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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