Suzuki Grand Vitara JB416 / JB420. Manual - part 114

1D-124 Engine Mechanical: For J20 Engine

Out-of-round and taper (uneven wear) of journals
An unevenly worn crankshaft journal shows up as a 
difference in diameter at a cross section or along its 
length (or both). This difference, if any, is determined by 
taking micrometer readings. If any one of journals is 
badly damaged or if amount of uneven wear in the sense 
exceeds its limit, regrind or replace crankshaft.

Limit on out-of-round and taper
0.01 mm (0.0004 in.)

Out-of-round
“A” – “B”

Taper
“a” – “b”

Main Bearings
Main bearings general information
• Service main bearings are available in standard size 

and 0.25 mm (0.0098 in.) undersize, and standard 
size has 5 kinds of bearings differing in tolerance.

• Upper half of bearing (1) has oil groove (2) as shown 

in figure.
Install this half with oil groove to cylinder block.

• Lower half of bearing does not have oil groove.

Main bearings inspection
Check bearings for pitting, scratches, wear or damage. 
If any malcondition is found, replace both upper and 
lower halves. Never replace either half without replacing 
the other half.

Main bearing clearance
Check clearance by using gauging plastic according to 
the following procedure.

1) Remove lower crankcase.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) to full width of 

bearing (parallel to crankshaft) on journal, avoiding 
oil hole.

4) Install lower crankcase to cylinder block referring to 

“Main Bearings, Crankshaft and Cylinder Block 
Removal and Installation: For J20 Engine”.

NOTE
Do not rotate crankshaft while gauging 
plastic is installed.

 

5) Remove lower crankcase and using scale (2) on 

gauging plastic envelop (1), measure gauging plastic 
width at its widest point. If clearance exceeds its 
limit, replace bearing. Always replace both upper 
and lower inserts as a unit.
A new standard bearing may produce proper 
clearance. If not, it will be necessary to regrind 
crankshaft journal for use of 0.25 mm undersize 
bearing.
After selecting new bearing, recheck clearance.

Main Bearing Clearance
Standard: 0.032 – 0.050 mm (0.0013 – 0.0019 in.)
Limit: 0.063 mm (0.0024 in.)

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Engine Mechanical: For J20 Engine 1D-125

Selection of main bearings
STANDARD BEARING:
If engine is under the following conditions, select a new 
standard bearing as followings and install it.
• Bearing is in malcondition.
• Bearing clearance is cut of specification.
• Crankshaft or cylinder block is replaced.

1) First check journal diameter. As shown in figure, 

crank web No.2 has stamped numbers.
Six kinds of numbers (“4” through “9”) represent the 
following journal diameters.

Journal diameter

Stamped numbers on crank web No.2 (3) represent 
journal diameters marked with an arrow in figure 
respectively. For example, stamped number “5” 
indicates that corresponding journal diameter is 
58.0000 – 58.0029 mm (2.28346 – 2.28357 in.).

2) Next, check journal bore diameter. On lower 

crankcase five alphabets are stamped as shown in 
figure.
Three kinds of alphabets (“A”, “B” and “C”) represent 
the following journal bore diameters.

Journal bore diameter

Stamped alphabets on lower crankcase represent 
journal diameter marked with an arrow in figure 
respectively.
For example, stamped alphabet “A” at No.2 journal 
indicates that (journal) bore diameter of No.2 journal 
is 62.0000 – 62.0060 mm (2.44094 – 2.44117 in.).

3) There are 5 kinds of standard bearings differing in 

thickness. To distinguish them, they are painted (1) 
in the following colors at the position as indicated in 
figure.
Each color indicates the following thickness at the 
center of bearing.

Standard size main bearing thickness

Stamped numbers

Journal diameter

4

58.0030 – 58.0060 mm 
(2.28358 – 2.28369 in.)

5

58.0000 – 58.0029 mm 
(2.28346 – 2.28357 in.)

6

57.9970 – 57.9999 mm 
(2.28334 – 2.28345 in.)

7

57.9940 – 57.9969 mm 
(2.28323 – 2.28333 in.)

8

57.9910 – 57.9939 mm 
(2.28311 – 2.28322 in.)

9

57.9880 – 57.9909 mm 
(2.28299 – 2.28310 in.)

1. Crankshaft pulley side

2. Flywheel side

Stamped alphabet

Journal bore diameter

A

62.0000 – 62.0060 mm 
(2.44094 – 2.44117 in.)

