Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 130

1D-46 Engine Mechanical: For M16A Engine with VVT

Piston clearance
Standard: 0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Standard (piston with coating (new one)): 0.016 – 
0.045 mm (0.0006 – 0.0018 in.)
Limit: 0.161 mm (0.0065 in.)

Ring groove clearance
Before checking, piston grooves must be clean, dry and 
free of carbon deposits.
Fit new piston ring (1) into piston groove, and measure 
clearance between ring and ring land by using thickness 
gauge (2). If clearance is out of specification, replace 
piston.

Ring groove clearance

Piston Ring
Piston ring end gap
To measure end gap, insert piston ring (2) into cylinder 
bore and then measure the gap by using thickness 
gauge (1).
If measured gap exceeds limit, replace ring.

NOTE
Decarbonize and clean top of cylinder bore 
before inserting piston ring.

 

Piston ring end gap

“a”: 19.5 mm (0.77 in.)

Standard

Limit

Top ring

0.03 – 0.07 mm

 (0.0012 – 0.0028 in.)

0.12 mm (0.0047 in.)

2nd ring

0.02 – 0.06 mm

 (0.0008 – 0.0024 in.)

0.10 mm (0.0039 in.)

Oil ring

0.03 – 0.17 mm

 (0.0012 – 0.0067 in.)

—

I4RS0A140022-01

I2RH01140159-01

Item

Standard

Limit

Top ring

0.20 – 0.35 mm

 (0.0079 – 0.0138 in.)

0.7 mm (0.0276 in.)

2nd ring

0.35 – 0.50 mm

 (0.0138 – 0.0197 in.)

1.0 mm (0.0394 in.)

Oil ring

0.20 – 0.70 mm

 (0.0079 – 0.0276 in.)

1.2 mm (0.0472 in.)

“a”: 120 mm (4.72 in.)

I2RH01140161-01

Engine Mechanical: For M16A Engine with VVT 1D-47

Piston Pins and Connecting Rods Inspection

S6JB0A1416032

Piston Pin
Visual inspection
Check piston pin, connecting rod small end bore and 
piston bore for wear or damage, paying particular 
attention to condition of small end bore bush. If pin, 
connecting rod small end bore or piston bore is badly 
worn or damaged, replace pin, connecting rod and/or 
piston.

Piston pin clearance
Check piston pin clearance in small end and piston. 
Replace connecting rod and/or piston if its small end is 
badly worn or damaged or if measured clearance 
exceeds limit.

Piston pin clearance in connecting rod small end
Standard: 0.003 – 0.014 mm (0.0001 – 0.0006 in.)
Limit: 0.05 mm (0.00020 in.)

Piston pin clearance in piston
Standard: 0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Limit: 0.05 mm (0.0020 in.)

Small-end bore
20.003 – 20.011 mm (0.7875 – 0.7878 in.)

Piston pin dia.
19.997 – 20.000 mm (0.7873 – 0.7874 in.)

Piston bore
20.006 – 20.014 mm (0.7876 – 0.7880 in.)

Connecting Rod
Big-end side clearance
Check big-end of connecting rod for side clearance, with 
rod fitted and connected to its crank pin in the normal 
manner. If measured clearance is found to exceed its 
limit, replace connecting rod.

Big-end side clearance
Standard: 0.25 – 0.40 mm (0.0098 – 0.0157 in.)
Limit: 0.55 mm (0.0217 in.)

Connecting rod alignment
Mount connecting rod on aligner to check it for bow and 
twist. If measured value exceeds the limit, replace it.

Connecting rod alignment
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)

I4RS0A140023-01

I2RH0B140148-01

I4RH01140053-01

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

S6JB0A1416033

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.)

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 

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.)

I2RH0B140119-01

1. Red paint

I2RH0B140120-01

I2RH01140164-01

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

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.

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

I2RH0B140121-01

I2RH0B140122-01

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.)

I2RH0B140123-01