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
   - Mechanical part of engine J20
       The general description
      - Routine maintenance
         Compression check
         Check of depression of the engine
         Check of pressure of oil
         Filtering element of the air filter
         The case throttle заслонок and an inlet collector
         Exhaust system collector
         Cover of a head of the cylinder
         Маслосборник and a grid of the oil pump
         The oil pump
         Cover of a chain of synchronisation
         The second chain of synchronisation and натяжитель chains
         The first chain of synchronisation and натяжитель chains
         Cam-shafts and regulators клапанного a backlash
         Valves and head of the block of the cylinder
         Pistons, piston rings, rods and cylinders
       Assembly armature of the engine
      The special tool
      Necessary service materials
      Technical characteristics of the rotating moment of an inhaling
    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





Pistons, piston rings, rods and cylinders

Components

1 — the top ring
2 — the second ring
3 — маслосъемное a ring
4 — the piston
5 — a rod
6 — a cover of the bearing of a rod
7 — the rod bearing
8 — a piston finger

9 — a lock ring of a piston finger
10 — the cylinder block
11 — the oil pump
12 — a cover of an asterisk of the oil pump
13 — a nut of a cover of the bearing of a rod
14 — a bolt of the oil pump
15 — a bolt of a cover of an asterisk of the oil pump


Do not grease with engine oil an internal surface of the big bottom head of a rod.

Do not grease with engine oil an internal surface of a cover.

Do not put engine oil between the big bottom head of a rod and the bearing, between a cover and the bearing.

The rotating moment of an inhaling.

Not to use repeatedly.

Grease with engine oil a sliding surface of each detail.

Removal

 PERFORMANCE ORDER

  1. Dump pressure of fuel.
  2. Disconnect a negative cable from the accumulator.
  3. Merge engine oil.
  4. Merge antifreeze.
  5. Remove a head of the cylinder with an inlet collector, a collector of an exhaust system and a water taking away pipe, having addressed to Section Valves and a head of the block of the cylinder in this Chapter.
  6. Remove the oil pump, having addressed to Section the Oil pump in this Chapter.
  7. Note cylinder number on all pistons, rods and covers of bearings of a rod.
  8. Remove covers of bearings of a rod.
  1. Establish directing hose (1) over a carving шатунных bolts. It prevents damage of a neck 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.

Dismantling

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

The cylinder

 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.
1 — 50 mm (1.96 inches)
2 — 95 mm (3.74 inches)
  • Limit of internal diameter of the cylinder: 84.050 mm (3.3090 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.

Pistons

 PERFORMANCE ORDER

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

Diameter of pistons

  1. Diameter of the piston should be measured in a point of 26.5 mm (1.04 inches) from the end of a skirt of the piston in a direction perpendicular to a piston finger.
1 — 26.5 mm (1.04 inches)
    • Diameter of the piston:
      • Standard diameter of the piston: 83.970 – 83.990 mm (3.3059 – 3.3066 inches)
      • Diameter of the piston большего the size (0.50 mm (0.0196 inches)): 84.470 – 84.490 mm (3.3256 – 3.3263 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 — 26.5 mm (1.04 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
      • The 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 – 0.014 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)

Piston rings

To measure a cut backlash, insert a piston ring (3) into a cylinder trunk, 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 any other dirt from top of a trunk of the cylinder before to insert a piston ring.

Backlash of a cut of a piston ring

Norm

Limit

The top ring

0.20 – 0.35 mm (0.0079 – 0.0137 inches)

0.7 mm (0.0275 inches)

The second ring

0.35 – 0.50 mm (0.0138 – 0.0196 inches)

0.7 mm (0.0275 inches)

Maslosemnoe ring

0.20 – 0.70 mm (0.0079 – 0.0275 inches)

1.8 mm (0.0708 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: 0.25 – 0.40 mm (0.0099 – 0.0157 inches)
      • Limit: 0.45 mm (0.0177 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.
    • Limit of bends: 0.05 mm (0.0020 inches)
    • Twisting limit: 0.10 mm (0.0039 inches)

Shatunnaja neck and rod bearings

Diameter шатунной necks

Check up шатунную a neck on presence of non-uniform deterioration or damage. Measure шатунную a neck on эллипсность or a bias with the help a micromeasure. If шатунная the neck is damaged or if эллипсность or a bias more than an admissible limit, replace коленвал or переточите шатунную a neck, having addressed to item 7).

Technical characteristics шатунной a neck and rod bearings

The size of bearings of a rod

Diameter шатунной necks

Norm

49.982 – 50.000 mm (1.9678 – 1.9685 inches)

0.25 mm (0.00984 inches) below the nominal

49.732 – 49.750 mm (1.9580 – 1.9586 inches)

  • Эллипсность шатунной necks (And-)
    • Limit: 0.01 mm (0.0004 inches)
  • Bias шатунной necks (and – b)
    • Limit: 0.01 mm (0.0004 inches)

The general information on rod bearings

1 — a paint

Repair bearings of a rod happen the standard size and on 0.25 mm (0.0098 inches) less, bearings of the smaller size happen 5 types different from each other by stability to influence. That it was possible to distinguish the bearing of the smaller size, it is painted in red colour in a point shown in drawing, the thickness of the bearing of the smaller size in the centre makes 1.605 – 1.615 mm (0.0632 – 0.0635 inches).

