Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 147

1D-114 Engine Mechanical: For J20 Engine

Piston pin
• 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 or
piston.

• Piston pin clearance: Check piston pin clearance in

small end.
Replace connecting rod if its small end is badly worn
or damaged or if measured clearance exceeds limit.

Piston pin clearance in small end
Standard: 0.003 – 0.014 mm (0.0001 – 0.0005 in.)

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

Small-end bore
21.003 – 21.011 mm (0.8269 – 0.8272 in.)

Piston pin diameter [B]
20.997 – 21.000 mm (0.8267 – 0.8268 in.)

Piston bore [A]
21.006 – 21.014 mm (0.8270 – 0.8273 in.)

Piston rings
To measure end gap, insert piston ring (2) into cylinder
bore and then measure the gap by using thickness
gauge (1).
If measured gap is out of specification, replace ring.

NOTE
Clean carbon and any other dirt from top of
cylinder bore before inserting piston ring.

Piston ring end gap

Piston rings end gap
“a”: 120 mm (4.72 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

I5JB0A142054-02

Item

Standard

Limit

Top

ring

0.20 – 0.33 mm

(0.0079 – 0.0129 in.)

0.7 mm (0.0276 in.)

2nd

ring

0.33 – 0.48 mm

(0.0129 – 0.0188 in.)

0.7 mm (0.0276 in.)

Oil ring

0.20 – 0.50 mm

(0.0079 – 0.0196 in.)

1.8 mm (0.0709 in.)

Standard

Limit

0.25 – 0.40 mm

(0.0099 – 0.0150 in.)

0.45 mm (0.0177 in.)

I2RH01140161-01

I4RH01140041-01

Engine Mechanical: For J20 Engine 1D-115

• Connecting rod alignment:

Mount connecting rod on aligner to check it for bow
and twist. If limit is exceeded, replace it.

Limit on bow
0.05 mm (0.0020 in.)

Limit on twist
0.10 mm (0.0039 in.)

Crank pin and connecting rod bearings
• 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 referring to the following step 6).

Connecting rod bearing and crank pin

Out-of-round
“A” – “B”

Taper
“a” – “b”

Out-of-round and taper limits
0.01 mm (0.0004 in.)

• Connecting rod bearing general information:

Inspect bearing shells for signs of fusion, pitting, burn
or flaking and observe contact pattern. Bearing shells
found in defective condition must be replaced.
Two kinds of connecting rod bearings are available;
standard size bearing and 0.25 mm (0.0098 in.)
undersize bearing. For identification of undersize
bearing, it is painted red (1) 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 clearance:

a. Before checking bearing clearance, clean bearing

and crank pin.

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

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

Item

Standard

Crank pin diameter

49.982 – 50.000 mm

(1.9768 – 1.9685 in.)

I4RH01140053-01

I2RH01140163-01

I2RH01140164-01

I2RH01140165-01

1D-116 Engine Mechanical: For J20 Engine

d. Install connecting rod bearing cap (1) as follows.

i.

Point arrow mark (2) on cap to crankshaft
pulley side.

ii. Apply engine oil to connecting rod bolts (3).
iii. Tighten all connecting rod bolts to 15 N

⋅m (1.5

kgf-m, 11.0 lb-ft).

iv. Retighten them by turning through 45

°.

v. Repeat step d) once again.

Tightening torque
Connecting rod bolt (a): Tighten 15 N

⋅m

(1.5 kgf-m, 11.0 lb-ft), 45

° and 45° by the

specified procedure.

NOTE
Do not turn crankshaft with gauging plastic
installed.

e. Remove connecting rod bearing cap, and using a

scale (2) on gauging plastic envelope, measure
gauging plastic (1) width at the widest point
(clearance).
If clearance exceeds its limit, select connecting
rod bearing referring to “Pistons, Piston Rings,
Connecting Rods and Cylinders Inspection and
Cleaning: For J20 Engine” below mentioned item.
After selecting new bearing, recheck clearance.

Bearing clearance

f.

If clearance can not be brought to within its limit
even by using a new standard size bearing,
replace crankshaft or regrind crankpin to
undersize as follows.
– Install 0.25 mm undersize bearing to

connecting rod big end.

– Measure bore diameter of connecting rod big

end.

– Regrind crankpin to the following finished

diameter.

– Confirm that bearing clearance is within the

standard value.

NOTE
After checking the connecting rod bearing
clearance, make sure that checking for
“Connecting rod bolt deformation”.

• 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 referring to numbers stamped on
connecting rod and its cap and/or
alphabets stamped on crank web of No. 3
cylinder.

Standard

Limit

0.045 – 0.063 mm

(0.0018 – 0.0025 in.)

0.08 mm (0.0031 in.)

I4RH01140037-01

I2RH01140167-01

Finished
crankpin

diameter

=

Measured big end bore

diameter (including

undersize bearing)

–

0.054 mm

(0.0021 in.)

Engine Mechanical: For J20 Engine 1D-117

a. 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 53.0000 – 53.0060 mm (2.0867 –
2.0868 in.).

Connecting rod big-end inside diameter

b. Next, check crank pin diameter. On crank web of

No. 3 cylinder, four alphabets are stamped as
shown in the figure.
Three kinds of alphabet (“A”, “B” and “C”)
represent the following crank pin diameter
respectively.
For example, stamped “A” indicates that
corresponding crank pin diameter is 49.9940 –
50.0000 mm (1.9683 – 1.9685 in.).

Crank pin diameter

Stamped numbers

Connecting rod big-end

inside diameter

1

53.0000 – 53.0060 mm

(2.0867 – 2.0868 in.)

2

53.0061 – 53.0120 mm

(2.0869 – 2.0870 in.)

3

53.0121 – 53.0180 mm

(2.0871 – 2.0873 in.)

[A]: Weight indication mark (It is not necessary in servicing)
[B]: Connecting rod big-end inside diameter number

I2RH01140210-01

Stamped alphabet

Crank pin diameter

(without bearing)

A

49.9940 – 50.0000 mm

(1.9683 – 1.9685 in.)

B

49.9880 – 49.9939 mm

(1.9681 – 1.9682 in.)

C

49.9820 – 49.9879 mm

(1.9677 – 1.9680 in.)

[A]: Crankshaft pin diameter for No.1 cylinder
[B]: Crankshaft pin diameter for No.2 cylinder

[C]: Crankshaft pin diameter for No.3 cylinder
[D]: Crankshaft pin diameter for No.4 cylinder

I5JB0A142055-01