1D-66 Engine Mechanical: For J20 Engine

For J20 Engine

General Description
Engine Construction Description
S5JB0A1421001
The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft)
valve mechanism arranged for “V” type valve configuration consisting of 16 valves (4 valves/one cylinder). The double
overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through timing chains, and no push
rods are provided in the valve train system.
Engine Mechanical: For J20 Engine 1D-67

I5JB0A142069-02
1D-68 Engine Mechanical: For J20 Engine

Air Cleaner Element Introduction

S5JB0A1421002
This air cleaner element is dry type. Remember that it needs cleaning according to “Air Cleaner Filter Inspection and
Cleaning: For J20 Engine”.

IMT (Intake Manifold Tuning) System

S5JB0A1421003
Description

2 3

4 5
I5JB0A142062-01
IMT (Intake manifold tuning) system consists of the following items:
• IMT valve (5) fixed on intake manifold (1)
• IMT valve actuator (4)
• IMT vacuum solenoid valve (2)
• Vacuum tank (3)
Vacuum tank contains the one way check valve (6) to maintain negative pressure constantly regardless of variation in
the intake manifold pressure.
Vacuum tank, therefore, supplies IMT vacuum solenoid valve actuator with stable negative pressure in whole engine
speed ranges.
 Engine Mechanical: For J20 Engine 1D-69

3 3

[A]

[B] [A + B]

4 4
min-1 min-1
(rpm) (rpm)

[A]: [B]:

I5JB0A142063-02

[A]: IMT valve open 1. IMT valve 3. Engine torque

[B]: IMT valve closed 2. Intake manifold 4. Engine speed

IMT (Intake manifold tuning) system varies effective length of intake pipe by opening and closing IMT valve in order to
improve air volumetric efficiency.
As intake valve in cylinder head is opened and closed repeatedly, intake air pulsation always exists. If intake valve is
opened when air pressure is momentarily maximum, intake air volumetric efficiency is increased. This momentary
maximum air pressure depends on effective intake pipe length.

When IMT valve is fully open [A]:

The effective intake pipe length is shorter. Engine torque between middle and high engine speed ranges is improved,
whilst it drops between low and middle engine speed ranges.

When IMT valve is totally closed [B]:

The effective intake pipe length is longer. Engine torque between middle and high engine speed ranges drops, while it
is improved between low and middle ranges.

IMT system utilizes this characteristic of engine. IMT valve is closed between low and middle engine speed ranges,
and opened between middle and high engine speed ranges.
In this way, engine torque is improved in whole engine speed ranges.
1D-70 Engine Mechanical: For J20 Engine

System Operation
IMT vacuum solenoid valve open:
When IMT vacuum solenoid valve is OFF, the actuator side of IMT vacuum solenoid valve is lead to relief port. Under
this condition, the negative pressure is not applied to IMT valve actuator. The IMT valve, therefore, is totally opened
due to the force of return spring in IMT valve actuator.
The effective intake pipe length, therefore, becomes shorter.
IMT valve closed:
When IMT vacuum solenoid valve is ON, the actuator side of IMT vacuum solenoid valve is lead to vacuum tank.
Under this condition, the negative pressure of vacuum tank is applied to IMT valve actuator. The IMT valve, therefore,
is totally closed because the return spring in IMT valve actuator is compressed due to the negative pressure.
The effective intake pipe length, therefore, becomes longer.

Diagnostic Information and Procedures

Compression Check 7) Disconnect fuel injector wire harness at the coupler.
S5JB0A1424001
Check compression pressure on all 4 cylinders as 8) Install special tool (Compression gauge) into spark
follows: plug hole.
1) Warm up engine. Special tool
2) Stop engine after warming up. (A): 09915–64512
(B): 09915–64530
NOTE (C): 09915–67010
After warming up engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake and block drive wheels.

3) Remove engine cover.

4) Disconnect ignition coil couplers.
5) Disconnect ignition coils (1).
6) Remove all spark plugs (2).
I5JB0A142001-01

9) Disengage clutch (to lighten starting load on engine)

for M/T vehicle, and depress accelerator pedal all
the way to make throttle fully open.

I2RH01140002-01

I2RH01140004-01
 Engine Mechanical: For J20 Engine 1D-71

10) Crank engine with fully charged battery, and read the Engine Vacuum Check
highest pressure on compression gauge. S5JB0A1424002
The engine vacuum that develops in the intake line is a
NOTE good indicator of the condition of the engine. The
vacuum checking procedure is as follows:
• For measuring compression pressure,
1) Warm up engine to normal operating temperature
crank engine at least 250 rpm by using
and make sure that engine idle speed is within
fully charged battery.
specification.
• If measuring compression pressure is
lower than limit value, check installation NOTE
condition of special tool. If it is properly. After warming up engine, place transmission
gear shift lever in “Neutral” (shift selector
Compression pressure
lever to “P” range for A/T model), and set
Standard: 1400 kPa (14.0 kg/cm2, 199.0 psi)
parking brake and block drive wheels.
Limit: 1100 kPa (11.0 kg/cm2, 158.0 psi)
Max. difference between any two cylinders: 100 2) Stop engine and remove engine cover.
kPa (1.0 kg/cm2, 14.2 psi)
3) Disconnect vacuum hose (1) from vacuum pipe.
11) Carry out Steps 8) through 10) on each cylinder to 4) Connect special tools (vacuum gauge and hose
obtain 4 readings. joint) to vacuum hose of intake manifold side.
12) After checking, install spark plugs (2) and ignition
Special tool
coils (1).
(A): 09915–67311
(B): 09918–08210
(C): 09355–35754–600 Hose, SUZUKI GENUINE
PARTS
(D): 09367–04002 3-way joint, SUZUKI GENUINE
PARTS

(A)

(D)
(B)
I2RH01140002-01

13) Install ignition coil couplers.

14) Connect injector wire harness at coupler.
15) Install engine cover.
(C)
I5JB0A142002-01

5) Start engine and run engine at specified idle speed,

and read vacuum gauge. Vacuum should be within
specification.
Vacuum specification
52.6 – 65.8 kPa (40 – 50 cmHg, 15.7 – 19.7 in.Hg)
at specified idle speed
6) After checking, remove special tools.
7) Connect vacuum hose to vacuum pipe.
8) Install engine cover.
1D-72 Engine Mechanical: For J20 Engine

Valve Lash (Clearance) Inspection 5) Check valve lashes with thickness gauge (4)
S5JB0A1424003 according to the following procedure.
1) Remove negative cable at battery. a) Check valve lashes of cylinder No.1.
2) Remove cylinder head cover referring to “Cylinder b) Turn crankshaft pulley by 180q clockwise.
Head Cover Removal and Installation: For J20
Engine”. c) Check valve lashes of cylinder No.3.
3) Using 17 mm wrench, turn crankshaft pulley (1) d) In the same manner as b) – c), check valve
clockwise until index (2) of cylinder block and index lashes of cylinder No.4 then cylinder No.3.
(3) of crankshaft pulley (1) are aligned. If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.
4) Check whether cam position (1) of No.1 cylinder is at
the specified position [A] as shown in figure. Valve clearance specification
If cam position is [B], locate cam position to [A] by When cold (Coolant When hot (Coolant
turning crankshaft one rotation. temperature is 15 – temperature is 60 –
25 qC (59 – 77 qF)) 68 qC (140 – 154 qF))
[A] 1 0.18 – 0.22 mm 0.21 – 0.27 mm
Intake
(0.007 – 0.009 in.) (0.008 – 0.011 in.)
0.28 – 0.32 mm 0.30 – 0.36 mm
Exhaust
(0.011 – 0.013 in.) (0.012 – 0.014 in.)

[B]
1

I5JB0A142064-01

[A]: TDC in compression for No.1 cylinder

[B]: TDC in exhaust for No.1 cylinder

I5JB0A142065-01
 Engine Mechanical: For J20 Engine 1D-73

Replacement of Shim c) Hold down the tappet so as not to contact the

1) Close the valve whose shim (2) is to be replaced by shim by installing special tool on camshaft
turning crankshaft, then turn tappet (3) till its cut housing with housing bolt (1) tighten housing
section (1) faces inside as shown in the figure. bolts to specified torque.
Special tool
(A): 09916–66510
Tightening torque
Camshaft housing bolts (a): 11 N˜m (1.1 kgf-
m, 8.0 lb-ft) for tightening of special tool

I2RH0B140006-01

2) Lift down the valve by turning crankshaft to 360q.

3) Hold tappet at that position using special tool as
follows.
a) Remove its housing bolts.
I3RM0A140005-01
b) Check housing No. and select special tool
corresponding to housing No., referring to 4) Turn camshaft by approximately 90q clockwise and
“Special tool selection table”. remove shim (3).

Special tool selection table

! WARNING
No. on camshaft Embossed mark on Never put in the hand between camshaft and
housing special tool tappet.
I2, I3, I4, I5 IN
E2, E3, E4, E5 EX

I2RH0B140013-01
I5JB0A142066-01
1. Special tool 2. Magnet
A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
1D-74 Engine Mechanical: For J20 Engine

5) Using a micrometer (2), measure the thickness of 7) Install new shim facing shim No. side with tappet.
the removed shim (1), and determine replacement
shim by calculating the thickness of new shim with
the following formula and table.
Shim thickness specification
Intake side:
A = B + C – 0.20 mm (0.008 in.)
Exhaust side:
A = B + C – 0.30 mm (0.012 in.)
A: Thickness of new shim
B: Thickness of removed shim I2RH0B140015-01
C: Measured valve clearance 8) Lift valve by turning crankshaft counterclockwise (in
opposite direction against above Step 4)) and
remove special tool.
Special tool
(A): 09916–66510

(A) 2

I2RH0B140014-01

For example of intake side:

When thickness of removed shim is 2.40 mm (0.094 1
in.), and measured valve clearance is 0.45 mm
(0.018 in.). I3RM0A140006-01

A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20 1. Tappet 2. Camshaft

mm (0.008 in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104 9) Install camshaft housing (1) and tighten bolts to
in.) specified torque.
6) Select new shim No. (1) with a thickness as close as Tightening torque
possible to calculated value. Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
Available new shims No. 8.0 lb-ft)
Thickness Thickness
Shim No. Shim No.
mm (in.) mm (in.)
2.175 (0.0856) 218 2.600 (0.1024) 260
2.200 (0.0866) 220 2.625 (0.1033) 263
2.225 (0.0876) 223 2.650 (0.1043) 265
2.250 (0.0886) 225 2.675 (0.1053) 268
2.275 (0.0896) 228 2.700 (0.1063) 270
2.300 (0.0906) 230 2.725 (0.1073) 273
2.325 (0.0915) 233 2.750 (0.1083) 275
2.350 (0.0925) 235 2.775 (0.1093) 278
I2RH0B140149-01
2.375 (0.0935) 238 2.800 (0.1102) 280
2.400 (0.0945) 240 2.825 (0.1112) 283 10) Turn crankshaft pulley more than 4 rotations.
2.425 (0.0955) 243 2.850 (0.1122) 285 11) Check valve clearance again after adjusting it.
2.450 (0.0965) 245 2.875 (0.1132) 288 12) After checking and adjusting all valves.
2.475 (0.0974) 248 2.900 (0.1142) 290 13) Install cylinder head cover referring to “Cylinder
2.500 (0.0984) 250 2.925 (0.1152) 293 Head Cover Removal and Installation: For J20
2.525 (0.0994) 253 2.950 (0.1161) 295 Engine”.
2.550 (0.1004) 255 2.975 (0.1171) 298
2.575 (0.1014) 258 3.000 (0.1181) 300
 Engine Mechanical: For J20 Engine 1D-75

Repair Instructions
Air Cleaner Assembly Removal and Installation Air Cleaner Filter Removal and Installation
S5JB0A1426044 S5JB0A1426002
Removal Removal
1) Disconnect breather hose (1) from air cleaner outlet 1) Remove air cleaner upper case (1) from lower case
hose (2). after hooking clamps (2) from upper case.
2) Remove air cleaner outlet hose (2). 2) Remove air cleaner filter.
3) Disconnect MAF sensor connector (3).
4) Remove air cleaner case (4). 1

1
2
I5JB0A142004-01

4
Installation
I5JB0A142003-01 Reverse removal procedure for installation.

Installation Air Cleaner Filter Inspection and Cleaning

1) Install air cleaner case (4). S5JB0A1426003

2) Connect MAF sensor connector (3). Inspection

3) Install air cleaner outlet hose (2). Check air cleaner filter for dirt.
4) Connect breather hose (1) to air cleaner outlet hose
(2). Cleaning
Blow off dust by compressed air from air outlet side of
3 element.

