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
      - Assembly fittings of the engine
         Major maintenance
         Crankshaft bearings, crankshaft and block of cylinders
      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





Crankshaft bearings, crankshaft and block of cylinders

Components

1 — the block of cylinders
2 — the pallet картера*
3 — the crankshaft
4 — ring consolidation
5 — a driving chain of the oil pump
6 — radical подшипник*
7 — persistent подшипник*
8 — back oil consolidation
9 — the lock valve
10 — a flywheel (M/t); leading disk (And/t)
11 — a disk of a case of coupling
12 — empty

13 — an arm of lateral fastening of the engine
14 — the water pump
15 — an exhaust pipe of a heater
16 — directing to a chain of the oil pump
17 — a flywheel or leader bolt диска*
18 — the sensor of detonation combustion
19 — an arm bolt from 10-mm by a carving in diameter
20 — an arm bolt from 8-mm by a carving in diameter
21 — a bolt of the water pump
22 — a bolt of an arm of lateral fastening of the engine


*2) Put hermetic 99000-31250 on the interfaced surface of the pallet of a case, having addressed to point 5 of procedure of installation.

*6) Grease with engine oil internal surfaces of the bearing.

*7) Establish the bearing party with flutes faced to crankshaft cheeks.

*17) Put hermetic 99000-31110 on the carving party.

The rotating moment of an inhaling.

Not to use repeatedly.

To grease with engine oil.

Removal

 PERFORMANCE ORDER

  1. Remove engine knot from a vehicle, having addressed to the Section Engine in this Chapter.
  2. Remove coupling and a flywheel (for M/t vehicles) or a leading disk (for vehicles And/t). To remove coupling address to the Section a coupling Cover, a disk of coupling and a flywheel In Head Coupling. Special tool (And): 09924-17811.
1 — a flywheel bolt
  1. Remove the case of butterfly valves, an inlet collector, a collector of an exhaust system.
  2. 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 to remove.
  3. Remove the oil pump.
  4. Uncover cylinder heads.
  5. Uncover synchronization chains, having addressed to the Section the Cover of a chain of synchronization in this Chapter for the purpose of dismantle.
  6. Remove directing to a synchronization chain, a natyazhitel of a chain, regulators of the natyazhitel, the second chain of synchronization and the first chain of synchronization.
  7. Remove knot of a head of the cylinder.
  8. Remove pistons and rods.
  9. Remove the sensor of position of the crankshaft (1).
1 — the sensor of position of the crankshaft
2 — the cylinder block
3 — the crankshaft
  1. Remove the water pump (1) and an exhaust pipe of a heater.
  1. Remove arms of lateral fastening of the engine (2) (right and left).
  2. Weaken bolts of a case and remove them.
1 — the case pallet
2 — a bolt (diameter of a carving of 10 mm)
3 — a bolt (diameter of a carving of 8 mm)
  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 and the pallet of a case (1) on the place. Twirl case bolts, having addressed to the item 6 of procedure of installation.
  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: 0.10-0.35 mm (0.0040 – 0.0137 inches)
      • limit: 0.42 mm (0.0165 inches)

Thickness of the persistent bearing of the crankshaft

Size of the bearing

Thickness

The standard

2.500 mm (0.984 inches)

Bigger size (0.125 mm (0.0049 inches))

2.563 mm (0.1009 inches)


1 — the persistent bearing
2 — a lubricant flute

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 how 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)
    • ellipsnost: And – In
    • bias: and – b

Radical bearings

General information

Radical bearings of the crankshaft 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 (1) has a lubricant flute (2). Establish this half with a lubricant flute in the block of cylinders.

On the bottom half of the bearing the lubricant flute is absent.

Check

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

Gap of the radical bearing of the crankshaft

 PERFORMANCE ORDER

  1. Check a gap by means of plaster solution, having executed the following procedure.
  2. Remove the case pallet.
  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 the pallet of a case (1) on the block of cylinders. Fasten case bolts, observing последовательност. Fasten case bolts the every rotating moment.
    • The rotating moment of an inhaling:
      • Case bolt from 10-mm by a carving in diameter (0.394 inches) (and): 60 N • m (6.0 kg-m, 43.5 pound on foot)
      • Case bolt from 8-mm by a carving in diameter (0.315 inches) (b): 27 N • m (2.7 kg-m, 19.5 pound on foot)

Do not turn the crankshaft with plaster solution inside.


1 — the case pallet
2 — a bolt (diameter of a carving of 10 mm)
3 — a bolt (diameter of a carving of 8 mm)
  1. Remove the pallet of a case 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 (0.00984 inches). Having chosen the new bearing, check a gap repeatedly.
    • Gap of the bearing of the crankshaft
      • norm: 0.032-0.052 mm (0.0013 – 0.0020 inches)
      • limit: 0.060 mm (0.0023 inches)

Choice of radical 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 and the case pallet 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 new pallet of a case.

