2001 SUZUKI GRAND VITARA engine

ENGINE MECHANICAL (H27 ENGINE) 6A2-31
Main bearing clearance
Check clearance by using gaging plastic (1) according to the fol-
lowing procedure.
1) Remove crankcase.
2) Clean bearings and main journals.
3) Place a piece of gaging plastic to full width of bearing (paral-
lel to crankshaft) on journal, avoiding oil hole.
4) Install crankcase to cylinder block.
Tighten crankcase bolts, following sequence in the figure.
Tighten crankcase bolts to specified torque.
Tightening torque
Thrust and journal bearing cap bolt (8 mm thread diame-
ter) (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
Thrust and journal bearing cap bolt (10 mm thread diame-
ter) (b) :
27 N·m (2.7 kg-m, 19.5 lb-ft)
5) Remove crankcase and using scale (2) on gaging plastic (1)
envelop, measure gaging plastic (1) width at its widest point.
If clearance exceeds its limit, replace bearing. Always
replace both upper and lower inserts as a unit.
A new standard bearing may produce proper clearance. If
not, it will be necessary to regrind crankshaft journal for use
of 0.25 mm undersize bearing.
After selecting new bearing, recheck clearance.
Main Bearing Clearance
Standard : 0.024 – 0.044 mm (0.0009 – 0.0017 in.)
Limit : 0.060 mm (0.0023 in.)
NOTE:
Tighten 10 mm thread diameter bolts first (following the
order shown in the figure) then tighten 8 mm thread
diameter bolts.
NOTE:
Do not rotate crankshaft while gaging plastic is installed.
1. Lower crankcase
2. Bolt (10 mm thread diameter)
3. Bolt (8 mm thread diameter)
4. Long bolt (8 mm thread diameter)

6A2-32 ENGINE MECHANICAL (H27 ENGINE)
Selection of main bearings
•STANDARD BEARING :
If bearing is in malcondition, or bearing clearance is out of
specification, select a new standard bearing according to the
following procedure and install it.
1) First check journal diameter. As shown in the figure, crank
web has stamped numbers and alphabet at the center.
3 kinds of numbers (“1”, “2” and “3”) represent the following
journal diameters.
Journal diameter :
2) Next, check crankcase (bearing cap) bore diameter without
bearing. On lower surface of lower crankcase 4 alphabets
are stamped as shown in the figure.
3 kinds of alphabets (A, B and C) represent the following cap
bore diameters.
Main bearing cap bore diameter :Stamped numbers Journal diameter
165.000 – 65.006 mm
(2.5590 – 2.5593 in.)
264.994 – 65.000 mm
(2.5588 – 2.5590 in.)
364.988 – 64.994 mm
(2.5586 – 2.5588 in.)
1. Crankshaft
2. Crank web
Stamped numbersBearing cap bore diameter
(without bearing)
A70.000 – 70.006 mm
(2.7559 – 2.7561 in.)
B70.006 – 70.012 mm
(2.7561 – 2.7563 in.)
C70.012 – 70.018 mm
(2.7563 – 2.7566 in.)
1. Crankshaft pulley side
2. Stamped alphabets
3. No.1 bearing
4. No.2 bearing
5. No.3 bearing
6. No.4 bearing

ENGINE MECHANICAL (H27 ENGINE) 6A2-33
3) There are 5 kinds of standard bearings differing in thickness.
To distinguish them, they are painted in following colors at
the position as shown in the figure.
Each color indicates the following thickness at the center of
bearing.
Standard size Main bearing thickness :
4) From number stamped on crank webs at its center and
alphabets stamped on crankcase lower side, determine new
standard bearing to be installed to journal, by referring to
table shown below.
For example, if number stamped on crank webs is “1” and
alphabet stamped on crankcase is “B”, install a new standard
bearing painted in “Black” to its journal.
New standard size bearing specification :
5) Using gaging plastic, check bearing clearance with newly
selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing
and recheck clearance.
6) When replacing crankshaft or cylinder block and crank case
due to any reason, select new standard bearings to be
installed by referring to number stamped on new crankshaft
or alphabets stamped on new crankcase lower side.Color painted Bearing thickness
Black2.496 – 2.500 mm
(0.0983 – 0.0984 in.)
Colorless (no paint)2.499 – 2.503 mm
(0.0984 – 0.0985 in.)
Yellow2.502 – 2.506 mm
(0.0985 – 0.0986 in.)
Blue2.505 – 2.509 mm
(0.0986 – 0.0987 in.)
Pink2.508 – 2.512 mm
(0.0987 – 0.0988 in.)
1. Paint
Number stamped on crank web
(Journal diameter)
123
Alphabet stamped
on lower crankcase
(Cap bore dia.)A Black Colorless Yellow
B Colorless Yellow Blue
C Yellow Blue Pink

