Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 131

1D-50 Engine Mechanical: For M16A Engine with VVT

2) Next, check crankshaft pin diameter. On crank web

No.3, four alphabets are stamped as shown in the
figure.
Three kinds of alphabet (“A”, “B” and “C”) represent
the following crankshaft pin diameter respectively.
For example, stamped “A” indicates that
corresponding crankshaft pin diameter is 41.994 –
42.000 mm (1.6533 – 1.6534 in.).

Crankshaft pin outer diameter

3) There are five kinds of standard bearings differing in

thickness. To distinguish them, they are painted in
the following colors at the position as indicated in the
figure.
Each color indicated the following thickness at the
center of bearing.

Standard size of connecting rod bearing
thickness

4) From number stamped on connecting rod and its cap

and alphabets stamped on crank web No.3,
determine new standard bearing to be installed to
connecting rod big end inside, by referring to the
table.
For example, if number stamped on connecting rod
and its cap is “1” and alphabet stamped on crank
web No.3 is “B”, install a new standard bearing
painted in “Black” to its connecting rod big end
inside.

Specification of new standard connecting rod
bearing size

[A]: Connecting rod big end inside diameter number
[B]: Weight indication mark

Stamped

alphabet

Crankshaft pin diameter

41.9940 – 42.0000 mm (1.6533 – 1.6534 in.)

41.9880 – 41.9939 mm (1.6531 – 1.6532 in.)

41.9820 – 41.9879 mm (1.6529 – 1.6530 in.)

[A]: Crankshaft pin diameter for No.1 cylinder
[B]: Crankshaft pin diameter for No.2 cylinder

[C]: Crankshaft pin diameter for No.3 cylinder
[D]: Crankshaft pin diameter for No.4 cylinder

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Color

painted

Bearing thickness

Blue

1.4991 – 1.5020 mm (0.05902 – 0.05913 in.)

Yellow 1.4961 – 1.4990 mm (0.05890 – 0.05901 in.)

Nothing 1.4931 – 1.4960 mm (0.05878 – 0.05889 in.)

Black

1.4901 – 1.4930 mm (0.05867 – 0.05877 in.)

Green

1.4870 – 1.4900 mm (0.05855 – 0.05866 in.)

1. Paint

Number stamped on

connecting rod and its cap

(connecting rod big end

inside diameter)

Alphabet stamped

on crank web No.3

(Crankshaft pin

diameter)

Green

Black

Nothing

Black

Nothing Yellow

C Nothing Yellow

Blue

New standard bearing to be

installed.

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Engine Mechanical: For M16A Engine with VVT 1D-51

Main Bearings, Crankshaft and Cylinder Block Components

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1. CKP sensor (if equipped)

: See “A”

10. Rear oil seal housing

: See “C”

19. Spring pin

2. Knock sensor

11. Rear oil seal

20. Sensor plate bolt

3. Cylinder block

12. Input shaft bearing

21. Oil pressure switch

1D-52 Engine Mechanical: For M16A Engine with VVT

Main Bearings, Crankshaft and Cylinder Block
Removal and Installation

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Removal

1) Remove engine assembly from vehicle referring to

“Engine Assembly Removal and Installation: For
M16A Engine with VVT”.

2) Remove clutch cover, clutch disc and flywheel by

using special tool.

Special tool
(A): 09924–17810

3) Remove piston and connecting rod referring to

“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation: For M16A
Engine with VVT”.

4) Remove rear oil seal housing (1).

5) Loosen main bearing cap No.1 and No.2 bolts in

such order as indicated in the figure and remove
them.

6) Remove crankshaft from cylinder block.

Installation

NOTE

• All parts to be installed must be perfectly

clean.

• Be sure to oil crankshaft journals, journal

bearings, thrust bearings, crankpins,
connecting rod bearings, pistons, piston
rings and cylinder bores.

• Journal bearings, bearing caps,

connecting rods, rod bearings, rod bearing
caps, pistons and piston rings are in
combination sets. Do not disturb such
combination and make sure that each part
goes back to where it came from, when
installing.

4. Venturi plug

13. Flywheel

: 22 N

⋅m (2.2 kgf-m, 16.0 lb-ft)

5. Main bearing

: See “B”

14. Main bearing cap

: 5 N

⋅m (0.5 kgf-m, 4.0 lb-ft)

6. Sensor plate

15. Flywheel mounting bolt

: 70 N

⋅m (7.0 kgf-m, 51.0 lb-ft)

7. Crankshaft timing sprocket key

16. Rear oil seal housing mounting bolt

: Tighten 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified

procedure.

8. Crankshaft

17. Main bearing cap No.2 bolt

: Tighten 30 N

⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-

m, 36.5 lb-ft) and 60

° by the specified procedure.

9. Thrust bearing

18. Main bearing cap No.1 bolt

: See “D”

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

“A”: When installing CKP sensor, use new sensor mounting bolt.

: 13 N

⋅m (1.3 kgf-m, 9.5 lb-ft)

“B”: Upper half of bearing has an oil groove.

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

“C”: Apply sealant 99000-31250 to mating surface.

: Do not reuse.

“D”: Check main bearing cap No.1 bolt, plastic deformation tightening bolt, for deformation

referring to “Main Bearing Cap No.1 Bolt” under “Main Bearings Inspection: For M16A
Engine with VVT”, if it is reused.

: Apply engine oil to inside / sliding surface.

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Engine Mechanical: For M16A Engine with VVT 1D-53

1) Install sensor plate (1) to crankshaft (2) and tighten

bolts to specified torque.

NOTE
When installing sensor plate, align spring pin
(3) on crankshaft and hole of sensor plate.

Tightening torque
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)

2) Install main bearings to cylinder block.

Upper half of bearing (1), has an oil groove (2).
Install it to cylinder block (3), and the other half
without oil groove to bearing cap.
Make sure that two halves are painted in the same
color.

3) Install thrust bearings (1) to cylinder block between

No.2 and No.3 cylinders. Face oil groove (2) sides to
crank webs.

4) Confirm that dowel pins (3) are installed to intake

side of each journal.

5) Install crankshaft to cylinder block.
6) Install bearing cap to cylinder block, making sure to

point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts ((1) – (10)) and main bearing cap No.2 bolts
((11) – (20)), tighten them gradually as follows.

NOTE
If main bearing cap No.1 bolt is reused, make
sure to check main bearing cap No.1 bolt for
deformation referring to “Main Bearing Cap
No.1 Bolt” under “Main Bearings Inspection:
For M16A Engine with VVT”.

a) Tighten bolts ((1) – (10)) to 30 N

⋅m (3.0 kgf-m,

22.0 lb-ft) according to numerical order as shown
by using a 12 corner socket wrenches.

b) In the same manner as in Step a), tighten them

to 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft).

c) In the same manner as in Step a), retighten them

to 60

°.

d) Tighten bolts ((11) – (20)) to 25 N

⋅m (2.5 kgf-m,

18.0 lb-ft) according to numerical order as
shown.

Tightening torque
Main bearing cap No.1 bolt ((1) – (10)): 30
N

⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-m,

36.5 lb-ft) and then retighten by turning
through 60

Main bearing cap No.2 bolt ((11) – (20)): 25
N·m (2.5 kgf-m, 18.0 lb-ft)

CAUTION

After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 N

⋅m (1.2 kgf-m, 9.0 lb-ft)

torque or below.

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