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
- Mechanical part of the J20 engine
+ General description
+ Routine maintenance
- Assembly fittings of the engine
Capital repairs
Crankshaft bearings, crankshaft and block of cylinders
Special tool
Necessary service materials
Technical characteristics of the rotating inhaling moment
+ 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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Crankshaft bearings, crankshaft and block of cylinders
Components
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* 2) Apply sealant 99000-31250 on the interfaced surface of the pallet of a case, having addressed point 5 of the procedure of installation. |
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* 6) Oil engine the internal surfaces of the bearing. |
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* 7) Establish the party of the bearing with flutes facing crankshaft cheeks. |
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* 17) Apply sealant 99000-31110 on the party of a carving. |
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The rotating inhaling moment. |
Removal
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Remove engine knot from the vehicle, having addressed the Section Engine in this Chapter.
Remove coupling and a flywheel (for M/T vehicles) or a drive plate (for And/T vehicles). To remove coupling address the Section Coupling Cover, a clutch plate and a flywheel In the Head Stsepleniye. Special tool (A): 09924-17811.
Remove the case of butterfly valves, an inlet collector, a collector of the exhaust system.
Remove an oil pan and a grid of the oil pump, having addressed the Section Oil pan and a grid of the oil pump in this Chapter to remove.
Remove the oil pump.
Uncover a cylinder head.
Uncover a synchronization chain, having addressed the Section Synchronization Chain Cover in this Chapter for the purpose of dismantle.
Remove a synchronization chain guide, a natyazhitel of a chain, regulators of a natyazhitel, the second chain of synchronization and the first chain of synchronization.
Remove cylinder head knot.
Remove pistons and rods.
Remove the sensor of position of the crankshaft (1).
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1 — the sensor of position of the crankshaft
2 — the cylinder block
3 — the crankshaft |
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Remove the water pump (1) and an exhaust pipe of the heater.
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Remove arms of side fastening of the engine (2) (right and left).
Weaken bolts of a case and remove them.
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1 — the case pallet
2 — a bolt (diameter of a carving of 10 mm)
3 — a bolt (diameter of a carving of 8 mm) |
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 and the pallet of a case (1) on the place. Twirl case bolts, having addressed item 6 of the procedure of installation.
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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: 0.10 – 0.35 mm (0.0040 – 0.0137 inches)
limit: 0.42 mm (0.0165 inches)
Thickness of the persistent bearing of the crankshaft
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Bearing size
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Thickness
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Standard
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2.500 mm (0.984 inches)
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Bigger size (0.125 mm (0.0049 inches))
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2.563 mm (0.1009 inches)
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1 — the persistent bearing
2 — a lubricant flute |
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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 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)
ovality: And – In
bias: and – b
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Radical bearings
General information
Radical bearings of the crankshaft 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 (1) has a lubricant flute (2). Install this half with a lubricant flute in the block of cylinders. |
On the lower half of the bearing the lubricant flute is absent.
Check
Check bearings regarding an ulceration, scratches, wear or damage. If any defects are found, replace both the top and lower halves. Never replace one half, without having replaced other half.
Gap of the radical bearing of the crankshaft
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Check a gap by means of plaster solution, having performed the following procedure.
Remove the case pallet.
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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Install the pallet of a case (1) on the block of cylinders. Fasten case bolts, observing последовательност. Fasten case bolts with the specified rotating moment.
The rotating inhaling moment:
Case bolt with a 10-mm carving in the diameter (0.394 inches) (and): 60 N • m (6.0 kg-m, 43.5 pound on foot)
Case bolt with a 8-mm carving in the diameter (0.315 inches) (b): 27 N • m (2.7 kg-m, 19.5 pound on foot)
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Do not turn the crankshaft with plaster solution inside. |
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1 — the case pallet
2 — a bolt (diameter of a carving of 10 mm)
3 — a bolt (diameter of a carving of 8 mm) |
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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 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 (0.00984 inches). Having chosen the new bearing, check a gap repeatedly.
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Crankshaft bearing gap
norm: 0.032 – 0.052 mm (0.0013 – 0.0020 inches)
limit: 0.060 mm (0.0023 inches)
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Choice of radical 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 and the pallet of a case for any reason choose new standard bearings to install them according to numbers printed on the new crankshaft and/or the letters printed on the new pallet of a case.
