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





The bearing of a cranked shaft, коленвал and the block of cylinders

1 — the block of cylinders
2 — forward oil consolidation
3 — the bearing коленвала*
4 — a bearing cover
5 — a cover bolt
6 — a pulley газораспределительного the mechanism
7 — коленвал
8 — the persistent bearing

9 — back oil consolidation
10 — a pin
11 — a bolt картера (short)
12 — the case сальника*
13 — a bolt картера (long)
14 — the bearing of a primary shaft
15 — a flywheel
16 — a flywheel bolt


*3) do not put engine oil between the block of cylinders and the bearing, between a cover of the bearing and the bearing.

*12) Put hermetic 99000-31250 on the interfaced surfaces

The rotating moment of an inhaling.

Not to use repeatedly.

Grease with engine oil sliding surfaces.

Removal

 PERFORMANCE ORDER

  1. Remove knot of the engine from the case, having addressed to Section the Engine in this Chapter.
  2. Remove a coupling casing, a disk of coupling and a flywheel (a leading disk for А/Т). The special tool: () 09924-17811.
1 — a flywheel bolt
  1. Remove a pulley коленвала, a drive belt газораспределительного the mechanism and a pulley газораспределительного the mechanism коленвала.
  2. Remove knot of a head of the cylinder.
  3. Remove маслосборник and a grid of the oil pump.
  4. Remove the oil pump (1).
1 — the oil pump
2 — a bolt
  1. Remove the epiploon case.
  1. Remove covers of bearings of a rod.
  2. Untwist bolts of covers of bearings коленвала in such order as it is specified in drawing, and remove covers of bearings.
  1. Remove коленвал from the block of cylinders.

Check

Коленвал

Deterioration коленвала

With the help циферблатного the indicator measure deterioration on a neck in the centre. Slowly rotate коленвал. If deterioration exceeds limit rates, replace коленвал. A deterioration limit коленвала: 0.06 mm (0.0023 inches).

Backlash of the persistent bearing коленвала

 PERFORMANCE ORDER

  1. Measure this backlash when коленвал is regularly in the block of cylinders, i.e. when the persistent bearing (1) and covers of a pin of bearings on a place.
  1. Use циферблатный a measuring instrument to take readings of a deviation in an axial direction коленвала. If the deviation falls outside the limits norms, replace the persistent bearing on new the standard size or большего the size to receive a standard backlash.
    • Backlash of the persistent bearing коленвала
      • Norm: 0.11 – 0.31 mm (0.0044 – 0.0122 inches)
      • Limit: 0.38 mm (0.0149 inches)
    • Thickness of the persistent bearing коленвала
      • Norm: 2.47 mm – 2.52 mm (0.0973 – 0.0992 inches)
    • The repair size (0.125 mm (0.0049 inches)): 2.533 – 2.583 mm (0.0998 – 0.1016 inches)

Эллипсность and a bias (non-uniform deterioration) necks коленвала

The difference speaks about non-uniform deterioration of a neck коленвала in diameter of cross-section section or along its length (or both that, and another). This difference if that is, is defined under indications a micromeasure. If one of necks is strongly damaged or if the general non-uniform deterioration, in that plan as it has been explained above, falls outside the limits norm, переточите or replace коленвала. A limit эллипсности and a neck bias коленвала: 0.01 mm (0.0004 inches).

Bearings коленвала

The general information

Bearings коленвала for repair are presented in the standard size and in the size less standard on 0.25 mm (0.0098 inches), and each of them is presented by 5 types of the bearings different from each other by the admission.

The top half of bearing (2) has a lubricant flute (3). Establish this half with a lubricant flute in the block of cylinders (1).
On each cover of the bearing коленвала the arrow and number is stamped. At installation of each cover of the bearing to the block of cylinders direct an arrow towards a pulley коленвала and establish each cover from this party towards a flywheel in ascending order numbers «1», «2», «3», «4» and «5». Fasten bolts of covers to the specified rotating moment.

Check

Check up bearings on a subject изъязвления, scratches, deterioration or damage. If any defects are found out, replace the top and bottom halves. Never replace one half, without having replaced other half.

