Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 133
1D-58 Engine Mechanical: For M16A Engine with VVT
2) Next, check bearing cap bore diameter without
bearing. On mating surface of cylinder block, five
alphabets are stamped as shown in the figure.
Three kinds of alphabets (“A”, “B” and “C”) or
numbers (“1”, “2” and “3”) represent the following
cap bore diameters.
Stamped alphabets or numbers on cylinder block
represent bearing cap bore diameter marked with an
arrow in the figure respectively.
For example, stamped “A” or “1” indicates that
corresponding bearing cap bore diameter is 56.0000
– 56.0060 mm (2.2048 – 2.2049 in.).
Crankshaft bearing cap bore
3) 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 crankshaft main bearing
thickness
4) From number stamped on crank web No.2 and
alphabets stamped on cylinder block, determine new
standard bearing to be installed to journal, by
referring to the table shown.
For example, if number stamped on crank web No.2
is “1” and alphabet stamped on cylinder block is “B”,
install a new standard bearing painted in “Brown” to
its journal.
New standard size crankshaft main bearing
specification
Stamped
alphabet
(number)
Bearing cap bore diameter (without
bearing)
A (1)
56.0000 – 56.0060 mm
(2.2048 – 2.2049 in.)
B (2)
56.0061 – 56.0120 mm
(2.2050 – 2.2051 in.)
C (3)
56.0121 – 56.0180 mm
(2.2052 – 2.2054 in.)
I2RH0B140143-02
Color
painted
Bearing thickness
Purple
1.992 – 1.996 mm (0.07843 – 0.07858 in.)
Brown
1.995 – 1.999 mm (0.07855 – 0.07870 in.)
Green
1.998 – 2.002 mm (0.07867 – 0.07882 in.)
Black
2.001 – 2.005 mm (0.07878 – 0.07893 in.)
Colorless
(no paint)
2.004 – 2.008 mm (0.07890 – 0.07906 in.)
1. Paint
Number stamped on crank
web No.2 (Journal diameter)
1
2
3
Alphabet
stamped on
cylinder block
(Cap bore dia.)
A (1) Purple
Brown
Green
B (2) Brown
Green
Black
C (3) Green
Black
Colorless
New standard bearing to be
installed
I2RH01140191-01
Engine Mechanical: For M16A Engine with VVT 1D-59
5) Using scale (1) on gauging plastic (2), check bearing
clearance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker
bearing and recheck clearance.
6) When replacing crankshaft or cylinder block due to
any reason, select new standard bearings to be
installed by referring to number stamped on new
crankshaft or alphabets stamped on new cylinder
block.
Undersize bearing (0.25 mm (0.0098 in.))
• 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness.
To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure.
Each color represents the following thickness at the center of bearing.
Undersize of crankshaft main bearing thickness
I2RH0B140141-01
Color painted
Bearing thickness
Red and Purple
2.117 – 2.121 mm (0.08335 – 0.08350 in.)
Red and Brown
2.120 – 2.124 mm (0.08347 – 0.08362 in.)
Red and Green
2.123 – 2.127 mm (0.08359 – 0.08374 in.)
Red and Black
2.126 – 2.130 mm (0.08371 – 0.08385 in.)
Red only
2.129 – 2.133 mm (0.08382 – 0.08397 in.)
1. Paint
I2RH01140192-01
1D-60 Engine Mechanical: For M16A Engine with VVT
• If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows.
a. Regrind journal to the following finished diameter.
Finished journal diameter
51.732 – 51.750 mm (2.0367 – 2.0374 in.)
b. Using micrometer, measure regrind journal diameter.
Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
c. Using journal diameter measured above and alphabets stamped on cylinder block, select an undersize bearing
by referring to the following table.
Check bearing clearance with newly selected undersize bearing.
New undersize crankshaft main bearing specification
Main Bearing Cap No.1 Bolt
Measure each thread diameter main bearing cap No.1
bolts (1) at “A” on 60 mm (2.36 in.) from seat side of
flange bolt and “B” on 90 mm (3.54 in.) from seat side of
flange bolt by using a micrometer (2).
Calculate difference in diameters (“A” – “B”).
Main bearing cap No.1 bolt diameter difference
Limit (“A” – “B”): 0.2 mm (0.008 in.)
Measured journal diameter
51.7440 – 51.7500 mm
(2.0372 – 2.0373 in.)
51.7380 – 51.7439 mm
(2.0370 – 2.0371 in.)
51.7320 – 51.7379 mm
(2.0367 – 2.0369 in.)
Alphabets stamped
on cylinder block
A (1)
Red and Purple
Red and Brown
Red and Green
B (2)
Red and Brown
Red and Green
Red and Black
C (3)
Red and Green
Red and Black
Red only
Undersize bearing to be installed
I2RH0B140144-01
“A”
“a”
“b”
“B”
1
1
2
I2RH0B140145-01
Engine Mechanical: For M16A Engine with VVT 1D-61
Sensor Plate Inspection
S6JB0A1416038
Check sensor plate for crack damage.
If malcondition is found, replace it.
Rear Oil Seal Inspection
S6JB0A1416039
Carefully inspect oil seal (1) for wear or damage. If its lip
is worn or damaged, replace it.
Flywheel Inspection
S6JB0A1416040
Visual Inspection
• If ring gear is damaged, cracked or worn, replace
flywheel.
• If the surface contacting clutch disc is damaged, or
excessively worn, replace flywheel.
Flywheel Face Runout
Check flywheel face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel face runout
Limit: 0.2 mm (0.0079 in.)
Cylinder Block Inspection
S6JB0A1416041
Distortion of Gasketed Surface
Using straightedge and thickness gauge, check
gasketed surface for distortion and, if flatness exceeds
its limit, correct It.
Cylinder block flatness
Limit: 0.05 mm (0.0020 in.)
Honing or Reboring Cylinders
1) When any cylinder needs reboring, all other
cylinders must also be rebored at the same time.
2) Select oversized piston according to amount of
cylinder wear.
Oversize piston specification
Oversize 0.50: 78.453 – 78.468 mm (3.0887 –
3.0893 in.)
3) Using micrometer, measure piston diameter.
Measurement position for piston diameter
“a”: 19.5 mm (0.77 in.)
4) Rebore and hone cylinder to the following
dimension.
NOTE
Before reboring, install all main bearing caps
in place and tighten to specification to avoid
distortion of bearing bores.
Cylinder bore diameter to be rebored
Oversize 0.50: 78.500 – 78.514 mm (3.0906 –
3.0911 in.)
5) Measure piston clearance after honing.
Piston clearance
0.032 – 0.061 mm (0.0013 – 0.0024 in.)
I2RH0B140151-01
I4RS0A140020-01
I2RH01140198-01
I2RH01140199-01
I2RH01140157-01
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