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





Bearing of a cranked shaft, crankshaft and block of cylinders

1 — the block of cylinders
2 — forward oil consolidation
3 — the bearing коленвала*
4 — a bearing cover
5 — a cover bolt
6 — a pulley of the gas-distributing mechanism
7 — the crankshaft
8 — the persistent bearing

9 — back oil consolidation
10 — a pin
11 — a case bolt (short)
12 — the case сальника*
13 — a case bolt (long)
14 — the bearing of primary shaft
15 — a flywheel
16 — a flywheel bolt


*3) Do not put engine oil between the block of cylinders and the bearing, between a cover of the bearing and the bearing.

*12) Put hermetic 99000-31250 on the interfaced surfaces

The rotating moment of an inhaling.

Not to use repeatedly.

Grease with engine oil sliding surfaces.

Removal

 PERFORMANCE ORDER

  1. Remove engine knot from the case, having addressed to the Section Engine in this Chapter.
  2. Remove a coupling casing, a disk of coupling and a flywheel (a leading disk for And/t). Special tool: (А) 09924-17811.
1 — a flywheel bolt
  1. Remove a crankshaft pulley, a belt of a drive of the gas-distributing mechanism and a pulley of the gas-distributing mechanism of the crankshaft.
  2. Remove knot of a head of the cylinder.
  3. Remove an oil pan and a grid of the oil pump.
  4. Remove the oil pump (1).
1 — the oil pump
2 — a bolt
  1. Remove the epiploon case.
  1. Remove covers of bearings of a rod.
  2. Untwist bolts of covers of bearings of the crankshaft in such order as it is specified in drawing, and remove covers of bearings.
  1. Remove the crankshaft from the block of cylinders.

Check

Crankshaft

Wear of the crankshaft

By means of the tsiferblatny indicator measure wear on a neck in the center. Slowly rotate the crankshaft. If wear exceeds limit rates, replace the crankshaft. Limit of wear of the crankshaft: 0.06 mm (0.0023 inches).

Gap of the persistent bearing of the crankshaft

 PERFORMANCE ORDER

  1. Measure this gap when the crankshaft is regularly in the block of cylinders, i.e. when the persistent bearing (1) and covers of a pin of bearings on a place.
  1. Use a tsiferblatny measuring instrument to take readings of a deviation in the axial direction of the crankshaft. If the deviation falls outside the limits norms, replace the persistent bearing on new the standard size or the bigger size to receive a standard gap.
    • Gap of the persistent bearing of the crankshaft
      • norm: 0.11-0.31 mm (0.0044 – 0.0122 inches)
      • limit: 0.38 mm (0.0149 inches)
    • Thickness of the persistent bearing of the crankshaft
      • norm: 2.47 mm – 2.52 mm (0.0973 – 0.0992 inches)
    • Repair size (0.125 mm (0.0049 inches)): 2.533-2.583 mm (0.0998 – 0.1016 inches)

Ellipsnost and bias (non-uniform wear) crankshaft necks

The difference speaks about non-uniform wear of a neck of the crankshaft in diameter of cross-section section or along its length (or both that, and another). This difference if that is, is determined by indications a micromeasure. If one of necks is strongly damaged or if the general non-uniform wear, in that plan as it was explained above, falls outside the limits norm, переточите or replace the crankshaft. Limit of an ellipsnost and bias of a neck of the crankshaft: 0.01 mm (0.0004 inches).

Crankshaft bearings

General information

Crankshaft bearings for repair are presented in the standard size and in the size less standard on 0.25 mm (0.0098 inches), and each of them is presented by 5 types of the bearings differing from each other by the admission.

The top half of the bearing (2) has a lubricant flute (3). Establish this half with a lubricant flute in the block of cylinders (1).
On each cover of the bearing of the crankshaft the arrow and number is stamped. At installation of each cover of the bearing to the block of cylinders send to the shooter towards a pulley of the crankshaft and establish each cover from this party towards a flywheel in ascending order numbers "1", "2", "3", "4" and "5". Fasten bolts of covers to the specified rotating moment.

Check

Check bearings about an ulceration, scratches, wear or damage. If any defects are found, replace the top and bottom halves. Never replace one half, without having replaced other half.

Gap of bearings of the crankshaft

 PERFORMANCE ORDER

  1. Check a gap by means of plaster solution, having executed the following procedure.
  2. Remove covers of bearings.
  3. Clean bearings and crankshaft necks.
  1. Put a part of plaster solution (1) for full width of the bearing (parallel to the crankshaft) on a neck, bypassing oil openings.
  1. Establish covers of bearings as it was shown above, and evenly tighten bolts of covers by the specified rotating moment. The cover of the bearing should be fastened according to technical requirements to provide the correct indications of a gap. The rotating moment of an inhaling: a bolt of a cover of the bearing of the crankshaft (and) — 54 N • m (5.4 kg-m, 39.0 pound on foot).

