Suzuka Grandee Vitara
The general information
Maintenance service and greasing
Heater, ventilation and the conditioner
Steering
Suspension bracket
Wheels and tyres
Forward приводной a shaft shaft/bearing. An oil epiploon
Kardannye shaft
Brake system
- Engines
   - Mechanical part of engine G16
       The general description
       Routine maintenance
      - Piston rod, piston rings, rods and cylinders
         Major repairs
         The bearing of a cranked shaft, коленвал and the block of cylinders
      The special tool
      Necessary service materials
      Technical characteristics of the rotating moment of an inhaling
    Mechanical part of engine J20
    Engine cooling
Fuel system
Ignition system
Start system
Release system
Transmissions
Coupling
Transfer
Forward and back differentials
Windows, mirrors, locks and security measures. An immobilizer
Electric equipment





Piston rod, piston rings, rods and cylinders

1 — the top ring
2 — the second ring
3 — маслосъемное a ring
4 — the piston
5 — шатун*

6 — a bearing cover шатуна*
7 — the bearing шатуна*
8 — a piston finger
9 — a lock ring of a piston finger
10 — a nut of a cover of the bearing of a rod


*5) do not grease with engine oil an internal surface штоковой a cylinder cavity.

*6) do not grease with engine oil an internal surface of a cover.

*7) do not put engine oil between штоковой a cavity of the cylinder and the bearing, between a cover and the bearing.

The rotating moment of an inhaling.
Not to use repeatedly.

Grease with engine oil sliding surfaces of each part.

Removal

 PERFORMANCE ORDER

  1. Remove a head of the cylinder from the block of cylinders, having addressed to section «Valves and a cylinder head» in this chapter.
  2. Merge engine oil.
  3. Remove маслосборник and a grid of the oil pump, having addressed to Razdelu Maslosbornik and a grid of the oil pump in this Chapter.
  4. Note cylinder number on all pistons, rods and covers of bearings of a rod, using a silver pencil or a quick-drying paint.
  5. Remove covers of bearings of a rod.
  1. Establish directing hose (1) over a carving шатунных bolts. It is necessary to avoid damage of a pin of the bearing and a carving шатунных bolts at rod removal.
  1. Remove a deposit from top of an aperture of the cylinder before to get the piston from the cylinder.
  2. Push out the piston and rod knot at the top from a cylinder aperture.

Removal

 PERFORMANCE ORDER

  1. By means of a dilator of piston rings remove two компрессионных rings (top and the second) and маслосъемное a ring from the piston.
  2. Remove a piston finger from a rod.
    • Ослабьте lock rings of a piston finger (1).
    • Remove a piston finger.

Cleaning

Remove a deposit from the bottom of the piston and flutes of a piston ring by means of the suitable tool.

Check

Cylinders

 PERFORMANCE ORDER

  1. Check up walls of cylinders about scratches, roughnesses or the ledges specifying in excessive deterioration. If a cylinder trunk very rough or strongly scratched, or with ledges, chisel the cylinder and use the piston большего the size.
  2. With the help компрессиметра measure internal diameter of the cylinder in a direction of draught and an axial direction in two positions. If you notice something from following positions, chisel the cylinder.
    • Internal diameter of the cylinder falls outside the limits norms.
    • The difference of measurements in two positions falls outside the limits a bias.
    • The difference between measurements of axial section and a draught direction leaves with a deviation from “круглости”.
      • Limit of internal diameter of the cylinder: 75.15 mm (2.9586 inches)
      • Bias of internal diameter of the cylinder
        • Limit: 0.10 mm (0.0039 inches)
      • Internal diameter of the cylinder with a deviation from круглости
        • Limit: 0.10 mm (0.0039 inches)

If though one of four cylinders has to be chiseled, chisel all four cylinders on the same больший the size. It is necessary for the purpose of uniformity and balance preservation.


1 — 50 mm (1.96 inches)
2 — 95 mm (3.74 inches)

Pistons

 PERFORMANCE ORDER

  1. Investigate pistons about defects, cracks and other damages. The damaged or defective pistons should be replaced.

Diameter of pistons

  1. Diameter of the piston should be measured on distance of 23 mm (0.91 inches) (1) from the end of a skirt of the piston in a direction perpendicular to a piston finger.

