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
   - Mechanical part of the J20 engine
      + General description
      - Routine maintenance
         Compression check
         Check of depression of the engine
         Check of pressure of oil
         Filtering element of the air filter
         Case of butterfly valves and inlet collector
         Collector of an exhaust system
         Cover of a head of the cylinder
         Oil pan and grid of the oil pump
         Oil pump
         Cover of a chain of synchronization
         Second chain of synchronization and natyazhitel of a chain
         First chain of synchronization and natyazhitel of a chain
         Cam-shafts and regulators of a klapanny gap
         Valves and head of the block of the cylinder
         Pistons, piston rings, rods and cylinders
      + Assembly fittings of the engine
      Special tool
      Necessary service materials
      Technical characteristics of the rotating moment of an inhaling
   + 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





Pistons, piston rings, rods and cylinders

Components

1 — the top ring
2 — the second ring
3 — a maslosjemny ring
4 — the piston
5 — a rod
6 — a cover of the bearing of a rod
7 — the rod bearing
8 — a piston finger

9 — a lock ring of a piston finger
10 — the cylinder block
11 — the oil pump
12 — a cover of an asterisk of the oil pump
13 — a nut of a cover of the bearing of a rod
14 — a bolt of the oil pump
15 — a bolt of a cover of an asterisk of the oil pump


Do not grease with engine oil an internal surface of a big bottom head of a rod.

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

Do not put engine oil between a big bottom head of a rod and the bearing, between a cover and the bearing.

The rotating moment of an inhaling.

Not to use repeatedly.

Grease with engine oil a sliding surface of each detail.

Removal

 PERFORMANCE ORDER

  1. Dump pressure of fuel.
  2. Disconnect a negative cable from the accumulator.
  3. Merge engine oil.
  4. Merge antifreeze.
  5. Remove a cylinder head with an inlet collector, a collector of an exhaust system and a water taking-away pipe, having addressed to the Section Valves and a head of the block of the cylinder in this Chapter.
  6. Remove the oil pump, having addressed to the Section the Oil pump in this Chapter.
  7. Note cylinder number on all pistons, rods and covers of bearings of a rod.
  8. Remove covers of bearings of a rod.
  1. Establish directing hose (1) over a carving of shatunny bolts. It prevents injury of a neck 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.

Dismantling

 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.
  1. Remove a piston finger from a rod.
  2. Weaken lock rings of a piston finger (1).
  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

Cylinder

 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 a kruglost.
1 — 50 mm (1.96 inches)
2 — 95 mm (3.74 inches)
  • Limit of internal diameter of the cylinder: 84.050 mm (3.3090 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.

Pistons

 PERFORMANCE ORDER

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

Diameter of pistons

  1. Diameter of the piston should be measured in a point of 26.5 mm (1.04 inches) from the end of a skirt of the piston in the direction perpendicular to a piston finger.
1 — 26.5 mm (1.04 inches)
    • Diameter of the piston:
      • standard diameter of the piston: 83.970-83.990 mm (3.3059 – 3.3066 inches)
      • diameter of the piston of the bigger size (0.50 mm (0.0196 inches)): 84.470-84.490 mm (3.3256 – 3.3263 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 — 26.5 mm (1.04 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
      • the 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: 0.003-0.014 mm (0.0001 – 0.0005 inches)
    • Internal diameter of a small head of a rod: 21.003-21.011 mm (0.8269 – 0.8272 inches)
    • Diameter of a piston finger: 20.997-21.000 mm (0.8267 – 0.8267 inches)

Piston rings

To measure a cut gap, insert a piston ring (3) into a cylinder trunk, 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 any other dirt from top of a trunk of the cylinder before inserting a piston ring.

Gap of a cut of a piston ring

Norm

Limit

Top ring

0.20-0.35 mm (0.0079 – 0.0137 inches)

0.7 mm (0.0275 inches)

Second ring

0.35-0.50 mm (0.0138 – 0.0196 inches)

0.7 mm (0.0275 inches)

Maslosjemnoye ring

0.20-0.70 mm (0.0079 – 0.0275 inches)

1.8 mm (0.0708 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: 0.25-0.40 mm (0.0099 – 0.0157 inches)
      • limit: 0.45 mm (0.0177 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.
    • Limit of bends: 0.05 mm (0.0020 inches)
    • Twisting limit: 0.10 mm (0.0039 inches)

Shatunny neck and rod bearings

Diameter of a shatunny neck

Check a shatunny neck on existence of non-uniform wear or damage. Measure a shatunny neck on an ellipsnost or a bias with the help a micromeasure. If the shatunny neck is injured or if an ellipsnost or a bias more admissible limit, replace the crankshaft or переточите a shatunny neck, having addressed to item 7).