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At first check diameter of a neck. As shown in the drawing, on cheeks of the crankshaft No. 2 (3) figures are printed. Three types of figures ("1", "2" and "3") represent the following diameters of necks.
Technical characteristics of necks of the crankshaft
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The printed figures
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Diameter of necks
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1
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58.000 – 58.0060 mm (2.2835 – 2.2836 inches)
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2
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57.9940 – 57.9999 mm (2.2833 – 2.2834 inches)
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3
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57.9880 – 57.9939 mm (2.2830 – 2.2832 inches)
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The figures printed on a crankshaft cheek No. 2 designate diameters of necks noted by a strelochka in the drawing, respectively. For example, the printed figure "1" indicates that diameter of the corresponding neck makes 58.000 – 58.0060 mm (2.2835 – 2.2836 inches).
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1 — the party of a pulley of the crankshaft
2 — the party of a flywheel
3 — a crankshaft cheek |
Further check the internal diameter of a case (a bearing cover) without bearing. On the pallet of a case five letters are printed. Three letters ("And", "In" and "With") designate the following internal diameters of covers.
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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62.0000 – 62.0060 mm (2.4409 – 2.4411 inches)
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In
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62.0061 – 62.0120 mm (2.4412 – 2.4414 inches)
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With
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62.0121 – 62.0180 mm (2.4415 – 2.4416 inches)
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The letters printed on the case pallet indicate the internal diameter of the case noted by an arrow in the drawing, respectively. For example, the letter "A" printed on a bearing No. 2 cover indicates that the internal diameter of a cover of the bearing No. 2 makes 62.0000 – 62.0060 mm (2.4409 – 2.4411 inches).
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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 party of a flywheel |
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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1.990 – 1.994 mm (0.07835 – 0.07850 inches)
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Black
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1.993 – 1.997 mm (0.07847 – 0.07862 inches)
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Colourless (there is no paint)
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2.996 – 2.000 mm (0.07859 – 0.07874 inches)
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Yellow
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1.999 – 2.003 mm (0.07870 – 0.07885 inches)
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Blue
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2.002 – 2.006 mm (0.07882 – 0.07897 inches)
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Determine the new standard bearing which has to be installed on a neck by the figure printed on a cheek of the crankshaft No. 2 and to the letters printed on the case pallet, having addressed the table given below. For example, if the figure printed on a cheek of the crankshaft No. 2 "1" and the letter printed on the case pallet – "In", install the new standard bearing painted in "Black" color on his neck.
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 case pallet (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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Check a bearing gap at the new chosen bearing of the standard size, having addressed subsection Radical bearings of the crankshaft in this Section. 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 (0.009842 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 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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2.115 – 2.119 mm (0.08327 – 0.08342 inches)
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Black and red
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2.118 – 2.122 mm (0.08339 – 0.08354 inches)
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Only red
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2.121 – 2.125 mm (0.08351 – 0.08366 inches)
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Yellow and red
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2.124 – 2.128 mm (0.08363 – 0.08377 inches)
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Blue and red
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2.127 – 2.131 mm (0.08374 – 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: 57.7439 – 57.7560 mm (2.2734 – 2.2738 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 case pallet 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 crankshaft of the smaller size
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The measured diameter of a neck
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57.7500 – 57.7560 mm (2.2737 – 2.2738 inches)
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57.7440 – 57.7499 mm (2.2734 – 2.2736 inches)
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57.7380 – 57.7439 mm (2.2732 – 2.2733 inches)
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The letters printed on the case pallet
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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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Yellow and red
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Blue and red
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Bearings of the smaller size to installation
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Asterisk of the oil pump
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Check teeth of an asterisk (2) regarding wear or damage. If any damage or wear is revealed, replace the crankshaft (1). |
Chain of the drive of the oil pump
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Check a chain of the drive of the oil pump regarding wear or damage. |
Back oil consolidation
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Attentively check back oil consolidation regarding wear or damage. If its edge is worn-out or damaged, replace it. |
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 (0.0024 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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Standard
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83.970 – 83.990 mm (3.3059 – 3.3066 inches)
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The size is 0.50 mm more (0.02 inches)
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84.470 – 84.480 mm (3.3256 – 3.3263 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, as follows:
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)
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1 — 26.5 mm (1.04 inches) |
Chisel also to a honinguyta the cylinder to calculated parameters.
