Suzuki Grand Vitara JB416 / JB420. Manual - part 95

1D-48 Engine Mechanical: For M16A Engine with VVT

Connecting rod bolt deformation (Plastic 
deformation tightening bolt)
Measure each thread diameter of connecting rod bolt (2) 
at “A” on 32 mm (1.25 in.) from bolt mounting surface 
and “B” on 40 mm (1.57 in.) from bolt mounting surface 
by using a micrometer (3).
Calculate difference in diameters (“A” – “B”). If it is 
exceeds limit, replace connected rod (1).

Connecting rod bolt measurement points
“a”: 32 mm (1.25 in.)
“b”: 40 mm (1.57 in.)

Connecting rod bolt diameter difference
Limit (“A” – “B”): 0.1 mm (0.004 in.)

Crank Pin and Connecting Rod Bearings 
Inspection

S5JB0A1416034

Crank Pin Diameter
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 to undersize 
and use undersize bearing.

Crank pin diameter

Out-of-round
A – B

Taper
a – b

Crank pin taper and out-of-round
Limit: 0.01 mm (0.0004 in.)

I2RH0B140119-01

Connecting rod bearing 

size

Crank pin diameter

Standard

41.982 – 42.000 mm

 (1.6528 – 1.6535 in.)

0.25 mm (0.0098 in.) 
undersize

41.732 – 41.750 mm

 (1.6430 – 1.6437 in.)

I2RH0B140120-01

Engine Mechanical: For M16A Engine with VVT 1D-49

Connecting Rod Bearing General Information
Service connecting rod bearings are available in 
standard size and 0.25 mm (0.0098 in.) undersize 
bearing, and standard size bearing has 5 kinds of 
bearings differing in tolerance.
For identification of undersize bearing, it is painted red 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 Visual Inspection
Inspect bearing shells for signs of fusion, pitting, burn or 
flaking and observe contact pattern. Bearing shells 
found in defective condition must be replaced.

Connecting Rod Bearing Clearance

1) Before checking bearing clearance, clean bearing 

and crank pin.

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

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

4) Install rod bearing cap (1) to connecting rod.

When installing cap, be sure to point arrow mark (2) 
on cap to crankshaft pulley side, as shown in the 
figure. After applying engine oil to rod bolts, tighten 
cap nuts (3) gradually as follows. 
a) Tighten all cap nuts to 15 N

⋅m (1.5 kgf-m, 11.0 lb-

ft)

b) Retighten them to 45

°

c) Repeat Step b) once again.

Tightening torque
Connecting rod bearing cap nut (a):  15 N

⋅m 

(1.5 kgf-m, 11.0 lb-ft) and then retighten by 
turning through 45

° twice

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

plastic envelope (2), measure gauging plastic (2) 
width at the widest point (clearance).
If clearance exceed its limit, use a new standard size 
bearing referring to “Selection of Connecting Rod 
Bearings: For M16A Engine with VVT”.
After selecting new bearing, recheck clearance.

Connecting rod bearing clearance
Standard: 0.029 – 0.047 mm (0.0011 – 0.0018 in.)
Limit: 0.065 mm (0.0026 in.)

6) If clearance can not be brought to its limit even by 

using a new standard size bearing, use next thicker 
bearing and recheck clearance or regrind crank pin 
to undersize and use 0.25 mm undersize bearing.

1. Red paint

I2RH01140164-01

I2RH0B140121-01

I2RH0B140122-01

I2RH0B140123-01

1D-50 Engine Mechanical: For M16A Engine with VVT

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

 

1) 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 45.000 – 45.006 mm (1.7717 – 1.7718 
in.).

Connecting rod big end inside diameter

2) Next, check crankshaft pin diameter. On crank web 

No.3, four alphabets are stamped as shown in the 
figure.
Three kinds of alphabet (“A”, “B” and “C”) represent 
the following crankshaft pin diameter respectively.
For example, stamped “A” indicates that 
corresponding crankshaft pin diameter is 41.994 – 
42.000 mm (1.6533 – 1.6534 in.).

Crankshaft pin outer diameter

Stamped 
numbers

Connecting rod big end inside diameter

1

45.0000 – 45.0060 mm (1.7717 – 1.7718 in.)

2

45.0061 – 45.0120 mm (1.7719 – 1.7721 in.)

3

45.0121 – 45.0180 mm (1.7722 – 1.7723 in.)

[A]: Connecting rod big end inside diameter number
[B]: Weight indication mark

I3RH0A140017-01

Stamped 

alphabet

Crankshaft pin diameter

A

41.9940 – 42.0000 mm (1.6533 – 1.6534 in.)

B

41.9880 – 41.9939 mm (1.6531 – 1.6532 in.)

C

41.9820 – 41.9879 mm (1.6529 – 1.6530 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

I3RH0A140018-01

Engine Mechanical: For M16A Engine with VVT 1D-51

3) There are five kinds of standard bearings differing in 

thickness. To distinguish them, they are painted in 
the following colors at the position as indicated in the 
figure.
Each color indicated the following thickness at the 
center of bearing.

Standard size of connecting rod bearing 
thickness

4) From number stamped on connecting rod and its cap 

and alphabets stamped on crank web No.3, 
determine new standard bearing to be installed to 
connecting rod big end inside, by referring to the 
table.
For example, if number stamped on connecting rod 
and its cap is “1” and alphabet stamped on crank 
web No.3 is “B”, install a new standard bearing 
painted in “Black” to its connecting rod big end 
inside.

Specification of new standard connecting rod 
bearing size

Color 

painted

Bearing thickness

Blue

1.4991 – 1.5020 mm (0.05902 – 0.05913 in.)

Yellow 1.4961 – 1.4990 mm (0.05890 – 0.05901 in.)

Nothing 1.4931 – 1.4960 mm (0.05878 – 0.05889 in.)

Black

1.4901 – 1.4930 mm (0.05867 – 0.05877 in.)

Green

1.4870 – 1.4900 mm (0.05855 – 0.05866 in.)

1. Paint

I3RH0A140019-01

Number stamped on 

connecting rod and its cap 

(connecting rod big end 

inside diameter)

1

2

3

Alphabet stamped 

on crank web No.3 

(Crankshaft pin 

diameter)

A

Green

Black

Nothing

B

Black

Nothing Yellow

C Nothing Yellow

Blue

New standard bearing to be 

installed.