4
I5JB0A142003-01

I2RH01140007-01
1D-76 Engine Mechanical: For J20 Engine

Throttle Body and Intake Manifold Components

S5JB0A1426007

I5JB0A142005-01

1. Intake manifold 4. Electric throttle body assembly

: Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is
found, replace it with new one.
2. O-ring : Do not reuse.
3. MAP sensor

Throttle Body On-Vehicle Inspection 3) Disconnect breather hose (1) from air cleaner outlet
S5JB0A1426045 hose (2).
Check electric throttle body assembly referring to
“Throttle Valve Operation Check” and “Electric Throttle 4) Disconnect air cleaner outlet hose (2) from air
Body Assembly Operation Check” under “Electric cleaner case and electric throttle body assembly.
Throttle Body Assembly On-Vehicle Inspection in
2
Section 1C”.

Electric Throttle Body Assembly Removal and

Installation
S5JB0A1426046

Removal
1) Disconnect negative cable at battery.
1
2) Drain coolant referring to “Cooling System Draining I5JB0A142006-01
in Section 1F”.
5) Disconnect engine coolant hoses (1) from electric
throttle body assembly (2).
 Engine Mechanical: For J20 Engine 1D-77

6) Disconnect connector (3) from electric throttle body 9) Perform calibration of electric throttle body assembly
assembly. referring to “Electric Throttle Body System
Calibration in Section 1C” if replaced.
1

Throttle Body Cleaning

S5JB0A1426010
Clean electric throttle body assembly referring to
“Throttle Valve Operation Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection in Section 1C”.

Intake Manifold Removal and Installation

S5JB0A1426012

! CAUTION
2 3
I5JB0A142007-01
Never disassemble intake manifold.
7) Remove electric throttle body assembly from intake Disassembly will spoil its original
manifold. performance. If faulty condition is found,
replace it with new one.
Installation
1) Clean mating surfaces, and install new throttle body Removal
gasket to intake manifold. 1) Disconnect negative cable at battery.
2) Install electric throttle body assembly (1) to intake 2) Drain cooling system referring to “Cooling System
manifold. Draining in Section 1F”.
3) Connect connector (2) to electric throttle body 3) Remove engine cover.
assembly securely.
4) Remove air cleaner outlet hose (1) and breather
4) Connect engine coolant hoses (3) to electric throttle hose (2).
body assembly (1).
1
3

2
I5JB0A142009-01

1 2
5) Remove electric throttle body assembly referring to
I5JB0A142008-01 “Electric Throttle Body Assembly Removal and
5) Connect air cleaner outlet hose (1) to air cleaner Installation: For J20 Engine”.
case and electric throttle body assembly. 6) Disconnect the following electric lead wires:
6) Connect breather hose (2) to air cleaner outlet hose • EVAP canister purge valve coupler (1)
(1). • MAP sensor coupler (2)
1
7) Disconnect the following hoses:
• Brake booster hose (3) from intake manifold
• PCV hose (4) from PCV valve
• Fuel pressure regulator vacuum hose (5) from
intake manifold
• Vacuum hose (6) from EVAP canister purge valve
• Vacuum hose (7) from vacuum tank
2 • EVAP canister purge hose (8) from EVAP canister
I5JB0A142009-01 purge valve
7) Refill coolant referring to “Cooling System Flush and 8) Remove EGR pipe bolt (9) from EGR pipe.
Refill in Section 1F”.
8) Connect negative cable at battery.
1D-78 Engine Mechanical: For J20 Engine

9) Remove EVAP canister purge valve bracket (10) Cylinder Head Cover Removal and Installation
form intake manifold. S5JB0A1426013
Removal
9 7 4 1) Disconnect negative cable at battery.
8
2) Remove engine cover.
3 3) Disconnect ignition coil couplers (1).
4) Remove ignition coils (4).
5) Remove oil level gauge (6).
5 6) Disconnect CMP sensor coupler (5) from cylinder
head cover.
2
7) Disconnect breather hose (2) and PCV hose (3) from
cylinder head cover (7).
10
1 6
I5JB0A142010-01 1
5
10) Remove water pump and generator drive belt
referring to “Water Pump and Generator Drive Belt
Removal and Installation (For J20 Engine) in Section 3
1J”.
11) With hose connected, detach P/S pump referring to
“P/S Pump Removal and Installation for J20 Engine
4
Model in Section 6C”.
12) Remove intake manifold and O-ring from cylinder 6
head.
2 7
I5JB0A142012-02
Installation 8) Remove PCV valve from cylinder head cover.
Reverse removal procedure for installation noting the
9) Remove cylinder head cover nuts in such order as
followings.
indicated in the figure.
• Use new intake manifold O-ring.
• Use new EGR pipe gasket. “2” “6” “4”

• Install intake manifold bolt (2) and nut (1) as shown in

figure.

“3” “5” “1”

I5JB0A142013-01

1 1

I5JB0A142011-01

• Check to ensure that all removed parts are back in

place.
Reinstall any necessary parts which have not been
reinstalled.
• Adjust water pump and generator drive belt referring
to “Water Pump and Generator Drive Belt On-Vehicle
Inspection (For J20 Engine) in Section 1J”.
• Refill cooling system referring to “Cooling System
Flush and Refill in Section 1F”.
• Upon completion of installation, turn ignition switch
ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant
leaks.
 Engine Mechanical: For J20 Engine 1D-79

Installation 7) Tighten cylinder head cover nuts in such order as

1) Install PCV valve to cylinder head cover referring to indicated in the figure a little at a time till they are
“EGR Valve Removal and Installation in Section 1B”. tightened to specified torque.
2) Remove oil, old sealant and dust from sealing • Use new seal washers.
surfaces on cylinder head and cover. Tightening torque
3) Install new cylinder head side seals (1) to cylinder Cylinder head cover nut (a): 11 N·m (1.1 kgf-m,
head. 8.0 lb-ft)
4) Apply sealant “A” to cylinder head sealing surface
“5”, (a) “1”, (a) “3”, (a)
area as shown in figure.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)

“4”, (a) “2”, (a) “6”, (a)

I5JB0A142014-01

8) Install oil level gauge (1).

9) Connect CMP sensor coupler (4).
I5JB0A142067-01
10) Connect breather hose (2) and PCV hose (3) to
5) Install new O-rings (3) and new cylinder head cover cylinder head cover.
gasket (2) to cylinder head cover (1).
4
NOTE
Be sure to check each of these parts for 3
deterioration or any damage before
installation and replace if found defective.

6) Install cylinder head cover to cylinder head.

1
2
I5JB0A142015-01

11) Install ignition coils referring to “Ignition Coil

Assembly (Including ignitor) Removal and
Installation in Section 1H”.
12) Install engine cover.
I5JB0A142068-02 13) Connect negative cable at battery.
1D-80 Engine Mechanical: For J20 Engine

Engine Mountings Components

S5JB0A1426043

7 (a)
9 (a)
2

7 (a) (a)

9 (a)

(a)

(a)

8 (a)
(a)

8 (a)
I5JB0A142016-01

1. Engine front mounting 6. Engine splash cover

2. Engine front mounting right bracket 7. Engine front mounting nut
3. Engine front mounting left bracket 8. Engine rear mounting member bolt
4. Engine rear mounting member 9. Engine front mounting bracket bolt
5. Engine rear mounting : 55 N˜m (5.5 kgf-m, 40.0 lb-ft)
 Engine Mechanical: For J20 Engine 1D-81

Engine Assembly Removal and Installation 10) Disconnect the following hoses:
S5JB0A1426019
• Brake booster hose (21) from intake manifold
Removal • Radiator inlet and outlet hoses (22) from each
1) Relieve fuel pressure according to “Fuel Pressure pipe
Relief Procedure in Section 1G”. • Heater inlet and outlet hoses (23) from each pipe
2) Disconnect negative cable at battery. • Fuel hoses (24) from fuel pipes
3) Drain engine oil referring to “Engine Oil and Filter • Purge hose (25) from purge valve
Change in Section 0B”. • Clutch oil pipe from transmission front case (For
4) Drain transmission oil referring to “Manual M/T model)
Transmission Oil Change in Section 5B”. • A/T fluid cooler hoses from radiator (For A/T
5) Drain A/T fluid referring to “A/T Fluid Change in model)
Section 5A”. 11) Disconnect A/T select cable from A/T (For A/T
6) Drain coolant referring to “Cooling System Draining model).
in Section 1F”.
7) Remove Air cleaner case referring to “Air Cleaner
Assembly Removal and Installation: For J20 19
20 27
Engine”.
18
8) Remove water pump and generator drive belt
referring to “Water Pump and Generator Drive Belt
Removal and Installation (For J20 Engine) in Section
1J”. 26

9) Disconnect the following electric wires:

• MAP sensor (1) 28

• ECT sensor (2)

29
• EGR valve (3)
• CMP sensor (4)
• EVAP canister purge valve (5)
• Ignition coil assembly (6)
• Injectors (7)
• HO2S (8)
• A/F sensor (9)
• Engine oil pressure switch (10)
3 2 4 12 8
23 11
• CKP sensor (11)
• Back up light switch (For M/T model) (12)
21
• Generator (13)
• Starting motor (14) 14

• Ground terminal 1 10

• Magnet clutch switch of A/C compressor (if 9

25
equipped) (15)
• P/S pump (16) 5
24
• Electric throttle body (17)
• Transfer actuator (18) 6

• Center differential switch (19) 17

• 4L/N switch (20)

• Each wire harness clamps
• Input shaft speed sensor (For A/T model) (26)
16 13 7 22 15
• Output shaft speed sensor (For A/T model) (27) I5JB0A142017-01
• Solenoid valve (For A/T model) (28)
• Transmission range sensor (For A/T model) (29)
1D-82 Engine Mechanical: For J20 Engine

12) For M/T model, remove shift control lever referring to 20) Remove engine rear mounting member bolts (1).
“Transmission Shift Control Lever Removal and
Installation in Section 5B”.
13) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust System Components in Section
1K”.
14) Remove front and rear propeller shafts referring to
“Propeller Shaft Removal and Installation in Section
1
3D”.
15) With hose connected, detach P/S pump from its
bracket (if equipped) referring to “P/S Pump
Removal and Installation for J20 Engine Model in
1
Section 6C”. I5JB0A142019-01

21) Before lowering engine, recheck to make sure all

! CAUTION
hoses, electric wires and cables are disconnected
Suspend removed P/S pump at a place where from engine.
no damage will be caused during removal 22) Lower engine with transmission, transfer, front
and installation of engine assembly. suspension frame and engine rear mounting
member from engine compartment.
16) With hose connected, detach A/C compressor from
its bracket (if equipped) referring to “Compressor ! CAUTION
Assembly Removal and Installation for J20 Engine
Before lowering engine, in order to avoid
Model in Section 7B”.
damage to A/C compressor and P/S pump,
! CAUTION make clearance by rising them.

Suspend removed A/C compressor at a place 23) Disconnect transmission from engine referring to
where no damage will be caused during “Manual Transmission Assembly Dismounting and
removal and installation of engine assembly. Remounting in Section 5B” or “Automatic
Transmission Unit Components in Section 5A”, if
17) Support front suspension frame and engine rear necessary.
mounting member using jack (2).
24) Remove engine with engine front mounting bracket
18) Carry out Step 1) to 12) of “Removal” under “Front (1) from engine front mounting (2), if necessary.
Suspension Frame, Stabilizer Bar and/or Bushings
Removal and Installation in Section 2B” in order to
lower engine with front suspension frame.
19) Remove front suspension frame mounting bolts (1).

