Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 148

1D-118 Engine Mechanical: For J20 Engine

c. 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 connecting rod bearing 
thickness

d. From number stamped on connecting rod and its 

cap and alphabet stamped on crank web No. 3 
cylinder, determine new standard bearing to be 
installed to connecting rod big-end inside, by 
referring to the table.
For example, if number stamped on connecting 
rod and its cap is “1” and alphabet stamped on 
crank web No. 3 cylinder is “B”, install a new 
standard bearing painted in “Black” to its 
connecting rod big-end inside.

Specifications of new standard connecting rod 
bearing size

e. Check bearing clearance with newly selected 

standard bearing referring to “Crank pin and 
connecting rod bearings: For J20 Engine”.
If clearance still exceeds its limit, use next thicker 
bearing and recheck clearance.

• Connecting rod bolt

Measure each thread diameter of connecting rod bolts 
(1) at “A” on 28.5 mm (1.12 in.) from bolt mounting 
surface and “B” on 42.0 mm (1.65 in.) from bolt 
mounting surface by using a micrometer (2).
Calculate difference in diameters (“A” – “B”). If it 
exceeds limit, replace connecting rod.

Connecting rod bolt measurement points
“a”: 28.5 mm (1.12 in.)
“b”: 42.0 mm (1.65 in.)

Connecting rod bolt diameter difference
limit (“A” – “B”): 0.1 mm (0.004 in.)

Cleaning
Clean carbon from piston head and ring grooves, using a 
suitable tool.

Color painted

Bearing thickness

Green

1.482 – 1.485 mm

(0.05835 – 0.05846 in.)

Black

1.485 – 1.488 mm

(0.05847 – 0.05858 in.)

Colorless

1.488 – 1.491 mm

(0.05859 – 0.05870 in.)

Yellow

1.491 – 1.494 mm

(0.05871 – 0.05881 in.)

Blue

1.494 – 1.497 mm

(0.05882 – 0.05893 in.)

1. Paint

Number stamped on 
connecting rod and its cap
(Connecting rod big end inside 
diameter)

1

2

3

Alphabet 
stamped on 
crank web of 
No. 3 cylinder
(Crank pin 
diameter)

A

Green

Black

Colorless

B

Black

Colorless

Yellow

C Colorless

Yellow

Blue

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1

2

1

‘‘a’’

‘‘b’’

‘‘A’’

‘‘B’’

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Engine Mechanical: For J20 Engine 1D-119

Main Bearings, Crankshaft and Cylinder Block Components

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1. Cylinder block

9. Check valve

17. Knock sensor

 2. Lower crankcase

: Apply sealant 99000-31250 to mating surface.

10. Flywheel

: Tighten 40 N

⋅m (4.0 kgf-m, 29.0 lb-ft), 0 

N

⋅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.

3. Crankshaft

11. Water pump

: Tighten 26 N

⋅m (2.6 kgf-m, 19.0 lb-ft) by 

the specified procedure.

4. O-ring

12. Heater outlet pipe

: 70 N

⋅m (7.0 kgf-m, 51.0 lb-ft)

5. Oil pump chain

13. CKP sensor

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

 6. Main bearing

: Do not apply engine oil between cylinder block 
and bearing, between lower crankcase and 
bearing. Upper half of bearing has an oil groove.

14. Crankcase bolt (10 mm thread 

diameter)

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

7. Thrust bearing

15. Crankcase bolt (8 mm thread diameter)

: Do not reuse.

8. Rear oil seal

16. Flywheel mounting bolt

: Apply engine oil to inside / sliding 

surface.

1D-120 Engine Mechanical: For J20 Engine

Main Bearings, Crankshaft and Cylinder Block 
Removal and Installation

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Removal

1) Remove engine assembly from vehicle. Refer to 

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

2) Remove clutch and flywheel (drive plate for A/T) by 

using special tool.

Special tool
(A):  09924–17810

3) Remove pistons and connecting rods referring to 

“Pistons, Piston Rings, Connecting Rods and 
Cylinders Removal and Installation: For J20 Engine”.

4) Remove CKP sensor (1).

5) Remove water pump (1) and heater outlet pipe.
6) Remove engine front mounting brackets (2).

7) Loosen crankcase bolts, in sequence shown in figure 

and remove them.

8) Remove crankshaft from cylinder block.

Installation

NOTE

• All parts to be installed must be perfectly 

clean.

• Be sure to oil crankshaft journals, journal 

bearings, thrust bearings, crankpins, 
connecting rod bearings, pistons, piston 
rings and cylinder bores.

• Journal bearings, crankcase (bearings 

caps), connecting rods, rod bearings, rod 
bearing caps, pistons and piston rings are 
in combination sets. Do not disturb 
combination and try to see that each part 
goes back to where it came from, when 
installing.

• Clean mating surface of cylinder block and 

lower crankcase, remove oil, old sealant 
and dust from mating surface.

 

1. Flywheel bolt

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1. Lower crankcase
2. Crankcase bolts (10 mm thread diameter)
3. Crankcase bolts (8 mm thread diameter)

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(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

(21)

(22)

1

2

3

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Engine Mechanical: For J20 Engine 1D-121

1) Fit main bearings to cylinder block (1).

One of two halves of main bearing (4) has oil groove 
(3).
Install this half with oil groove to cylinder block and 
another half without oil groove to lower crankcase.
Make sure that two halves are painted in the same 
color.

2) Install new O-ring (2) to cylinder block.
3) Install knock pins (5) to cylinder block.

4) Fit thrust bearings (1) to cylinder block between No.2 

and No.3 cylinders. Face oil groove (2) sides to 
crank webs.

5) Confirm that dowel pins (3) are installed to cylinder 

block.

6) Put crankshaft (1) with oil pump chain to cylinder 

block.

7) Apply sealant “A” to lower crankcase (1) mating 

surface area as shown in figure.

“A”:  Water tight sealant 99000–31250 (SUZUKI 
Bond No.1207F) 

Sealant amount for lower crankcase
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)

8) Install lower crankcase (1) to cylinder block.

After applying engine oil to all crankcase bolts ((1) – 
(22)), tighten them gradually as follows.
a) Tighten bolts ((1) – (10)) to 30 N

⋅m (3.0 kgf-m, 

21.5 lb-ft) according to numerical order as 
shown.

b) Tighten bolts ((1) – (10)) to 42 N

⋅m (4.2 kgf-m, 

30.5 lb-ft) according to numerical order as 
shown.

c) In the same manner as in step a), tighten them to 

the specified torque.

d) Tighten bolts ((11) – (22)) to the specified torque 

according to numerical order as shown.

Tightening torque
Crankcase bolt with 10 mm thread diameter 
((1) – (10)):  Tighten 40 N

⋅m (4.0 kgf-m, 29.0 

lb-ft), 0 N

⋅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.

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2. Bearing

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