Suzuki Grand Vitara SQ416/SQ420/420WD

Dump fuel pressure. Disconnect a negative cable from the accumulator. Merge engine oil. Merge antifreeze. Remove a cylinder head with an inlet collector, a collector of the exhaust system and the water taking-away pipe, having addressed the Section Valves and a head of the block of the cylinder in this Chapter. Remove the oil pump, having addressed the Section the Oil pump in this Chapter. Note number of the cylinder on all pistons, rods and covers of bearings of a rod. Uncover rod bearings.

Remove a deposit from cylinder opening top before getting the piston from the cylinder. Push out the piston and knot of a rod at the top from a cylinder opening.

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

Check walls of cylinders regarding the scratches, roughnesses or 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. By means of a kompressimetr measure the 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 goes beyond norms. The difference of measurements in two provisions goes beyond a bias. The difference between measurements of axial section and the direction of draft leaves with a deviation from roundness.

Investigate pistons regarding defects, cracks and other damages. The damaged or faulty pistons have to be replaced.

Diameter of pistons

Diameter of the piston has to 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.

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

Gap of grooves of rings

If the gap does not conform 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)

Gap of a piston finger

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)

Side gap of a big lower head of a rod

Side gap of a big lower head of a rod
norm: 0.25 – 0.40 mm (0.0099 – 0.0157 inches) limit: 0.45 mm (0.0177 inches)

Alignment of a rod

Install a rod on the equalizer to check it for 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)

Before checking a bearing gap, clean the bearing and a neck of a rod. Install the bearing in a rod and a cover of the bearing.

Establish a rod bearing cover on a rod.

If it is impossible to bring a gap into norm limits even with the new bearing of the standard size, replace the crankshaft or you peretochit a conrod neck one size smaller nominal as follows. Install the 0.25-millimeter bearing of the smaller size on a big head of a rod. Measure the internal diameter of a big head of a rod. Peretochite a conrod neck to the following complete diameter.

Make sure that a bearing gap within the standard value stated above.

Check the printed figures on a rod and its cover. Three types of numbers ("1", "2" and "3") represent the following internal diameters of a big head of a rod. For example, the printed number "1" indicates that the 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 lower head of a rod

Further check diameter of a conrod 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 conrod necks, respectively. For example, the printed letter "A" indicates 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

There are five types of the bearings of the standard size differing from each other on thickness. In order that they could be distinguished, they are painted in the next colors in the point shown in the drawing. Every color designates the following thickness in the center of the bearing.

Thickness of the bearing of a rod of the standard size

According to number printed on a rod and its cover and the letters printed on a cylinder No. 3 crankshaft cheek, determine the new size of the bearing which has to be established in a big lower head of a rod, having addressed the table. For example, number printed on a rod and its cover - "1" and the letter printed on a cylinder No. 3 crankshaft cheek – "In", install the new bearing of the standard size painted in "Black" color in a big lower head of a rod.

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

On the block of the cylinder (2) are also printed number (6) 1 or 2, and it is also painted in red or blue color (3). Number indicates the internal diameter of the cylinder.

Number printed on the piston, and mark paint (or the printed number) on the block of the cylinder have to coincide. I.e. install the piston number 2 on the cylinder which is noted 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

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.

Install a piston finger in the piston (1) and a rod: Having oiled engine a piston finger and openings of a piston finger in the piston and a rod (3), install a rod in the piston and implant a piston finger into the piston and a rod, and put lock rings of a piston finger.

After installation of three rings (the first, the second and oil scraper), distribute their gaps of a section.

Oil engine pistons, rings, walls of cylinders, bearings of a rod and conrod necks.

At installation of the piston and knot of a rod in a trunk of the cylinder of the shooter on a head of the piston has to point to the party of a pulley of the crankshaft (1).

Repeat the procedure of dismantle upside-down for the purpose of installation. Adjust a tension of a belt of the drive of the cooling fan, having addressed the Section Regulation and check of a tension of a belt of the cooling fan in the Head Okhlazhdeniye of the engine. Adjust a side play of a rope of an accelerator and a side play of a cable of the drive of butterfly valves And/T (for vehicles with And/T). Check whether everything the removed parts are put into place. Repeatedly establish any necessary parts which were not earlier established. Fill the engine with engine oil, having addressed the Section Engine oil and the filter in the Head Maintenance and lubricant. Fill the cooling system, having addressed the Section Washing and filling of the cooling system in the Head Okhlazhdeniye of the engine. Fill the case of forward differential with gearbox oil, having addressed the Section Servicing in the Head Forward differential. Fill system of steering with special liquid, having addressed the Section Power Steering Liquid in the Head Sistema of the power steering. Connect a negative cable to the accumulator. Check whether there is no leak of fuel, antifreeze, oil and exhaust gas on each connection. Make sure that installation of a corner of an advancing of ignition or injection of fuel conforms to technical requirements, and adjust if necessary, having addressed the Section Check and adjustment of time of an advancing of ignition in the Head Sistema of ignition for the J20 engine.