1 1

2
I5JB0A142020-01

1 2 25) Remove clutch cover and clutch disk referring to

I5JB0A142018-01
“Clutch Cover, Clutch Disc and Flywheel Removal
and Installation in Section 5C”, if necessary.
 Engine Mechanical: For J20 Engine 1D-83

Installation 13) Install water pump and generator drive belt referring
1) Install clutch cover and clutch disk referring to to “Water Pump and Generator Drive Belt Removal
“Clutch Cover, Clutch Disc and Flywheel Removal and Installation (For J20 Engine) in Section 1J”.
and Installation in Section 5C”, if removed. 14) Adjust water pump and generator drive belt tension
2) Install engine with engine front mounting bracket to referring to “Water Pump and Generator Drive Belt
engine front mounting. For tightening torque, On-Vehicle Inspection (For J20 Engine) in Section
referring to “Engine Mountings Components: For J20 1J”.
Engine”, if removed. 15) Install air cleaner assembly referring to “Air Cleaner
3) Connect transmission from engine referring to Assembly Removal and Installation: For J20
“Manual Transmission Assembly Dismounting and Engine”.
Remounting in Section 5B” or “Automatic 16) Check all removed parts are back in place.
Transmission Unit Components in Section 5A”, if 17) For A/T model, adjust select cable referring to
removed. “Select Cable Adjustment in Section 5A”.
4) Lift engine with transmission, front suspension frame 18) Refill cooling system with coolant referring to
and engine rear mounting member into engine “Cooling System Flush and Refill in Section 1F”.
compartment with jack.
19) Refill engine with engine oil referring to “Engine Oil
! CAUTION and Filter Change in Section 0B”.
20) Bleed air from clutch system referring to “Air
Before lifting engine, to avoid damage to A/C
Bleeding of Brake System in Section 4A” for air
compressor and P/S pump, make clearance
bleeding procedure.
by rising them.
21) Install engine hood after disconnecting windshield
5) Tighten engine rear mounting member bolt referring washer hose.
to “Engine Mountings Components: For J20 Engine”. 22) Connect negative cable at battery.
6) Carry out Step 5) to 19) of “Installation” under “Front 23) With engine OFF, turn ignition switch to ON position
Suspension Frame, Stabilizer Bar and/or Bushings and check for fuel leakage.
Removal and Installation in Section 2B” in order to lift 24) Start engine and check coolant, oil and exhaust gas
engine with front suspension frame. leakage at each connection.
7) Remove engine jack.
8) Install front and rear propeller shafts referring to
“Propeller Shaft Removal and Installation in Section
3D”.
9) Install exhaust No.1, No.2 and center pipes referring
to “Exhaust System Components in Section 1K”.
10) Install A/C compressor to its bracket (if equipped)
referring to “Compressor Assembly Removal and
Installation for J20 Engine Model in Section 7B”.
11) Install P/S pump to its bracket referring to “P/S Pump
Removal and Installation for J20 Engine Model in
Section 6C”.
12) Return disconnected hoses, cables and electric wire
noting the followings.
• Tighten nuts to specified torque.
Tightening torque
Starting motor terminal nut: 11 N·m (1.1 kgf-m,
8.0 lb-ft)
Generator terminal nut: 7 N·m (0.7 kgf-m, 5.0 lb-
ft)
1D-84 Engine Mechanical: For J20 Engine

Timing Chain Cover Components

S5JB0A1426020

4 1207B 1207F

9 (d)

6 (b)
10

7
3
8 (c)
2

1 (a)
I5JB0A142021-01

1. Crankshaft pulley bolt 6. Timing chain cover bolt and nut : 150 N˜m (15.0 kgf-m, 108.5 lb-ft)
2. Crankshaft pulley 7. Idler pulley : 11 N˜m (1.1 kgf-m, 8.0 lb-ft)
3. Oil seal 8. Idler pulley nut : 42 N˜m (4.2 kgf-m, 30.5 lb-ft)
: Apply engine oil to oil seal lip.
4. Timing chain cover 9. Generator belt tensioner bolt : 25 N˜m (2.5 kgf-m, 18.0 lb-ft)
: See “A”
: See “B”
5. Belt tensioner 10. Pin : Do not reuse.
“A”: Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.
“B”: Apply sealant 99000-31250 to the mating surface of timing chain cover referring to the figure of Step 3) in “Timing Chain Cover Removal and
Installation: For J20 Engine”.

Timing Chain Cover Removal and Installation NOTE

S5JB0A1426021
Be sure to use the following bolts instead of
Removal pins in order to fix crankshaft pulley by
special tool.
1) Remove engine assembly from vehicle referring to
Bolt size: M8, P1.25 L = 25 mm (0.98 in.)
“Engine Assembly Removal and Installation: For J20
Strength: 7T
Engine”.
2) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation: For J20 Engine in
Section 1E”.
3) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation: For J20
Engine”.
4) Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool
(camshaft pulley holder) as shown in figure.
Special tool
(a): 09917–68221
I2RH01140051-01

2. Bolt 3. Wrench
 Engine Mechanical: For J20 Engine 1D-85

5) Remove crankshaft pulley (1). Installation

To remove crankshaft pulley, use special tools 1) Clean sealing surfaces on timing chain cover,
(Steering wheel remover, Bearing puller attachment) cylinder block and cylinder head.
with it as shown in figure. Remove oil, oil sealant and dust from sealing
Special tool surface.
(A): 09944–36011 2) Install new oil seal (2) to timing chain cover using
(B): 09926–58010 special tool, if removed.

NOTE
When installing new oil seal (2), drive it until
its surface is flash with edge of timing chain
cover (1).

Special tool
(A): 09913–75510

I2RH01140052-01

6) Remove idler pulley (1), water pump pulley (2) and

belt tensioner (3).

I2RH01140061-01

I2RH01140054-01

7) Remove timing chain cover (1) bolts (3) and nut (2).

I2RH01140055-01
1D-86 Engine Mechanical: For J20 Engine

3) Apply sealant “A” and “B” to specific area as shown 4) Apply engine oil to oil seal lip, then install timing
in figure. chain cover (1). Tighten bolts and nut to specified
torque.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F) NOTE
“B”: Water tight sealant 99000–31140 (SUZUKI
Before installing timing chain cover, check
Bond No.1207B)
that pin is securely fitted.
Sealant amount for timing chain cover
“a”: 3 mm (0.12 in.) Tightening torque
“b”: 2 mm (0.08 in.) Timing chain cover bolt and nut (a): 11 N·m (1.1
“c”: 6 mm (0.24 in.) kgf-m, 8.0 lb-ft)
“d”: 16 mm (0.63 in.)
“e”: 14 mm (0.55 in.)
“f”: 65 mm (2.56 in.)
“g”: 73 mm (2.87 in.)
“h”: 4 mm (0.16 in.)

I2RH01140057-01

5) Install belt idler pulley (1). Tighten nut to specified

torque.
Tightening torque
Idler pulley nut (a): 42 N·m (4.2 kgf-m, 30.5 lb-ft)
6) Install belt tensioner (2). Tighten bolts to specified
torque.
Tightening torque
Generator belt tensioner bolt (b): 25 N·m (2.5
kgf-m, 18.5 lb-ft)
7) Install water pump pulley (3).

I2RH01140058-01

I5JB0A142022-03 8) Install cylinder head cover referring to “Cylinder

2. Cylinder head 5. Rub into Head Cover Removal and Installation: For J20
3. Cylinder head gasket 6. Jig Engine”.
4. Cylinder block [C]: View C 9) Install oil pan. Refer to “Oil Pan and Oil Pump
Strainer Removal and Installation: For J20 Engine in
Section 1E” for installation.
10) Install crankshaft pulley. To lock crankshaft pulley
(1), use special tool (camshaft pulley holder) as
shown in figure.
Special tool
(A): 09917–68221
 Engine Mechanical: For J20 Engine 1D-87

NOTE 11) Install engine assembly to vehicle referring to

Be sure to use the following bolts instead of “Engine Assembly Removal and Installation: For J20
pins in order to fix crank pulley by special Engine”.
tool.
Bolt size: M8, P1.25 L = 25 mm (0.98 in.) Timing Chain Cover Cleaning and Inspection
S5JB0A1426022
Strength: 7T
Clean
Tightening torque
Clean sealing surface on timing chain cover, crank case,
Crankshaft pulley bolt (a): 150 N·m (15.0 kgf-m,
cylinder block and cylinder head.
108.5 lb-ft)
Remove oil, old sealant, and dust from sealing surface.

Inspection
Check oil seal lip for fault or other damage. Replace as
necessary.

I2RH01140060-01

2. Bolt 3. Wrench

2nd Timing Chain and Chain Tensioner Components

S5JB0A1426023

10

9
3

5
OIL

9 1
8 (a)
6 (b)
OIL

2
7 (c)
I5JB0A142023-02

1. 2nd timing chain 6. Camshaft timing sprocket bolt : 11 N˜m (1.1 kgf-m, 8.0 lb-ft)
: Apply engine oil
2. Timing chain tensioner adjuster No.2 7. Timing chain tensioner adjuster No.2 nut : 80 N˜m (8.0 kgf-m, 58.0 lb-ft)
: Apply engine oil to sliding surface.
3. Tensioner adjuster No.2 gasket 8. Timing chain tensioner adjuster No.2 bolt : 45 N˜m (4.5 kgf-m, 32.5 lb-ft)
4. Intake camshaft timing sprocket 9. Pin : Do not reuse.
5. Exhaust camshaft timing sprocket 10. Oil relief valve
1D-88 Engine Mechanical: For J20 Engine

2nd Timing Chain and Chain Tensioner 5) Turn crankshaft clockwise to meet the following
Removal and Installation conditions.
S5JB0A1426024
• Key on crankshaft match with mark on cylinder
! CAUTION block (I).
After 2nd timing chain is removed, never turn • Arrow mark on idler sprocket points upward (II).
intake camshaft, exhaust camshaft and • Marks on cam sprockets match with marks on
crankshaft independently more than such an cylinder head (III).
extent as shown. If turned, interference may • Mark on crank sprocket match with mark on lower
occur between piston and valves and valves crankcase (IV).
themselves, and parts related to piston and
valves may be damaged. 1, (III) 2, (III)

3, (II)

4, (I)

5, (IV)

I5JB0A142024-01

I5JB0A142060-01
1. Timing marks of intake camshaft timing sprocket
2. Timing marks of exhaust camshaft timing sprocket
1. Knock pin of intake camshaft
3. Arrow mark on idler sprocket
2. Knock pin of exhaust camshaft
4. Key on crankshaft
3. Timing mark of intake side
5. Timing mark of crankshaft timing sprocket
4. Timing mark of exhaust side
5. Match mark on crank timing sprocket
6. Timing mark on lower crankcase
6) Remove timing chain tensioner adjuster No.2 (1) and
“a”: Camshafts (IN & EX) allowable turning range..... Within 20q on both
gasket. To remove them, slacken 2nd timing chain
right and left by turning intake camshaft counterclockwise a little
“b”: Crankshaft allowable turning range..... Within 90q on both right and left while pushing back pad.

Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation: For J20
Engine”.
2) Remove oil pan. Refer to “Oil Pan and Oil Pump
Strainer Removal and Installation: For J20 Engine in
Section 1E” for removal.
3) Remove cylinder head cover. Refer to “Cylinder
Head Cover Removal and Installation: For J20
I2RH01140064-01
Engine” for removal.
4) Remove timing chain cover. Refer to “Timing Chain
Cover Removal and Installation: For J20 Engine” for
removal.
 Engine Mechanical: For J20 Engine 1D-89

7) Remove intake and exhaust camshaft timing 4) Install 2nd timing chain by aligning yellow plate (1) of
sprocket bolts (1). To remove them, fit a spanner (4) 2nd timing chain and match marks on idler sprocket.
to hexagonal part (3) at the center of camshaft to
hold it stationary.
8) Remove camshaft timing sprockets and 2nd timing
chain (2).