Diameter of the piston

The size of the piston

Diameter of the piston

Norm

74.970 – 74.990 mm (2.9516 – 2.9523 inches)

The repair size: 0.50 mm (0.0196 inches)

75.470 – 75.480 mm (2.9713 – 2.9716 inches)

Piston backlash

  1. Measure internal diameter of the cylinder and diameter of the piston to find a difference which will be a piston backlash. The piston backlash should correspond to the technical requirements specified below. If it does not correspond to technical requirements, chisel the cylinder and use the piston большего the size. A piston backlash: 0.02 – 0.04 mm (0.0008 – 0.0015 inches).

The internal diameters of the cylinder used here, are measured in a draught direction in two positions.


1 — 23 mm (0.01 inches)

Backlash of grooves of rings

  1. Before to check, it is necessary to clear, dry and release from a deposit of a groove of the piston. Put a new piston ring (1) in a piston groove, and measure a backlash between a ring and a crosspiece between two flutes of piston rings with the help калибромера (2).
  1. If the backlash does not correspond to technical requirements, replace the piston.
    • Backlash 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)

Piston finger

 PERFORMANCE ORDER

  1. Check up a piston finger, internal diameter of the plug of a piston head and internal diameter of the piston about deterioration or damage, paying special attention on a condition of the plug of a piston head of a rod. If the piston finger, internal diameter of the plug of a piston head of a rod or internal diameter of the piston are worn strongly out or damaged, replace a piston finger, a rod or the piston.

Backlash of a piston finger

  1. Check up a backlash of a piston finger on the top head of a rod. Replace a rod if its top head is worn strongly out or damaged or if the measured backlash leaves for an admissible limit.
Piston backlash on the top head of a rod:
  • Norm: 0.003 – 0.016 mm (0.0001 – 0.0006 inches)
  • Limit: 0.05 mm (0.0020 inches)

Internal diameter of a small head of a rod: 19.003 – 19.011 mm (0.7482 – 0.7484 inches)

 Diameter of a piston finger: 18.995 – 19.000 mm (0.7478 – 0.7480 inches)

Piston rings

To measure a cut backlash, insert a piston ring (3) into the cylinder, and then measure a backlash with the help калибромера (2). If the measured backlash does not correspond to technical requirements, replace a ring.

Clean a deposit and clean the top part of the cylinder before to insert a piston ring.

Backlash of a cut of a piston ring

 

Norm

Limit

The top ring

0.2 – 0.35 mm (0.0079 – 0.0137 inches)

0.7 mm (0.0275 inches)

The second ring

0.2 – 0.35 mm (0.0079 – 0.0137 inches)

0.7 mm (0.0275 inches)

Maslosemnoe ring

0.20 – 0.70 mm (0.0079 – 0.0275 inches)

1.7 mm (0.0669 inches)


1 — the cylinder block
2 — калибромер
3 — a piston ring
4 — 120 mm (4.72 inches)

Rod

 PERFORMANCE ORDER

Lateral backlash of the big bottom head of a rod

  1. Check up a lateral backlash of the big head of a rod, having inserted and having attached a rod to it шатунной to a neck regularly. If it will appear that the measured backlash falls outside the limits norm, replace a rod.
    • Lateral backlash of the big bottom head of a rod
      • Norm: 0.10 – 0.20 mm (0.—39 – 0.0079 inches)
      • Limit: 0.35 mm (0.0137 inches)

Rod alignment:

  1. Establish a rod on the equalizer to check up it on presence of bends and twisting if the limit is more than norm, replace it.
    • Rod alignment
      • Limit of bends: 0.05 mm (0.0020 inches)
      • Twisting limit: 0.10 mm (0.0039 inches)

Shatunnaja neck and rod bearings

 PERFORMANCE ORDER

  1. Check up шатунную a neck on presence of non-uniform deterioration or damage. Measure шатунную a neck on a deviation or a bias with the help a micromeasure. If шатунная the neck is damaged or if a deviation or a bias more than an admissible limit, replace коленвал or переточите шатунную a neck, having addressed to point f).