 PERFORMANCE ORDER

  1. At first check diameter of a neck. As is shown in drawing, on cheeks of the crankshaft No. 2 (3) figures are printed. Three types of figures («1», «2» and «3») represent the next diameters of necks.

Technical characteristics of necks of the crankshaft

The printed figures

Diameter of necks

1

58.000-58.0060 mm (2.2835 – 2.2836 inches)

2

57.9940-57.9999 mm (2.2833 – 2.2834 inches)

3

57.9880-57.9939 mm (2.2830 – 2.2832 inches)

  1. The figures printed on a cheek of No. 2 crankshafts, designate diameters of necks noted by a strelochka in drawing, respectively. For example, the printed figure «1» specifies that diameter of the corresponding neck makes 58.000 – 58.0060 mm (2.2835 – 2.2836 inches).
1 — the party of a pulley of the crankshaft
2 — the flywheel party
3 — a crankshaft cheek
  1. Further check internal diameter of a case (a bearing cover) without the bearing. On the pallet of a case 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

62.0000-62.0060 mm (2.4409 – 2.4411 inches)

In

62.0061-62.0120 mm (2.4412 – 2.4414 inches)

With

62.0121-62.0180 mm (2.4415 – 2.4416 inches)

  1. The letters printed on the pallet of a case, indicate internal diameter of the case noted by an arrow in drawing, respectively. For example, the letter "And" printed on a cover of the bearing No. 2, specifies that internal diameter of a cover of the bearing No. 2 makes 62.0000 – 62.0060 mm (2.4409 – 2.4411 inches).
1 — a bearing No. 1 cover
2 — a bearing No. 2 cover
3 — a bearing No. 3 cover
4 — a bearing No. 4 cover
5 — a bearing No. 5 cover
6 — the party of a pulley of the crankshaft
7 — the flywheel party
  1. 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

1.990-1.994 mm (0.07835 – 0.07850 inches)

The black

1.993-1.997 mm (0.07847 – 0.07862 inches)

Colourless (there is no paint)

2.996-2.000 mm (0.07859 – 0.07874 inches)

The yellow

1.999-2.003 mm (0.07870 – 0.07885 inches)

The blue

2.002-2.006 mm (0.07882 – 0.07897 inches)


1 — paint
  1. On the figure printed on a cheek of the crankshaft No. 2 and letters, printed on the case pallet, 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 No. 2 "1", and a letter printed on the pallet of a case, – "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 pallet of a case (internal diameter of a 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. Check a bearing gap at the new chosen bearing of the standard size, having addressed to subsection Radical bearings of the crankshaft in this Section. 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 (0.009842 inches))

The bearing of the smaller size on 0.25 mm (0.009842 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

2.115-2.119 mm (0.08327 – 0.08342 inches)

Black and red

2.118-2.122 mm (0.08339 – 0.08354 inches)

Only the red

2.121-2.125 mm (0.08351 – 0.08366 inches)

Yellow and red

2.124-2.128 mm (0.08363 – 0.08377 inches)

Blue and red

2.127-2.131 mm (0.08374 – 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: 57.7439-57.7560 mm (2.2734 – 2.2738 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 pallet of a case, 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 crankshaft of the smaller size

The measured diameter of a neck

57.7500-57.7560 mm (2.2737 – 2.2738 inches)

57.7440-57.7499 mm (2.2734 – 2.2736 inches)

57.7380-57.7439 mm (2.2732 – 2.2733 inches)

The letters printed on the pallet of a case

And

Green and red

Black and red

Only the red

In

Black and red

Only the red

Yellow and red

With

Only the red

Yellow and red

Blue and red

Bearings of the smaller size to installation

Asterisk of the oil pump

Check a teeth of an asterisk (2) about wear or damage. If any damage or wear is revealed, replace the crankshaft (1).

Chain of a drive of the oil pump

Check a chain of a drive of the oil pump about wear or damage.

Back oil consolidation

Attentively check back oil consolidation about wear or damage. If its edge is worn-out or damaged, replace it.

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 (0.0024 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. 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 standard

83.970-83.990 mm (3.3059 – 3.3066 inches)

The size is more on 0.50 mm (0.02 inches)

84.470-84.480 mm (3.3256 – 3.3263 inches)

  1. With the help a micromeasure measure diameter of the piston.
    • Calculate, what internal diameter of the cylinder is necessary for chiseling, as follows:
      • 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)
1 — 26.5 mm (1.04 inches)
  1. Chisel and хонингуйте the cylinder to settlement parameters.

Before chiseling, establish the pallet of a case and fasten according to technical requirements to avoid deformation of internal diameters of bearings.