Backlash of bearings коленвала

 PERFORMANCE ORDER

  1. Check up a backlash by means of a plaster solution, having executed the following procedure.
  2. Remove covers of bearings.
  3. Clean bearings and necks коленвала.
  1. Put a part of a plaster solution (1) for full width of the bearing (in parallel коленвалу) on a neck, bypassing oil apertures.
  1. Establish covers of bearings as it has been shown above, and in regular intervals tighten bolts of covers by the specified rotating moment. The bearing cover should be fastened according to technical requirements to provide correct indications of a backlash. The rotating moment of an inhaling: a bolt of a cover of the bearing коленвала () — 54 Н•м (5.4 kg th, 39.0 pound on foot).

Do not turn коленвал with a plaster solution inside.


  1. Uncover and by means of a ruler (2) measure width on a plaster covering (1) in the widest point. If the backlash falls outside the limits norm, replace the bearing. Always replace the top and bottom half, as a unit. The new standard bearing can create a necessary backlash. If it has not occurred, it is necessary переточить a neck коленвала 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 up a backlash repeatedly.
    • Bearing backlash коленвала
      • Norm: 0.02 – 0.04 mm (0.0008 – 0.0015 inches)
      • Limit: 0.060 mm (0.0023 inches)

Choice of bearings коленвала

The standard bearing

  • If the bearing in failure condition or if the backlash of the bearing falls outside the limits norm, choose the new standard bearing according to the following procedure, and establish it.
  • At replacement коленвала or the block of cylinders for any reason choose new standard bearings to establish them according to numbers printed on new коленвале, and-or the letters printed on the interfaced surface of the new block of cylinders.

 PERFORMANCE ORDER

  1. At first check up diameter of a neck by means of the following procedure. On cheeks коленвала cylinders №2 and №3 it is printed five figures. Three types of figures («1», «2» and «3») represent the next diameters of necks.

Technical characteristics of diameter of necks

The printed figures

Diameter of necks

1

51.9940 – 52.0000 mm (2.0470 – 2.0472 inches)

2

51.9880 – 51.9939 mm (2.0468 – 2.0469 inches)

3

51.9820 – 51.9879 mm (2.0466 – 2.0467 inches)

  1. The first, the second, the third, the fourth and the fifth (from left to right) the printed figures designate diameters of necks on covers of bearings «1», «2», «3», «4» and «5», accordingly.
  2. For example, in drawing the first (the most extreme at the left) figure "3" specifies that diameter of a neck on a cover of the bearing «1» within 51.9820 – 51.9879 mm (2.0466 – 2.0467 inches), and the second figure "1" specifies that diameter of a neck on a cover «2» makes 51.9940 – 52.0000 mm (2.0470 – 2.0472 inches).
1 — cylinders of №2 and №3 cheeks коленвала
  1. Further check up internal diameter of covers of bearings without bearings. On the interfaced surface of the block of cylinders it is printed five letters. Three letters ("And", "In" and "With") designate the next internal diameters of covers.

Technical characteristics of internal diameters of covers of bearings коленвала

The printed letters

Internal diameter of covers of bearings (without bearings)

AND

56.0000 – 56.0061 mm (2.2048 – 2.2049 inches)

IN

56.0061 – 56.0120 mm (2.2050 – 2.2051 inches)

WITH

56.0121 – 56.0180 mm (2.2052 – 2.2054 inches)

  1. The first, the second, the third, the fourth and the fifth (from left to right) the printed letters specify internal diameter of covers of bearings «1», «2», «3», «4» and «5», accordingly. For example, in drawing the first (the most extreme at the left) the letter "In" specifies that internal diameter of a cover of the bearing «1» makes 56.0061 – 56.0120 mm (2.2050 – 2.2051 inches), and the fifth (the most extreme on the right) the letter "And" specifies that internal diameter of a cover «5» makes 56.0000 – 56.0061 mm (2.2048 – 2.2049 inches).
  2. There are five types of the standard bearings different from each other on a thickness. That they could be distinguished, they are painted in following colours in a place shown in drawing. Each colour designates a certain thickness in the bearing centre.

Technical characteristics of bearings коленвала

Colour

Thickness of the bearing

The green

1.996 – 2.000 mm (0.07859 – 0.07874 inches)

The black

1.999 – 2.003 mm (0.07870 – 0.07885 inches)

Colourless (there is no paint)

2.002 – 2.006 mm (0.07882 – 0.07897 inches)

The yellow

2.008 – 2.012 mm (0.07906 – 0.07921 inches)

The blue

2.008 – 2.012 mm (0.07906 – 0.07921 inches)


1 — a paint
  1. On the figures printed on cheeks коленвала of cylinders №2 both №3 and letters, printed on the interfaced surface of the block of cylinders, define the new standard bearing which should be established on a neck, having addressed to the table resulted more low. For example, if the figure printed on a cheek коленвала «1», and the letter printed on the interfaced surface – "In", establish the new standard bearing painted in black »colour on its neck.

