Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 150

1D-126 Engine Mechanical: For J20 Engine

4) From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard

bearing to be installed to journal by referring to table shown.
For example, if number stamped on crank web No.2 is “5” and alphabet stamped on lower crankcase is “A”, install
new standard bearings painted in “Green” to cylinder block side journal and “Black” to lower crankcase side
journal.

NOTE
The meaning of “Upper” and “Lower” described in below table are the following.
• Upper: It is instruction of main bearing installed in cylinder block side journal.
• Lower: It is instruction of main bearing installed in lower crankcase side journal.

Main bearing cross-reference table (new standard bearing)

5) Check main bearing clearance with newly selected standard bearing referring to “Main Bearing Clearance”.

If clearance still exceeds its limit, use next thicker bearing and recheck clearance.

UNDERSIZE BEARING (0.25 mm):
• 0.25 mm undersize bearing is available, in five kinds varying in thickness.

To distinguish them, each bearing is painted (1) in the following colors at such position as indicated in figure.
Each color represents the following thickness at the center of bearing.

Undersize main bearing thickness

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

a. Regrind journal to the following finished diameter.

Finished journal diameter
57.7380 – 57.7560 mm (2.27315 – 2.27385 in.)

Standard number on crank web No.2

Standard

alphabet on

lower crankcase

Green

Upper: Green

Lower: Black

Black

Upper: Black

Lower: Colorless

Colorless

Upper: Colorless

Lower: Yellow

Black

Upper: Black

Lower: Colorless

Colorless

Upper: Colorless

Lower: Yellow

Yellow

Upper: Yellow

Lower: Blue

C Colorless

Upper: Colorless

Lower: Yellow

Yellow

Upper: Yellow

Lower: Blue

Blue

Color painted

Bearing thickness

Green & Red

2.1160 – 2.1190 mm (0.08331 – 0.08342 in.)

Black & Red

2.1190 – 2.1220 mm (0.08343 – 0.08354 in.)

Red only

2.1220 – 2.1250 mm (0.08355 – 0.08366 in.)

Yellow & Red

2.1250 – 2.1280 mm (0.08367 – 0.08377 in.)

Blue & Red

2.1280 – 2.1310 mm (0.08378 – 0.08389 in.)

I2RH01140192-01

Engine Mechanical: For J20 Engine 1D-127

b. Using micrometer, measure reground 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 and alphabets stamped on lower crankcase, select an undersize bearing by

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

Undersize bearing specification

Crankshaft Position Sensor Plate
Check teeth of plate for damage.
If any damage is found, replace crankshaft (1).

Oil Pump Sprocket
Check teeth of sprocket for wear or damage.
If any damage or wear is found, replace crankshaft (1).

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.)

Measured journal diameter

57.7500 – 57.7560 mm

(2.27362 – 2.27385 in.)

57.7440 – 57.7499 mm
(2.27338 – 2.27361 in.)

57.7380 – 57.7439 mm

(2.27315 – 2.27337 in.)

Alphabets stamped

on lower crankcase

Green & Red

Black & Red

Red only

Black & Red

Red only

Yellow & Red

Red only

Yellow & Red

Blue & Red

I2RH01140193-01

2. Crankshaft position sensor plate

2. Oil pump sprocket

I2RH01140194-01

I2RH01140195-01

I2RH01140196-01

I2RH01140198-01

1D-128 Engine Mechanical: For J20 Engine

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.)

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

S6JB0A1427001

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

)

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