Suzuki Grand Vitara JB416 / JB420. Manual - part 94

1D-44 Engine Mechanical: For M16A Engine with VVT

Pistons, Piston Rings, Connecting Rods and 
Cylinders Disassembly and Assembly

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Disassembly

1) Using piston ring expander, remove two 

compression rings (Top and 2nd) and oil ring from 
piston.

2) Remove piston pin from connecting rod as follows.

a) Ease out piston pin circlips (1), as shown.

b) Force piston pin out.

Assembly

1) Decarbonize piston head and ring grooves using a 

suitable tool.

2) Install piston pin to piston (1) and connecting rod (2):

a) After applying engine oil to piston pin and piston 

pin holes in piston and connecting rod.

b) Fit connecting rod as shown in the figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).

NOTE
Circlip should be installed with its cut part 
facing as shown in the figure. Install so that 
circlip end gap comes within such range as 
indicated by arrow.

 

3) Install piston rings to piston:

• As indicated in the figure, 1st and 2nd rings have 

“T” mark (4) respectively. When installing these 
piston rings to piston, direct marked side of each 
ring toward top of piston.

• 1st ring (1) differs from 2nd ring (2) in thickness, 

shape and color of surface contacting cylinder 
wall.
Distinguish 1st ring from 2nd ring by referring to 
the figure.

• When installing oil ring (3), install spacer first and 

then two rails.

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Engine Mechanical: For M16A Engine with VVT 1D-45

4) After installing three rings (1st, 2nd and oil rings), 

distribute their end gaps as shown in the figure.

Cylinders, Pistons and Piston Rings Inspection

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Cylinder
Visual inspection
Inspect cylinder walls for scratches, roughness or ridges 
which indicate excessive wear. If cylinder bore is very 
rough or deeply scratched, or ridged, rebore cylinder and 
use over size piston.

Cylinder bore diameter, taper and out-of-round
Using a cylinder gauge (1), measure cylinder bore in 
thrust and axial directions at two positions (“a” and “b”) 
as shown in the figure.
If any of the following conditions is noted, rebore 
cylinder.

1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions 

exceeds taper limit.

3) Difference between thrust and axial measurements 

exceeds out-of-round limit.

Cylinder bore diameter
Standard: 78.00 – 78.014 mm (3.0709 – 3.0714 in.)
Limit: 78.114 mm (3.075 in.)

Cylinder taper and out-of-round
Limit: 0.10 mm (0.004 in.)

NOTE
If any one of four cylinders has to be rebored, 
rebore all four to the same next oversize. 
This is necessary for the sake of uniformity 
and balance.

 

Piston
Visual inspection
Inspect piston for faults, cracks or other damages.
Damaged or faulty piston should be replaced.

Piston diameter
As indicated in the figure, piston diameter should be 
measured at a position 19.5 mm (0.77 in.) (“a”) from 
piston skirt end in the direction perpendicular to piston 
pin.

Piston diameter specification
Standard size: 77.953 – 77.968 mm (3.0690 – 3.0696 
in.)
Standard size (new one (with coating)): 77.969 – 
77.984 mm (3.0696 – 3.0702 in.)
Oversize (0.50 mm (0.0196 in.)): 78.453 – 78.468 mm 
(3.0887 – 3.0893 in.)

1. Front mark

4. Oil ring upper rail gap

2. 1st ring end gap

5. Oil ring lower rail gap

3. 2nd ring end gap and oil ring spacer gap

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“a”: 50 mm (1.96 in.)

“b”: 95 mm (3.74 in.)

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1D-46 Engine Mechanical: For M16A Engine with VVT

Piston clearance
Measure cylinder bore diameter and piston diameter to 
find their difference which is piston clearance. Piston 
clearance should be within specification as follows. If it is 
out of specification, rebore cylinder and use oversize 
piston.

NOTE
Cylinder bore diameters used here are 
measured in thrust direction at two positions.

 

Piston clearance
Standard: 0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Standard (piston with coating (new one)): 0.016 – 
0.045 mm (0.0006 – 0.0018 in.)
Limit: 0.161 mm (0.0065 in.)

Ring groove clearance
Before checking, piston grooves must be clean, dry and 
free of carbon deposits.
Fit new piston ring (1) into piston groove, and measure 
clearance between ring and ring land by using thickness 
gauge (2). If clearance is out of specification, replace 
piston.

Ring groove clearance

Piston Ring
Piston ring end gap
To measure end gap, insert piston ring (2) into cylinder 
bore and then measure the gap by using thickness 
gauge (1).
If measured gap exceeds limit, replace ring.

NOTE
Decarbonize and clean top of cylinder bore 
before inserting piston ring.

 

Piston ring end gap

“a”: 19.5 mm (0.77 in.)

Standard

Limit

Top ring

0.03 – 0.07 mm

 (0.0012 – 0.0028 in.)

0.12 mm (0.0047 in.)

2nd ring

0.02 – 0.06 mm

 (0.0008 – 0.0024 in.)

0.10 mm (0.0039 in.)

Oil ring

0.03 – 0.17 mm

 (0.0012 – 0.0067 in.)

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Item

Standard

Limit

Top ring

0.20 – 0.35 mm

 (0.0079 – 0.0138 in.)

0.7 mm (0.0276 in.)

2nd ring

0.35 – 0.50 mm

 (0.0138 – 0.0197 in.)

1.0 mm (0.0394 in.)

Oil ring

0.20 – 0.70 mm

 (0.0079 – 0.0276 in.)

1.2 mm (0.0472 in.)

“a”: 120 mm (4.72 in.)

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Engine Mechanical: For M16A Engine with VVT 1D-47

Piston Pins and Connecting Rods Inspection

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Piston Pin
Visual inspection
Check piston pin, connecting rod small end bore and 
piston bore for wear or damage, paying particular 
attention to condition of small end bore bush. If pin, 
connecting rod small end bore or piston bore is badly 
worn or damaged, replace pin, connecting rod and/or 
piston.

Piston pin clearance
Check piston pin clearance in small end and piston. 
Replace connecting rod and/or piston if its small end is 
badly worn or damaged or if measured clearance 
exceeds limit.

Piston pin clearance in connecting rod small end
Standard: 0.003 – 0.014 mm (0.0001 – 0.0006 in.)
Limit: 0.05 mm (0.00020 in.)

Piston pin clearance in piston
Standard: 0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Limit: 0.05 mm (0.0020 in.)

Small-end bore
20.003 – 20.011 mm (0.7875 – 0.7878 in.)

Piston pin dia.
19.997 – 20.000 mm (0.7873 – 0.7874 in.)

Piston bore
20.006 – 20.014 mm (0.7876 – 0.7880 in.)

Connecting Rod
Big-end side clearance
Check big-end of connecting rod for side clearance, with 
rod fitted and connected to its crank pin in the normal 
manner. If measured clearance is found to exceed its 
limit, replace connecting rod.

Big-end side clearance
Standard: 0.25 – 0.40 mm (0.0098 – 0.0157 in.)
Limit: 0.55 mm (0.0217 in.)

Connecting rod alignment
Mount connecting rod on aligner to check it for bow and 
twist. If measured value exceeds the limit, replace it.

Connecting rod alignment
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)

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