Visual survey of the bearing of a rod

Examine bearing loose leaves on a subject оплавления, изъязвлений, прожога or отслаивания and examine drawing of an arrangement of contact. Bearing loose leaves in failure condition should be replaced.

Backlash of the bearing of a rod

 PERFORMANCE ORDER

  1. Before to check a bearing backlash, clean the bearing and a rod neck.
  2. Establish the bearing in a rod and a bearing cover.
  1. 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.
  1. Establish a cover of the bearing of a rod on a rod.
  1. At cover installation be convinced that the arrow (1) on a cover specifies in the pulley party коленвала. Having greased with engine oil rod bolts, twirl cover nuts by the specified rotating moment. The rotating moment of an inhaling: a nut of a cover of the bearing of a rod (): 45 Н•м (4.5 kg th, 33.0 pound on foot).

DO NOT TURN коленвал with a plaster solution inside.


  1. Uncover and by means of a ruler (2) on a cover of a plaster solution (1), measure width of a plaster solution (1) in the widest place (backlash). If the backlash falls outside the limits norms, use the new bearing of the standard size, having addressed to subsection the Selection of bearings of a rod in this Section. After selection of the new bearing try on a backlash.
    • Backlash of the bearing of a rod:
      • Norm: 0.045 – 0.063 mm (0.0018 – 0.0024 inches)
      • Limit: 0.08 mm (0.0031 inches)
  1. 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.
  2. Establish the 0.25-millimetric bearing of the smaller size on the big head of a rod.
  3. Measure internal diameter of the big head of a rod.
  4. 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)

 

0.054 mm (0.0021 inches)

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

Selection of bearings of a rod

  • If the bearing is faulty or the bearing backlash does not correspond to technical characteristics, choose the new bearing of the standard size according to the following procedure and establish it.
  • If for any reason replace коленвал or a rod and its bearing, choose the new bearing of the standard size for installation, having addressed to the figures printed on a rod and its cover and-or letters, printed on a cheek коленвала the cylinder №3.

 PERFORMANCE ORDER

  1. Check up the printed figures on a rod and its cover. Three types of numbers (1, 2 and 3) represent the next internal diameters of the big head of a rod. For example, printed number 1 specifies that internal diameter of a corresponding big head of a rod makes 53.0000 – 53.0060 mm (2.0867 – 2.0868 inches).

Internal diameter of the big bottom head of a rod

The printed figures

Internal diameter of the big bottom head of a rod

1

53.0000 – 53.0060 mm (2.0867 – 2.0868 inches)

2

53.0061 – 53.0120 mm (2.0869 – 2.0870 inches)

3

53.0121 – 53.0180 mm (2.0871 – 2.0873 inches)


And — a mark specifying in weight
In — figure of internal diameter of the big bottom head of a rod
  1. Further check up diameter шатунной necks. On a cheek коленвала the cylinder №3 4 letters are printed. Three types of letters ("And", "In" and "With") represent the following of diameter шатунных necks, accordingly. For example, the printed letter "And" specifies that diameter of a corresponding neck коленвала makes 49.9940 – 50.0000 mm (1.9683 – 1.9685 inches).

Diameter of a neck коленвала

The printed letters

Diameter of a neck коленвала (without the bearing)

AND

49.9940 – 50.0000 mm (1.9683 – 1.9685 inches)

IN

49.9880 – 49.9939 mm (1.9681 – 1.9682 inches)

WITH

49.9820 – 49.9879 mm (1.9677 – 1.9680 inches)


And — diameter of a neck коленвала for the cylinder №1
In — diameter of a neck коленвала for the cylinder №2
  1. There are five types of bearings of the standard size different from each other on a thickness. That they could be distinguished, they are painted in following colours in a point shown in drawing. Each colour designates the next thickness in the bearing centre.

Thickness of the bearing of a rod of the standard size

Colour of colouring

Thickness of the bearing

The blue

1.494 – 1.497 mm (0.05882 – 0.5893 inches)

The yellow

1.491 – 1.494 mm (0.05871 – 0.05881 inches)

The colourless

1.488 – 1.491 mm (0.05859 – 0.05870 inches)

The black

1.485 – 1.488 mm (0.05847 – 0.05858 inches)

The green

1.482 – 1.485 mm (0.05835 – 0.05846 inches)


1 — a paint
  1. Under number printed on a rod both its cover, and the letters printed on a cheek коленвала of the cylinder №3, define the new size of the bearing which should be established in the big bottom head of a rod, having addressed to the table. For example, number printed on a rod and its cover, - 1 and the letter printed on a cheek коленвала of the cylinder №3 – "In", establish the new bearing of the standard size painted in "Black" colour in the big bottom head of a rod.