I2RH01140069-01

2. Match mark of 2nd timing chain (Arrow mark)

I5JB0A142025-01 5) Install sprockets to intake and exhaust camshafts by

aligning dark blue plate of 2nd timing chain, match
Installation marks on intake sprocket and exhaust sprocket
1) Check that match mark (1) on crank timing sprocket respectively.
is in match with timing mark (2) on lower crankcase
as shown in figure. ! CAUTION
Do not turn more than allowable turning
range.
If turned excessively, valve and piston may
be damaged.

NOTE
As an arrow mark is provided on both sides,
camshaft timing sprocket has no specific
installation direction.

I2RH01140067-01

2) Check that arrow mark (1) on idler sprocket faces

upward as shown in figure.
3) Check that knock pins of intake (2) and exhaust (3)
camshafts are aligned with timing marks on cylinder
head as shown in figure.

I2RH01140070-01

1. Dark blue
2. Arrow mark on intake camshaft timing sprocket
3. Arrow mark on exhaust camshaft timing sprocket

I2RH01140068-01

4. Timing mark of intake side

5. Timing mark of exhaust side
1D-90 Engine Mechanical: For J20 Engine

6) Tighten intake and exhaust camshaft timing sprocket At this time, check timing marks (3, 5 and 7) of
bolts (1) to specified torque. To tighten it, fit a sprockets are in match with timing marks (4, 6 and 8)
spanner (2) to hexagonal part (3) at the center of of cylinder head, cylinder block and lower crank
camshaft to hold it stationary. case. Also, check arrow mark (9) on idler sprocket
faces upward as shown in figure.
Tightening torque
Camshaft timing sprocket bolt (a): 80 N·m (8.0
kgf-m, 57.5 lb-ft) 7
5

6 8

I5JB0A142061-01
1
7) Push back plunger (1) into tensioner body (2), and
hold it at the position by inserting stopper (3) into 2
3
body.

I5JB0A142026-01

3. Timing mark on crank timing sprocket

4. Timing mark on lower crankcase
5. Timing mark on intake camshaft timing sprocket
6. Timing mark of intake camshaft timing sprocket
I2RH01140072-01 7. Timing mark on exhaust camshaft timing sprocket
8. Timing mark of exhaust camshaft timing sprocket
8) Install timing chain tensioner adjuster No.2 (1) with
9. Arrow mark on idler sprocket point upward
new gasket.
Tightening torque 11) Apply oil to timing chains, tensioner, tensioner
Timing chain tensioner adjuster No.2 bolt (a): 11 adjusters, sprockets and guides.
N·m (1.1 kgf-m, 8.0 lb-ft) 12) Install timing chain cover. Refer to “Timing Chain
Timing chain tensioner adjuster No.2 nut (b): 45 Cover Removal and Installation: For J20 Engine” for
N·m (4.5 kgf-m, 33.0 lb-ft) installation.
9) Pull out stopper (2) from timing chain tensioner 13) Install cylinder head cover. Refer to “Cylinder Head
adjuster No.2. Cover Removal and Installation: For J20 Engine” for
installation.
14) Install oil pan. Refer to “Oil Pan and Oil Pump
Strainer Removal and Installation: For J20 Engine in
Section 1E” for installation.
15) Install engine assembly to vehicle referring to
“Engine Assembly Removal and Installation: For J20
Engine”.

2nd Timing Chain and Chain Tensioner

Inspection
S5JB0A1426025

I2RH01140073-01
Timing Chain Guide No.2
10) Turn crankshaft two rotations clockwise, and then
Check shoe (2) for wear or damage.
align timing mark (1) on crankshaft and timing mark
(2) on cylinder block as shown in figure.
 Engine Mechanical: For J20 Engine 1D-91

Timing Chain
Check timing chain for wear or damage.

I2RH01140077-01

Tensioner Adjuster No.2

I2RH01140075-01
Check shoe (1) for wear or damage and latch functions
1. Timing chain guide No.2 properly.

Camshaft Sprocket
Check teeth of sprocket for wear or damage.

I2RH01140078-01

I2RH01140076-01

1st Timing Chain and Chain Tensioner Components

S5JB0A1426026
OIL

1
OIL

3
OIL

2
OIL

8 (a)

9 (b)
OIL

10 (c)

4
I5JB0A142027-01

1. 1st timing chain 6. Timing chain tensioner adjuster No.1 : 25 N˜m (2.5 kgf-m, 18.0 lb-ft)
2. Idler sprocket 7. Timing chain guide No.1 : 9 N˜m (0.9 kgf-m, 6.5 lb-ft)
3. Idler sprocket shaft 8. Timing chain tensioner nut : 11 N˜m (1.1 kgf-m, 8.0 lb-ft)
4. Crankshaft timing sprocket 9. Timing chain guide No.1 bolt : Apply engine oil to sliding surface.

5. Timing chain tensioner 10. Timing chain tensioner adjuster No.1 bolt
1D-92 Engine Mechanical: For J20 Engine

1st Timing Chain and Chain Tensioner Removal 2) Check that match mark (1) on crankshaft timing
and Installation sprocket is in match with timing mark (2) on lower
S5JB0A1426027 crankcase.
! CAUTION
After timing chain is removed, never turn
crankshaft and camshafts independently
more than its allowable turning range
described referring to “2nd Timing Chain and
Chain Tensioner Removal and Installation:
For J20 Engine”.
If turned, interference may occur between
piston and valves and valves themselves,
and parts related to piston and valves may be
damaged.
I2RH01140082-01

Removal 3) Apply oil to bush of idler sprocket (1).

1) Remove 2nd timing chain. Refer to “2nd Timing 4) Install idler sprocket and sprocket shaft.
Chain and Chain Tensioner Removal and 5) Install 1st timing chain by aligning dark blue plate (4)
Installation: For J20 Engine” for removal. of 1st timing chain (3) and match mark (2) on idler
2) Remove timing chain guide No.1 (1). sprocket (1).
3) Remove timing chain tensioner adjuster No.1 (2).
4) Remove timing chain tensioner (3).
5) Remove idler sprocket (4) and 1st timing chain (5).
6) Remove crankshaft timing sprocket (6).

I2RH01140084-01

6) Bring gold plate (4) of 1st timing chain (3) into match
with match mark (2) on crankshaft timing sprocket
(1).

I4RH01140029-01

Installation
1) Install crankshaft timing sprocket (2) as shown in
figure.

I2RH01140085-01

7) Apply engine oil to sliding surface of timing chain

tensioner (1) and then install it as shown in figure.
Tighten tensioner nut to specified torque.
Tightening torque
Timing chain tensioner nut (a): 25 N·m (2.5 kgf-
I2RH01140083-01 m, 18.0 lb-ft)
1. Crankshaft 3. Cylinder block
 Engine Mechanical: For J20 Engine 1D-93

I2RH01140086-01
I2RH01140089-01
2. Spacer
12) Check that dark blue and yellow plates of 1st timing
8) With latch of tensioner adjuster No.1 returned and chain are in match with match marks on sprockets
plunger (1) pushed back into body, insert stopper (4) respectively.
into latch (2) and body (3).
After inserting it, check to make sure that plunger will
not come out.

I2RH01140087-01

9) Install timing chain tensioner (2) adjuster No.1 (1).

Tightening torque
Timing chain tensioner adjuster No.1 bolt (a): 11
N·m (1.1 kgf-m, 8.0 lb-ft) I2RH01140090-01

1. Match mark on idler sprocket

10) Pull out stopper (3) from adjuster No.1.
2. Dark blue plate
3. Match mark on crank timing sprocket
4. Yellow plate

13) Install 2nd timing chain. Refer to “2nd Timing Chain

and Chain Tensioner Removal and Installation: For
J20 Engine” for installation.
14) Install timing chain cover. Refer to “Timing Chain
Cover Removal and Installation: For J20 Engine” for
installation.
15) Install cylinder head cover. Refer to “Cylinder Head
I2RH01140088-01
Cover Removal and Installation: For J20 Engine” for
11) Apply engine oil to sliding surface of timing chain installation.
guide No.1 (1) and then install it.
16) Install oil pan. Refer to “Oil Pan and Oil Pump
Tighten guide bolts to specified torque.
Strainer Removal and Installation: For J20 Engine in
Tightening torque Section 1E” for installation.
Timing chain guide No.1 bolt (a): 9 N·m (0.9 kgf- 17) Install engine assembly to vehicle referring to
m, 6.5 lb-ft) “Engine Assembly Removal and Installation: For J20
Engine”.
1D-94 Engine Mechanical: For J20 Engine

1st Timing Chain and Chain Tensioner Idler Sprocket

Inspection Check teeth and bush (1) of sprocket for wear or
S5JB0A1426028 damage.

Timing Chain Guide No.1

Check shoe for wear or damage.

I2RH01140094-01

1st Timing Chain

I2RH01140091-01
Check timing chain for wear or damage.
1. Timing chain guide No.1

Timing Chain Tensioner

Check shoe (1) for wear or damage.

I2RH01140077-01

Timing Chain Tensioner Adjuster No.1

Check that latch (1) and tooth surface (2) are free from
damage and latch functions properly.

I2RH01140092-01

Crankshaft Timing Sprocket

Check teeth of sprocket for wear or damage.
I2RH01140095-01

I2RH01140093-01
 Engine Mechanical: For J20 Engine 1D-95

Camshafts, Tappet and Shim Components

S5JB0A1426029

I5JB0A142028-01

1. Intake camshaft 5. Exhaust camshaft housing 9. Timing chain guide No.2

2. Exhaust camshaft 6. Shim 10. Camshaft housing bolt
: Direct shim No. side toward tappet.
3. Camshaft housing 7. Tappet : 11 N˜m (1.1 kgf-m, 8.0 lb-ft)
4. Intake camshaft housing 8. Oil relief valve : Apply engine oil to sliding surface of each part.

Camshafts, Tappet and Shim Removal and 3) Remove camshaft housings.

Installation 4) Remove camshafts.
S5JB0A1426030
5) Remove tappets with shims.
! CAUTION
Installation
• Keep working table, tools and hands clean
while overhauling. 1) Apply engine oil around tappet (1), and then install
tappets with shims to cylinder head.
• Use special care to handle aluminum parts
so as not to damage them. NOTE
• Do not expose removed parts to dust. When installing shim, make sure to direct
Keep them always clean. shim No. side toward tappet.

Removal
1) Remove 2nd timing chain. Refer to “2nd Timing
Chain and Chain Tensioner Removal and
Installation: For J20 Engine” for removal. 1
2) Loosen camshaft housing bolts in such order as
indicated in figure and remove them.

“12” “13” “20” “21” “16” “17” “6”

“2”
I5JB0A142030-01
“5” “7”
“3”
“4” “9”

“1”
“10” “11” “18” “19” “14” “15” “8”
I5JB0A142029-01
1D-96 Engine Mechanical: For J20 Engine

2) Match match mark (1) on crank timing sprocket and 5) Check position of camshaft housings.
mating surface of cylinder block and lower Embossed marks are provided on each camshaft
crankcase (2). housing, indicating position and direction for
installation. Install housings as indicated by these
marks.

