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
      - Assembly armature of the engine
         Major repairs
         Bearings коленвала, коленвал and the block of cylinders
      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





Bearings коленвала, коленвал and the block of cylinders

Components

1 — the block of cylinders
2 — the pallet картера*
3 — коленвал
4 — ring consolidation
5 — приводная a chain of the oil pump
6 — radical подшипник*
7 — persistent подшипник*
8 — back oil consolidation
9 — the lock valve
10 — a flywheel (М/Т); a leading disk (А/Т)
11 — a disk картера couplings
12 — empty

13 — an arm of lateral fastening of the engine
14 — the water pump
15 — a heater exhaust pipe
16 — directing to a chain of the oil pump
17 — a flywheel or conducting bolt диска*
18 — the gauge of detonation combustion
19 — a bolt of an arm from 10-mm a carving in diameter
20 — a bolt of an arm from 8-mm a carving in diameter
21 — a bolt of the water pump
22 — a bolt of an arm of lateral fastening of the engine


*2) Put hermetic 99000-31250 on the interfaced surface of the pallet картера, having addressed to point 5 of procedure of installation.

*6) Grease with engine oil internal surfaces of the bearing.

*7) Establish the party of the bearing with flutes faced to cheeks коленвала.

*17) Put hermetic 99000-31110 on the carving party.

The rotating moment of an inhaling.

Not to use repeatedly.

To grease with engine oil.

Removal

 PERFORMANCE ORDER

  1. Remove knot of the engine from a vehicle, having addressed to Section the Engine in this Chapter.
  2. Remove coupling and a flywheel (for vehicles М/Т) or a leading disk (for vehicles А/Т). To remove coupling address to Section a coupling Cover, a disk of coupling and a flywheel In the Head Coupling. The special tool (): 09924-17811.
1 — a flywheel bolt
  1. Remove the case throttle заслонок, an inlet collector, an exhaust system collector.
  2. Remove маслосборник and a grid of the oil pump, having addressed to Razdelu Maslosbornik and a grid of the oil pump in this Chapter to remove.
  3. Remove the oil pump.
  4. Uncover cylinder heads.
  5. Uncover synchronisation chains, having addressed to Section the Cover of a chain of synchronisation in this Chapter for the purpose of dismantle.
  6. Remove directing to a synchronisation chain, натяжитель chains, regulators натяжителя, the second chain of synchronisation and the first chain of synchronisation.
  7. Remove knot of a head of the cylinder.
  8. Remove pistons and rods.
  9. Remove the position gauge коленвала (1).
1 — the position gauge коленвала
2 — the cylinder block
3 — коленвал
  1. Remove the water pump (1) and a heater exhaust pipe.
  1. Remove arms of lateral fastening of the engine (2) (right and left).
  2. Ослабьте bolts картера also remove them.
1 — the pallet картера
2 — a bolt (diameter of a carving of 10 mm)
3 — a bolt (diameter of a carving of 8 mm)
  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 and the pallet картера (1) on the place. Twirl bolts картера, having addressed to item 6 of procedure of installation.
  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: 0.10 – 0.35 mm (0.0040 – 0.0137 inches)
      • Limit: 0.42 mm (0.0165 inches)

Thickness of the persistent bearing коленвала

The size of the bearing

Thickness

The standard

2.500 mm (0.984 inches)

The bolshego size (0.125 mm (0.0049 inches))

2.563 mm (0.1009 inches)


1 — the persistent bearing
2 — a lubricant flute

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 how it has been explained above, falls outside the limits norm, переточите or replace коленвала.
  • Limit эллипсности and a neck bias коленвала: 0.01 mm (0.0004 inches)
    • эллипсность: And – In
    • Bias: and – b

Radical bearings

The general information

Radical 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 (1) has a lubricant flute (2). Establish this half with a lubricant flute in the block of cylinders.

On the bottom half of bearing the lubricant flute is absent.

Check

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

Backlash of the radical bearing коленвала

 PERFORMANCE ORDER

  1. Check up a backlash by means of a plaster solution, having executed the following procedure.
  2. Remove the pallet картера.
  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 the pallet картера (1) on the block of cylinders. Fasten bolts картера, observing последовательност. Fasten bolts картера with the specified rotating moment.
    • The rotating moment of an inhaling:
      • Bolt картера from 10-mm a carving in diameter (0.394 inches) (): 60 Н•м (6.0 kg th, 43.5 pound on foot)
      • Bolt картера from 8-mm a carving in diameter (0.315 inches) (b): 27 Н•м (2.7 kg th, 19.5 pound on foot)

Do not turn коленвал with a plaster solution inside.


