Suzuki Grand Vitara JB416 / JB420. Manual — part 98
1D-60 Engine Mechanical: For M16A Engine with VVT
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
• 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.
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
I2RH0B140144-01
Engine Mechanical: For M16A Engine with VVT 1D-61
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.)
Sensor Plate Inspection
S5JB0A1416039
Check sensor plate for crack damage.
If malcondition is found, replace it.
Rear Oil Seal Inspection
S5JB0A1416040
Carefully inspect oil seal (1) for wear or damage. If its lip
is worn or damaged, replace it.
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
“A”
“a”
“b”
“B”
1
1
2
I2RH0B140145-01
I2RH0B140151-01
I4RS0A140020-01
1D-62 Engine Mechanical: For M16A Engine with VVT
Flywheel Inspection
S5JB0A1416041
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
S5JB0A1416042
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.)
I2RH01140198-01
I2RH01140199-01
I2RH01140157-01
Engine Mechanical: For M16A Engine with VVT 1D-63
Specifications
Tightening Torque Specifications
S5JB0A1417001
NOTE
The specified tightening torque is also described in the following.
“Throttle Body and Intake Manifold Components: For M16A Engine with VVT”
“Engine Mountings Components: For M16A Engine with VVT”
“Timing Chain Cover Components: For M16A Engine with VVT”
“Timing Chain and Chain Tensioner Components: For M16A Engine with VVT”
“Camshaft, Tappet and Shim Components: For M16A Engine with VVT”
“Valves and Cylinder Head Components: For M16A Engine with VVT”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components: For M16A Engine with VVT”
“Main Bearings, Crankshaft and Cylinder Block Components: For M16A Engine with VVT”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.
Fastening part
Tightening torque
Note
N
⋅m
kgf-m
lb-ft
Camshaft housing bolts
8 N
⋅m (0.8 kgf-m, 6.0 lb-ft) for tightening of
special tool
Camshaft housing bolt
11
1.1
8.0
Cylinder head cover bolt
8
0.8
6.0
Air intake pipe bolt
3
0.3
2.5
Starting motor terminal nut
11
1.1
8.0
Generator terminal nut
7
0.7
5.0
Timing chain cover bolt and nut
25
2.5
18.0
Oil gallery pipe No.2 and No.3 bolt
11
1.1
8.0
Crankshaft pulley bolt
150
15.0
108.5
Oil control valve mounting nut
11
1.1
8.0
Oil gallery pipe No.1 bolt
30
3.0
21.5
Timing chain No.1 guide bolt
11
1.1
8.0
Timing chain tensioner bolt
25
2.5
18.0
Timing chain tensioner adjuster bolt
11
1.1
8.0
Intake cam timing sprocket bolt
60
6.0
43.5
Venturi plug
5
0.5
3.5
Cylinder head bolt for M8
25
2.5
18.0
Cylinder head bolt for M10
20 N
⋅m (2.0 kgf-m, 14.5 lb-ft), 40 N⋅m (4.0
kgf-m, 29.0 lb-ft) and then retighten by
turning through to 60
° twice
Connecting rod bearing cap nut
15 N
⋅m (1.5 kgf-m, 11.0 lb-ft) and then
retighten by turning through 45
° twice
Sensor plate bolt
11
1.1
8.0
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
2.5
18.0
Rear oil seal housing bolt
11
1.1
8.0
Flywheel bolt
70
7.0
51.0
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