6A2-34 ENGINE MECHANICAL (H27 ENGINE)
•UNDERSIZE BEARING (0.25 mm) :
0.25 mm undersize bearing is available, in 5 kinds varying in
thickness.
To distinguish them, each bearing is painted in the following
colors at such position as shown in the figure.
Each color represents the following thickness at the center of
bearing.
Under size main bearing thickness
•If necessary, regrind crankshaft journal and select undersize
bearing to use with it as follows.
1) Regrind journal to the following finished diameter.
Finished journal diameter :
64.738 – 64.756 mm (2.5487 – 2.5494 in.)
2) Using micrometer, measure reground journal diameter.
Measurement should be taken in 2 directions perpendicular
to each other in order to check for out-of-round.
3) Using journal diameter measured above and alphabets
stamped on lower crankcase, select an undersize bearing by
referring to table given below.
Check bearing clearance with newly selected undersize
bearing.
Under size bearing specification :Color painted Bearing thickness
Black & Red2.621 – 2.625 mm
(0.1032 – 0.1033 in.)
Red2.624 – 2.628 mm
(0.1033 – 0.1034 in.)
Red & Yellow2.627 – 2.631 mm
(0.1034 – 0.1035 in.)
Red & Blue2.630 – 2.634 mm
(0.1035 – 0.1036 in.)
Red & Pink2.633 – 2.637 mm
(0.1036 – 0.1037 in.)
1. Paint
Measured journal diameter
64.750 – 64.756 mm
(2.5492 – 2.5494 in.)64.744 – 64.750 mm
(2.5489 – 2.5492 in.)64.738 – 64.744 mm
(2.5487– 2.5489 in.)
Alphabets stamped on
lower crankcaseA Black & Red Red Red & Yellow
B Red Red & Yellow Red & Blue
C Red & Yellow Red & Blue Red & Pink

ENGINE MECHANICAL (H27 ENGINE) 6A2-35
INSPECTION
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must
also be rebored at the same time.
2) Select oversized piston according to amount of cylinder
wear.
Oversize piston specification :
3) Using micrometer, measure piston diameter.
4) Calculate cylinder bore diameter to be rebored as follows.
D = A + B – C
Cylinder bore diameter to be rebored
A : Piston diameter as measured
B : Piston clearance = 0.02 – 0.04 mm (0.0008 – 0.0015 in.)
C : Allowance for honing = 0.02 mm (0.0008 in.)
5) Rebore and hone cylinder to calculated dimension.
6) Measure piston clearance after honing.Size Piston diameter
Standard 87.970 – 87.990 mm (3.4634 – 3.4642 in.)
Oversize 0.25 88.220 – 88.240 mm (3.4732 – 3.4740 in.)
Oversize 0.50 88.470 – 88.490 mm (3.4831 – 3.4839 in.)
NOTE:
Before reboring, install all main bearing caps in place
and tighten to specification to avoid distortion of bearing
bores.

6A2-36 ENGINE MECHANICAL (H27 ENGINE)
Special Tool
09911-97810 09913-75510 09915-47310 09915-64510
Oil seal installer Bearing installer Oil filter wrench Compression gauge
09915-64530 09915-67010 09915-67310 09915-77310
Compression gauge hose Compression gauge
attachment (c)Vacuum gauge Oil pressure gauge
09916-14510 09916-14910 09916-34541 09916-37810
Valve lifter Valve lifter attachment Reamer handle Reamer (6 mm)
09916-38210 09916-44910 09916-58210 09916-77310
Reamer (11 mm) Valve guide remover Valve guide installer han-
dlePiston ring compressor

ENGINE MECHANICAL (H27 ENGINE) 6A2-37
09916-84511 09917-68221 09917-87810 09917-98221
Forceps Camshaft lock holder Valve guide installer Valve stem seal installer
09918-08210 09919-28610 09924-17810 09926-58010
Vacuum gauge hose joint Protective sleeve Flywheel holder Bearing puller attachment
09944-36011 09911-97710 09915-76510
Steering wheel remover Oil seal guide Oil pressure gauge
attachment

6A2-38 ENGINE MECHANICAL (H27 ENGINE)