  1. Measure a piston gap after a honingovaniye.

Lock valve

Check the lock valve on existence of a zasor and formation of the got stuck lumps.

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, case (cover 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.
  • Clean the interfaced surface of the block of cylinders and the case pallet, remove oil, old hermetic and a dust from the interfaced surface.

 PERFORMANCE ORDER

  1. Establish radical bearings of the crankshaft (4) in the block of cylinders (1). One of two halves of the bearing of the crankshaft has an oil flute (3). Establish this half with an oil flute in the block of cylinders, and other half without an oil flute in the case pallet. Be convinced that both halves are noted by the same paint.
  2. Establish ring consolidation (2) in the block of cylinders.
1 — the block of cylinders
2 — ring consolidation
3 — an oil flute
4 — crankshaft bearings
5 — a pin
  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. Place the crankshaft (1) with a chain of a drive of the oil pump in the block of cylinders. Be convinced that on a plate of the sensor of position of the crankshaft (2) there are no metal particles and damage.
  1. Put hermetic "A" on the interfaced surface of the pallet of a case (1). "And": hermetic 99000-31250.
"and" — 3 mm (0.12 inches)
«b» — 2 mm (0.08 inches)
1 — a surface of the pallet of a case
2 — the bearing
  1. Establish the pallet of a case (1) in the cylinder block. Having greased with engine oil all bolts of a case ((1) – (22)), fasten them gradually, as follows.
  1. Tighten bolts (1) – (10) to 42 N • m (4.2 kg-m, 30.5 pound on foot) according to digital order.
  1. Weaken bolts (1) – (10) until the rotating moment of an inhaling will not decrease to 0 (zero) as it should be the return to fastening.
  2. Just as in point 7, fasten them to 42 N • m (4.2 kg-m, 30.5 pound on foot).
  3. In the same way, as in point 7, fasten them the every rotating moment.
  4. Fasten bolts (11) – (22) the every rotating moment according to their digital order.
    • The rotating moment of an inhaling:
      • Case bolt with a carving of 10 mm in diameter (1) – (10)
        • (а): 60 N • m (6.0 kg-m, 43.5 pound on foot)
        • (b): 27 N • m (2.7 kg-m, 19.5 pound on foot)

Having fastened case bolts, be convinced that the crankshaft rotates smoothly when it you turn a hand.

  1. Establish back oil consolidation (1) by means of a plastic hammer and special tools.
    • Special tool
      • (А): 09911-97710
      • (В): 09911-97811
1 — back oil consolidation
2 — the crankshaft party
3 — the party of oil consolidation
  1. Establish the sensor of position of the crankshaft (1) and fix its plaits of wires an arm. The rotating moment of an inhaling: bolt of the sensor of position of the crankshaft (and): 6 N • m (0.6 kg-m, 4.5 pound on foot).
1 — the sensor of position of the crankshaft
2 — the cylinder block
3 — the crankshaft
  1. Establish a flywheel (for M/t vehicles) or a leading disk (for vehicles And/t). By means of the special tool fix a flywheel or a leading disk and, having greased with hermetic, fasten bolts of a flywheel or a leading disk (1) according to technical requirements.
    • "And": hermetic 99000-31110
      • special tool (And): 09924-17811
    • the rotating moment of an inhaling:
      • bolt of a flywheel or leading disk (c): 70 N • m (7.0 kg-m, 51.0 pound on foot)
  1. Establish arms of lateral fastening of the engine (1) (right and left). Fasten bolts of arms the every rotating moment. The rotating moment of an inhaling: a bolt of an arm of lateral fastening of the engine (d) — 55 N • m (5.5 kg-m, 40.0 pound on foot).
  1. Establish the water pump (2) and an exhaust pipe of a heater (3), having addressed to Sections the Water pump and Hoses or water pipes of system of cooling in Head engine Cooling.
  2. Establish pistons and rods, having addressed to the Section Pistons, piston rings, rods and cylinders in this Chapter.
  3. Establish the oil pump, having addressed to the Section the Oil pump in this Chapter.
  4. Establish knot of a head of the cylinder in the cylinder block, having addressed to the Section Valves and a head of the block of the cylinder in this Chapter.
  5. Establish synchronization chains, a natyazhitel of a chain of the synchronization, directing to a chain of synchronization, an asterisk of a chain of synchronization, a cover of a chain of synchronization, a crankshaft pulley, a pulley of the water pump etc. Address to the Section the First chain of synchronization and a natyazhitel of a chain in this Chapter.
  6. Establish a grid of the oil pump and an oil pan.
  7. Establish coupling on a flywheel (for M/t vehicles). Address to the Section a coupling Cover, a disk of coupling and a flywheel in Head Coupling to establish coupling.
  8. Establish engine knot in a vehicle, having addressed to the Section Engine in this Chapter.