Do not turn the crankshaft with plaster solution inside.


  1. Uncover and by means of a ruler (2) measure width on a plaster covering (1) in the widest point. If the gap falls outside the limits norm, replace the bearing. Always replace the top and bottom half, as a unit. The new standard bearing can create a necessary gap. If it did not occur, it is necessary переточить a crankshaft neck in order that it was possible to use the bearing of the smaller size of 0.25 mm (0.009842 inches). Having chosen the new bearing, check a gap repeatedly.
    • Gap of the bearing of the crankshaft
      • norm: 0.02-0.04 mm (0.0008 – 0.0015 inches)
      • limit: 0.060 mm (0.0023 inches)

Choice of bearings of the crankshaft

Standard bearing

  • If the bearing in failure condition or if the gap of the bearing falls outside the limits norm, choose the new standard bearing according to the following procedure, and establish it.
  • At replacement of the crankshaft or the block of cylinders for any reason choose new standard bearings to establish them according to numbers printed on the new crankshaft, and/or the letters printed on the interfaced surface of the new block of cylinders.

 PERFORMANCE ORDER

  1. At first check diameter of a neck by means of the following procedure. On cheeks of the crankshaft of cylinders No. 2 and No. 3 five figures are printed. Three types of figures («1», «2» and «3») represent the next diameters of necks.

Technical characteristics of diameter of necks

The printed figures

Diameter of necks

1

51.9940-52.0000 mm (2.0470 – 2.0472 inches)

2

51.9880-51.9939 mm (2.0468 – 2.0469 inches)

3

51.9820-51.9879 mm (2.0466 – 2.0467 inches)

  1. The first, the second, the third, the fourth and the fifth (from left to right) the printed figures designate diameters of necks on covers of bearings "1", "2", "3", "4" and "5", respectively.
  2. For example, in drawing the first (the most extreme at the left) figure «3» specifies that diameter of a neck on a bearing "1" cover within 51.9820 – 51.9879 mm (2.0466 – 2.0467 inches), and the second figure «1» specifies that diameter of a neck on a cover «2» makes 51.9940 – 52.0000 mm (2.0470 – 2.0472 inches).
1 — cylinders No. 2 and No. of 3 cheeks of the crankshaft
  1. Further check internal diameter of covers of bearings without bearings. On the interfaced surface of the block of cylinders five letters are printed. Three letters ("And", "In" and "With") designate the next internal diameters of covers.

Technical characteristics of internal diameters of covers of bearings of the crankshaft

The printed letters

Internal diameter of covers of bearings (without bearings)

And

56.0000-56.0061 mm (2.2048 – 2.2049 inches)

In

56.0061-56.0120 mm (2.2050 – 2.2051 inches)

With

56.0121-56.0180 mm (2.2052 – 2.2054 inches)

  1. The first, the second, the third, the fourth and the fifth (from left to right) the printed letters specify internal diameter of covers of bearings "1", "2", "3", "4" and "5", respectively. For example, in drawing the first (the most extreme at the left) the letter "In" specifies that internal diameter of a cover of the bearing "1" makes 56.0061 – 56.0120 mm (2.2050 – 2.2051 inches), and the fifth (the most extreme on the right) the letter "And" specifies that internal diameter of a cover «5» makes 56.0000 – 56.0061 mm (2.2048 – 2.2049 inches).
  2. There are five types of the standard bearings differing from each other on thickness. In order that they could be distinguished, they are painted in the following colors in a place shown in drawing. Each color designates a certain thickness in the bearing center.

Technical characteristics of bearings of the crankshaft

Color

Thickness of the bearing

The green

1.996-2.000 mm (0.07859 – 0.07874 inches)

The black

1.999-2.003 mm (0.07870 – 0.07885 inches)

Colourless (there is no paint)

2.002-2.006 mm (0.07882 – 0.07897 inches)

The yellow

2.008-2.012 mm (0.07906 – 0.07921 inches)

The blue

2.008-2.012 mm (0.07906 – 0.07921 inches)


1 — paint
  1. On the figures printed on cheeks of the crankshaft of cylinders No. 2 and No. 3 and letters, printed on the interfaced surface of the block of cylinders, define the new standard bearing which should be established on a neck, having addressed to the table provided below. For example, if the figure printed on a cheek of the crankshaft "1", and the letter printed on the interfaced surface – "In", establish the new standard bearing painted in black» color on his neck.

