod bolt (2)
at “A” on 32 mm (1.25 in.) from bolt mounting surface
and “B” on 40 mm (1.57 in.) from bolt mounting surface
by using a micrometer (3).
Calculate difference in diameters (“A” – “B”). If it is
exceeds limit, replace connected rod (1).

Connecting rod bolt measurement points
“a”: 32 mm (1.25 in.)
“b”: 40 mm (1.57 in.)

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

Crank Pin and Connecting Rod Bearings
Inspection

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Crank Pin Diameter
Inspect crank pin for uneven wear or damage. Measure
crank pin for out-of-round or taper with a micrometer. If
crank pin is damaged or out-of round or taper is out of
limit, replace crankshaft or regrind crank pin to undersize
and use undersize bearing.

Crank pin diameter

Out-of-round
A – B

Taper
a – b

Crank pin taper and out-of-round
Limit: 0.01 mm (0.0004 in.)

Connecting Rod Bearing General Information
Service connecting rod bearings are available in
standard size and 0.25 mm (0.0098 in.) undersize
bearing, and standard size bearing has 5 kinds of
bearings differing in tolerance.
For identification of undersize bearing, it is painted red at
the position as indicated in the figure, undersize bearing
thickness is 1.605 – 1.615 mm (0.0632 – 0.0635 in.) at
the center of it.

Connecting Rod Bearing Visual Inspection
Inspect bearing shells for signs of fusion, pitting, burn or
flaking and observe contact pattern. Bearing shells
found in defective condition must be replaced.

Connecting rod bearing

size

Crank pin diameter

Standard

41.982 – 42.000 mm

(1.6528 – 1.6535 in.)

0.25 mm (0.0098 in.)
undersize

41.732 – 41.750 mm

(1.6430 – 1.6437 in.)

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1. Red paint

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Engine Mechanical: For M16A Engine with VVT 1D-49

Connecting Rod Bearing Clearance

1) Before checking bearing clearance, clean bearing

and crank pin.

2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gauging plastic (1) to full width of

crank pin as contacted by bearing (parallel to
crankshaft), avoiding oil hole.

4) Install rod bearing cap (1) to connecting rod.

When installing cap, be sure to point arrow mark (2)
on cap to crankshaft pulley side, as shown in the
figure. After applying engine oil to rod bolts, tighten
cap nuts (3) gradually as follows.
a) Tighten all cap nuts to 15 N

⋅m (1.5 kgf-m, 11.0 lb-

ft)

b) Retighten them to 45

°

c) Repeat Step b) once again.

Tightening torque
Connecting rod bearing cap nut (a): 15 N

⋅m

(1.5 kgf-m, 11.0 lb-ft) and then retighten by
turning through 45

° twice

5) Remove cap and using a scale (1) on gauging

plastic envelope (2), measure gauging plastic (2)
width at the widest point (clearance).
If clearance exceed its limit, use a new standard size
bearing referring to “Selection of Connecting Rod
Bearings: For M16A Engine with VVT”.
After selecting new bearing, recheck clearance.

Connecting rod bearing clearance
Standard: 0.029 – 0.047 mm (0.0011 – 0.0018 in.)
Limit: 0.065 mm (0.0026 in.)

6) If clearance can not be brought to its limit even by

using a new standard size bearing, use next thicker
bearing and recheck clearance or regrind crank pin
to undersize and use 0.25 mm undersize bearing.

Selection of Connecting Rod Bearings

NOTE

• If bearing is in malcondition, or bearing

clearance is out of specification, select a
new standard bearing according to the
following procedure and install it.

• When replacing crankshaft or connecting

rod and its bearing due to any reason,
select new standard bearings to be
installed by referring to numbers stamped
on connecting rod and its cap and/or
alphabets stamped on crank web of No.3
cylinder.

1) Check stamped numbers on connecting rod and its

cap as shown.
Three kinds of numbers (“1”, “2” and “3”) represent
the following connecting rod big end inside
diameters.
For example, stamped number “1” indicates that
corresponding connecting rod big end inside
diameter is 45.000 – 45.006 mm (1.7717 – 1.7718
in.).

Connecting rod big end inside diameter

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Stamped
numbers

Connecting rod big end inside diameter

1

45.0000 – 45.0060 mm (1.7717 – 1.7718 in.)

2

45.0061 – 45.0120 mm (1.7719 – 1.7721 in.)

3

45.0121 – 45.0180 mm (1.7722 – 1.7723 in.)

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