Suzuki Grand Vitara SQ416/SQ420/420WD

since 1998 of release

Repair and car operation



Suzuki Grandee of Wetar
+ General information
+ Maintenance and greasing
+ Heater, ventilation and conditioner
+ Steering
+ Suspension bracket
+ Wheels and tires
+ Forward driving shaft/bearing of a shaft. Oil epiploon
+ Driveshafts
+ Brake system
- Engines
   - Mechanical part of the G16 engine
      + General description
      + Routine maintenance
      - Piston rod, piston rings, rods and cylinders
         Major maintenance
         Bearing of a cranked shaft, crankshaft and block of cylinders
      Special tool
      Necessary service materials
      Technical characteristics of the rotating moment of an inhaling
   + Mechanical part of the J20 engine
   + engine Cooling
+ Fuel system
+ ignition System
+ start System
+ release System
+ Transmissions
+ Coupling
+ Transfer
+ Forward and back differentials
+ Windows, mirrors, locks and security measures. Immobilizer
+ Electric equipment





Piston rod, piston rings, rods and cylinders

1 — the top ring
2 — the second ring
3 — a maslosjemny ring
4 — the piston
5 — шатун*

6 — a bearing cover шатуна*
7 — the bearing шатуна*
8 — a piston finger
9 — a lock ring of a piston finger
10 — a nut of a cover of the bearing of a rod


*5) Do not grease with engine oil an internal surface of a shtokovy cavity of the cylinder.

*6) Do not grease with engine oil an internal surface of a cover.

*7) Do not put engine oil between a shtokovy cavity of the cylinder and the bearing, between a cover and the bearing.

The rotating moment of an inhaling.
Not to use repeatedly.

Grease with engine oil sliding surfaces of each part.

Removal

 PERFORMANCE ORDER

  1. Remove a cylinder head from the block of cylinders, having addressed to the section «Valves and a cylinder head» in this chapter.
  2. Merge engine oil.
  3. Remove an oil pan and a grid of the oil pump, having addressed to the Section Oil pan and a grid of the oil pump in this Chapter.
  4. Note cylinder number on all pistons, rods and covers of bearings of a rod, using a silver pencil or quick-drying paint.
  5. Remove covers of bearings of a rod.
  1. Establish directing hose (1) over a carving of shatunny bolts. It is necessary to avoid damage of a pin of the bearing and a carving of shatunny bolts at rod removal.
  1. Remove a deposit from top of an opening of the cylinder before getting the piston from the cylinder.
  2. To Vytolknita the piston and rod knot at the top from a cylinder opening.

Removal

 PERFORMANCE ORDER

  1. By means of a dilator of piston rings remove two kompressionny rings (top and the second) and a maslosjemny ring from the piston.
  2. Remove a piston finger from a rod.
    • Weaken lock rings of a piston finger (1).
    • Remove a piston finger.

Cleaning

Remove a deposit from the bottom of the piston and flutes of a piston ring by means of the suitable tool.

Check

Cylinders

 PERFORMANCE ORDER

  1. Check walls of cylinders about scratches, roughnesses or the ledges indicating excessive wear. If a cylinder trunk very rough or strongly scratched, or with ledges, chisel the cylinder and use the piston of the bigger size.
  2. With the help компрессиметра measure internal diameter of the cylinder in the direction of draft and the axial direction in two provisions. If you notice something from the following provisions, chisel the cylinder.
    • Internal diameter of the cylinder falls outside the limits norms.
    • The difference of measurements in two provisions falls outside the limits a bias.
    • The difference between measurements of axial section and the direction of draft leaves with a deviation from "kruglost".
      • Limit of internal diameter of the cylinder: 75.15 mm (2.9586 inches)
      • Bias of internal diameter of the cylinder
        • limit: 0.10 mm (0.0039 inches)
      • Internal diameter of the cylinder with a deviation from a kruglost
        • limit: 0.10 mm (0.0039 inches)

If though one of four cylinders has to be chiseled, chisel all four cylinders for the same bigger size. It is necessary for the purpose of uniformity and balance preservation.


