Suzuki Grand Vitara
+ General information
+ Maintenance and lubricant
+ 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
Capital repairs
Bearing of a bent shaft, crankshaft and block of cylinders
Special tool
Necessary service materials
Technical characteristics of the rotating inhaling moment
+ Mechanical part of the J20 engine
+ Cooling of the engine
+ Fuel system
+ System of ignition
+ System of start
+ System of release
+ Transmissions
+ Coupling
+ Transfer
+ Forward and back differentials
+ Windows, mirrors, locks and security measures. Immobilizer
+ Electric equipment
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Bearing of a bent shaft, crankshaft and block of cylinders
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* 3) You do not apply engine oil between the block of cylinders and the bearing, between a cover of the bearing and the bearing. |
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* 12) Apply sealant 99000-31250 on the interfaced surfaces |
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The rotating inhaling moment. |
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Oil engine the sliding surfaces. |
Removal
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Remove engine knot from the case, having addressed the Section Engine in this Chapter.
Remove a coupling casing, a clutch plate and a flywheel (a drive plate for And/T). Special tool: (A) 09924-17811.
Remove a crankshaft pulley, a belt of the drive of the gas-distributing mechanism and a pulley of the gas-distributing mechanism of the crankshaft.
Remove cylinder head knot.
Remove an oil pan and a grid of the oil pump.
Remove the oil pump (1).
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1 — the oil pump
2 — a bolt |
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Remove the epiploon case.
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Uncover rod bearings.
Untwist bolts of covers of bearings of the crankshaft in such order as it is specified in the drawing, and uncover bearings.
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Remove the crankshaft from the block of cylinders.
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Check
Crankshaft
Wear of the crankshaft
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By means of the dial 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
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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 the place.
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Use the dial measuring instrument to take readings of a deviation in the axial direction of the crankshaft. If the deviation goes beyond 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)
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Ovality and bias (uneven wear) of crankshaft necks
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The difference in the diameter of cross section or along its length speaks about uneven wear of a neck of the crankshaft (or both). This difference if that is, the micromeasure is determined by indications. If one of necks is strongly injured or if the general uneven wear, in that plan as it was explained above, goes beyond norm, peretochit or replace the crankshaft. Limit of ovality and bias of a neck of the crankshaft: 0.01 mm (0.0004 inches). |
Crankshaft bearings
General information
Crankshaft bearings for repair are presented by the standard size and 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 in the admission.
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The top half of the bearing (2) has a lubricant flute (3). Install this half with a lubricant flute in the block of cylinders (1). |
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On each cover of the bearing of the crankshaft the arrow and number is stamped. At installation of each cover of the bearing send to the shooter towards a pulley of the crankshaft to the block of cylinders and establish each cover from this party towards a flywheel in ascending order of numbers "1", "2", "3", "4" and "5". Fasten bolts of covers to the specified rotating moment. |
Check
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Check bearings regarding an ulceration, scratches, wear or damage. If any defects are found, replace the top and lower halves. Never replace one half, without having replaced other half. |
Gap of bearings of the crankshaft
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Check a gap by means of plaster solution, having performed the following procedure.
Uncover bearings.
Clean bearings and necks of the crankshaft.
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Put a part of plaster solution (1) on the full width of the bearing (parallel to the crankshaft) on a neck, bypassing oil openings.
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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 has to be fastened according to technical requirements to provide the correct indications of a gap. The rotating inhaling moment: a bolt of a cover of the bearing of the crankshaft (a) — 54 N • m (5.4 kg-m, 39.0 pound on foot).
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Do not turn the crankshaft with plaster solution inside. |
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Uncover and by means of a ruler (2) measure width on a plaster covering (1) in the widest point. If the gap goes beyond norm, replace the bearing. Always replace the top and lower half, as a unit. The new standard bearing can create a necessary gap. If it did not occur, it is necessary to peretochit 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.
Crankshaft bearing gap
norm: 0.02 – 0.04 mm (0.0008 – 0.0015 inches)
limit: 0.060 mm (0.0023 inches)
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Choice of bearings of the crankshaft
Standard bearing
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- If the bearing in failure condition or if the gap of the bearing goes beyond norm, choose the new standard bearing according to the following procedure, and establish it.
- When replacing the crankshaft or 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.
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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 following diameters of necks.
Technical characteristics of diameter of necks
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The printed figures
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Diameter of necks
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1
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51.9940 – 52.0000 mm (2.0470 – 2.0472 inches)
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2
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51.9880 – 51.9939 mm (2.0468 – 2.0469 inches)
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3
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51.9820 – 51.9879 mm (2.0466 – 2.0467 inches)
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The first, the second, the third, fourth and fifth (from left to right) the printed figures designate diameters of necks on covers of 1, 2, 3, 4 and 5 bearings, respectively.
For example, in the drawing the first (the most extreme at the left) figure "3" indicates that diameter of a neck on a cover of the 1 bearing within 51.9820 – 51.9879 mm (2.0466 – 2.0467 inches), and the second figure "1" indicates that diameter of a neck on a cover "2" makes 51.9940 – 52.0000 mm (2.0470 – 2.0472 inches).