1 — the pallet картера
2 — a bolt (diameter of a carving of 10 mm)
3 — a bolt (diameter of a carving of 8 mm)
  1. Remove the pallet картера 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 (0.00984 inches). Having chosen the new bearing, check up a backlash repeatedly.
    • Bearing backlash коленвала
      • Norm: 0.032 – 0.052 mm (0.0013 – 0.0020 inches)
      • Limit: 0.060 mm (0.0023 inches)

Choice of radical 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 and the pallet картера for any reason choose new standard bearings to establish them according to numbers printed on new коленвале, and-or the letters printed on the new pallet картера.

 PERFORMANCE ORDER

  1. At first check up diameter of a neck. As is shown in drawing, on cheeks коленвала №2 (3) figures are printed. Three types of figures (1, 2 and 3) represent the next diameters of necks.

Technical characteristics of necks коленвала

The printed figures

Diameter of necks

1

58.000 – 58.0060 mm (2.2835 – 2.2836 inches)

2

57.9940 – 57.9999 mm (2.2833 – 2.2834 inches)

3

57.9880 – 57.9939 mm (2.2830 – 2.2832 inches)

  1. The figures printed on a cheek №2 коленвала, designate diameters of necks noted стрелочкой in drawing, accordingly. For example, the printed figure "1" specifies that diameter of a corresponding neck makes 58.000 – 58.0060 mm (2.2835 – 2.2836 inches).
1 — the pulley party коленвала
2 — the flywheel party
3 — a cheek коленвала
  1. Further check up internal diameter картера (a bearing cover) without the bearing. On the pallet картера 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

62.0000 – 62.0060 mm (2.4409 – 2.4411 inches)

IN

62.0061 – 62.0120 mm (2.4412 – 2.4414 inches)

WITH

62.0121 – 62.0180 mm (2.4415 – 2.4416 inches)

  1. The letters printed on the pallet картера, specify for internal diameter картера, noted by an arrow in drawing, accordingly. For example, the letter "And", printed on a cover of the bearing №2, specifies that internal diameter of a cover of the bearing №2 makes 62.0000 – 62.0060 mm (2.4409 – 2.4411 inches).
1 — a cover of the bearing №1
2 — a cover of the bearing №2
3 — a cover of the bearing №3
4 — a cover of the bearing №4
5 — a cover of the bearing №5
6 — the pulley party коленвала
7 — the flywheel party
  1. 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

1.990 – 1.994 mm (0.07835 – 0.07850 inches)

The black

1.993 – 1.997 mm (0.07847 – 0.07862 inches)

Colourless (there is no paint)

2.996 – 2.000 mm (0.07859 – 0.07874 inches)

The yellow

1.999 – 2.003 mm (0.07870 – 0.07885 inches)

The blue

2.002 – 2.006 mm (0.07882 – 0.07897 inches)


1 — a paint
  1. On the figure printed on a cheek коленвала №2 and letters, printed on the pallet картера, 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 №2 1, and the letter printed on the pallet картера, – "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 pallet картера (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. Check up a bearing backlash at the new chosen bearing of the standard size, having addressed to subsection Radical bearings коленвала in this Section. 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 (0.009842 inches))

The bearing of the smaller size on 0.25 mm (0.009842 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

2.115 – 2.119 mm (0.08327 – 0.08342 inches)

Black and red

2.118 – 2.122 mm (0.08339 – 0.08354 inches)

Only the red

2.121 – 2.125 mm (0.08351 – 0.08366 inches)

Yellow and red

2.124 – 2.128 mm (0.08363 – 0.08377 inches)

Blue and red

2.127 – 2.131 mm (0.08374 – 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: 57.7439 – 57.7560 mm (2.2734 – 2.2738 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 pallet картера, 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.

Bearing technical characteristics коленвала the smaller size

The measured diameter of a neck

57.7500 – 57.7560 mm (2.2737 – 2.2738 inches)

57.7440 – 57.7499 mm (2.2734 – 2.2736 inches)

57.7380 – 57.7439 mm (2.2732 – 2.2733 inches)

The letters printed on the pallet картера

AND

Green and red

Black and red

Only the red

IN

Black and red

Only the red

Yellow and red

WITH

Only the red

Yellow and red

Blue and red

Bearings of the smaller size to installation

Asterisk of the oil pump

Check up a teeth of an asterisk (2) about deterioration or damage. If any damage or deterioration is revealed, replace коленвал (1).

Chain of a drive of the oil pump

Check up a chain of a drive of the oil pump about deterioration or damage.

Back oil consolidation

Attentively check up back oil consolidation about deterioration or damage. If its edge is worn out or damaged, replace it.

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 (0.0024 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. 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 standard

83.970 – 83.990 mm (3.3059 – 3.3066 inches)

The size is more on 0.50 mm (0.02 inches)

84.470 – 84.480 mm (3.3256 – 3.3263 inches)

  1. With the help a micromeasure measure diameter of the piston.
    • Calculate, what internal diameter of the cylinder is necessary for chiseling, as follows:
      • 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)
1 — 26.5 mm (1.04 inches)
  1. Chisel and хонингуйте the cylinder to settlement parametres.