Technical characteristics of the new bearing of the crankshaft of the standard size

 

The figure printed on a cheek of the crankshaft (diameter of a neck)

1

2

3

The letter printed on the interfaced surface (internal diameter of the cover of the bearing)

And

The green

The black

The colourless

In

The black

The colourless

The yellow

With

The colourless

The yellow

The blue

 

 

To establish the new bearing of the standard size


1 — cheeks of the crankshaft of cylinders No. 2 and No. 3
  1. Check a bearing gap at the new chosen bearing of the standard size. If the gap still falls outside the limits norm, use the bearing of the size following on thickness and recheck a gap.

Bearing of the smaller size (0.25 mm (0.00984 inches))

The bearing of the smaller size on 0.25 mm (0.00984 inches) is presented by five types differing from each other on thickness. In order that they could be distinguished, each bearing is painted in the following colors in a place specified in drawing. Each color represents a certain thickness in the bearing center.

Thickness of bearings of the smaller size of the crankshaft

Color

Thickness of the bearing

Green and red

2.121-2.125 mm (0.08351 – 0.08366 inches)

Black and red

2.124-2.128 mm (0.08363 – 0.08377 inches)

Only the red

2.127-2.131 mm (0.08374 – 0.08389 inches)

Yellow and red

2.130-2.134 mm (0.08386 – 0.08401 inches)

Blue and red

2.133-2.137 mm (0.08398 – 0.08413 inches)


1 — paint

If it is necessary, переточите a neck of the crankshaft and choose for it the bearing of the smaller size as follows.

 PERFORMANCE ORDER

  1. To Peretochita a neck till next complete diameter. Complete diameter of a neck of the crankshaft: 51.732-51.750 mm (2.0367 – 2.0373 inches).
  1. With the help a micromeasure measure peretochenny diameter of a neck. Indications of measurement should act in film in two directions perpendicularly each other to check an ellipsnost.
  1. By means of diameter of a neck measured above, and the letters printed on the interfaced surface of the block of cylinders, choose the bearing of the smaller size, having addressed to the table provided below. Check a bearing gap with the new chosen bearing of the smaller size.

Technical characteristics of the bearing of the smaller size of the crankshaft

 

The measured diameter of a neck

51.7440-51.7500 mm (2.0371 – 2.0373 inches)

51.7380-51.7439 mm (2.0369 – 2.0371 inches)

51.7320-51.7379 mm (2.0367 – 2.0369 inches)

The letters printed on the interfaced surface of the block of cylinders

And

Green and red

Black and red

Only the red

In

Black and red

Only the red

Yellow and red

With

Only the red

Blue and red

Blue and red

 

Bearings of the smaller size to installation

Back oil consolidation

 PERFORMANCE ORDER

  1. Attentively check back oil consolidation (1) about wear or damage. If its edge is worn-out or damaged, replace it.
  1. To establish oil consolidation, densely press back oil consolidation (1), adjusting until the end face of the case of an epiploon (2) will not be drowned aflush with an end face of oil consolidation.

Flywheel

 PERFORMANCE ORDER

  1. If the gear wreath is damaged, will burst or is worn-out, replace a flywheel.
  2. If the surface contacting to a disk of coupling, is damaged or strongly worn-out, replace a flywheel.
  1. Check a flywheel about wear of an obverse surface by means of the tsiferblatny indicator. If wear exceeds admissible norms, replace a flywheel. Limit of wear of a flywheel: 0.2 mm (0.0078 inches).

Block of cylinders

Deformation of the condensed surface

By means of a kalibromer check the condensed surface about deformation and if the planshetnost exceeds admissible norms, correct it. Limit of deformation of the block of cylinders: 0.06 mm (0.0023 inches).

Honingovaniye or boring of cylinders

 PERFORMANCE ORDER

  1. If it is required to chisel one of the cylinders, all other cylinders should be also chiseled in one and too time.
  2. Pick up the piston of the bigger size according to the general wear of the cylinder.

Diameter of the piston

Size

Diameter of the piston

The size is more on 0.50 mm (0.020 inches)

75.470-75.480 mm (2.9713 – 2.9716 inches)

  1. With the help a micromeasure measure diameter of the piston.
1 — 23 mm (0.91 inches)
  1. Calculate, what internal diameter of the cylinder is necessary for chiseling.
    • D= AND + IN – WITH
    • D: Internal diameter of the cylinder which is necessary for turning.
    • А: The measured diameter of the piston.
    • В: A piston gap = 0.02 – 0.04 mm (0.0008 – 0.0015 inches)
    • С: The admission for a honingovaniye = 0.02 mm (0.0008 inches)
  2. Chisel and хонингуйте the cylinder to settlement parameters.