1 — 50 mm (1.96 inches)
2 — 95 mm (3.74 inches)

Pistons

 PERFORMANCE ORDER

  1. Investigate pistons about defects, cracks and other damages. The damaged or defective pistons should be replaced.

Diameter of pistons

  1. Diameter of the piston should be measured at distance of 23 mm (0.91 inches) (1) from the end of a skirt of the piston in the direction perpendicular to a piston finger.

Diameter of the piston

Size of the piston

Diameter of the piston

Norm

74.970-74.990 mm (2.9516 – 2.9523 inches)

Repair size: 0.50 mm (0.0196 inches)

75.470-75.480 mm (2.9713 – 2.9716 inches)

Piston gap

  1. Measure internal diameter of the cylinder and diameter of the piston to find a difference which will be a piston gap. The gap of the piston should correspond to the technical requirements specified below. If it does not correspond to technical requirements, chisel the cylinder and use the piston of the bigger size. Piston gap: 0.02-0.04 mm (0.0008 – 0.0015 inches).

The internal diameters of the cylinder used here, are measured in the draft direction in two provisions.


1 — 23 mm (0.01 inches)

Gap of grooves of rings

  1. Before checking, it is necessary to clear, dry and release from a deposit of a groove of the piston. Put a new piston ring (1) in a piston groove, and measure a gap between a ring and a crossing point between two flutes of piston rings by means of a kalibromer (2).
  1. If the gap does not correspond to technical requirements, replace the piston.
    • Gap of a groove of rings:
      • top: 0.03-0.07 mm (0.0012 – 0.0027 inches)
      • the second: 0.02-0.06 mm (0.0008 – 0.0023 inches)

Piston finger

 PERFORMANCE ORDER

  1. Check a piston finger, internal diameter of the plug of a piston head and internal diameter of the piston about wear or damage, paying special attention to a condition of the plug of a piston head of a rod. If the piston finger, internal diameter of the plug of a piston head of a rod or internal diameter of the piston are strongly worn-out or injured, replace a piston finger, a rod or the piston.

Gap of a piston finger

  1. Check a gap of a piston finger on the top head of a rod. Replace a rod if its top head is strongly worn-out or damaged or if the measured gap leaves out of an admissible limit.
Piston gap on the top head of a rod:
  • norm: 0.003-0.016 mm (0.0001 – 0.0006 inches)
  • limit: 0.05 mm (0.0020 inches)

Internal diameter of a small head of a rod: 19.003-19.011 mm (0.7482 – 0.7484 inches)

 Diameter of a piston finger: 18.995-19.000 mm (0.7478 – 0.7480 inches)

Piston rings

To measure a cut gap, insert a piston ring (3) into the cylinder, and then measure a gap by means of a kalibromer (2). If the measured gap does not correspond to technical requirements, replace a ring.

Clean a deposit and clean the top part of the cylinder before inserting a piston ring.

Gap of a cut of a piston ring

 

Norm

Limit

Top ring

0.2-0.35 mm (0.0079 – 0.0137 inches)

0.7 mm (0.0275 inches)

Second ring

0.2-0.35 mm (0.0079 – 0.0137 inches)

0.7 mm (0.0275 inches)

Maslosjemnoye ring

0.20-0.70 mm (0.0079 – 0.0275 inches)

1.7 mm (0.0669 inches)


1 — the cylinder block
2 — a kalibromer
3 — a piston ring
4 — 120 mm (4.72 inches)

Rod

 PERFORMANCE ORDER

Lateral gap of a big bottom head of a rod

  1. Check a lateral gap of a big head of a rod, having inserted and having attached a rod to his shatunny neck regularly. If it will appear that the measured gap falls outside the limits norm, replace a rod.
    • Lateral gap of a big bottom head of a rod
      • norm: 0.10-0.20 mm (0. — 39-0.0079 inch)
      • limit: 0.35 mm (0.0137 inches)

Rod alignment:

  1. Establish a rod on the equalizer to check it on existence of bends and twisting if the limit is more than norm, replace it.
    • Rod alignment
      • Limit of bends: 0.05 mm (0.0020 inches)
      • Twisting limit: 0.10 mm (0.0039 inches)

Shatunny neck and rod bearings

 PERFORMANCE ORDER

  1. Check a shatunny neck on existence of non-uniform wear or damage. Measure a shatunny neck on a deviation or a bias with the help a micromeasure. If the shatunny neck is injured or if a deviation or a bias more admissible limit, replace the crankshaft or переточите a shatunny neck, having addressed to point f).