Technical characteristics of the new bearing коленвала the standard size

 

The figure printed on a cheek коленвала (diameter of a neck)

1

2

3

The letter printed on the interfaced surface (internal diameter of a cover of the bearing)

AND

The green

The black

The colourless

IN

The black

The colourless

The yellow

WITH

The colourless

The yellow

The blue

 

 

To establish the new bearing of the standard size


1 — cheeks коленвала cylinders №2 and №3
  1. Check up a bearing backlash at the new chosen bearing of the standard size. If the backlash still falls outside the limits norm, use the following bearing on a thickness of the size and recheck a backlash.

The 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 different from each other on a thickness. That they could be distinguished, each bearing is painted in following colours in a place specified in drawing. Each colour represents a certain thickness in the bearing centre.

Thickness of bearings of the smaller size коленвала

Colour

Thickness of the bearing

Green and red

2.121 – 2.125 mm (0.08351 – 0.08366 inches)

Black and red

2.124 – 2.128 mm (0.08363 – 0.08377 inches)

Only the red

2.127 – 2.131 mm (0.08374 – 0.08389 inches)

Yellow and red

2.130 – 2.134 mm (0.08386 – 0.08401 inches)

Blue and red

2.133 – 2.137 mm (0.08398 – 0.08413 inches)


1 — a paint

If it is necessary, переточите a neck коленвала and choose for it the bearing of the smaller size as follows.

 PERFORMANCE ORDER

  1. Переточите a neck till next complete diameter. Complete diameter of a neck коленвала: 51.732 – 51.750 mm (2.0367 – 2.0373 inches).
  1. With the help a micromeasure measure переточенный diameter of a neck. Measurement indications should act in film in two directions perpendicularly each other to check up эллипсность.
  1. 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 to the table resulted more low. Check up a backlash of the bearing with the new chosen bearing of the smaller size.

Technical characteristics of the bearing of the smaller size коленвала

 

The measured diameter of a neck

51.7440 – 51.7500 mm (2.0371 – 2.0373 inches)

51.7380 – 51.7439 mm (2.0369 – 2.0371 inches)

51.7320 – 51.7379 mm (2.0367 – 2.0369 inches)

The letters printed on the interfaced surface of the block of cylinders

AND

Green and red

Black and red

Only the red

IN

Black and red

Only the red

Yellow and red

WITH

Only the red

Blue and red

Blue and red

 

Bearings of the smaller size to installation

Back oil consolidation

 PERFORMANCE ORDER

  1. Attentively check up back oil consolidation (1) about deterioration or damage. If its edge is worn out or damaged, replace it.
  1. To establish oil consolidation, densely press back oil consolidation (1), adjusting until the end face of the case of an epiploon (2) will not be drowned заподлицо with an end face of oil consolidation.

Flywheel

 PERFORMANCE ORDER

  1. If the gear wreath is damaged, will burst or is worn out, replace a flywheel.
  2. If the surface contacting to a disk of coupling, is damaged or worn strongly out, replace a flywheel.
  1. Check up a flywheel about deterioration of an obverse surface with the help циферблатного the indicator. If deterioration exceeds admissible norms, replace a flywheel. A limit of deterioration of a flywheel: 0.2 mm (0.0078 inches).

The block of cylinders

Deformation of the condensed surface

With the help калибромера check up the condensed surface about deformation and if планшетность exceeds admissible norms, correct it. A limit of deformation of the block of cylinders: 0.06 mm (0.0023 inches).

Хонингование or расточка cylinders

 PERFORMANCE ORDER

  1. If it is required to chisel one of the cylinders, all other cylinders should be chiseled also in one and too time.
  2. Pick up the piston большего the size according to the general deterioration of the cylinder.

Diameter of the piston

The size

Diameter of the piston

The size is more on 0.50 mm (0.020 inches)

75.470 – 75.480 mm (2.9713 – 2.9716 inches)

  1. With the help a micromeasure measure diameter of the piston.
1 — 23 mm (0.91 inches)
  1. Calculate, what internal diameter of the cylinder is necessary for chiseling.
    • D = AND IN – WITH
    • D: Internal diameter of the cylinder which is necessary for turning.
    • And: the Measured diameter of the piston.
    • In: a piston Backlash = 0.02 – 0.04 mm (0.0008 – 0.0015 inches)
    • With: the Admission for хонингования = 0.02 mm (0.0008 inches)
  2. Chisel and хонингуйте the cylinder to settlement parametres.