Technical characteristics шатунной a neck and rod bearings

The size of bearings of a rod

Diameter шатунной necks

Norm

43.982 – 44.000 mm (1.7316 – 1.7322 inches)

0.25 mm (0.00984 inches) below the nominal

43.732 – 43.750 mm (1.7218 – 1.7224 inches)

  • Deviation шатунной necks:
    • Limit: 0.01 mm (0.0004 inches)
  • Bias шатунной necks:
    • Limit: 0.01 mm (0.0004 inches)

The rod bearing

  1. Check up bearing loose leaves on presence оплавления, изъязвлений, прожига or peelings and examine a configuration of contacts. The damaged loose leaves of the bearing should be replaced. There are two types of bearings of a rod available: the bearing of the standard size and the bearing less than standard size of 0.25 mm. That they could be distinguished, on the bearing of the smaller size of 0.25 mm are number (US 025), printed on its back party, and the bearing of the standard size without number.

Backlash of the bearing of a rod

a. Before to check a bearing backlash, clean the bearing and a rod neck.
b. Establish the bearing in a rod and a bearing cover.
c. Put a part of a plaster solution (1) for full width of a neck of a rod in a place of contact of the bearing (in parallel коленвалу), bypassing lubricant apertures.

d. Establish a cover of the bearing of a rod (1) on a rod. At cover installation be convinced that the arrow (2) on a cover specifies in the pulley party коленвала (3). Having greased with engine oil rod bolts, twirl nuts of a cover with specified rotating the moment. Do not turn коленвал with a plaster solution inside. The rotating moment of an inhaling: a nut of a cover of the bearing of a rod () — 35 Н•м (3.5 kg th, 25.5 pound on foot).

e. Uncover and by means of a ruler (2) on a cover of a plaster solution (1), measure width of a plaster solution in the widest place (backlash). If the backlash falls outside the limits norms, use the new bearing of the standard size and try on a backlash.
  • Oil backlash of the bearing of a rod
    • Norm: 0.020 – 0.050 mm (0.0008 – 0.0019 inches)
    • Limit: 0.080 mm (0.0031 inches)

f. If it is impossible to result a backlash in norm limits even with the new bearing of the standard size, replace коленвал or переточите шатунную a neck on the size less nominal as follows.

  • Establish the 0.25-millimetric bearing less than nominal size (0.00984 inches) on the big head of a rod.
  • Measure internal diameter of the big head of a rod.
  • Переточите шатунную a neck till next complete diameter.

Complete diameter шатунной necks

=

The measured internal diameter of the big head (including the bearing less than nominal size)

0.035 mm (0.0014 inches)

    • Be convinced of that a backlash of the bearing within the standard value specified above.

Assemblage

To provide a necessary backlash between the piston and the cylinder, there are two sizes of pistons available, in quality spare parts of the standard size. Establishing the piston of the standard size, do not forget to adjust the piston with the cylinder as follows.


On each piston (5) number 1 or 2 (6) is printed. He specifies in external diameter of the piston.

On blocks of cylinders numbers 1 and 2 (6) also are printed. The first number specifies in internal diameter of the first cylinder (1), the second number for internal diameter of the second cylinder (2), the third number for internal diameter of the third cylinder (3) and the fourth number for internal diameter of the fourth cylinder (4).

And — the pulley party коленвала
In — the flywheel party
Number printed on the piston, and number on the block of cylinders should coincide. I.e. establish the piston number 2 on the cylinder at number 2, and the piston number 1 on the cylinder number 1.

Piston and cylinder technical characteristics

The piston

The cylinder

Backlash between the piston and the cylinder

Number on top (mark)

The external

Diameter

Number (mark)

Internal diameter

1

74.9801 – 74.9900 mm (2.9520 – 2.9523 inches)

1

75.0101 – 75.0200 mm (2.9531 – 2.9535 inches)

0.02 – 0.04 mm (0.0008 – 0.0015 inches)

2

74.9700 – 74.9800 mm (2.9516 – 2.9519 inches)

2

75.000 – 75.0100 mm (2.9528 – 2.9531 inches)

0.02 – 0.04 mm (0.0008 – 0.0015 inches)

On heads of pistons letters also are printed And, In or With, but as a rule there is no necessity to distinguish each piston under this letter.