Technical characteristics of a shatunny neck and rod bearings

Size of bearings of a rod

Diameter of a shatunny neck

Norm

49.982-50.000 mm (1.9678 – 1.9685 inches)

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

49.732-49.750 mm (1.9580 – 1.9586 inches)

  • Ellipsnost of a shatunny neck (And - In)
    • limit: 0.01 mm (0.0004 inches)
  • Bias of a shatunny neck (and – b)
    • limit: 0.01 mm (0.0004 inches)

General information on rod bearings

1 — paint

Repair bearings of a rod happen the standard size and on 0.25 mm (0.0098 inches) less, bearings of the smaller size happen 5 types differing from each other by stability to influence. In order that it was possible to distinguish the bearing of the smaller size, it is painted in red color in a point shown in drawing, the thickness of the bearing of the smaller size in the center makes 1.605 – 1.615 mm (0.0632 – 0.0635 inches).

Visual survey of the bearing of a rod

Examine bearing loose leaves about an oplavleniye, ulcerations, прожога or an otslaivaniye and examine drawing of an arrangement of contact. Bearing loose leaves in failure condition should be replaced.

Gap of the bearing of a rod

 PERFORMANCE ORDER

  1. Before checking a bearing gap, clean the bearing and a rod neck.
  2. Establish the bearing in a rod and a bearing cover.
  1. 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.
  1. Establish a cover of the bearing of a rod on a rod.
  1. At installation of a cover be convinced that the arrow (1) on a cover indicates the party of a pulley of the crankshaft. Having greased with engine oil rod bolts, put the clamps covers by the specified rotating moment. The rotating moment of an inhaling: nut of a cover of the bearing of a rod (and): 45 N • m (4.5 kg-m, 33.0 pound on foot).

DO NOT TURN the crankshaft with plaster solution inside.


  1. Uncover and by means of a ruler (2) on a cover of plaster solution (1), measure width of plaster solution (1) in the widest place (gap). If the gap falls outside the limits norms, use the new bearing of the standard size, having addressed to subsection the Selection of bearings of a rod in this Section. After selection of the new bearing try on a gap.
    • Gap of the bearing of a rod:
      • norm: 0.045-0.063 mm (0.0018 – 0.0024 inches)
      • limit: 0.08 mm (0.0031 inches)
  1. 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.
  2. Establish the 0.25-millimetric bearing of the smaller size on a big head of a rod.
  3. Measure internal diameter of a big head of a rod.
  4. 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)

 

0.054 mm (0.0021 inches)

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

Selection of bearings of a rod

  • If the bearing is faulty or the gap of the bearing does not correspond to technical characteristics, choose the new bearing of the standard size according to the following procedure and establish it.
  • If for any reason replace the crankshaft or a rod and its bearing, choose the new bearing of the standard size for installation, having addressed to the figures printed on a rod and its cover and/or letters, printed on a cheek of the crankshaft of the cylinder No. 3.

 PERFORMANCE ORDER

  1. Check the printed figures on a rod and its cover. Three types of numbers («1», «2» and «3») represent the next internal diameters of a big head of a rod. For example, printed number "1" specifies that internal diameter of the corresponding big head of a rod makes 53.0000 – 53.0060 mm (2.0867 – 2.0868 inches).

Internal diameter of a big bottom head of a rod

The printed figures

Internal diameter of a big bottom head of a rod

1

53.0000-53.0060 mm (2.0867 – 2.0868 inches)

2

53.0061-53.0120 mm (2.0869 – 2.0870 inches)

3

53.0121-53.0180 mm (2.0871 – 2.0873 inches)


And — the mark indicating weight
In — figure of internal diameter of a big bottom head of a rod
  1. Further check diameter of a shatunny neck. On a cheek of the crankshaft of the cylinder No. 3 4 letters are printed. Three types of letters ("And", "In" and "With") represent the following of diameter of shatunny necks, respectively. For example, the printed letter "And" specifies that diameter of the corresponding neck of the crankshaft makes 49.9940 – 50.0000 mm (1.9683 – 1.9685 inches).

Diameter of a neck of the crankshaft

The printed letters

Diameter of a neck of the crankshaft (without the bearing)

And

49.9940-50.0000 mm (1.9683 – 1.9685 inches)

In

49.9880-49.9939 mm (1.9681 – 1.9682 inches)

With

49.9820-49.9879 mm (1.9677 – 1.9680 inches)


And — diameter of a neck of the crankshaft for the cylinder No. 1
In — diameter of a neck of the crankshaft for the cylinder No. 2
  1. There are five types of bearings of the standard size differing from each other on thickness. In order that they could be distinguished, they are painted in the following colors in a point shown in drawing. Each color designates the next thickness in the bearing center.

Thickness of the bearing of a rod of the standard size

Color of coloring

Thickness of the bearing

The blue

1.494-1.497 mm (0.05882 – 0.5893 inches)

The yellow

1.491-1.494 mm (0.05871 – 0.05881 inches)

The colourless

1.488-1.491 mm (0.05859 – 0.05870 inches)

The black

1.485-1.488 mm (0.05847 – 0.05858 inches)

The green

1.482-1.485 mm (0.05835 – 0.05846 inches)


1 — paint
  1. According to number printed on a rod both its cover, and the letters printed on a cheek of the crankshaft of the cylinder No. 3, define the new size of the bearing which should be established in a big bottom head of a rod, having addressed to the table. For example, number printed on a rod and its cover, - «1» and a letter printed on a cheek of the crankshaft of the cylinder No. 3 – "In", establish the new bearing of the standard size painted in "Black" color in a big bottom head of a rod.