I2RH01140103-01

3) Install camshafts.
I2RH01140106-01
Apply oil to sliding surface of each camshaft and
camshaft journal then install them by aligning match 1. I: Intake side or E: Exhaust side

marks on cylinder head and camshafts as shown in 2. Position from timing chain side
3. Pointing to timing chain side
figure.
6) After applying oil to housing bolts, tighten them
temporarily first. Then tighten them by following
numerical order in figure.
Tighten a little at a time and evenly among bolts and
repeat tightening sequence two or three times before
they are tightened to specified torque.
Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
I5JB0A142031-01 8.0 lb-ft)
1. Knock pin of intake camshaft
2. Knock pin of exhaust camshaft “10”, (a) “2”, (a) “6”, (a) “16”, (a)
3. Match mark of intake camshaft “9”, (a) “1”, (a) “5”, (a)
4. Match mark of exhaust camshaft “20”, (a)

4) Install camshaft housing pins (3) as shown in figure. “17”, (a) “15”, (a)
“19”, (a)
“18”, (a) “13”, (a)

“21”, (a)
“11”, (a) 3”, (a) “7”, (a)
“12”, (a) “4”, (a) “8”, (a) “14”, (a)
I5JB0A142032-01

7) Turn crankshaft clockwise then align crankshaft

I4RH01140032-01
timing sprocket key (1) with timing mark (2).
1. Intake camshaft 2. Exhaust camshaft

I5JB0A142033-01

8) Install 2nd timing chain. Refer to “2nd Timing Chain

and Chain Tensioner Removal and Installation: For
J20 Engine” for installation.
 Engine Mechanical: For J20 Engine 1D-97

9) Install timing chain cover. Refer to “Timing Chain Camshaft Journal Wear
Cover Removal and Installation: For J20 Engine” for Check camshaft journals and camshaft housings for
installation. pitting, scratches, wear or damage.
10) Install cylinder head cover. Refer to “Cylinder Head If any malcondition is found, replace camshaft or cylinder
Cover Removal and Installation: For J20 Engine” for head with housing. Never replace cylinder head without
installation. replacing housings.
11) Install oil pan. Refer to “Oil Pan and Oil Pump
Strainer Removal and Installation: For J20 Engine in
Section 1E” for installation.
12) Install engine assembly to vehicle referring to
“Engine Assembly Removal and Installation: For J20
Engine”.
13) Check valve lashes referring to “Valve Lash
(Clearance) Inspection: For J20 Engine”. IYSQ01143105-01

Check clearance by using gauging plastic. Checking

Camshaft, Tappet and Shim Inspection procedure is as follows.
S5JB0A1426031
1) Clean housings and camshaft journals.
Cam Wear 2) Make sure that all tappets with shims are removed
Using a micrometer, measure cam height. If measured and install camshafts to cylinder head.
height is below its limit, replace camshaft. 3) Place a piece of gauging plastic to full width of
Cam height “a” journal of camshaft (parallel to camshaft).
Cam 4) Install camshaft housing.
Standard Limit
height 5) Tighten camshaft housing bolts in such order as
Intake 45.669 – 45.829 mm 45.550 mm indicated in figure a little at a time till they are
cam (1.798 – 1.8043 in.) (1.793 in.) tightened to specified torque.
Exhaust 45.550 – 45.710 mm 45.430 mm
cam (1.7933 – 1.7996 in.) (1.789 in.) NOTE
Do not rotate camshaft while gauging plastic
is installed.

Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)

“10”, (a) “2”, (a) “6”, (a) “16”, (a)

“9”, (a) “1”, (a) “5”, (a)
“20”, (a)

I5JB0A142034-01 “17”, (a) “15”, (a)

“19”, (a)
“18”, (a) “13”, (a)
Camshaft Runout
Set camshaft between two “V” blocks, and measure its
runout by using a dial gauge. “21”, (a)
“11”, (a) “3”, (a) “7”, (a)
If measured runout exceeds the specified limit, replace
“12”, (a) “4”, (a) “8”, (a) “14”, (a)
camshaft. I5JB0A142035-02

Runout limit
0.03 mm (0.0012 in.)

I2RH01140109-01
1D-98 Engine Mechanical: For J20 Engine

6) Remove housing, and using scale (2) on gauging

plastic envelop (1), measure gauging plastic width at
its widest point.
Journal clearance
Standard Limit
0.020 – 0.074 mm (0.0008 –
0.12 mm (0.0047 in.)
0.0029 in.)

I2RH0B140085-01

Measure cylinder head bore and tappet outside diameter

to determine cylinder head-to-tappet clearance. If
clearance exceeds limit, replace tappet or cylinder head.
Cylinder head bore and tappet outside diameter
Item Standard Limit
Tappet outside 32.456 – 32.472 mm
—
diameter [A] (1.2778 – 1.2784 in.)
IYSQ01143107-01 Cylinder head bore 32.500 – 32.525 mm
—
If measured camshaft journal clearance exceeds [B] (1.2795 – 1.2805 in.)
limit, measure journal (housing) bore and outside Cylinder head to 0.028 – 0.069 mm 0.15 mm
diameter of camshaft journal. Replace camshaft or tappet clearance (0.0011 – 0.0027 in.) (0.0059 in.)
cylinder head assembly whichever the difference
from specification is greater.
Camshaft journal
Item Standard
Camshaft journal bore 26.000 – 26.033 mm
diameter. (IN & EX) [A] (1.0236 – 1.0249 in.)
Camshaft journal O.D. (IN & 25.959 – 25.980 mm
EX) [B] (1.0221 – 1.0228 in.)

I5JB0A142038-01

Oil Relief Valve

Check oil relief valve for clogging and ball for being
stuck.

I5JB0A142036-01

Wear of Tappet and Shim

I2RH01140111-01
Check tappet and shim for pitting, scratches, or damage.
If any malcondition is found, replace.
 Engine Mechanical: For J20 Engine 1D-99

Valves and Cylinder Head Components

S5JB0A1426032

I5JB0A142039-01

1. Cylinder block 7. Valve stem seal 13. Cylinder head bolt (M6)
: Be sure to tighten cylinder head bolt (M8) after securing
cylinder head bolt (M10).
2. Cylinder head 8. Valve spring 14. Knock pin
3. Cylinder head gasket 9. Valve spring retainer : Tighten 52 N˜m (5.2 kgf-m, 38.0 lb-ft), 82 N˜m (8.2 kgf-m, 59.5
: Identification number provided on gasket comes lb-ft), 0 N˜m (0 kgf-m, 0 lb-ft), 52 N˜m (5.2 kgf-m, 38.0 lb-ft)
to crankshaft pully side, facing up. and 103 N˜m (10.3 kgf-m, 74.5 lb-ft) by the specified
procedure.
4. Intake valve 10. Valve cotter : 11 N˜m (1.1 kgf-m, 8.0 lb-ft)
5. Exhaust valve 11. Valve guide : Do not reuse.
6. Valve spring seat 12. Cylinder head bolt (M10) : Apply engine oil to sliding surface of each part.

Valves and Cylinder Head Removal and 4) Remove timing chain cover. Refer to “Timing Chain
Installation Cover Removal and Installation: For J20 Engine” for
S5JB0A1426033 removal.
5) Remove 2nd timing chain and 1st timing chain. Refer
Removal
to “2nd Timing Chain and Chain Tensioner Removal
1) Remove engine assembly from vehicle referring to and Installation: For J20 Engine” and “1st Timing
“Engine Assembly Removal and Installation: For J20 Chain and Chain Tensioner Removal and
Engine”. Installation: For J20 Engine” for removal.
2) Remove oil pan referring to “Oil Pan and Oil Pump 6) Remove camshafts, tappets and shims. Refer to
Strainer Removal and Installation: For J20 Engine in “Camshafts, Tappet and Shim Removal and
Section 1E”. Installation: For J20 Engine” for removal.
3) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation: For J20
Engine”.
1D-100 Engine Mechanical: For J20 Engine

7) Loosen cylinder head bolts (M10) in such order as

numbered in figure and remove them.

NOTE
Don’t forget to remove cylinder head bolt
(M6) (3) as shown in figure.

“5” “9” “11” “7” “3”

I5JB0A142041-01

5. Flywheel side

1 2 5) Install cylinder head to cylinder block.

Apply engine oil to cylinder head bolts and tighten
them gradually as follows.
a) Tighten cylinder head bolts (M10) to 52 N˜m (5.2
kgf-m, 38.0 lb-ft) according to numerical order in
“4” 3, “1” “8” “10” “6” “2” figure.
I5JB0A142040-02

1. Crankshaft pulley side 2. Flywheel side

b) In the same manner as in step a), retighten
cylinder head bolts (M10) to 82 N˜m (8.2 kgf-m,
8) Check all around cylinder head for any other parts 59.5 lb-ft).
required to be removed or disconnected and remove
or disconnect whatever necessary. “7” “5” “1” “3” “10”

9) Remove cylinder head with intake manifold, exhaust

manifold and water outlet cap. Use lifting device, if
necessary.
1 2
Installation
1) Match match mark (1) on crank timing sprocket and
mating surface (2) of cylinder block and lower
crankcase.
“9” “4” “2” “6” “8”
I5JB0A142042-01

1. Crankshaft pulley side 2. Flywheel side

c) Loosen cylinder head bolts (M10) until tightening

torque is reduced to 0 according to numerical
order in figure.

“4” “8” “10” “6” “2”

I2RH01140118-01

2) Clean mating surface of cylinder head and cylinder 1 2

block (2). Remove oil, old gasket and dust from
mating surface.
3) Install knock pins (3) to cylinder block.
4) Install new cylinder head gasket (1) to cylinder block.
“3” “7” “9” “5” “1”
Identification number (6) provided on gasket comes I5JB0A142043-01
to crankshaft pulley side (4), facing up (toward 1. Crankshaft pulley side 2. Flywheel side
cylinder head side).
 Engine Mechanical: For J20 Engine 1D-101

d) Tighten cylinder head bolts (M10) to 52 N˜m (5.2 Valves and Cylinder Head Disassembly and
kgf-m, 38.0 lb-ft) according to numerical order in Assembly
figure. S5JB0A1426034

e) In the same manner as in step b), retighten

Disassembly
cylinder head bolts (M10) to 103 N˜m (10.3 kgf-
m, 74.5 lb-ft). 1) When servicing cylinder head, remove intake
manifold, injectors, exhaust manifold and water
f) Tighten cylinder head bolt (M6) to specified
outlet cap from cylinder head.
torque.
2) Using special tools, compress valve springs and
Tightening torque then remove valve cotters (1) also by using special
Cylinder head bolt (M10) (a): Tighten 52 N˜m tool.
(5.2 kgf-m, 38.0 lb-ft), 82 N˜m (8.2 kgf-m, 59.5
lb-ft), 0 N˜m (0 kgf-m, 0 lb-ft), 52 N˜m (5.2 kgf- Special tool
m, 38.0 lb-ft) and 103 N˜m (10.3 kgf-m, 74.5 lb- (A): 09916–14510
ft) by the specified procedure. (B): 09916–16510
Cylinder head bolt (M6) (b): 11 N·m (1.1 kgf- (C): 09919–28610
m, 8.0 lb-ft) (D): 09916–84511

“7”, (a) “5”, (a) “1”, (a) “3”, (a) “10”, (a)

“9”, (a) 3, “11”, (b) “4”, (a) “2”, (a) “6”, (a) “8”, (a)
I5JB0A142044-02

1. Crankshaft pulley side 2. Flywheel side

6) Install camshafts and tappets and shims. Refer to

“Camshafts, Tappet and Shim Removal and
Installation: For J20 Engine” for installation.
7) Install 1st timing chain. Refer to “1st Timing Chain
and Chain Tensioner Removal and Installation: For
J20 Engine” for installation.
8) Install 2nd timing chain. Refer to “2nd Timing Chain
and Chain Tensioner Removal and Installation: For
J20 Engine” for installation.
9) Install timing chain cover. Refer to “Timing Chain I5JB0A142045-01

Cover Removal and Installation: For J20 Engine” for

installation.
10) Check intake and exhaust valve lashes referring to
“Valve Lash (Clearance) Inspection: For J20
Engine”.
11) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation: For J20
Engine”.
12) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation: For J20 Engine in
Section 1E”.
13) Install engine assembly to vehicle referring to
“Engine Assembly Removal and Installation: For J20
Engine”.
1D-102 Engine Mechanical: For J20 Engine

3) Release special tool, and remove spring retainers Assembly

and valve springs. 1) Before installing valve guide into cylinder head, ream
4) Remove valve from combustion chamber side. guide hole with special tool (11 mm reamer) so as to
5) Remove valve stem seal (1) from valve guide, and remove burrs and make it truly round.
then valve spring seat (2). Special tool
NOTE (A): 09916–34542
(B): 09916–38210
Do not reuse seal once disassembled. Be
sure to use new seal when assembling.

