Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 164

1D-182 Engine Mechanical: For F9Q Engine

b) Set connecting rod (1) and bearing (2) to special 

tool (A) and (B) as shown in figure.

c) Install connecting rod bearing to connecting rod 

by pushing special tool (B) as shown in figure.

d) Set bearing cap (1) and connecting rod bearing 

(2) to special tool (A) and (B) as shown in figure.

e) Install bearing to bearing cap by pushing special 

tool (B) as shown in figure.

4) Assemble piston and connecting rod with piston pin 

as follows.
a) Apply engine oil to piston pin and piston pin hole 

of piston (1) and connecting rod (2).

b) Fit connecting rod to piston so that flat part (4) of 

connecting rod and arrow mark (3) of piston 
come on opposite side as shown in figure.

c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (5) as shown in figure.

5) Apply engine oil to pistons, rings, cylinder walls, 

connecting rod bearings and crank pins.

NOTE
Do not apply oil between connecting rod and 
bearing and between bearing cap and 
bearing.

 

6) When installing piston and connecting rod assembly 

into cylinder bore, point arrow mark (1) on piston 
head to flywheel side (2).

7) Distribute end gaps of three piston rings (1st, 2nd 

and oil rings) as shown in figure.

I5JB0B140100-01

I5JB0B140101-01

I5JB0B140102-01

1. 1st ring end gap

3. Oil ring end gap

2. 2nd ring end gap

I5JB0B140103-01

I5JB0B140104-01

Engine Mechanical: For F9Q Engine 1D-183

8) Install piston and connecting rod assembly into 

cylinder bore with matching cylinder number marked 
in removal. Use special tool to compress rings. 
Guide connecting rod into place on crankshaft. Using 
a hammer handle (1), 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 

9) Install bearing cap (1) to applicable cylinder with 

matching cylinder number marked in removal, and 
tighten new connecting rod bearing cap bolts as 
follows.
a) Tighten all new cap bolts to 20 N

⋅m (2.0 kgf-m, 

14.5 lb-ft).

b) Retighten them by turning through 40

°.

NOTE
After tightening bearing cap bolts, check to 
be sure that crankshaft rotates smoothly.

 

Tightening torque
Connecting rod bearing cap bolt  (a):  
Tighten 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft) and 40° 

by the specified procedure

10) Turn crankshaft clockwise until key groove (1) 

comes in middle of two ribs (2) and install special 
tool (A) to TDC pin hole.

Special tool
(A):  09912–46510

11) Install oil pump referring to “Oil Pump, Oil Pump 

Chain and Gasket Holder Plate Removal and 
Installation: For F9Q Engine in Section 1E”.

12) Install oil pan referring to “Oil Pan and Oil Pump 

Strainer Removal and Installation: For F9Q Engine in 
Section 1E”.

13) Install cylinder head referring to “Valve and Cylinder 

Head Assembly Removal and Installation: For F9Q 
Engine”.

14) Install timing belt referring to “Timing Belt and Belt 

Tensioner Removal and Installation: For F9Q 
Engine”.

15) Install engine assembly referring to “Engine 

Assembly Removal and Installation: For F9Q 
Engine”.

Cylinders, Pistons and Piston Rings Inspection

S6JB0A1436033

Cylinder
Visual inspection
Inspect cylinder walls for scratches, roughness or ridges 
which indicate excessive wear. If cylinder bore is very 
rough or deeply scratched, or ridged, replace cylinder 
block.

Piston
Visual inspection
Inspect piston for faults, cracks or other damages.
Damaged or faulty piston should be replaced.

I5JB0B140135-01

I5JB0B140105-01

I5JB0B140138-01

1D-184 Engine Mechanical: For F9Q Engine

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

Piston diameter specification
79.8585 – 79.8735 mm (3.144036 – 3.144625 in.)

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 out of specification, replace ring.

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

 

Piston ring end gap
Top ring: 0.20 – 0.35 mm (0.0079 – 0.0137 in.)
2nd ring: 0.70 – 0.90 mm (0.0276 – 0.0354 in.)
Oil ring: 0.25 – 0.50 mm (0.0099 – 0.0196 in.)

Piston and Related Parts Specifications (for 
Reference)

Piston ring

Piston Pins and Connecting Rods Inspection

S6JB0A1436034

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
0.013 – 0.030 mm (0.00052 – 0.00118 in.)

Small-end bore
28.013 – 28.025 mm (1.10288 – 1.10334 in.)

Piston pin dia.
27.995 – 28.000 mm (1.10217 – 1.10236 in.)

“a”: 39.0 mm (1.535 in.)

Item

Specification

Piston ring 

thickness

1st ring

2.47 – 2.49 mm

(0.0973 – 0.0980 in.)

2nd ring 

1.97 – 1.99 mm

(0.0776 – 0.0783 in.)

Oil ring

2.97 – 2.99 mm

(0.1170 – 0.1177 in.)

I2RH01140157-01

I5JB0B140136-01

I4RS0A140023-01

Engine Mechanical: For F9Q Engine 1D-185

Connecting Rod
Connecting rod thrust play
Check big-end of connecting rod for thrust play, with rod 
fitted and connected to its crank pin in the normal 
manner. If measured thrust play is out of specification, 
replace connecting rod.

Connecting rod big end play
0.220 – 0.482 mm (0.00867 – 0.01897 in.)

Connecting Rod and Related Parts Specifications 
(for Reference)

Connecting Rod

Piston Pin

Crank Pin and Connecting Rod Bearings 
Inspection

S6JB0A1436035

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 
specification, replace crankshaft.

Crank pin diameter
48.000 – 48.020 mm (1.88977 – 1.89055 in.)

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 Clearance

1) Before checking bearing clearance, clean bearing 

and crank pin.

2) Install connecting rod bearings referring to Step 3) of 

“Installation” under “Piston, Piston Ring and 
Connecting Rod Removal and Installation: For F9Q 
Engine”.

3) Place a piece of gauging plastic (1) to full width of 

crank pin as contacted by bearing (parallel to 
crankshaft), avoiding oil hole.

NOTE
Do not rotate crankshaft while gauging 
plastic is installed.

 

Item

Specification

Connecting rod big end 

bore “a”

51.587 – 51.606 mm

(2.03099 – 2.03173 in.)

Connecting rod length “b”

178.80 – 178.91 mm

(7.0394 – 7.0397 in.)

Item

Specification

Piston pin inside diameter

12.8 – 13.1 mm

(0.504 – 0.515 in.)

Piston pin length

59.5 – 60.0 mm

(2.343 – 2.362 in.)

I5JB0B140107-01

“a”

“b”

I5JB0B140108-02

I5JB0B140137-01

I2RH0B140121-01