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

Number printed on a rod and its cover (internal diameter of the big bottom head of a rod)

1

2

3

The letter printed on a cheek коленвала of the cylinder №3 (diameter шатунной necks)

AND

The green

The black

The colourless

IN

The black

The colourless

The yellow

WITH

The colourless

The yellow

The blue

The standard size of the new bearing to installation


  1. Check up a bearing backlash at again chosen bearing of the standard size, having addressed to subsection Selection of bearings of a rod in this Section. If the backlash still exceeds norms, use the bearing following on a thickness and repeatedly check up a backlash.

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.


 PERFORMANCE ORDER

  1. On each piston (1) number (7 1 or 2 is printed. He specifies in external diameter of the piston.
  1. On the block of the cylinder (2) numbers (6 1 or 2 also are printed, and it also is painted in red or blue colour (3). Number specifies in internal diameter of the cylinder.
2 — the cylinder block
3 — colour окраса on the cylinder block
4 — the pulley party коленвала
5 — the flywheel party
6 — numbers
8 — the cylinder №1
9 — the cylinder №2
10 — the cylinder №3
11 — the cylinder №4
  1. Number printed on the piston, and mark a paint (or printed number) on the cylinder block should coincide. I.e. establish the piston number 2 on the cylinder which is noted by a blue paint or number 2 (4), and the piston number 1 on the cylinder with a red mark or at number 1 (3).

Piston and cylinder technical characteristics

The piston

The cylinder

Backlash between the piston and the cylinder

Number on top (mark)

The external

Diameter

Mark

Internal diameter

1

83.9800 – 83.9900 mm (3.3063 – 3.3066 inches)

Red or 1

84.0101 – 84.0200 mm (3.3075 – 3.3078 inches)

0.02 – 0.04 mm (0.0008 – 0.0015 inches)

2

83.9700 – 83.9799 mm (3.3059 – 3.3062 inches)

Blue or 2

84.0000 – 84.0100 mm (3.3071 – 3.3074 inches)

0.02 – 0.04 mm (0.0008 – 0.0015 inches)

  1. On a piston head letters also are printed And, In or With, but as a rule there is no necessity to distinguish each piston under this letter.
1 — the pulley party коленвала
2 — the flywheel party
5 — the cylinder №1
6 — the cylinder №2
7 — the cylinder №3
8 — the cylinder №4
  1. Establish a piston finger in the piston (1) and a rod: Having greased with engine oil a piston finger and apertures of a piston finger in the piston and a rod (3), 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 mark 86 F on a rod should be on the pulley party коленвала.


1 — the piston
2 — an arrow
3 — a piston finger

Do not forget to clamp a lock ring a backlash of the cut established in a range of an arrow.


1 — the piston
2 — an arrow
3 — a rod
4 — a lubricant aperture
6 — the pulley party коленвала
  1. Establish piston rings in the piston:
    • The first ring (1) differs from the second ring (2) on width, 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

Installation

 PERFORMANCE ORDER

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

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 neck 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 — the pulley party 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 bearing cover. Establish an arrow (1) on a cover towards a pulley коленвала. Fasten cover nuts according to technical recommendations. The rotating moment of an inhaling: a nut of a cover of the bearing of a rod () — 45 Н•м (4.5 kg th, 33.0 pounds on foot).
  1. Repeat dismantle procedure upside-down for the purpose of installation.
  2. Adjust a tension of a belt of a drive of the cooling fan, having addressed to Section Regulation and check of a tension of a belt of the cooling fan in the Head engine Cooling.
  3. Adjust люфт a rope of an accelerator and люфт a cable of a drive throttle заслонок А/Т (for vehicles with А/Т).
  4. Check up, whether all removed parts are put into place. Repeatedly establish any necessary parts which have not been earlier established.
  5. Fill the engine with engine oil, having addressed to Section Engine oil and the filter in the Head Maintenance service and greasing.
  6. Fill cooling system, having addressed to Section Washing and filling of system of cooling in the Head engine Cooling.
  7. Fill the case of forward differential трансмиссионным with oil, having addressed to Section Servicing in the Head Forward differential.
  8. Fill system of a steering with a special liquid, having addressed to Section the Liquid of the hydraulic booster of a wheel in the Head System of the hydraulic booster of a wheel.
  9. Connect a negative cable to the accumulator.
  10. Check up, whether there is no leak of fuel, antifreeze, oil and exhaust gas on each connection.
  11. Be convinced of that installation of a corner of an advancing of ignition or fuel injection corresponds to technical requirements, and adjust if necessary, having addressed to Section Check and adjustment of time of an advancing of ignition in the Head System of ignition for engine J20.