Before to chisel, establish the pallet картера and fasten according to technical requirements to avoid deformation of internal diameters of bearings.

  1. Measure a backlash of the piston after хонингования.

The lock valve

Check up the lock valve on presence засора and formations of the got stuck lumps.

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, картер (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.
  • Clean the interfaced surface of the block of cylinders and the pallet картера, remove oil, old hermetic and a dust from the interfaced surface.

 PERFORMANCE ORDER

  1. Establish radical bearings коленвала (4) in the block of cylinders (1). One of two halves of the bearing коленвала has an oil flute (3). Establish this half with an oil flute in the block of cylinders, and other half without an oil flute in the pallet картера. Be convinced that both halves are noted by the same paint.
  2. Establish ring consolidation (2) in the block of cylinders.
1 — the block of cylinders
2 — ring consolidation
3 — an oil flute
4 — bearings коленвала
5 — a pin
  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. Place коленвал (1) with a chain of a drive of the oil pump in the block of cylinders. Be convinced that on a plate of the gauge of position коленвала (2) there are no metal particles and damage.
  1. Put hermetic "And" on the interfaced surface of the pallet картера (1). "And": hermetic 99000-31250.
"And" — 3 mm (0.12 inches)
b — 2 mm (0.08 inches)
1 — a pallet surface картера
2 — the bearing
  1. Establish the pallet картера (1) in the cylinder block. Having greased with engine oil all bolts картера ((1) – (22)), fasten them gradually, as follows.
  1. Tighten bolts (1) – (10) to 42 Н•м (4.2 kg th, 30.5 pound on foot) according to digital order.
  1. Ослабьте bolts (1) – (10) until the rotating moment of an inhaling will not decrease to 0 (zero) as it should be the return to fastening.
  2. Just as in point 7, fasten them to 42 Н•м (4.2 kg th, 30.5 pound on foot).
  3. In the same way, as in point 7, fasten them with the specified rotating moment.
  4. Fasten bolts (11) – (22) with the specified rotating moment according to their digital order.
    • The rotating moment of an inhaling:
      • Bolt картера with a carving of 10 mm in diameter (1) – (10)
        • (): 60 Н•м (6.0 kg th, 43.5 pound on foot)
        • (b): 27 Н•м (2.7 kg th, 19.5 pound on foot)

Having fastened bolts картера, be convinced that коленвал rotates smoothly when it you turn a hand.

  1. Establish back oil consolidation (1) by means of a plastic hammer and special tools.
    • The special tool
      • (): 09911-97710
      • (): 09911-97811
1 — back oil consolidation
2 — the party коленвала
3 — the party of oil consolidation
  1. Establish the position gauge коленвала (1) and fix its plaits of wires an arm. The rotating moment of an inhaling: a bolt of the gauge of position коленвала (): 6 Н•м (0.6 kg th, 4.5 pound on foot).
1 — the position gauge коленвала
2 — the cylinder block
3 — коленвал
  1. Establish a flywheel (for vehicles М/Т) or a leading disk (for vehicles А/Т). By means of the special tool fix a flywheel or a leading disk and, having greased with hermetic, fasten bolts of a flywheel or a leading disk (1) according to technical requirements.
    • "And": hermetic 99000-31110
      • The special tool (): 09924-17811
    • The rotating moment of an inhaling:
      • Bolt of a flywheel or leading disk (): 70 Н•м (7.0 kg th, 51.0 pound on foot)
  1. Establish arms of lateral fastening of the engine (1) (right and left). Fasten bolts of arms with the specified rotating moment. The rotating moment of an inhaling: a bolt of an arm of lateral fastening of the engine (d) — 55 Н•м (5.5 kg th, 40.0 pound on foot).
  1. Establish the water pump (2) and an exhaust pipe of a heater (3), having addressed to Sections the Water pump and Hoses or water pipes of system of cooling in the Head engine Cooling.
  2. Establish pistons and rods, having addressed to Section Pistons, piston rings, rods and cylinders in this Chapter.
  3. Establish the oil pump, having addressed to Section the Oil pump in this Chapter.
  4. Establish knot of a head of the cylinder in the cylinder block, having addressed to Section Valves and a head of the block of the cylinder in this Chapter.
  5. Establish synchronisation chains, натяжитель the synchronisation chains, directing chains of synchronisation, an asterisk of a chain of synchronisation, a cover of a chain of synchronisation, a pulley коленвала, a pulley of the water pump etc. Address to Section the First chain of synchronisation and натяжитель chains in this Chapter.
  6. Establish a grid of the oil pump and маслосборник.
  7. Establish coupling on a flywheel (for vehicles М/Т). Address to Section a coupling Cover, a disk of coupling and a flywheel in the Head Coupling to establish coupling.
  8. Establish engine knot in a vehicle, having addressed to Section the Engine in this Chapter.