I2RH01140127-01

2) Install valve guide to cylinder head.

Heat cylinder head uniformly at a temperature of 80
to 100 qC (176 to 212 qF) so that head will not be
I2RH01140125-01

6) Using special tool (Valve guide remover), drive valve distorted, and drive new valve guide into hole with
guide out from combustion chamber side to valve special tools.
spring side. Drive in new valve guide until special tool (Valve
Special tool guide installer) contacts cylinder head.
(A): 09916–46020 After installing, make sure that valve guide protrudes
by 13.0 mm (0.51 in.) from cylinder head.
NOTE
Special tool
Do not reuse valve guide once disassembled. (A): 09916–57350
Be sure to use new valve guide (oversize) (B): 09916–57340
when assembling.
NOTE
• Do not reuse valve guide once
disassembled. Install new valve guide
(Oversize).
• Intake and exhaust valve guides are
identical.

Valve guide oversize

0.03 mm (0.0012 in.)
Valve guide protrusion “a” (In and Ex)
13.0 mm (0.51 in.)
I2RH01140126-01

7) Place disassembled parts except valve stem seal

and valve guide in order so that they can be installed
in their original positions.

I2RH01140128-01
 Engine Mechanical: For J20 Engine 1D-103

3) Ream valve guide bore with special tool (6.0 mm 6) Install valve to valve guide.
reamer). After reaming, clean bore. Before installing valve to valve guide, apply engine
oil to stem seal, valve guide bore, and valve stem.
Special tool
(A): 09916–34542
(B): 09916–37810

I2RH01140130-01

7) Install valve spring and spring retainer.

Each valve spring has top end (large-pitch end (1))
I2RH01140127-01
and bottom end (small-pitch end (2)). Be sure to
4) Install valve spring seat to cylinder head. position spring in place with its bottom end (small-
5) Install new valve stem seal (1) to valve guide. pitch end) facing the bottom (valve spring seat side).
After applying engine oil to seal and spindle of
special tool (Valve guide installer handle), fit oil seal
to spindle, and then install seal to valve guide by
pushing special tool by hand.
After installing, check to be sure that seal is properly
fixed to valve guide.
Special tool
(A): 09917–98221
(B): 09916–57350

NOTE
• Do not reuse seal once disassembled. Be I2RH0B140100-01
sure to install new seal. A: Valve spring retainer side B: Valve spring seat side
• When installing, never tap or hit special
tool with a hammer or else. Install seal to 8) Using special tool (Valve lifter), compress valve
guide only by pushing special tool by spring and fit two valve cotters (1) into groove in
hand. Tapping or hitting special tool may valve stem.
cause damage to seal.
Special tool
(A): 09916–14510
(B): 09916–16510
(C): 09919–28610
(D): 09916–84511

I2RH01140129-01

I2RH01140132-01
1D-104 Engine Mechanical: For J20 Engine

9) Install intake manifold referring to “Intake Manifold Removal and Installation: For J20 Engine”.
10) Install exhaust manifold referring to “Exhaust Manifold Removal and Installation (For J20 Engine Model) in Section
1K”.
11) Install injectors referring to “Fuel Injector Removal and Installation in Section 1G”.

Valves and Valve Guides Inspection

S5JB0A1426035

Valve Guide

Valve stem-to-guide clearance

Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance.
Be sure to take reading at more than one place along the length of each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem and valve guide specification
Item Standard Limit
In 5.965 – 5.980 mm (0.2348 – 0.2354 in.) —
Valve stem diameter [A]
Ex 5.940 – 5.955 mm (0.2339 – 0.2344 in.) —
Valve guide bore [B] In & Ex 6.000 – 6.012 mm (0.2362 – 0.2366 in.) —
In 0.020 – 0.047 mm (0.0008 – 0.0018 in.) 0.070 mm (0.0028 in.)
Stem-to-guide clearance
Ex 0.045 – 0.072 mm (0.0017 – 0.0028 in.) 0.090 mm (0.0035 in.)

I4RS0B140016-01

Valve stem end deflection

If bore gauge is not available, check end deflection of valve stem with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end deflection.
If deflection exceeds its limit, replace valve stem and valve guide.
Valve stem end deflection limit
In: 0.14 mm (0.005 in.)
Ex: 0.18 mm (0.007 in.)

IYSQ01141096-01
 Engine Mechanical: For J20 Engine 1D-105

Valve Valve head radial runout

Check each valve for radial runout with a dial gauge and
Visual inspection “V” block. To check runout, rotate valve slowly. If runout
• Remove all carbon from valves. exceeds its limit, replace valve.
• Inspect each valve for wear, burn or distortion at its Valve head radial runout
face and stem end, as necessary, replace it. Limit: 0.08 mm (0.003 in.)
• Inspect valve stem end face for pitting and wear. If
pitting or wear is found there, valve stem end may be
resurfaced, but not too much to grind off its chamber.
When it is worn out too much that its chamber is gone,
replace valve.

I2RH01140136-01

Seating contact width

Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotatingly tapping seat
with valve head. Valve lapper (tool used in valve lapping)
I2RH01140135-01
must be used.
Valve head thickness Pattern produced on seating face of valve must be a
Measure thickness “a” of valve head. If measured continuous ring without any break, and the width of
thickness exceeds limit, replace valve. pattern must be within specified range.

Valve head thickness “a” Standard seating width “a” revealed by contact
Intake pattern on valve face
Standard: 1.25 – 1.55 mm (0.049 – 0.061 in.) Intake and Exhaust: 1.0 – 1.4 mm (0.0389 – 0.0551
Limit: 0.9 mm (0.035 in.) in.)
Exhaust
Standard: 1.45 – 1.75 mm (0.057 – 0.069 in.)
Limit: 1.1 mm (0.04 in.)

I2RH0B140103-01

I2RH0B140102-01
1D-106 Engine Mechanical: For J20 Engine

Valve seat repair Cylinder Head Inspection

A valve seat not producing a uniform contact with its S5JB0A1426047

valve or showing width of seating contact that is out of • Remove all carbon deposits from combustion
specified range must be repaired by regrinding or by chambers.
cutting and regrinding and finished by lapping.
NOTE
1) Exhaust valve seat:
Use valve seat cutters (1) to make two cuts as Do not use any sharp-edged tool to scrape
illustrated in the figure. Two cutters must be used: off carbon deposits. Be careful not to scuff or
the first for making 15q angle, and the second for nick metal surfaces when decarbonizing. The
making 45q angle. The second cut must be made to same applies to valves and valve seats, too.
produce desired seat width.
Seat width for exhaust valve seat
“a”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)
2) Intake valve seat:
Use valve seat cutters (1) to make three cuts as
illustrated in the figure. Three cutters must be used:
the 1st for making 25q angle, the 2nd for making 60q
angle, and 3rd for making 45q angle. The 3rd cut
(45q) must be made to produce desired seat width.
Seat width for intake valve seat
“b”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)
I2RH0B140105-01

3) Valve lapping: • Check cylinder head for cracks on intake and exhaust
Lap valve on seat in two steps, first with coarse size ports, combustion chambers, and head surface. Using
lapping compound applied to face and the second a straightedge and thickness gauge, check flatness of
with fine-size compound, each time using valve gasketed surface at a total of 6 locations. If distortion
lapper according to usual lapping method. limit is exceeded, correct gasketed surface with a
surface plate and abrasive paper of about #400
(Waterproof silicon carbide abrasive paper): place
abrasive paper on and over surface plate, and rub
gasketed surface against paper to grind off high spots.
Should this fail to reduce thickness gauge readings to
within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint
is often due to warped gasketed surface: such
leakage results in reduced power output.
Distortion for cylinder head surface on piston side
Limit: 0.03 mm (0.001 in.)

I5JB0A142047-02
 Engine Mechanical: For J20 Engine 1D-107

Valve Spring Inspection

S5JB0A1426048

Valve Spring Free Length and Preload

Referring to data, check to be sure that each spring is in
sound condition, free of any evidence of breakage or
weakening. Remember, weakened valve springs can
cause chatter, not to mention possibility of reducing
power output due to gas leakage caused by decreased
seating pressure.
Valve spring free length
Standard: 51.13 mm (2.013 in.)
Limit: 50.13 mm (1.974 in.)
Valve spring preload
Standard: 219 – 241 N (21.9 – 24.1 kg) for 37.60 mm
(48.3 – 53.1 lb/1.480 in.)
Limit: 208 N (20.8 kg) for 37.60 mm (45.9 lb/1.480 in.)

I2RH0B140106-01

• Distortion of manifold seating faces:

Check seating faces of cylinder head for manifolds,
using a straightedge and thickness gauge, in order to
determine whether these faces should be corrected or
cylinder head replaced.
Distortion for cylinder head surface on intake and
exhaust manifold
Limit: 0.05 mm (0.002 in.)
I2RH01140143-01

Spring Squareness
Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. Valve springs found to exhibit a
larger clearance than limit must be replaced.
Valve spring squareness
Limit: 1.6 mm (0.063 in.)

I2RH0B140107-01

I2RH01140144-01
1D-108 Engine Mechanical: For J20 Engine

Pistons, Piston Rings, Connecting Rods and Cylinders Components

S5JB0A1426036

I5JB0A142048-02

1. Top ring 8. Piston pin

: “TOP” mark provided on piston ring comes to facing up.
2. 2nd ring 9. Piston pin circlip
: “TOP” mark provided on piston ring comes to facing up.
3. Oil ring 10. Connecting rod bolt
: Check connecting rod bolt, plastic deformation tightening bolt, for deformation when
reuse it due to plastic deformation tightening referring to “Connecting Rod Bolt” under
“Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning: For
J20 Engine” if it is reused.
4. Piston : 15 N˜m (1.5 kgf-m, 11.0 lb-ft) 45q and 45q by the specified procedure.
5. Connecting rod : Apply engine oil to sliding surface of each part.

6. Connecting rod bearing cap : Do not reuse.

: See “A”
7. Connecting rod bearing
: See “B”
“A”: Point arrow mark on cap to crankshaft pulley side. Do not apply engine oil to inner surface of bearing cap.
“B”: Do not apply engine oil between con-rod big end and bearing, between cap and bearing.

Pistons, Piston Rings, Connecting Rods and Installation

Cylinders Removal and Installation 1) Apply engine oil to pistons, rings, cylinder walls,
S5JB0A1426037
connecting rod bearings and crank pins.
Removal NOTE
1) Remove engine assembly from vehicle referring to Do not apply oil between connecting rod and
“Engine Assembly Removal and Installation: For J20 bearing or between bearing cap and bearing.
Engine”.
2) Remove oil pump with oil pump strainer. Refer to “Oil 2) When installing piston and connecting rod assembly
Pump Removal and Installation: For J20 Engine in into cylinder bore, point front mark (3) on piston head
Section 1E” for removal. to crankshaft pulley side (1).
3) Remove cylinder head. Refer to “Valves and
Cylinder Head Removal and Installation: For J20
Engine” for removal.
4) Mark cylinder number on all pistons, connecting rods
and connecting rod caps.
5) Remove connecting rod bearing caps.
6) Clean carbon from top of cylinder bore before
removing piston from cylinder.
I5JB0A142049-01
7) Push piston and connecting rod assembly out
2. Flywheel side
through the top of cylinder bore.
 Engine Mechanical: For J20 Engine 1D-109

3) Install piston and connecting rod assembly into 5) Install cylinder head. Refer to “Valves and Cylinder
cylinder bore. Use special tool (Piston ring Head Removal and Installation: For J20 Engine” for
compressor) to compress rings. Guide connecting installation.
rod into place on crankshaft. 6) Install oil pan. Refer to “Oil Pan and Oil Pump
Using a hammer handle, tap piston head to install Strainer Removal and Installation: For J20 Engine in
piston into bore. Hold ring compressor firmly against Section 1E” for installation.
cylinder block until all piston rings have entered
7) Install engine assembly to vehicle referring to
cylinder bore.
“Engine Assembly Removal and Installation: For J20
Special tool Engine”.
(A): 09916–77310
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly
S5JB0A1426038

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

I2RH01140149-01

4) Install connecting rod bearing cap (1) as follows.