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Before chiseling, install the pallet of a case and fasten according to technical requirements to avoid deformation of internal diameters of bearings. |
Measure a piston gap after a honingovaniye.
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Lock valve
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Check the lock valve for existence of a blockage and formation of the got stuck lumps. |
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, case (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.
- Clean the interfaced surface of the block of cylinders and the pallet of a case, remove oil, old sealant and dust from the interfaced surface.
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Install 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). Install this half with an oil flute in the block of cylinders, and other half without oil flute in the case pallet. Make sure that both halves are noted by the same paint.
Install ring consolidation (2) in the block of cylinders.
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1 — the block of cylinders
2 — ring consolidation
3 — an oil flute
4 — crankshaft bearings
5 — a pin |
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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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Place the crankshaft (1) with a chain of the drive of the oil pump in the block of cylinders. Make sure that on a plate of the sensor of position of the crankshaft (2) there are no metal particles and damage.
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Apply sealant "A" on the interfaced surface of the pallet of a case (1). "And": sealant 99000-31250.
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"and" — 3 mm (0.12 inches)
"b" — 2 mm (0.08 inches)
1 — the surface of the pallet of a case
2 — the bearing |
Install the pallet of a case (1) in the cylinder block. Having oiled engine all bolts of a case ((1) – (22)), fasten them gradually, as follows.
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Tighten bolts (1) – (10) to 42 N • m (4.2 kg-m, 30.5 pound on foot) according to a digital order.
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Weaken bolts (1) – (10) until the rotating moment of an inhaling does not decrease to 0 (zero) as it should be the return to fastening.
Just as in point 7, fasten them to 42 N • m (4.2 kg-m, 30.5 pound on foot).
In the same way as in point 7, fasten them with the specified rotating moment.
Fasten bolts (11) – (22) with the specified rotating moment according to their digital order.
The rotating inhaling moment:
Case bolt with a carving of 10 mm in the diameter (1) – (10)
(a): 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)
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Having fastened case bolts, be convinced that the crankshaft rotates smoothly when you turn it a hand. |
Establish back oil consolidation (1) by means of the plastic hammer and special tools.
Special tool
(A): 09911-97710
(C): 09911-97811
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1 — back oil consolidation
2 — the party of the crankshaft
3 — the party of oil consolidation |
Install the sensor of position of the crankshaft (1) and fix its plaits of wires by an arm. The rotating inhaling moment: bolt of the sensor of position of the crankshaft (a): 6 N • m (0.6 kg-m, 4.5 pound on foot).
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1 — the sensor of position of the crankshaft
2 — the cylinder block
3 — the crankshaft |
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Establish a flywheel (for M/T vehicles) or a drive plate (for And/T vehicles). By means of the special tool record a flywheel or a drive plate and, having greased with sealant, fasten bolts of a flywheel or a drive plate (1) according to technical requirements.
"And": sealant 99000-31110
special tool (A): 09924-17811
the rotating inhaling moment:
bolt of a flywheel or drive plate (c): 70 N • m (7.0 kg-m, 51.0 pound on foot)
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Establish arms of side fastening of the engine (1) (right and left). Fasten bolts of arms with the specified rotating moment. The rotating inhaling moment: a bolt of an arm of side fastening of the engine (d) — 55 N • m (5.5 kg-m, 40.0 pound on foot).
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Install the water pump (2) and an exhaust pipe of the heater (3), having addressed Sections the Water pump and Hoses or water pipes of the cooling system in the Head Okhlazhdeniye of the engine.
Install pistons and rods, having addressed the Section Pistons, piston rings, rods and cylinders in this Chapter.
Install the oil pump, having addressed the Section the Oil pump in this Chapter.
Install cylinder head knot in the cylinder block, having addressed the Section Valves and a head of the block of the cylinder in this Chapter.
Establish synchronization chains, a natyazhitel of a chain of synchronization, directing chains of synchronization, a synchronization chain asterisk, a synchronization chain cover, a crankshaft pulley, a pulley of the water pump, etc. Address the Section the First chain of synchronization and a natyazhitel of a chain in this Chapter.
Establish a grid of the oil pump and an oil pan.
Establish coupling on a flywheel (for M/T vehicles). Address the Section Coupling Cover, a clutch plate and a flywheel in the Head Stsepleniye to establish coupling.
Establish engine knot in the vehicle, having addressed the Section Engine in this Chapter.
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