Technical characteristics of the new standard size of the bearing of a rod

Number printed on a rod and its cover (internal diameter of a big bottom head of a rod)

1

2

3

The letter printed on a cheek of the crankshaft of the cylinder No. 3 (diameter of a shatunny neck)

And

The green

The black

The colourless

In

The black

The colourless

The yellow

With

The colourless

The yellow

The blue

The standard size of the new bearing to installation


  1. Check a bearing gap at again chosen bearing of the standard size, having addressed to subsection Selection of bearings of a rod in this Section. If the gap still exceeds norms, use the bearing following on thickness and repeatedly check a gap.

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.


 PERFORMANCE ORDER

  1. On each piston (1) number (7) 1 or 2 is printed. It points to external diameter of the piston.
  1. On the block of the cylinder (2) numbers (6) 1 or 2 are also printed, and it is also painted in red or blue color (3). Number indicates internal diameter of the cylinder.
2 — the cylinder block
3 — color of a color on the cylinder block
4 — the party of a pulley of the crankshaft
5 — the flywheel party
6 — numbers
8 — the cylinder No. 1
9 — the cylinder No. 2
10 — the cylinder No. 3
11 — the cylinder No. 4
  1. Number printed on the piston, and mark paint (or printed number) on the block of the cylinder should coincide. I.e. establish the piston number 2 on the cylinder which is marked out by blue paint or number 2 (4), and the piston number 1 on the cylinder with a red mark or at number 1 (3).

Technical characteristics of the piston and cylinder

Piston

Cylinder

Gap between the piston and the cylinder

Number on top (mark)

The external

diameter

Mark

Internal diameter

1

83.9800-83.9900 mm (3.3063 – 3.3066 inches)

Red or 1

84.0101-84.0200 mm (3.3075 – 3.3078 inches)

0.02-0.04 mm (0.0008 – 0.0015 inches)

2

83.9700-83.9799 mm (3.3059 – 3.3062 inches)

Blue or 2

84.0000-84.0100 mm (3.3071 – 3.3074 inches)

0.02-0.04 mm (0.0008 – 0.0015 inches)

  1. On a head of the piston letters A, B or C are also printed, but as a rule there is no need to distinguish each piston on this letter.
1 — the party of a pulley of the crankshaft
2 — the flywheel party
5 — the cylinder No. 1
6 — the cylinder No. 2
7 — the cylinder No. 3
8 — the cylinder No. 4
  1. Establish a piston finger in the piston (1) and a rod: Having greased with engine oil a piston finger and openings of a piston finger in the piston and a rod (3), 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 mark of «86 F» on a rod should be on the party of a pulley of the crankshaft.


1 — the piston
2 — an arrow
3 — a piston finger

Do not forget to clamp a lock ring a gap of the cut established in a range arrows.


1 — the piston
2 — an arrow
3 — a rod
4 — a lubricant opening
6 — the party of a pulley of the crankshaft
  1. Establish piston rings in the piston:
    • The first ring (1) differs from the second ring (2) on width, 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

Installation

 PERFORMANCE ORDER

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

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 neck 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 — the party of a pulley of the crankshaft
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 (And): 09916-77310.
  1. Establish a bearing cover. Establish an arrow (1) on a cover towards a crankshaft 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) — 45 N • m (4.5 kg-m, 33.0 pounds on foot).
  1. Repeat dismantle procedure upside-down for the purpose of installation.
  2. Adjust a tension of a belt of a drive of the cooling fan, having addressed to the Section Regulation and check of a tension of a belt of the cooling fan in Head engine Cooling.
  3. Adjust люфт a rope of an accelerator and люфт a cable of a drive of butterfly valves And/t (for vehicles with And/t).
  4. Check, whether everything the removed parts are put into place. Repeatedly establish any necessary parts which were not earlier established.
  5. Fill the engine with engine oil, having addressed to the Section Engine oil and the filter in Head Maintenance and greasing.
  6. Fill cooling system, having addressed to the Section Washing and filling of system of cooling in Head engine Cooling.
  7. Fill the case of forward differential with transmission oil, having addressed to the Section Servicing in Head Forward differential.
  8. Fill steering system with special liquid, having addressed to the Section power steering Liquid in Head power steering System.
  9. Connect a negative cable to the accumulator.
  10. Check, whether there is no leakage of fuel, antifreeze, oil and exhaust gas on each connection.
  11. Be convinced of that installation of a corner of an advancing of ignition or injection of fuel corresponds to technical requirements, and adjust if necessary, having addressed to the Section Check and adjustment of time of an advancing of ignition in Head ignition System for the J20 engine.