Suzuki Grand Vitara JB416 / JB420. Manual — part 96

1D-52 Engine Mechanical: For M16A Engine with VVT

Main Bearings, Crankshaft and Cylinder Block Components

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Engine Mechanical: For M16A Engine with VVT 1D-53

Main Bearings, Crankshaft and Cylinder Block
Removal and Installation

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Removal

1) Remove engine assembly from vehicle referring to

“Engine Assembly Removal and Installation: For
M16A Engine with VVT”.

2) Remove clutch cover, clutch disc and flywheel by

using special tool.

Special tool
(A): 09924–17810

3) Remove piston and connecting rod referring to

“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation: For M16A
Engine with VVT”.

4) Remove rear oil seal housing (1).

5) Loosen main bearing cap No.1 and No.2 bolts in

such order as indicated in the figure and remove
them.

6) Remove crankshaft from cylinder block.

1. CKP sensor (if equipped)

: See “A”

10. Rear oil seal housing

: See “C”

19. Spring pin

2. Knock sensor

11. Rear oil seal

20. Sensor plate bolt

3. Cylinder block

12. Input shaft bearing

21. Oil pressure switch

4. Venturi plug

13. Flywheel

: 22 N

⋅m (2.2 kgf-m, 16.0 lb-ft)

5. Main bearing

: See “B”

14. Main bearing cap

: 5 N

⋅m (0.5 kgf-m, 4.0 lb-ft)

6. Sensor plate

15. Flywheel mounting bolt

: 70 N

⋅m (7.0 kgf-m, 51.0 lb-ft)

7. Crankshaft timing sprocket key

16. Rear oil seal housing mounting bolt

: Tighten 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified

procedure.

8. Crankshaft

17. Main bearing cap No.2 bolt

: Tighten 30 N

⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-

m, 36.5 lb-ft) and 60

° by the specified procedure.

9. Thrust bearing

18. Main bearing cap No.1 bolt

: See “D”

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

“A”: When installing CKP sensor, use new sensor mounting bolt.

: 13 N

⋅m (1.3 kgf-m, 9.5 lb-ft)

“B”: Upper half of bearing has an oil groove.

Do not apply oil between connecting rod and bearing or between bearing cap and
bearing.

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

“C”: Apply sealant 99000-31250 to mating surface.

: Do not reuse.

“D”: Check main bearing cap No.1 bolt, plastic deformation tightening bolt, for deformation

referring to “Main Bearing Cap No.1 Bolt” under “Main Bearings Inspection: For M16A
Engine with VVT”, if it is reused.

: Apply engine oil to inside / sliding surface.

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1D-54 Engine Mechanical: For M16A Engine with VVT

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, bearing caps,

connecting rods, rod bearings, 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.

1) Install sensor plate (1) to crankshaft (2) and tighten

bolts to specified torque.

NOTE
When installing sensor plate, align spring pin
(3) on crankshaft and hole of sensor plate.

Tightening torque
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)

2) Install main bearings to cylinder block.

Upper half of bearing (1), has an oil groove (2).
Install it to cylinder block (3), and the other half
without oil groove to bearing cap.
Make sure that two halves are painted in the same
color.

3) Install thrust bearings (1) to cylinder block between

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

4) Confirm that dowel pins (3) are installed to intake

side of each journal.

5) Install crankshaft to cylinder block.
6) Install bearing cap to cylinder block, making sure to

point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts ((1) – (10)) and main bearing cap No.2 bolts
((11) – (20)), tighten them gradually as follows.

NOTE
If main bearing cap No.1 bolt is reused, make
sure to check main bearing cap No.1 bolt for
deformation referring to “Main Bearing Cap
No.1 Bolt” under “Main Bearings Inspection:
For M16A Engine with VVT”.

a) Tighten bolts ((1) – (10)) to 30 N

⋅m (3.0 kgf-m,

22.0 lb-ft) according to numerical order as shown
by using a 12 corner socket wrenches.

b) In the same manner as in Step a), tighten them

to 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft).

c) In the same manner as in Step a), retighten them

to 60

°.

d) Tighten bolts ((11) – (20)) to 25 N

⋅m (2.5 kgf-m,

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

Tightening torque
Main bearing cap No.1 bolt ((1) – (10)): 30
N

⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-m,

36.5 lb-ft) and then retighten by turning
through 60

°

Main bearing cap No.2 bolt ((11) – (20)): 25
N·m (2.5 kgf-m, 18.0 lb-ft)

CAUTION

!

After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 N

⋅m (1.2 kgf-m, 9.0 lb-ft)

torque or below.

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Engine Mechanical: For M16A Engine with VVT 1D-55

7) If necessary, press-fit rear oil seal (1) to oil seal

housing (2) by using special tool as shown in the
figure.

Special tool
(A): 09911–97821

Crank rear oil seal installing position
(dimension)
“a”: 2 mm (0.08 in.)

8) Apply sealant to mating surface of rear oil seal

housing (1).

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

Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)

9) Install rear oil seal housing (1) and tighten new bolts

to specified torque by using special tool.

Special tool
(A): 09911–97720

Tightening torque
Rear oil seal housing bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)

10) Install flywheel (for M/T).

Using special tool, lock flywheel, and tighten
flywheel bolts to specified torque.

NOTE
Use new flywheel bolts.

Special tool
(A): 09924–17810

Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)

11) Install piston and connecting rod referring to

“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation: For M16A
Engine with VVT”.

12) Install engine assembly to vehicle referring to

“Engine Assembly Removal and Installation: For
M16A Engine with VVT”.

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A: Crankshaft side

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