B

62.0061 – 62.0120 mm 
(2.44118 – 2.44141 in.)

C

62.0121 – 62.0180 mm 
(2.44142 – 2.44164 in.)

1

2

3

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1. No.1 journal

5. No.5 journal

2. No.2 journal

6. Crankshaft pulley side

3. No.3 journal

7. Flywheel side

4. No.4 journal

Color painted

Bearing thickness

Green

1.9910 – 1.9940 mm 

(0.07839 – 0.07850 in.)

Black

1.9940 – 1.9970 mm 

(0.07851 – 0.07862 in.)

Colorless (no painted)

1.9970 – 2.0000 mm 

(0.07863 – 0.07874 in.)

Yellow

2.0000 – 2.0030 mm 

(0.07874 – 0.07885 in.)

Blue

2.0030 – 2.0060 mm 

(0.07886 – 0.07897 in.)

6

7

2

3

4

5

1

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1D-126 Engine Mechanical: For J20 Engine

4) From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard 

bearing to be installed to journal by referring to table shown.
For example, if number stamped on crank web No.2 is “5” and alphabet stamped on lower crankcase is “A”, install 
new standard bearings painted in “Green” to cylinder block side journal and “Black” to lower crankcase side 
journal.

NOTE
The meaning of “Upper” and “Lower” described in below table are the following.
• Upper: It is instruction of main bearing installed in cylinder block side journal.
• Lower: It is instruction of main bearing installed in lower crankcase side journal.

 

Main bearing cross-reference table (new standard bearing)

5) Check main bearing clearance with newly selected standard bearing referring to “Main Bearing Clearance”.

If clearance still exceeds its limit, use next thicker bearing and recheck clearance.

UNDERSIZE BEARING (0.25 mm):
• 0.25 mm undersize bearing is available, in five kinds varying in thickness.

To distinguish them, each bearing is painted (1) in the following colors at such position as indicated in figure.
Each color represents the following thickness at the center of bearing.

Undersize main bearing thickness

Standard number on crank web No.2

4

5

6

7

8

9

Standard 

alphabet on 

lower crankcase

A

Green

Upper: Green

Lower: Black

Black

Upper: Black

Lower: Colorless

Colorless

Upper: Colorless

Lower: Yellow

B

Black

Upper: Black

Lower: Colorless

Colorless

Upper: Colorless

Lower: Yellow

Yellow

Upper: Yellow

Lower: Blue

C Colorless

Upper: Colorless

Lower: Yellow

Yellow

Upper: Yellow

Lower: Blue

Blue

Blue

Color painted

Bearing thickness

Green & Red

2.1160 – 2.1190 mm (0.08331 – 0.08342 in.)

Black & Red

2.1190 – 2.1220 mm (0.08343 – 0.08354 in.)

Red only

2.1220 – 2.1250 mm (0.08355 – 0.08366 in.)

Yellow & Red

2.1250 – 2.1280 mm (0.08367 – 0.08377 in.)

Blue & Red

2.1280 – 2.1310 mm (0.08378 – 0.08389 in.)

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Engine Mechanical: For J20 Engine 1D-127

• If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows.

a. Regrind journal to the following finished diameter.

Finished journal diameter
57.7380 – 57.7560 mm (2.27315 – 2.27385 in.)

b. Using micrometer, measure reground 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 and alphabets stamped on lower crankcase, select an undersize bearing by 

referring to the following table.
Check bearing clearance with newly selected undersize bearing.

Undersize bearing specification

Crankshaft Position Sensor Plate
Check teeth of plate for damage. 
If any damage is found, replace crankshaft (1).

Oil Pump Sprocket
Check teeth of sprocket for wear or damage.
If any damage or wear is found, replace crankshaft (1).

Measured journal diameter

57.7500 – 57.7560 mm

(2.27362 – 2.27385 in.)

57.7440 – 57.7499 mm
(2.27338 – 2.27361 in.)

57.7380 – 57.7439 mm

(2.27315 – 2.27337 in.)

Alphabets stamped

on lower crankcase

A

Green & Red

Black & Red

Red only

B

Black & Red

Red only

Yellow & Red

C

Red only

Yellow & Red

Blue & Red

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2. Crankshaft position sensor plate

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2. Oil pump sprocket

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