Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 146

1D-110 Engine Mechanical: For J20 Engine

3) Install piston and connecting rod assembly into 

cylinder bore. Use special tool (Piston ring 
compressor) to compress rings. Guide connecting 
rod into place on crankshaft.
Using a hammer handle, tap piston head to install 
piston into bore. Hold ring compressor firmly against 
cylinder block until all piston rings have entered 
cylinder bore.

Special tool
(A):  09916–77310

4) Install connecting rod bearing cap (1) as follows.

NOTE
If connecting rod bolt is reused, make sure to 
check connecting rod bolt for deformation 
referring to “Connecting Rod Bolt 
Deformation (Plastic Deformation Tightening 
Bolt)” under “Pistons, Piston Rings, 
Connecting Rods and Cylinders Inspection 
and Cleaning: For J20 Engine”.

 

a) Point arrow mark (2) on cap to crankshaft pulley 

side.

b) Apply engine oil to new connecting rod bolts (3).
c) Tighten all connecting rod bolts to 15 N

⋅m (1.5 

kgf-m, 11.0 lb-ft).

d) Retighten them by turning through 45

°.

e) Repeat step d) once again.

Tightening torque
Connecting rod bolt (a):  Tighten 15 N

⋅m (1.5 

kgf-m, 11.0 lb-ft), 45

° and 45° by the specified 

procedure.

5) Install cylinder head. Refer to “Valves and Cylinder 

Head Removal and Installation: For J20 Engine” for 
installation.

6) Install oil pan. Refer to “Oil Pan and Oil Pump 

Strainer Removal and Installation: For J20 Engine in 
Section 1E” for installation.

7) Install engine assembly to vehicle referring to 

“Engine Assembly Removal and Installation: For J20 
Engine”.

Pistons, Piston Rings, Connecting Rods and 
Cylinders Disassembly and Assembly

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Disassembly

1) Using piston ring expander, remove two 

compression rings (Top and 2nd) and oil ring from 
piston.

2) Remove piston pin from connecting rod.

• Ease out piston pin circlips (1), as shown.

• Force piston pin out.

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Engine Mechanical: For J20 Engine 1D-111

Assembly

NOTE
Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder 
clearance. When installing a standard size piston, make sure to match piston with cylinder as follows.

 

1) Each piston (1) has stamped number (2) as shown. It represents outer diameter of piston.
2) There are also painted color (3) of red or blue on cylinder block (2) as shown.

3) Stamped number on piston and painted color (or stamped number) on cylinder block should correspond. That is, 

install number “2” stamped piston to cylinder which is identified with blue painted (or “2” stamped) and a number 
“1” piston to cylinder with red painted (or “1” stamped).
Also, a letter “A” or “B” is stamped on piston head but ordinarily it is not necessary to discriminate each piston by 
this letter.

Piston outer diameter and cylinder bore diameter specification

4. Crank shaft pulley side

7. No.2 cylinder

5. Flywheel side

8. No.3 cylinder

6. No.1 cylinder

9. No.4 cylinder

Piston

Cylinder

Number

Outer diameter

Paint 

(Number)

Bore diameter

1

83.9800 – 83.9900 mm

(3.3063 – 3.3066 in.)

Red (1)

84.0101 – 84.0200 mm

(3.3075 – 3.3078 in.)

2

83.9700 – 83.9799 mm

(3.3059 – 3.3062 in.)

Blue (2)

84.0000 – 84.0100 mm

(3.3071 – 3.3074 in.)

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1D-112 Engine Mechanical: For J20 Engine

4) Install piston pin to piston (1) and connecting rod (3):

After applying engine oil to piston pin and piston pin 
holes in piston and connecting rod, fit connecting rod 
to piston as shown in figure and insert piston pin to 
piston and connecting rod, and install piston pin 
circlips.

NOTE
Oil hole (4) come on intake side.

 

NOTE
Circlip (4) should be installed so that circlip 
end gap comes within such range as 
indicated by arrow.

 

5) Install piston rings to piston:

• As indicated in figure at the left, 1st and 2nd rings 

have “TOP” mark respectively. When installing 
these piston rings to piston, direct marked side of 
each ring toward top of piston.

• 1st ring (1) differs from 2nd ring (2) in thickness, 

shape and color of surface contacting cylinder 
wall.
Distinguish 1st ring from 2nd ring by referring to 
figure.

• When installing oil ring (3), install spacer first and 

then two rails.

6) After installing three rings (1st, 2nd and oil rings), 

distribute their end gaps as shown in figure.

Pistons, Piston Rings, Connecting Rods and 
Cylinders Inspection and Cleaning

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Inspection
Cylinder
• Inspect cylinder walls for scratches, roughness, or 

ridges which indicate excessive wear. If cylinder bore 
is very rough or deeply scratched, or ridged, rebore 
cylinder and use over size piston.

• Using a cylinder gauge, measure cylinder bore in 

thrust and axial directions at two positions as shown in 
figure.
If any of following conditions is noted, rebore cylinder.

1) Cylinder bore diameter exceeds limit.
2) Difference of measurements at two positions 

exceeds taper limit.

3) Difference between thrust and axial measurements 

exceeds out-of-round limit.

Cylinder bore diameter
Standard: 84.000 – 84.020 mm (3.3070 – 3.3078 
in.)
Limit: 84.050 mm (3.3090 in.)

Taper and out-of-round
Limit: 0.10 mm (0.004 in.)

2. Front mark

4. Oil hole

1. Piston

3. Connecting rod

2. Front mark

5. Oil hole

1

2

3

4

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4

5

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1. Front mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap
6. Intake side
7. Exhaust side

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Engine Mechanical: For J20 Engine 1D-113

NOTE
If any one of four cylinders has to be rebored, 
rebore all four to the same next oversize. 
This is necessary for the sake of uniformity 
and balance.

 

Pistons
• Inspect piston for faults, cracks or other damages.

Damaged or faulty piston should be replaced.

• Piston diameter: 

As indicated in figure, piston diameter should be 
measured at a position 26.5 mm (1.04 in.) (“a”) from 
piston skirt end in the direction perpendicular to piston 
pin.

Piston diameter

• Piston clearance: 

Measure cylinder bore diameter and piston diameter 
to find their difference which is piston clearance. 
Piston clearance should be within specification as 
follows. If it is out of specification, rebore cylinder and 
use oversize piston.

Piston clearance
0.02 – 0.04 mm (0.0008 – 0.0015 in.)

NOTE
Cylinder bore diameters used here are 
measured in thrust direction at two positions.

 

• Ring groove clearance: 

Before checking, piston grooves must be clean, dry 
and free of carbon. 
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

1. 50 mm (1.96 in.)

2. 95 mm (3.74 in.)

Standard

83.9700 – 83.9900 mm 

(3.3059 – 3.3067 in.)

Oversize: 0.50 mm 

(0.0196 in.)

84.4700 – 84.4900 mm 

(3.3256 – 3.3264 in.)

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Item

Standard

Limit

Top 

ring

0.03 – 0.07 mm 

(0.0120 – 0.0027 in.)

0.12 mm (0.0047 in.)

2nd 

ring

0.02 – 0.06 mm 

(0.0008 – 0.0023 in.)

0.1 mm (0.0039 in.)

Oil ring

0.06 – 0.15 mm 

(0.0024 – 0.0059 in.)

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