Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 133

1D-58 Engine Mechanical: For M16A Engine with VVT

2) Next, check bearing cap bore diameter without 

bearing. On mating surface of cylinder block, five 
alphabets are stamped as shown in the figure.
Three kinds of alphabets (“A”, “B” and “C”) or 
numbers (“1”, “2” and “3”) represent the following 
cap bore diameters.
Stamped alphabets or numbers on cylinder block 
represent bearing cap bore diameter marked with an 
arrow in the figure respectively.
For example, stamped “A” or “1” indicates that 
corresponding bearing cap bore diameter is 56.0000 
– 56.0060 mm (2.2048 – 2.2049 in.).

Crankshaft bearing cap bore

3) There are 5 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 crankshaft main bearing 
thickness

4) From number stamped on crank web No.2 and 

alphabets stamped on cylinder block, determine new 
standard bearing to be installed to journal, by 
referring to the table shown.
For example, if number stamped on crank web No.2 
is “1” and alphabet stamped on cylinder block is “B”, 
install a new standard bearing painted in “Brown” to 
its journal.

New standard size crankshaft main bearing 
specification

Stamped 

alphabet 

(number)

Bearing cap bore diameter (without 

bearing)

A (1)

56.0000 – 56.0060 mm

(2.2048 – 2.2049 in.)

B (2)

56.0061 – 56.0120 mm

(2.2050 – 2.2051 in.)

C (3)

56.0121 – 56.0180 mm

(2.2052 – 2.2054 in.)

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Color 

painted

Bearing thickness

Purple

1.992 – 1.996 mm (0.07843 – 0.07858 in.)

Brown

1.995 – 1.999 mm (0.07855 – 0.07870 in.)

Green

1.998 – 2.002 mm (0.07867 – 0.07882 in.)

Black

2.001 – 2.005 mm (0.07878 – 0.07893 in.)

Colorless 
(no paint)

2.004 – 2.008 mm (0.07890 – 0.07906 in.)

1. Paint

Number stamped on crank 

web No.2 (Journal diameter)

1

2

3

Alphabet 

stamped on 

cylinder block 

(Cap bore dia.)

A (1) Purple

Brown

Green

B (2) Brown

Green

Black

C (3) Green

Black

Colorless

New standard bearing to be 

installed

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Engine Mechanical: For M16A Engine with VVT 1D-59

5) Using scale (1) on gauging plastic (2), check bearing 

clearance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker 
bearing and recheck clearance.

6) When replacing crankshaft or cylinder block due to 

any reason, select new standard bearings to be 
installed by referring to number stamped on new 
crankshaft or alphabets stamped on new cylinder 
block.

Undersize bearing (0.25 mm (0.0098 in.))
• 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness.

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

Undersize of crankshaft main bearing thickness

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Color painted

Bearing thickness

Red and Purple

2.117 – 2.121 mm (0.08335 – 0.08350 in.)

Red and Brown

2.120 – 2.124 mm (0.08347 – 0.08362 in.)

Red and Green

2.123 – 2.127 mm (0.08359 – 0.08374 in.)

Red and Black

2.126 – 2.130 mm (0.08371 – 0.08385 in.)

Red only

2.129 – 2.133 mm (0.08382 – 0.08397 in.)

1. Paint

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1D-60 Engine Mechanical: For M16A Engine with VVT

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

a. Regrind journal to the following finished diameter.

Finished journal diameter
51.732 – 51.750 mm (2.0367 – 2.0374 in.)

b. Using micrometer, measure regrind 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 above and alphabets stamped on cylinder block, select an undersize bearing 

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

New undersize crankshaft main bearing specification

Main Bearing Cap No.1 Bolt
Measure each thread diameter main bearing cap No.1 
bolts (1) at “A” on 60 mm (2.36 in.) from seat side of 
flange bolt and “B” on 90 mm (3.54 in.) from seat side of 
flange bolt by using a micrometer (2).
Calculate difference in diameters (“A” – “B”).

Main bearing cap No.1 bolt diameter difference
Limit (“A” – “B”): 0.2 mm (0.008 in.)

Measured journal diameter

51.7440 – 51.7500 mm

(2.0372 – 2.0373 in.)

51.7380 – 51.7439 mm

(2.0370 – 2.0371 in.)

51.7320 – 51.7379 mm

(2.0367 – 2.0369 in.)

Alphabets stamped

on cylinder block

A (1)

Red and Purple

Red and Brown

Red and Green

B (2)

Red and Brown

Red and Green

Red and Black

C (3)

Red and Green

Red and Black

Red only

Undersize bearing to be installed

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“A”

“a”

“b”

“B”

 

1

1

2

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Engine Mechanical: For M16A Engine with VVT 1D-61

Sensor Plate Inspection

S6JB0A1416038

Check sensor plate for crack damage. 
If malcondition is found, replace it.

Rear Oil Seal Inspection

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Carefully inspect oil seal (1) for wear or damage. If its lip 
is worn or damaged, replace it.

Flywheel Inspection

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Visual Inspection
• If ring gear is damaged, cracked or worn, replace 

flywheel.

• If the surface contacting clutch disc is damaged, or 

excessively worn, replace flywheel.

Flywheel Face Runout
Check flywheel face runout with a dial gauge. 
If runout exceeds its limit, replace flywheel.

Flywheel face runout
Limit: 0.2 mm (0.0079 in.)

Cylinder Block Inspection

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Distortion of Gasketed Surface
Using straightedge and thickness gauge, check 
gasketed surface for distortion and, if flatness exceeds 
its limit, correct It.

Cylinder block flatness
Limit: 0.05 mm (0.0020 in.)

Honing or Reboring Cylinders

1) When any cylinder needs reboring, all other 

cylinders must also be rebored at the same time.

2) Select oversized piston according to amount of 

cylinder wear.

Oversize piston specification
Oversize 0.50: 78.453 – 78.468 mm (3.0887 – 
3.0893 in.)

3) Using micrometer, measure piston diameter.

Measurement position for piston diameter
“a”: 19.5 mm (0.77 in.)

4) Rebore and hone cylinder to the following 

dimension.

NOTE
Before reboring, install all main bearing caps 
in place and tighten to specification to avoid 
distortion of bearing bores.

 

Cylinder bore diameter to be rebored
Oversize 0.50: 78.500 – 78.514 mm (3.0906 – 
3.0911 in.)

5) Measure piston clearance after honing.

Piston clearance
0.032 – 0.061 mm (0.0013 – 0.0024 in.)

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