Technical characteristics of a shatunny neck and rod bearings

Size of bearings of a rod

Diameter of a shatunny neck

Norm

43.982-44.000 mm (1.7316 – 1.7322 inches)

0.25 the mm (0.00984 inches) is lower than the nominal

43.732-43.750 mm (1.7218 – 1.7224 inches)

  • Deviation of a shatunny neck:
    • limit: 0.01 mm (0.0004 inches)
  • Bias of a shatunny neck:
    • limit: 0.01 mm (0.0004 inches)

Rod bearing

  1. Check bearing loose leaves on existence of an oplavleniye, ulcerations, прожига or peelings and examine a configuration of contacts. The damaged loose leaves of the bearing should be replaced. There are two types of bearings of a rod available: bearing of the standard size and bearing less standard size of 0.25 mm. In order that they could be distinguished, on the bearing of the smaller size of 0.25 mm there is number (US 025) printed on its back party, and the bearing of the standard size without number.

Gap of the bearing of a rod

a. Before checking a bearing gap, clean the bearing and a rod neck.
b. Establish the bearing in a rod and a bearing cover.
c. Put a part of plaster solution (1) for full width of a neck of a rod in a place of contact of the bearing (parallel to the crankshaft), bypassing lubricant openings.

d. Establish a cover of the bearing of a rod (1) on a rod. At installation of a cover be convinced that the arrow (2) on a cover indicates the party of a pulley of the crankshaft (3). Having greased with engine oil rod bolts, put the clamps covers with specified rotating the moment. Do not turn the crankshaft with plaster solution inside. The rotating moment of an inhaling: a nut of a cover of the bearing of a rod (and) — 35 N • m (3.5 kg-m, 25.5 pound on foot).

e. Uncover and by means of a ruler (2) on a cover of plaster solution (1), measure width of plaster solution in the widest place (gap). If the gap falls outside the limits norms, use the new bearing of the standard size and try on a gap.
  • Oil gap of the bearing of a rod
    • norm: 0.020-0.050 mm (0.0008 – 0.0019 inches)
    • limit: 0.080 mm (0.0031 inches)

f. If it is impossible to bring a gap into norm limits even with the new bearing of the standard size, replace the crankshaft or переточите a shatunny neck on the size less nominal as follows.

  • Establish the 0.25-millimetric bearing less nominal size (0.00984 inches) on a big head of a rod.
  • Measure internal diameter of a big head of a rod.
  • To Peretochita a shatunny neck till next complete diameter.

Complete diameter of a shatunny neck

=

The measured internal diameter of a big head (including the bearing less nominal size)

0.035 mm (0.0014 inches)

    • Be convinced of that a bearing gap within the standard value specified above.

Assembly

To provide a necessary gap between the piston and the cylinder, there are two sizes of pistons available, as the spare part of the standard size. Establishing the piston of the standard size, do not forget to adjust the piston with the cylinder as follows.


On each piston (5) number 1 or 2 (6) is printed. It points to external diameter of the piston.

On blocks of cylinders numbers 1 and 2 (6) are also printed. The first number indicates internal diameter of the first cylinder (1), second number for internal diameter of the second cylinder (2), third number for internal diameter of the third cylinder (3) and fourth number for internal diameter of the fourth cylinder (4).

And — the party of a pulley of the crankshaft
In — the flywheel party
Number printed on the piston, and number on the block of cylinders should coincide. I.e. establish the piston number 2 on the cylinder at number 2, and the piston number 1 on the cylinder number 1.

Technical characteristics of the piston and cylinder

Piston

Cylinder

Gap between the piston and the cylinder

Number on top (mark)

The external

diameter

Number (mark)

Internal diameter

1

74.9801-74.9900 mm (2.9520 – 2.9523 inches)

1

75.0101-75.0200 mm (2.9531 – 2.9535 inches)

0.02-0.04 mm (0.0008 – 0.0015 inches)

2

74.9700-74.9800 mm (2.9516 – 2.9519 inches)

2

75.000-75.0100 mm (2.9528 – 2.9531 inches)

0.02-0.04 mm (0.0008 – 0.0015 inches)

On heads of pistons letters A, B or C are also printed, but as a rule there is no need to distinguish each piston on this letter.