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1 — cylinders No. 2 and No. 3 of cheeks of the crankshaft |
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Further check the 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 following internal diameters of covers.
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Technical characteristics of internal diameters of covers of bearings of the crankshaft
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The printed letters
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Internal diameter of covers of bearings (without bearings)
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And
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56.0000 – 56.0061 mm (2.2048 – 2.2049 inches)
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In
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56.0061 – 56.0120 mm (2.2050 – 2.2051 inches)
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With
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56.0121 – 56.0180 mm (2.2052 – 2.2054 inches)
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The first, the second, the third, fourth and fifth (from left to right) the printed letters specify the internal diameter of covers of 1, 2, 3, 4 and 5 bearings, respectively. For example, in the drawing the first (the most extreme at the left) the letter "B" indicates that the internal diameter of a cover of the 1 bearing makes 56.0061 – 56.0120 mm (2.2050 – 2.2051 inches), and the fifth (the most extreme on the right) a letter "A" points that the internal diameter of a cover "5" makes 56.0000 – 56.0061 mm (2.2048 – 2.2049 inches).
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 next colors in the place shown in the drawing. Every color designates a certain thickness in the center of the bearing.
Technical characteristics of bearings of the crankshaft
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Color
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Bearing thickness
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Green
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1.996 – 2.000 mm (0.07859 – 0.07874 inches)
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Black
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1.999 – 2.003 mm (0.07870 – 0.07885 inches)
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Colourless (there is no paint)
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2.002 – 2.006 mm (0.07882 – 0.07897 inches)
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Yellow
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2.008 – 2.012 mm (0.07906 – 0.07921 inches)
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Blue
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2.008 – 2.012 mm (0.07906 – 0.07921 inches)
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Determine the new standard bearing which has to be installed on a neck by the figures printed on cheeks of the crankshaft of cylinders No. 2 and No. 3 and to the letters printed on the interfaced surface of the block of cylinders, having addressed the table given below. For example, if the figure printed on a cheek of the 1 crankshaft and the letter printed on the interfaced surface – "In", install the new standard bearing painted in black" color on his neck.
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Technical characteristics of the new bearing of the crankshaft of the standard size
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The figure printed on a crankshaft cheek (diameter of a neck)
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1
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2
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3
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The letter printed on the interfaced surface (internal diameter of a cover of the bearing)
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And
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Green
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Black
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Colourless
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In
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Black
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Colourless
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Yellow
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With
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Colourless
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Yellow
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Blue
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To install the new bearing of the standard size
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1 — cheeks of the crankshaft of cylinders No. 2 and No. 3 |
Check a bearing gap at the new chosen bearing of the standard size. If the gap still goes beyond norm, use the bearing of the size following on thickness and recheck a gap.
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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 next colors in the place specified in the drawing. Every color represents a certain thickness in the center of the bearing.
Thickness of bearings of the smaller size of the crankshaft
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Color
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Bearing thickness
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Green and red
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2.121 – 2.125 mm (0.08351 – 0.08366 inches)
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Black and red
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2.124 – 2.128 mm (0.08363 – 0.08377 inches)
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Only red
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2.127 – 2.131 mm (0.08374 – 0.08389 inches)
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Yellow and red
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2.130 – 2.134 mm (0.08386 – 0.08401 inches)
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Blue and red
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2.133 – 2.137 mm (0.08398 – 0.08413 inches)
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If it is necessary, you peretochit a neck of the crankshaft and choose for it the bearing of the smaller size as follows.
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Peretochite a neck to the following complete diameter. Complete diameter of a neck of the crankshaft: 51.732 – 51.750 mm (2.0367 – 2.0373 inches).
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With the help a micromeasure measure the peretochenny diameter of a neck. Readings of measurement have to be taken in two directions perpendicularly each other to check ovality.
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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 the table given 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
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The measured diameter of a neck
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51.7440 – 51.7500 mm (2.0371 – 2.0373 inches)
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51.7380 – 51.7439 mm (2.0369 – 2.0371 inches)
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51.7320 – 51.7379 mm (2.0367 – 2.0369 inches)
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The letters printed on the interfaced surface of the block of cylinders
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And
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Green and red
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Black and red
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Only red
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In
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Black and red
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Only red
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Yellow and red
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With
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Only red
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Blue and red
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Blue and red
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Bearings of the smaller size to installation
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Back oil consolidation
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Attentively check back oil consolidation (1) regarding wear or damage. If its edge is worn-out or damaged, replace it.
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To establish oil consolidation, densely press back oil consolidation (1), adjusting until the end face of the case of an epiploon (2) is not drowned aflush with an end face of oil consolidation.
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Flywheel
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If the gear wreath is damaged, will burst or is worn-out, replace a flywheel.
If the surface contacting to a clutch plate is damaged or strongly worn-out, replace a flywheel.