Before to chisel, establish all covers of bearings коленвала into place and fasten them according to technical requirements to avoid deformation of internal diameters of bearings.

  1. Measure a backlash of the piston after хонингования.

Installation

  • All parts of installation should be washed ideally up.
  • Do not forget to grease a neck коленвала, basic bearings, persistent bearings, шатунные a neck, 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 has returned there, whence it has come.

 PERFORMANCE ORDER

  1. Establish bearings коленвала in the block of cylinders (1). One of two halves of the bearing коленвала has an oil flute (3). Establish it in the block of cylinders, and other half without an oil flute in a bearing cover. Be convinced that both halves are noted by the same paint.
1 — the block of cylinders
2 — the top half of bearing
3 — an oil flute
  1. Establish persistent bearings (1) in the block of cylinders between №2 and №3 cylinders. The parties with an oil flute (2) turn an obverse surface to cheeks коленвала.
  1. Establish коленвал in the block of cylinders.
  1. Establish covers of bearings in the block of cylinders, without forgetting that the arrow (on each cover) should specify towards a pulley коленвала. Put them consistently in ascending order numbers 1, 2, 3, 4 and 5, since the pulley party.
  1. Having greased with engine oil all bolts of covers of bearings, fasten bolts of covers of bearings in such order as указанно in drawing in the small portions, and repeat a twisting until they will not be fastened to the specified moment of rotation. The moment of rotation of an inhaling: a bolt of a cover of the bearing коленвала () — 54 Н•м (5.4 kg th, 39.0 pounds on foot).

Having fastened bolts of covers, be convinced that коленвал rotates smoothly when it you turn the moment of rotation 8.0 Н•м (0.8 kg th, 5.8 pound on foot) or downwards.

  1. Put hermetic on the interfaced surface of the case of a back epiploon. "And": hermetic 99000-31250.
"And" — 3 mm (0.12 inches)
«b» — 2 mm (0.08 inches)
  1. Establish the case of a back epiploon (1) and fasten bolts to the specified rotating moment. The rotating moment of an inhaling: a bolt of the case of back oil consolidation () — 11 Н•м (1.1 kg th, 8.0 pound on foot).

As there are 2 types of bolts of the case available, address to drawing that them correctly to use.


1 — long bolts
2 — short bolts
  1. Establish the oil pump, having addressed to Section the Oil pump in this Chapter.
  1. Establish a flywheel (for models М/Т) or a leading disk (for models А/Т). By means of the special tool fix a flywheel or a leading disk and fasten its bolts according to technical requirements. The special tool: () 09924-17811. The rotating moment of an inhaling: a bolt of a flywheel or a leading disk () — 78 Н•м (7.8 kg th, 56.5 pound on foot).
  1. Establish pistons and rods, having addressed to Section Pistons, piston rings, rods and cylinders in the Head the Mechanical part of engine J20.
  2. Establish a grid of the oil pump and маслосборник, having addressed to Razdelu Maslosbornik and a grid of the oil pump in this Chapter.
  1. Establish a head of the block of the cylinder on the block of cylinders, having addressed to Section Valves and a head of the block of cylinders in this Chapter.
  1. Establish a cam-shaft, a pulley of a belt of a drive газораспределительного the cam-shaft mechanism, a drive belt газораспределительного the mechanism, a pulley коленвала, a pulley of the water pump etc. Address to Razdelam Koromyslo of the valve, an axis коромысел and a cam-shaft and a drive Belt газораспределительного the mechanism and the tension device for a belt in this Chapter.
  2. Establish coupling on a flywheel (for vehicles М/Т), having addressed to Section a coupling Cover, a disk of coupling and a flywheel in the Head Coupling.
  1. Establish arms of fastening of the engine.
    • The rotating moment of an inhaling:
      • Bolt and nut of an arm of fastening of the engine () — 55 Н•м (5.5 kg th, 40.0 pound on foot)
      • Nut and arm bolt боковины engine fastenings (b) — 93 Н•м (9.3 kg th, 67 pound on foot)
  1. Establish engine knot in a vehicle, having addressed to Section the Engine in this Chapter.