 PERFORMANCE ORDER

  1. Establish a piston finger in the piston (1) and a rod (3): having greased with engine oil a piston finger and openings of a piston finger in the piston and a rod, establish a rod in the piston, and insert a piston finger into the piston and a rod, and put lock rings of a piston finger.

The lock ring should be established by a detachable part up or down.

Party of a pulley of the crankshaft


1 — the piston
2 — an arrow
3 — a rod
4 — a lubricant opening
  1. Establish piston rings in the piston:
    • The first ring (1) differs from the second ring (2) in a form and marking. Distinguish the first ring from the second, having looked at drawing, and establish these piston rings in the piston, directing the marked party of each ring on the top of the piston.
    • Establishing a maslosjemny ring (3), at first put a strut, and then two erasing edges of a maslosjemny ring.
  1. After installation of three rings (the first, the second and maslosjemny), distribute their gaps of a cut.
1 — an arrow
2 — a gap of a cut of the 1st ring
3 — a gap of a cut of the 2nd ring and a gap of a strut of a maslosjemny ring
4 — a gap of the top erasing edge of a maslosjemny ring
5 — a gap of the bottom erasing edge of a maslosjemny ring
6 — the party on an admission
7 — the party on release

Installation or connection

 PERFORMANCE ORDER

  1. Grease with engine oil pistons, rings, walls of cylinders, bearings of a rod and a shatunny neck.

Do not put oil between a rod and the bearing or between a cover of the bearing and the bearing.


  1. Establish directing sleeves over rod bolts. These directing sleeves protect a shatunny head and a carving of bolts of a rod from damage at installation of a rod and piston knot.
  1. At installation of the piston and rod knot in a trunk of the cylinder of the shooter on a head of the piston should point to the party of a pulley of the crankshaft (1).
1 — a crankshaft pulley
2 — the flywheel party
  1. Establish the piston and rod knot in a cylinder trunk. Use the special tool (the compressor of piston rings) to compress rings. Direct a rod into place in the crankshaft. By means of the handle of a hammer besiege in easy blows a piston head to establish the piston in a trunk. Firmly hold the compressor of rings against the block of cylinders until all piston rings will not enter into a cylinder trunk. Special tool: (А) 09916-77310.
  1. Establish a bearing (1) cover: establish an arrow (2) on a cover towards a crankshaft (3) pulley. Fasten cover nuts according to technical recommendations. The rotating moment of an inhaling: a nut of a cover of the bearing of a rod (and) — 35 N • m (3.5 kg-m, 25.5 pounds on foot).
  1. Repeat dismantle procedure upside-down for the purpose of installation as it was earlier depicted in general.
  2. Adjust a tension of a belt of a drive of the water pump, having addressed to the Section Regulation and check of a tension of a belt of the cooling fan in Head engine Cooling.
  3. Adjust a tension of a belt of the pump of the hydraulic booster of a steering or a tension of a belt of the And/t compressor if that is available. Address to the Section Engine in Head Maintenance and greasing.
  4. Adjust gaps of inlet and exhaust valves, having addressed to Razdelu Klapanny a gap in this Chapter.
  5. Adjust люфт a cable of an accelerator and люфт a cable of a drive of butterfly valves And/t (for And/t models).
  6. Check, whether everything the removed parts are put into place. Repeatedly establish any necessary parts which were not earlier established.
  7. Fill the engine with engine oil, having addressed to the Section Engine oil and the filter in Head Maintenance and greasing.
  8. Fill cooling system, having addressed to the Section Washing and filling of system of cooling in Head engine Cooling.
  9. Fill the case of forward differential with transmission oil, having addressed to Servicing in Head Forward differential.
  10. Connect a negative cable to the accumulator.
  11. Check, whether there is no leakage of fuel, antifreeze, oil and exhaust gas on each connection.
  12. Be convinced of that installation of a corner of an advancing of ignition or injection of fuel corresponds to technical requirements, having addressed to Head ignition System.