NOTE
If connecting rod bolt is reused, make sure to
check connecting rod bolt for deformation
referring to “Connecting Rod Bolt
Deformation (Plastic Deformation Tightening
Bolt)” under “Pistons, Piston Rings,
Connecting Rods and Cylinders Inspection I2RH01140151-01

and Cleaning: For J20 Engine”. • Force piston pin out.

a) Point arrow mark (2) on cap to crankshaft pulley

side.
b) Apply engine oil to new connecting rod bolts (3).
c) Tighten all connecting rod bolts to 15 N˜m (1.5
kgf-m, 11.0 lb-ft).
d) Retighten them by turning through 45q.
e) Repeat step d) once again.
Tightening torque
Connecting rod bolt (a): Tighten 15 N˜m (1.5
kgf-m, 11.0 lb-ft), 45q and 45q by the specified I2RH01140152-01

procedure.

I4RH01140037-01
1D-110 Engine Mechanical: For J20 Engine

Assembly

NOTE
Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder
clearance. When installing a standard size piston, make sure to match piston with cylinder as follows.

1) Each piston (1) has stamped number (2) as shown. It represents outer diameter of piston.
2) There are also painted color (3) of red or blue on cylinder block (2) as shown.

I5JB0A142050-01

4. Crank shaft pulley side 7. No.2 cylinder

5. Flywheel side 8. No.3 cylinder
6. No.1 cylinder 9. No.4 cylinder

3) Stamped number on piston and painted color (or stamped number) on cylinder block should correspond. That is,
install number “2” stamped piston to cylinder which is identified with blue painted (or “2” stamped) and a number
“1” piston to cylinder with red painted (or “1” stamped).
Also, a letter “A” or “B” is stamped on piston head but ordinarily it is not necessary to discriminate each piston by
this letter.
Piston outer diameter and cylinder bore diameter specification
Piston Cylinder
Paint
Number Outer diameter Bore diameter
(Number)
83.9800 – 83.9900 mm 84.0101 – 84.0200 mm
1 Red (1)
(3.3063 – 3.3066 in.) (3.3075 – 3.3078 in.)
83.9700 – 83.9799 mm 84.0000 – 84.0100 mm
2 Blue (2)
(3.3059 – 3.3062 in.) (3.3071 – 3.3074 in.)
 Engine Mechanical: For J20 Engine 1D-111

4) Install piston pin to piston (1) and connecting rod (3): 5) Install piston rings to piston:
After applying engine oil to piston pin and piston pin • As indicated in figure at the left, 1st and 2nd rings
holes in piston and connecting rod, fit connecting rod have “TOP” mark respectively. When installing
to piston as shown in figure and insert piston pin to these piston rings to piston, direct marked side of
piston and connecting rod, and install piston pin each ring toward top of piston.
circlips.
• 1st ring (1) differs from 2nd ring (2) in thickness,
NOTE shape and color of surface contacting cylinder
wall.
Oil hole (4) come on intake side.
Distinguish 1st ring from 2nd ring by referring to
figure.
1 • When installing oil ring (3), install spacer first and
2 then two rails.

I5JB0A142051-01 I5JB0A142052-02

2. Front mark 4. Oil hole 6) After installing three rings (1st, 2nd and oil rings),
distribute their end gaps as shown in figure.
NOTE
Circlip (4) should be installed so that circlip
end gap comes within such range as
indicated by arrow.

I5JB0A142053-01

1. Front mark
2. 1st ring end gap
5
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
I4RH01140039-01
5. Oil ring lower rail gap
1. Piston 3. Connecting rod 6. Intake side
2. Front mark 5. Oil hole 7. Exhaust side
1D-112 Engine Mechanical: For J20 Engine

Pistons, Piston Rings, Connecting Rods and Pistons

Cylinders Inspection and Cleaning • Inspect piston for faults, cracks or other damages.
S5JB0A1426039
Damaged or faulty piston should be replaced.
Inspection • Piston diameter:
As indicated in figure, piston diameter should be
Cylinder measured at a position 26.5 mm (1.04 in.) (“a”) from
piston skirt end in the direction perpendicular to piston
• Inspect cylinder walls for scratches, roughness, or
pin.
ridges which indicate excessive wear. If cylinder bore
is very rough or deeply scratched, or ridged, rebore Piston diameter
cylinder and use over size piston. Standard 83.9700 – 83.9900 mm
• Using a cylinder gauge, measure cylinder bore in (3.3059 – 3.3067 in.)
thrust and axial directions at two positions as shown in Oversize: 0.50 mm 84.4700 – 84.4900 mm
figure. (0.0196 in.) (3.3256 – 3.3264 in.)
If any of following conditions is noted, rebore cylinder.
1) Cylinder bore diameter 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: 84.000 – 84.020 mm (3.3070 – 3.3078 I2RH01140157-01

in.) • Piston clearance:

Limit: 84.050 mm (3.3090 in.) Measure cylinder bore diameter and piston diameter
to find their difference which is piston clearance.
Taper and out-of-round
Piston clearance should be within specification as
Limit: 0.10 mm (0.004 in.)
follows. If it is out of specification, rebore cylinder and
NOTE use oversize piston.
If any one of four cylinders has to be rebored, Piston clearance
rebore all four to the same next oversize. 0.02 – 0.04 mm (0.0008 – 0.0015 in.)
This is necessary for the sake of uniformity
and balance. NOTE
Cylinder bore diameters used here are
measured in thrust direction at two positions.

• Ring groove clearance:

Before checking, piston grooves must be clean, dry
and free of carbon.
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
Item Standard Limit
Top 0.03 – 0.07 mm
0.12 mm (0.0047 in.)
ring (0.0120 – 0.0027 in.)
2nd 0.02 – 0.06 mm
0.1 mm (0.0039 in.)
ring (0.0008 – 0.0023 in.)
0.06 – 0.15 mm
Oil ring —
(0.0024 – 0.0059 in.)

I5JB0A142046-01

1. 50 mm (1.96 in.) 2. 95 mm (3.74 in.)

 Engine Mechanical: For J20 Engine 1D-113

Piston rings
To measure end gap, insert piston ring (2) into cylinder
bore and then measure the gap by using thickness
gauge (1).
If measured gap is out of specification, replace ring.

NOTE
Clean carbon and any other dirt from top of
cylinder bore before inserting piston ring.

Piston ring end gap

I2RH01140159-01 Item Standard Limit
Top 0.20 – 0.33 mm
0.7 mm (0.0276 in.)
Piston pin ring (0.0079 – 0.0129 in.)
• Check piston pin, connecting rod small end bore and 2nd 0.33 – 0.48 mm
0.7 mm (0.0276 in.)
piston bore for wear or damage, paying particular ring (0.0129 – 0.0188 in.)
attention to condition of small end bore bush. If pin, 0.20 – 0.50 mm
Oil ring 1.8 mm (0.0709 in.)
connecting rod small end bore or piston bore is badly (0.0079 – 0.0196 in.)
worn or damaged, replace pin, connecting rod or
piston. Piston rings end gap
“a”: 120 mm (4.72 in.)
• Piston pin clearance: Check piston pin clearance in
small end.
Replace connecting rod if its small end is badly worn
or damaged or if measured clearance exceeds limit.
Piston pin clearance in small end
Standard: 0.003 – 0.014 mm (0.0001 – 0.0005 in.)
Piston pin clearance in piston
Standard: 0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Small-end bore
21.003 – 21.011 mm (0.8269 – 0.8272 in.)
Piston pin diameter [B]
20.997 – 21.000 mm (0.8267 – 0.8268 in.)
Piston bore [A]
21.006 – 21.014 mm (0.8270 – 0.8273 in.)
I2RH01140161-01

I5JB0A142054-02
1D-114 Engine Mechanical: For J20 Engine

Connecting rod Crank pin and connecting rod bearings

• Big-end side clearance: • Inspect crank pin for uneven wear or damage.
Check big-end of connecting rod for side clearance, Measure crank pin for out-of-round or taper with a
with rod fitted and connected to its crank pin in the micrometer. If crank pin is damaged, or out-of round
normal manner. If measured clearance is found to or taper is out of limit, replace crankshaft or regrind
exceed its limit, replace connecting rod. crank pin referring to the following step 6).
Big-end side clearance Connecting rod bearing and crank pin
Standard Limit Item Standard
0.25 – 0.40 mm Crank pin diameter 49.982 – 50.000 mm
0.45 mm (0.0177 in.)
(0.0099 – 0.0150 in.) (1.9768 – 1.9685 in.)

Out-of-round
“A” – “B”
Taper
“a” – “b”
Out-of-round and taper limits
0.01 mm (0.0004 in.)

I4RH01140041-01

• Connecting rod alignment:

Mount connecting rod on aligner to check it for bow
and twist. If limit is exceeded, replace it.
Limit on bow
0.05 mm (0.0020 in.)
Limit on twist
0.10 mm (0.0039 in.)
I2RH01140163-01

• Connecting rod bearing general information:

Inspect bearing shells for signs of fusion, pitting, burn
or flaking and observe contact pattern. Bearing shells
found in defective condition must be replaced.
Two kinds of connecting rod bearings are available;
standard size bearing and 0.25 mm (0.0098 in.)
undersize bearing. For identification of undersize
bearing, it is painted red (1) at the position as
I4RH01140053-01 indicated in the figure, undersize bearing thickness is
1.605 – 1.615 mm (0.0632 – 0.0635 in.) at the center
of it.

I2RH01140164-01
 Engine Mechanical: For J20 Engine 1D-115

• Connecting rod bearing clearance: e. Remove connecting rod bearing cap, and using a
a. Before checking bearing clearance, clean bearing scale (2) on gauging plastic envelope, measure
and crank pin. gauging plastic (1) width at the widest point
(clearance).
b. Install bearing in connecting rod and bearing cap.
If clearance exceeds its limit, select connecting
c. Place a piece of gauging plastic (1) to full width of rod bearing referring to “Pistons, Piston Rings,
crank pin as contacted by bearing (parallel to Connecting Rods and Cylinders Inspection and
crankshaft), avoiding oil hole. Cleaning: For J20 Engine” below mentioned item.
After selecting new bearing, recheck clearance.
Bearing clearance
Standard Limit
0.045 – 0.063 mm 0.08 mm (0.0031 in.)
(0.0018 – 0.0025 in.)

I2RH01140165-01

d. Install connecting rod bearing cap (1) as follows.

i. Point arrow mark (2) on cap to crankshaft
pulley side.
ii. Apply engine oil to connecting rod bolts (3).
iii. Tighten all connecting rod bolts to 15 N˜m (1.5
kgf-m, 11.0 lb-ft). I2RH01140167-01

iv. Retighten them by turning through 45q. f. If clearance can not be brought to within its limit
v. Repeat step d) once again. even by using a new standard size bearing,
replace crankshaft or regrind crankpin to
Tightening torque undersize as follows.
Connecting rod bolt (a): Tighten 15 N˜m – Install 0.25 mm undersize bearing to
(1.5 kgf-m, 11.0 lb-ft), 45q and 45q by the connecting rod big end.
specified procedure.
– Measure bore diameter of connecting rod big
NOTE end.
Do not turn crankshaft with gauging plastic – Regrind crankpin to the following finished
installed. diameter.
Finished Measured big end bore
0.054 mm
crankpin = diameter (including –
(0.0021 in.)
diameter undersize bearing)

– Confirm that bearing clearance is within the

standard value.

NOTE
After checking the connecting rod bearing
clearance, make sure that checking for
“Connecting rod bolt deformation”.

