Suzuki Grand Vitara JB419. Manual - part 50

Engine Mechanical:  1D-46

Cylinder Head Inspection

S5JB0B1406028

• Remove all carbon deposits from combustion 

chambers.

NOTE
Do not use any sharp-edged tool to scrape 
off carbon deposits. Be careful not to scuff or 
nick metal surfaces when decarbonizing. The 
same applies to valves and valve seats, too.

 

• Check cylinder head for cracks on intake and exhaust 

ports, combustion chambers, and head surface. Using 
a straightedge and thickness gauge, check flatness of 
gasketed surface at a total of 6 locations. If distortion 
limit is exceeded, replace cylinder head. 
Leakage of combustion gases from this gasketed joint 
is often due to warped gasketed surface: such 
leakage results in reduced power output.

Distortion for cylinder head surface on piston side
Limit: 0.05 mm (0.0020 in.)

Cylinder Head and Related Parts Specification (for 
Reference)

Cylinder head with valve guide

I2RH0B140105-01

I2RH0B140106-01

Item

Specification

Valve guide position “a”

80.65 – 81.45 mm

(3.1752 – 3.2066 in.)

Valve guide angle “b”

90

°

I5JB0B140091-01

1D-47 Engine Mechanical: 

Cylinder head

Cylinder head gasket

Valve Spring Inspection

S5JB0B1406029

Valve Spring Free Length and Preload
Referring to data, check to be sure that each spring is in 
sound condition, free of any evidence of breakage or 
weakening. Remember, weakened valve springs can 
cause chatter, not to mention possibility of reducing 
power output due to gas leakage caused by decreased 
seating pressure.

Valve spring free length
44 – 48 mm (1.74 – 1.88 in.)

Valve spring preload
27 N (2.7 kg, 6.0 lb) for 37.5 mm (1.476 in.)
61.4 N (6.14 kg, 13.5 lb) for 27.5 mm (1.083 in.)

Item

Specification

Cylinder head height “a”

161.00 – 164.50 mm

(6.3386 – 6.4763 in.)

Valve seat 

housing inside 

diameter “b”

Intake valve

36.877 – 36.907 mm

(1.45185 – 1.45303 in.)

Exhaust 

valve

33.500 – 33.529 mm

(1.31890 – 1.32003 in.)

Valve guide housing inside 

diameter “c”

11.95 – 11.98 mm

(0.4705 – 0.4716 in.)

I5JB0B140092-01

I5JB0B140093-01

I5JB0B140094-01

Item

Specification

Cylinder head gasket 

thickness “a”

1.27 – 1.37 mm

(0.0500 – 0.0539 in.)

“b”: Measured point

I5JB0B140095-01

I2RH01140143-01

Engine Mechanical:  1D-48

Piston, Piston Ring, Connecting Rod and Cylinder Components

S5JB0B1406030

Piston, Piston Ring and Connecting Rod 
Removal and Installation

S5JB0B1406065

NOTE

• All parts to be installed must be perfectly 

clean.

• Connecting rods, connecting rod bearings, 

connecting rod bearing caps, pistons and 
piston rings are in combination sets. Do 
not disturb such combination and make 
sure that each part goes back to where it 
came from, when installing.

 

Removal

1) Remove engine assembly referring to “Engine 

Assembly Removal and Installation”.

2) Remove cylinder head referring to “Valve and 

Cylinder Head Assembly Removal and Installation”.

3) Remove oil pump referring to “Oil Pump, Oil Pump 

Chain and Gasket Holder Plate Removal and 
Installation in Section 1E”.

4) Remove special tool.

Special tool
(A):  09912–46510

5) Mark cylinder number on all pistons, connecting rods 

(1) and connecting rod bearing caps (2) using silver 
pencil or quick drying paint (3) for installation.

5

6

(a)

8

9

9

1

2

3

4

7

I5JB0B140096-01

1. Top ring

8. Piston pin

2. 2nd ring

9. Piston pin circlip

3. Oil ring

: Tighten 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft) and 40° by the specified procedure.

4. Piston

: Apply engine oil to sliding surface of each part.

5. Connecting rod

: Do not reuse.

6. Connecting rod bearing cap

: See “A”

“A”: Point arrow mark on cap to fly wheel side.

7. Connecting rod bearing

: See “B”

“B”: Do not apply oil between connecting rod and bearing and between bearing cap and bearing.

I5JB0B140024-01

I5JB0B140097-01

1D-49 Engine Mechanical: 

6) Remove connecting rod bearing caps.
7) Decarbon top of cylinder bore before removing 

piston from cylinder.

8) Push piston and connecting rod assembly out 

through the top of cylinder bore.

9) Remove piston pin from connecting rod as follows.

a) Ease out piston pin circlips (1) as shown in 

figure.

b) Force piston pin out.

10) Remove connecting rod bearings

11) Using piston ring expander, remove two 

compression rings (1st and 2nd) and oil ring from 
piston, if necessary.

Installation

1) Decarbonize piston head and ring grooves using a 

suitable tool.

2) Install piston ring to piston noting the following, if 

removed.
• As indicated in figure. 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 as shown in 
figure.

• When installing oil ring, install spring ring (3) first 

and then rail (4).

3) Assemble connecting rod bearing to connecting rod / 

bearing cap as follows.
a) Install special tool (B) to special tool (A).

Special tool
(A):  09913–98110 
(B):  09913–86520

I2RH0B140113-01

I2RH0B140114-01

I5JB0B140098-01

I5JB0B140099-01