 PERFORMANCE ORDER

  1. Establish a piston finger in the piston (1) and a rod (3): having greased with engine oil a piston finger and apertures of a piston finger in the piston and a rod, establish a rod in the piston, and insert a piston finger into the piston and a rod, and put lock rings of a piston finger.

The lock ring should be established a detachable part upwards or downwards.

The pulley party коленвала


1 — the piston
2 — an arrow
3 — a rod
4 — a lubricant aperture
  1. Establish piston rings in the piston:
    • The first ring (1) differs from the second ring (2) under the form and marks. Distinguish the first ring from the second, having looked at drawing, and establish these piston rings in the piston, directing the marked party of each ring on the top of the piston.
    • Establishing маслосъемное a ring (3), at first put распорку, and then two erasing edges маслосъемного rings.
  1. After installation of three rings (the first, the second and маслосъемного), distribute their backlashes of a cut.
1 — an arrow
2 — a backlash of a cut of 1st ring
3 — a backlash of a cut of 2nd ring and a backlash распорки маслосъемного rings
4 — a backlash of the top erasing edge маслосъемного rings
5 — a backlash of the bottom erasing edge маслосъемного rings
6 — the party on an admission
7 — the party on release

Installation or connection

 PERFORMANCE ORDER

  1. Grease with engine oil pistons, rings, walls of cylinders, bearings of a rod and шатунную a neck.

Do not put oil between a rod and the bearing or between a cover of the bearing and the bearing.


  1. Establish directing sleeves over rod bolts. These directing sleeves protect шатунную a head and a carving of bolts of a rod from damage at installation of a rod and piston knot.
  1. At installation of the piston and rod knot in a trunk of the cylinder of the marksman on a piston head should specify in the pulley party коленвала (1).
1 — a pulley коленвала
2 — the flywheel party
  1. Establish the piston and rod knot in a cylinder trunk. Use the special tool (the compressor of piston rings) to compress rings. Direct a rod into place in коленвале. By means of the hammer handle besiege easy blows a piston head to establish the piston in a trunk. Firmly hold the compressor of rings against the block of cylinders until all piston rings will not enter into a cylinder trunk. The special tool: () 09916-77310.
  1. Establish a cover of the bearing (1): establish an arrow (2) on a cover towards a pulley коленвала (3). Fasten cover nuts according to technical recommendations. The rotating moment of an inhaling: a nut of a cover of the bearing of a rod () — 35 Н•м (3.5 kg th, 25.5 pounds on foot).
  1. Repeat dismantle procedure upside-down for the purpose of installation as it has been earlier depicted in general.
  2. Adjust a tension of a belt of a drive of the water pump, having addressed to Section Regulation and check of a tension of a belt of the cooling fan in the Head engine Cooling.
  3. Adjust a tension of a belt of the pump of the hydraulic booster of a steering or a tension of a belt of compressor A/T if that is available. Address to Section the Engine in the Head Maintenance service and greasing.
  4. Adjust backlashes of inlet and exhaust valves, having addressed to Razdelu Klapannyj a backlash in this Chapter.
  5. Adjust люфт a cable of an accelerator and люфт a cable of a drive throttle заслонок А/Т (for models А/Т).
  6. Check up, whether all removed parts are put into place. Repeatedly establish any necessary parts which have not been earlier established.
  7. Fill the engine with engine oil, having addressed to Section Engine oil and the filter in the Head Maintenance service and greasing.
  8. Fill cooling system, having addressed to Section Washing and filling of system of cooling in the Head engine Cooling.
  9. Fill the case of forward differential трансмиссионным with oil, having addressed to Servicing in the Head Forward differential.
  10. Connect a negative cable to the accumulator.
  11. Check up, whether there is no leak of fuel, antifreeze, oil and exhaust gas on each connection.
  12. Be convinced of that installation of a corner of an advancing of ignition or fuel injection corresponds to technical requirements, having addressed to the Head ignition System.