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Check a flywheel regarding wear of a front surface by means of the dial indicator. If wear exceeds admissible norms, replace a flywheel. Limit of wear of a flywheel: 0.2 mm (0.0078 inches).
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Block of cylinders
Deformation of the condensed surface
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By means of a kalibromer check the condensed surface regarding 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
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If it is required to chisel one of cylinders, all other cylinders have to 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
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Size
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Diameter of the piston
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The size is 0.50 mm more (0.020 inches)
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75.470 – 75.480 mm (2.9713 – 2.9716 inches)
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With the help a micromeasure measure diameter of the piston.
Expect what internal diameter of the cylinder needs to be chiseled.
D = AND + IN – WITH
D: Internal diameter of the cylinder which needs to be turned.
А: The measured diameter of the piston.
В: Piston gap = 0.02 – 0.04 mm (0.0008 – 0.0015 inches)
С: The admission for a honingovaniye = 0.02 mm (0.0008 inches)
Chisel also to a honinguyta the cylinder to calculated parameters.
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Before chiseling, establish all covers of bearings of the crankshaft into place and fasten them according to technical requirements to avoid deformation of internal diameters of bearings. |
Measure a piston gap after a honingovaniye.
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Installation
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All parts of installation have to be washed ideally up.
- Do not forget to grease crankshaft necks, basic bearings, persistent bearings, conrod 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 united in separate sets. Do not separate such sets and provide at installation that each detail returned there from where it came.
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Install crankshaft bearings in the block of cylinders (1). One of two halves of the bearing of the crankshaft has an oil flute (3). Install it in the block of cylinders, and other half without oil flute in a bearing cover. Make sure that both halves are noted by the same paint.
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1 — the block of cylinders
2 — the top half of the bearing
3 — an oil flute |
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Install persistent bearings (1) in the block of cylinders between No. 2 and No. 3 cylinders. Turn the parties with an oil flute (2) a front surface to crankshaft cheeks.
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Install the crankshaft in the block of cylinders.
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Install covers of bearings in the block of cylinders, without forgetting that the arrow (on each cover) has to specify towards a crankshaft pulley. Put them consistently in ascending order of numbers 1, 2, 3, 4 and 5, since the party of a pulley.
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Having oiled engine all bolts of covers of bearings, fasten bolts of covers of bearings in such order as it is specified in the drawing in the small portions, and repeat twisting until they are not fastened to the specified rotation moment. Moment of rotation of an inhaling: a bolt of a cover of the bearing of the crankshaft (a) — 54 N • m (5.4 kg-m, 39.0 pounds on foot).
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Having fastened bolts of covers, be convinced that the crankshaft rotates smoothly when you turn it the moment of rotation of 8.0 N • m (0.8 kg-m, 5.8 pound on foot) or down. |
Apply sealant on the interfaced surface of the case of a back epiploon. "And": sealant 99000-31250.
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"and" — 3 mm (0.12 inches)
"b" — 2 mm (0.08 inches) |
Install the case of a back epiploon (1) and fasten bolts to the specified rotating moment. The rotating inhaling moment: a bolt of the case of back oil consolidation (a) — 11 N • m (1.1 kg-m, 8.0 pound on foot).
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As there are 2 types of bolts of the case available, address the drawing in order that it is correct to use them. |
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1 — long bolts
2 — short bolts |
Install the oil pump, having addressed the Section the Oil pump in this Chapter.
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Establish a flywheel (for the M/T models) or a drive plate (for the And/T models). By means of the special tool record a flywheel or a drive plate and fasten its bolts according to technical requirements. Special tool: (A) 09924-17811. The rotating inhaling moment: a bolt of a flywheel or a drive plate (a) — 78 N • m (7.8 kg-m, 56.5 pound on foot).
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Install pistons and rods, having addressed the Section Pistons, piston rings, rods and cylinders in the Head the Mechanical part of the J20 engine.
Establish a grid of the oil pump and an oil pan, having addressed the Section Oil pan and a grid of the oil pump in this Chapter.
Establish a cam-shaft, a pulley of a belt of the drive of the gas-distributing mechanism of a cam-shaft, a belt of the drive of the gas-distributing mechanism, a crankshaft pulley, a pulley of the water pump, etc. Address the Sections Valve Yoke, an axis of yokes and a cam-shaft and the Belt of the drive of the gas-distributing mechanism and the tension device for a belt in this Chapter.
Establish coupling on a flywheel (for M/T vehicles), having addressed the Section Coupling Cover, a clutch plate and a flywheel in the Head Stsepleniye.
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Establish arms of fastening of the engine.
The rotating inhaling moment:
bolt and nut of an arm of fastening of the engine (a) — 55 N • m (5.5 kg-m, 40.0 pound on foot)
nut and bolt of an arm of a sidewall of fastening of the engine (b) — 93 N • m (9.3 kg-m, the 67th pound on foot)
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Establish engine knot in the vehicle, having addressed the Section Engine in this Chapter.
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