Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 163

1D-178 Engine Mechanical: For F9Q Engine

Cylinder Head Inspection

S6JB0A1436028

• Remove all carbon deposits from combustion

chambers.

NOTE
Do not use any sharp-edged tool to scrape
off carbon deposits. Be careful not to scuff or
nick metal surfaces when decarbonizing. The
same applies to valves and valve seats, too.

• Check cylinder head for cracks on intake and exhaust

ports, combustion chambers, and head surface. Using
a straightedge and thickness gauge, check flatness of
gasketed surface at a total of 6 locations. If distortion
limit is exceeded, replace cylinder head.
Leakage of combustion gases from this gasketed joint
is often due to warped gasketed surface: such
leakage results in reduced power output.

Distortion for cylinder head surface on piston side
Limit: 0.05 mm (0.0020 in.)

Cylinder Head and Related Parts Specification (for
Reference)

Cylinder head with valve guide

I2RH0B140105-01

Item

Specification

Valve guide position “a”

80.65 – 81.45 mm

(3.1752 – 3.2066 in.)

Valve guide angle “b”

90

°

I2RH0B140106-01

I5JB0B140091-01

Engine Mechanical: For F9Q Engine 1D-179

Cylinder head

Cylinder head gasket

Valve Spring Inspection

S6JB0A1436029

Valve Spring Free Length and Preload
Referring to data, check to be sure that each spring is in
sound condition, free of any evidence of breakage or
weakening. Remember, weakened valve springs can
cause chatter, not to mention possibility of reducing
power output due to gas leakage caused by decreased
seating pressure.

Valve spring free length
44 – 48 mm (1.74 – 1.88 in.)

Valve spring preload
27 N (2.7 kg, 6.0 lb) for 37.5 mm (1.476 in.)
61.4 N (6.14 kg, 13.5 lb) for 27.5 mm (1.083 in.)

Item

Specification

Cylinder head height “a”

161.00 – 164.50 mm

(6.3386 – 6.4763 in.)

Valve seat

housing inside

diameter “b”

Intake valve

36.877 – 36.907 mm

(1.45185 – 1.45303 in.)

Exhaust

valve

33.500 – 33.529 mm

(1.31890 – 1.32003 in.)

Valve guide housing inside

diameter “c”

11.95 – 11.98 mm

(0.4705 – 0.4716 in.)

I5JB0B140092-01

I5JB0B140093-01

I5JB0B140094-01

Item

Specification

Cylinder head gasket

thickness “a”

1.27 – 1.37 mm

(0.0500 – 0.0539 in.)

“b”: Measured point

I5JB0B140095-01

I2RH01140143-01

1D-180 Engine Mechanical: For F9Q Engine

Piston, Piston Ring, Connecting Rod and Cylinder Components

S6JB0A1436030

Piston, Piston Ring and Connecting Rod
Removal and Installation

S6JB0A1436065

NOTE

• All parts to be installed must be perfectly

clean.

• Connecting rods, connecting rod bearings,

connecting rod bearing caps, pistons and
piston rings are in combination sets. Do
not disturb such combination and make
sure that each part goes back to where it
came from, when installing.

Removal

1) Remove engine assembly referring to “Engine

Assembly Removal and Installation: For F9Q
Engine”.

2) Remove cylinder head referring to “Valve and

Cylinder Head Assembly Removal and Installation:
For F9Q Engine”.

3) Remove oil pump referring to “Oil Pump, Oil Pump

Chain and Gasket Holder Plate Removal and
Installation: For F9Q Engine in Section 1E”.

4) Remove special tool.

Special tool
(A): 09912–46510

5

6

(a)

8

9

9

1

2

3

4

7

I5JB0B140096-01

1. Top ring

8. Piston pin

2. 2nd ring

9. Piston pin circlip

3. Oil ring

: Tighten 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft) and 40° by the specified procedure.

4. Piston

: Apply engine oil to sliding surface of each part.

5. Connecting rod

: Do not reuse.

6. Connecting rod bearing cap

: See “A”

“A”: Point arrow mark on cap to fly wheel side.

7. Connecting rod bearing

: See “B”

“B”: Do not apply oil between connecting rod and bearing and between bearing cap and bearing.

I5JB0B140024-01

Engine Mechanical: For F9Q Engine 1D-181

5) Mark cylinder number on all pistons, connecting rods

(1) and connecting rod bearing caps (2) using silver
pencil or quick drying paint (3) for installation.

6) Remove connecting rod bearing caps.
7) Decarbon top of cylinder bore before removing

piston from cylinder.

8) Push piston and connecting rod assembly out

through the top of cylinder bore.

9) Remove piston pin from connecting rod as follows.

a) Ease out piston pin circlips (1) as shown in

figure.

b) Force piston pin out.

10) Remove connecting rod bearings

11) Using piston ring expander, remove two

compression rings (1st and 2nd) and oil ring from
piston, if necessary.

Installation

1) Decarbonize piston head and ring grooves using a

suitable tool.

2) Install piston ring to piston noting the following, if

removed.
• As indicated in figure. 1st and 2nd rings have

“TOP” mark respectively. When installing these
piston rings to piston, direct marked side of each
ring toward top of piston.

• 1st ring (1) differs from 2nd ring (2) in thickness,

shape and color of surface contacting cylinder
wall.
Distinguish 1st ring from 2nd ring by as shown in
figure.

• When installing oil ring, install spring ring (3) first

and then rail (4).

3) Assemble connecting rod bearing to connecting rod /

bearing cap as follows.
a) Install special tool (B) to special tool (A).

Special tool
(A): 09913–98110
(B): 09913–86520

I5JB0B140097-01

I2RH0B140113-01

I2RH0B140114-01

I5JB0B140098-01

I5JB0B140099-01