Before chiseling, establish all covers of bearings of the crankshaft on a place and fasten them according to technical requirements to avoid deformation of internal diameters of bearings.

  1. Measure a piston gap after a honingovaniye.

Installation

  • All parts of installation should be washed ideally up.
  • Do not forget to grease crankshaft necks, basic bearings, persistent bearings, shatunny necks, rod bearings, pistons, piston rings and trunks of cylinders.
  • Basic bearings, covers of bearings, rods, bearings of rods, covers of bearings of rods, pistons and piston rings are incorporated in separate sets. Do not separate such sets and provide at installation that each detail returned there, from where it came.

 PERFORMANCE ORDER

  1. Establish crankshaft bearings in the block of cylinders (1). One of two halves of the bearing of the crankshaft has an oil flute (3). Establish it in the block of cylinders, and other half without an oil flute in a bearing cover. Be convinced that both halves are noted by the same paint.
1 — the block of cylinders
2 — the top half of the bearing
3 — an oil flute
  1. Establish persistent bearings (1) in the block of cylinders between No. 2 and No. 3 cylinders. The parties with an oil flute (2) turn an obverse surface to crankshaft cheeks.
  1. Establish the crankshaft in the block of cylinders.
  1. Establish covers of bearings in the block of cylinders, without forgetting that the arrow (on each cover) should indicate towards a crankshaft pulley. Put them consistently in ascending order numbers 1, 2, 3, 4 and 5, since the pulley party.
  1. Having greased with engine oil all bolts of covers of bearings, fasten bolts of covers of bearings in such order as it is specified in drawing in the small portions, and repeat a twisting until they will not be fastened to the specified moment of rotation. Moment of rotation of an inhaling: a bolt of a cover of the bearing of the crankshaft (and) — 54 N • m (5.4 kg-m, 39.0 pounds on foot).

Having fastened bolts of covers, be convinced that the crankshaft rotates smoothly when it you turn the moment of rotation of 8.0 N • m (0.8 kg-m, 5.8 pound on foot) or down.

  1. Put hermetic on the interfaced surface of the case of a back epiploon. "And": hermetic 99000-31250.
"and" — 3 mm (0.12 inches)
«b» — 2 mm (0.08 inches)
  1. Establish the case of a back epiploon (1) and fasten bolts to the specified rotating moment. The rotating moment of an inhaling: a bolt of the case of back oil consolidation (and) — 11 N • m (1.1 kg-m, 8.0 pound on foot).

As there are 2 types of bolts of the case available, address to drawing in order that they are correct for using.


1 — long bolts
2 — short bolts
  1. Establish the oil pump, having addressed to the Section the Oil pump in this Chapter.
  1. Establish a flywheel (for M/t models) or a leading disk (for And/t models). By means of the special tool fix a flywheel or a leading disk and fasten its bolts according to technical requirements. Special tool: (А) 09924-17811. The rotating moment of an inhaling: a bolt of a flywheel or a leading disk (and) — 78 N • m (7.8 kg-m, 56.5 pound on foot).
  1. Establish pistons and rods, having addressed to the Section Pistons, piston rings, rods and cylinders in Head the Mechanical part of the J20 engine.
  2. Establish a grid of the oil pump and an oil pan, having addressed to the Section Oil pan and a grid of the oil pump in this Chapter.
  1. Establish a head of the block of the cylinder on the block of cylinders, having addressed to the Section Valves and a head of the block of cylinders in this Chapter.
  1. Establish a cam-shaft, a pulley of a belt of a drive of the gas-distributing mechanism of a cam-shaft, a belt of a drive of the gas-distributing mechanism, a crankshaft pulley, a pulley of the water pump etc. Address to Sections a valve Yoke, an axis of yokes and a cam-shaft and the Belt of a drive of the gas-distributing mechanism and the tension device for a belt in this Chapter.
  2. Establish coupling on a flywheel (for M/t vehicles), having addressed to the Section a coupling Cover, a disk of coupling and a flywheel in Head Coupling.
  1. Establish arms of fastening of the engine.
    • The rotating moment of an inhaling:
      • bolt and nut of an arm of fastening of the engine (and) — 55 N • m (5.5 kg-m, 40.0 pound on foot)
      • nut and arm bolt боковины fastenings of the engine (b) — 93 N • m (9.3 kg-m, the 67th pound on foot)
  1. Establish engine knot in a vehicle, having addressed to the Section Engine in this Chapter.