Suzuki Grand Vitara JB419. Manual — part 52

Engine Mechanical: 1D-54

4) Install bearing cap referring to connecting rod and

bearing cap referring to Step 9) of “Installation” under
“Piston, Piston Ring and Connecting Rod Removal
and Installation”.

5) Remove cap, and using a scale (1) on gauging

plastic envelope (2), measure gauging plastic (2)
width at the widest point (clearance).
If measured clearance is out of specification, use a
new connecting rod bearing.
After install new bearing, recheck clearance.

Connecting rod bearing clearance
0.027 – 0.086 mm (0.00107 – 0.00338 in.)

6) If clearance can not be brought to its specification

even by using a new connecting rod bearing and/or
replace crankshaft.

Piston Protrusion

1) Install piston and connecting rod assembly to

cylinder block referring to Step 1) through 9) of
“Install” under “Piston, Piston Ring and Connecting
Rod Removal and Installation”.

2) Using special tool and dial gauge, measure piston

protrusion at specified position (2) as shown in figure
when piston (1) reaches top dead center. Repeat this
procedure with each piston.If measured protrusion is
out of specification, proceed to next step.

Piston protrusion
“a”: 0.50 – 0.62 mm (0.0197 – 0.0244 in.)

3) Check connecting rod length referring to

“Connecting Rod and Related Parts Specification
(for Reference)” under “Cylinders, Pistons and
Piston Rings Inspection”.If connecting rod is normal,
proceed to next step.

4) Replace piston (1) as follows in order to adjust piston

protrusion to specified value.
a) Remove piston, and measure the following

specification.
• Piston pin hole diameter “b”
• Distance “c” between top of piston and top of

piston pin hole

b) Obtain distance “d” between top of piston and

center of piston pin hole by formula below.
“d” = “b” / 2 + “c”

c) Using piston protrusion “a” measured at Step 2),

obtain adjusting distance “e” by formula below.
“e” = “d” + 0.56 mm (0.0220 in.) – “a”
Example:
When distance “d” of removed piston is 47.026
mm (1.85142 in.), and measured piston
protrusion “a” is 0.45 mm (0.0177 in.)
Calculated adjusting distance “e” = 47.026 mm
(1.85142 in.) + 0.56 mm (0.0220 in.) – 0.45 mm
(0.0177 in.) = 47.136 mm (1.85575 in.)

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1D-55 Engine Mechanical:

d) Select new piston so that distance “e” is within

range of distance “d” of new piston.

NOTE
Piston class (1) is marked on piston top as
shown in figure.

Available new piston class

e) Replace piston with selected piston.
f) Check piston protrusion, again.

Main Bearing, Crankshaft and Cylinder Block Component

S5JB0B1406068

Piston class (1)

Distance “d”

S

47.026 – 47.066 mm

(1.85142 – 1.85299 in.)

T

47.068 – 47.108 mm

(1.85307 – 1.85464 in.)

U

47.110 – 47.150 mm

(1.85473 – 1.85629 in.)

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1

5

7

3

2

(a)

6

6

4

3

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1. Cylinder block

6. Oil jet

2. Flywheel side crankshaft oil seal

7. Bearing cap seal

3. Main bearing

: Do not apply oil between cylinder block and bearing and between, main bearing
cap and bearing.

: Tighten 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft) and 62° by the specified

procedure.

4. Thrust bearing

: Do not reuse.

5. Main bearing cap

: Apply engine oil to inside / sliding surface.

Engine Mechanical: 1D-56

Main Bearing, Crankshaft and Cylinder Block
Removal and Installation

S5JB0B1406066

Removal

1) Remove piston and connecting rod referring to

“Piston, Piston Ring and Connecting Rod Removal
and Installation”.

2) Remove heat exchanger referring to “Heat

Exchanger Removal and Installation in Section 1E”,
if necessary.

3) Loosen main bearing cap bolts in numerical order as

indicated in figure, and remove them.

4) Remove main bearing cap No.1 using special tool as

follows.

Special tool
(A): 09917–56510

a) Install special tool to main bearing cap No.1 (1).
b) Pull out main bearing cap No.1 from cylinder

block by tightening bolt (2) of special tool.

c) Remove main bearing cap from special tool.

5) Remove main bearing caps (No.2 through No.5) and

crankshaft from cylinder block.

6) Remove main bearings (1) and thrust bearings (2).

7) Disconnect fresh air vent hose (1), and remove oil

fresh air vent pipe (2) from cylinder block, if
necessary.

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1D-57 Engine Mechanical:

8) Remove oil jet as follows, if necessary.

a) Pack rag into cylinder in order to prevent swart

from entering.

b) Remove spring stop (1) and spring (2) using 7

mm (0.28 in.) diameter drill (4).

CAUTION

!

Do not remove ball (3) to prevent swarf from
entering lubrication circuit.

c) Desorb swarf from cylinder and oil jet.
d) Install special tool (A) to drilled hole of oil jet (1).
e) Remove oil jets from cylinder using special tool

(A) and (B).

Special tool
(A): 09916–48120
(B): 09916–58120

Installation

NOTE

• Use new bearing cap bolts. They are

deformed after tightening once because
they are plastic deformation tightening
bolts.

• All parts to be installed must be perfectly

clean.

• Be sure to oil crankshaft journals, main

bearings and thrust bearings.

• Main bearings and bearing caps 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) Remove oil, old sealant and dust from mating

surface of cylinder block, bearing caps and
crankshaft.

2) Using special tool, install oil jets as follows, if

removed.

Special tool
(A): 09912–86510
(B): 09912–86520

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1. Oil jet No.1

4. Oil jet No.4

7. Plate

2. Oil jet No.2

5. Flywheel side

8. Guide rod

3. Oil jet No.3

6. Pushrod

9. Plate bolt

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