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Suzuki Grand Vitara JB416 / JB420. Manual - part 115

1D-128 Engine Mechanical: For J20 Engine

Oil Pump Chain
Check oil pump chain for wear or damage.

Flywheel
• If ring gear is damaged, cracked or worn, replace

flywheel.

• If the surface contacting clutch disc is damaged, or

excessively worn, replace flywheel.

• Check flywheel for face runout with a dial gauge.

If runout exceeds its limit, replace flywheel.

Limit on runout
0.2 mm (0.0078 in.)

Cylinder Block
• Distortion of gasketed surface
• Using straightedge and thickness gauge, check

gasketed surface for distortion and, if flatness
exceeds its limit, correct It.

Flatness Limit
0.06 mm (0.0024 in.)

Honing or reboring cylinders

1) When any cylinder needs reboring, all other

cylinders must also be rebored at the same time.

Oversize piston specification

2) Using micrometer, measure piston diameter.
3) Calculate cylinder bore diameter to be rebored as

follows.
D = A + B – C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.02 – 0.04 mm (0.0008 –
0.0015 in.)
C: Allowance for honing = 0.02 mm (0.0008 in.)

4) Rebore and hone cylinder to calculated dimension.

NOTE
Before reboring, install lower crankcase and
tighten to specification to avoid distortion of
bearing bores.

5) Measure piston clearance after honing.

Check Valve
Check check valve for clogging and ball for being stuck.

Size

Piston diameter

STD

83.970 – 83.990 mm (3.3059 – 3.3067 in.)

O/S 0.50 84.470 – 84.490 mm (3.3256 – 3.3264 in.)

I2RH01140196-01

I2RH01140198-01

I2RH01140199-01

“e”: 50 mm (1.96 in.)

“g”: 26.5 mm (1.04 in.)

“f”: 95 mm (3.74 in.)

I5JB0A142059-01

I2RH01140201-01

Engine Mechanical: For J20 Engine 1D-129

Specifications

Tightening Torque Specifications

S5JB0A1427001

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Fastening part

Tightening torque

Note

⋅m

kgf-m

lb-ft

Camshaft housing bolts

11 N

⋅m (1.1 kgf-m, 8.0 lb-ft) for tightening of

special tool

)

Camshaft housing bolt

1.1

8.0

)

/ ) / )

Cylinder head cover nut

1.1

8.0

)

Starting motor terminal nut

1.1

8.0

)

Generator terminal nut

0.7

5.0

)

Timing chain cover bolt and nut

1.1

8.0

)

Idler pulley nut

4.2

30.5

)

Generator belt tensioner bolt

2.5

18.5

)

Crankshaft pulley bolt

150

15.0

108.5

)

Camshaft timing sprocket bolt

8.0

57.5

)

Timing chain tensioner adjuster No.2 bolt

1.1

8.0

)

Timing chain tensioner adjuster No.2 nut

4.5

33.0

)

Timing chain tensioner nut

2.5

18.0

)

Timing chain tensioner adjuster No.1 bolt

1.1

8.0

)

Timing chain guide No.1 bolt

0.9

6.5

)

Cylinder head bolt (M10)

Tighten 52 N

⋅m (5.2 kgf-m, 38.0 lb-ft), 82

⋅m (8.2 kgf-m, 59.5 lb-ft), 0 N⋅m (0 kgf-m,

0 lb-ft), 52 N

⋅m (5.2 kgf-m, 38.0 lb-ft) and

103 N

⋅m (10.3 kgf-m, 74.5 lb-ft) by the

specified procedure.

)

Cylinder head bolt (M6)

1.1

8.0

)

Connecting rod bolt

Tighten 15 N

⋅m (1.5 kgf-m, 11.0 lb-ft), 45°

and 45

° by the specified procedure.

)

/ )

Crankcase bolt with 10 mm thread diameter ((1)
– (10))

Tighten 40 N

⋅m (4.0 kgf-m, 29.0 lb-ft), 0

⋅m (0 kgf-m, 0 lb-ft), 40 N⋅m (4.0 kgf-m,

29.0 lb-ft) and 58 N

⋅m (5.8 kgf-m, 42.0 lb-ft)

by the specified procedure.

)

Crankcase bolt with 8 mm thread diameter ((11)
– (22))

Tighten 26 N

⋅m (2.6 kgf-m, 19.0 lb-ft) by the

specified procedure.

)

CKP sensor bolt

1.1

8.0

)

Flywheel bolt

7.0

51.0

)

Drive plate bolt

6.5

47.0

)

Engine front mounting bracket bolt

5.5

40.0

)

1D-130 Engine Mechanical: For J20 Engine

Special Tools and Equipment

Recommended Service Material

S5JB0A1428001

NOTE
Required service material is also described in the following.
“Timing Chain Cover Components: For J20 Engine”
“2nd Timing Chain and Chain Tensioner Components: For J20 Engine”
“1st Timing Chain and Chain Tensioner Components: For J20 Engine”
“Camshafts, Tappet and Shim Components: For J20 Engine”
“Valves and Cylinder Head Components: For J20 Engine”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components: For J20 Engine”
“Main Bearings, Crankshaft and Cylinder Block Components: For J20 Engine”

Special Tool

S5JB0A1428002

Material

SUZUKI recommended product or Specification

Note

Water tight sealant

SUZUKI Bond No.1207B

P/No.: 99000–31140

)

SUZUKI Bond No.1207F

P/No.: 99000–31250

)

/ ) / )

09355–35754–600

09367–04002

Hose

3-way joint

)

09911–97710

09911–97811

Oil seal guide

Oil seal installer

)

09913–75510

09915–64512

Bearing installer

Compression gauge

)

09915–64530

09915–67010

Compression gauge hose

Compression gauge
attachment (C)

)

09915–67311

09916–14510

Vacuum gauge

Valve lifter

)

/ )

Engine Mechanical: For J20 Engine 1D-131

09916–16510

09916–34542

Valve lifter attachment

Reamer handle

)

/ )

)

/ )

09916–37810

09916–38210

Valve guide reamer (6 mm)

Valve guide reamer (11 mm)

)

09916–46020

09916–57340

Valve guide remover

Valve guide installer
attachment

)

09916–57350

09916–66510

Valve guide installer handle
(6 mm)

Tappet holder

)

/ )

)

/ )

09916–77310

09916–84511

Piston ring compressor (50-
125 mm)

Forceps

)

/ )

09917–68221

09917–98221

Camshaft pulley holder

Valve guide stem
attachment

)

/ )

)

09918–08210

09919–28610

Vacuum gauge hose joint

Protector sleeve

)

/ )

09924–17810

09926–58010

Flywheel holder (drive plate
stopper)

Bearing remover attachment

)

/ )

)

Content .. 113 114 115 116 ..