I4RH01140037-01
1D-116 Engine Mechanical: For J20 Engine

• Selection of connecting rod bearings: b. Next, check crank pin diameter. On crank web of
No. 3 cylinder, four alphabets are stamped as
NOTE shown in the figure.
• If bearing is in malcondition or bearing Three kinds of alphabet (“A”, “B” and “C”)
clearance is out of specification, select a represent the following crank pin diameter
new standard bearing according to the respectively.
following procedure and install it. For example, stamped “A” indicates that
corresponding crank pin diameter is 49.9940 –
• When replacing crankshaft or connecting
50.0000 mm (1.9683 – 1.9685 in.).
rod and its bearing due to any reason,
select new standard bearings to be Crank pin diameter
installed referring to numbers stamped on Crank pin diameter
connecting rod and its cap and/or Stamped alphabet
(without bearing)
alphabets stamped on crank web of No. 3 49.9940 – 50.0000 mm
cylinder. A
(1.9683 – 1.9685 in.)
49.9880 – 49.9939 mm
a. Check stamped numbers on connecting rod and B
(1.9681 – 1.9682 in.)
its cap as shown. 49.9820 – 49.9879 mm
Three kinds of numbers (“1”, “2” and “3”) C
(1.9677 – 1.9680 in.)
represent the following connecting rod big end
inside diameters.
For example, stamped number “1” indicates that
corresponding connecting rod big-end inside
diameter is 53.0000 – 53.0060 mm (2.0867 –
2.0868 in.).
Connecting rod big-end inside diameter
Connecting rod big-end
Stamped numbers
inside diameter
53.0000 – 53.0060 mm
1
(2.0867 – 2.0868 in.)
53.0061 – 53.0120 mm
2
(2.0869 – 2.0870 in.)
53.0121 – 53.0180 mm
3
(2.0871 – 2.0873 in.)
I5JB0A142055-01

[A]: Crankshaft pin diameter for No.1 cylinder

[B]: Crankshaft pin diameter for No.2 cylinder
[C]: Crankshaft pin diameter for No.3 cylinder
[D]: Crankshaft pin diameter for No.4 cylinder

c. There are 5 kinds of standard bearings differing in

thickness. To distinguish them, they are painted in
the following colors at the position as indicated in
the figure.
Each color indicated the following thickness at the
center of bearing.
Standard size of connecting rod bearing
thickness
Color painted Bearing thickness
1.482 – 1.485 mm
Green
(0.05835 – 0.05846 in.)
1.485 – 1.488 mm
Black
I2RH01140210-01 (0.05847 – 0.05858 in.)
[A]: Weight indication mark (It is not necessary in servicing) 1.488 – 1.491 mm
Colorless
[B]: Connecting rod big-end inside diameter number (0.05859 – 0.05870 in.)
1.491 – 1.494 mm
Yellow
(0.05871 – 0.05881 in.)
1.494 – 1.497 mm
Blue
(0.05882 – 0.05893 in.)
 Engine Mechanical: For J20 Engine 1D-117

• Connecting rod bolt

Measure each thread diameter of connecting rod bolts
(1) at “A” on 28.5 mm (1.12 in.) from bolt mounting
surface and “B” on 42.0 mm (1.65 in.) from bolt
mounting surface by using a micrometer (2).
Calculate difference in diameters (“A” – “B”). If it
exceeds limit, replace connecting rod.

IYSQ01141169-01
Connecting rod bolt measurement points
“a”: 28.5 mm (1.12 in.)
1. Paint
“b”: 42.0 mm (1.65 in.)
d. From number stamped on connecting rod and its Connecting rod bolt diameter difference
cap and alphabet stamped on crank web No. 3 limit (“A” – “B”): 0.1 mm (0.004 in.)
cylinder, determine new standard bearing to be
installed to connecting rod big-end inside, by 1 ‘‘A’’ ‘‘B’’
referring to the table.
For example, if number stamped on connecting
rod and its cap is “1” and alphabet stamped on
crank web No. 3 cylinder is “B”, install a new
standard bearing painted in “Black” to its ‘‘a’’
connecting rod big-end inside.
‘‘b’’
Specifications of new standard connecting rod
bearing size
2
Number stamped on
connecting rod and its cap
(Connecting rod big end inside 1
diameter)
1 2 3
Alphabet A Green Black Colorless
stamped on B Black Colorless Yellow
crank web of
I4RH01140043-01
No. 3 cylinder
C Colorless Yellow Blue
(Crank pin
Cleaning
diameter)
Clean carbon from piston head and ring grooves, using a
e. Check bearing clearance with newly selected suitable tool.
standard bearing referring to “Crank pin and
connecting rod bearings: For J20 Engine”.
If clearance still exceeds its limit, use next thicker
bearing and recheck clearance.
1D-118 Engine Mechanical: For J20 Engine

Main Bearings, Crankshaft and Cylinder Block Components

S5JB0A1426040

I5JB0A142056-02
 Engine Mechanical: For J20 Engine 1D-119

1. Cylinder block 9. Check valve 17. Knock sensor

2. Lower crankcase 10. Flywheel : Tighten 40 N˜m (4.0 kgf-m, 29.0 lb-ft), 0
: Apply sealant 99000-31250 to mating N˜m (0 kgf-m, 0 lb-ft), 40 N˜m (4.0 kgf-m,
surface. 29.0 lb-ft) and 58 N˜m (5.8 kgf-m, 42.0
lb-ft) by the specified procedure.
3. Crankshaft 11. Water pump : Tighten 26 N˜m (2.6 kgf-m, 19.0 lb-ft) by
the specified procedure.
4. O-ring 12. Heater outlet pipe : 70 N˜m (7.0 kgf-m, 51.0 lb-ft)
5. Oil pump chain 13. CKP sensor : 11 N˜m (1.1 kgf-m, 8.0 lb-ft)
6. Main bearing 14. Crankcase bolt (10 mm thread diameter) : 23 N˜m (2.3 kgf-m, 17.0 lb-ft)
: Do not apply engine oil between cylinder
block and bearing, between lower crankcase
and bearing. Upper half of bearing has an oil
groove.
7. Thrust bearing 15. Crankcase bolt (8 mm thread diameter) : Do not reuse.
8. Rear oil seal 16. Flywheel mounting bolt : Apply engine oil to inside / sliding
surface.

Main Bearings, Crankshaft and Cylinder Block

Removal and Installation
S5JB0A1426041

Removal
1) Remove engine assembly from vehicle. Refer to
“Engine Assembly Removal and Installation: For J20
Engine”.
2) Remove clutch and flywheel (drive plate for A/T) by
using special tool.
Special tool
(A): 09924–17810

I2RH01140170-01

5) Remove water pump (1) and heater outlet pipe.

6) Remove engine front mounting brackets (2).

I2RH01140169-01

1. Flywheel bolt

3) Remove pistons and connecting rods referring to

“Pistons, Piston Rings, Connecting Rods and I2RH01140171-01
Cylinders Removal and Installation: For J20 Engine”.
4) Remove CKP sensor (1).
1D-120 Engine Mechanical: For J20 Engine

7) Loosen crankcase bolts, in sequence shown in figure

and remove them.

1
(3)
(8) (10) (12) (5)
(2)
(18)
(16) (20)
(22) (14)

(15) (19) (21) (17)

(13)
2
(4) (6) (11) (9) (7) (1)
3 I4RH01140055-01
I4RH01140045-01 4) Fit thrust bearings (1) to cylinder block between No.2
1. Lower crankcase and No.3 cylinders. Face oil groove (2) sides to
2. Crankcase bolts (10 mm thread diameter) crank webs.
3. Crankcase bolts (8 mm thread diameter)
5) Confirm that dowel pins (3) are installed to cylinder
block.
8) Remove crankshaft from cylinder block.

Installation

NOTE
• All parts to be installed must be perfectly
clean.
• Be sure to oil crankshaft journals, journal
bearings, thrust bearings, crankpins,
connecting rod bearings, pistons, piston
rings and cylinder bores.
• Journal bearings, crankcase (bearings
I5JB0A142057-01
caps), connecting rods, rod bearings, rod
bearing caps, pistons and piston rings are 6) Put crankshaft (1) with oil pump chain to cylinder
in combination sets. Do not disturb block.
combination and try to see that each part
goes back to where it came from, when
installing.
• Clean mating surface of cylinder block and
lower crankcase, remove oil, old sealant
and dust from mating surface.

1) Fit main bearings to cylinder block (1).

One of two halves of main bearing (4) has oil groove
(3).
Install this half with oil groove to cylinder block and I2RH01140175-01
another half without oil groove to lower crankcase. 7) Apply sealant “A” to lower crankcase (1) mating
Make sure that two halves are painted in the same surface area as shown in figure.
color.
2) Install new O-ring (2) to cylinder block. “A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
3) Install knock pins (5) to cylinder block.
Sealant amount for lower crankcase
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
 Engine Mechanical: For J20 Engine 1D-121

9) Pull out dowel pin (2) from crankshaft (1) and then
install rear oil seal (3) by using special tools and
plastic hammer.
Special tool
(A): 09911–97710
(B): 09911–97811
10) Install dowel pin (2).

I2RH01140176-01

2. Bearing

8) Install lower crankcase (1) to cylinder block.

After applying engine oil to all crankcase bolts ((1) –
(22)), tighten them gradually as follows.
a) Tighten bolts ((1) – (10)) to 30 N˜m (3.0 kgf-m,
21.5 lb-ft) according to numerical order as
shown.
b) Tighten bolts ((1) – (10)) to 42 N˜m (4.2 kgf-m,
30.5 lb-ft) according to numerical order as
shown.
c) In the same manner as in step a), tighten them to
the specified torque.
d) Tighten bolts ((11) – (22)) to the specified torque
according to numerical order as shown. I5JB0A142058-01

Tightening torque 4. Crankshaft side 5. Oil seal side

Crankcase bolt with 10 mm thread diameter
((1) – (10)): Tighten 40 N˜m (4.0 kgf-m, 29.0 11) Install CKP sensor (1) and fix its wire harness with
lb-ft), 0 N˜m (0 kgf-m, 0 lb-ft), 40 N˜m (4.0 kgf- bracket.
m, 29.0 lb-ft) and 58 N˜m (5.8 kgf-m, 42.0 lb-ft)
Tightening torque
by the specified procedure.
CKP sensor bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Crankcase bolt with 8 mm thread diameter
((11) – (22)): Tighten 26 N˜m (2.6 kgf-m, 19.0
lb-ft) by the specified procedure.

NOTE
• After tightening crankcase bolts, check to
be sure that crankshaft rotates smoothly
when turned by hand.
• Use new crankcase bolt (10 mm thread
diameter).
I2RH01140179-01

I4RH01140046-01
1D-122 Engine Mechanical: For J20 Engine

12) Install flywheel (drive plate for A/T). 18) Install, timing chain sprockets, timing chains, timing
Using special tool, lock flywheel or drive plate, and chain tensioner, tensioner adjusters, timing chain
tighten flywheel or drive plate bolts (1) applied with guides, timing chain cover, crankshaft pulley, water
sealant to specification. pump pulley. Refer to “Timing Chain Cover Removal
and Installation: For J20 Engine”, “2nd Timing Chain
Special tool
and Chain Tensioner Removal and Installation: For
(A): 09924–17810
J20 Engine” and “1st Timing Chain and Chain
Tightening torque Tensioner Removal and Installation: For J20
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft) Engine”.
Drive plate bolt: 65 N·m (6.5 kgf-m, 47.0 lb-ft) 19) Install oil pump strainer and oil pan referring to “Oil
Pan and Oil Pump Strainer Removal and Installation:
For J20 Engine in Section 1E”.
20) Install clutch to flywheel (for M/T vehicle). For clutch
installation, refer to “Clutch Cover, Clutch Disc and
Flywheel Removal and Installation in Section 5C”.
21) Install engine assembly to vehicle. Refer to “Engine
Assembly Removal and Installation: For J20
Engine”.

Main Bearings, Crankshaft and Cylinder Block

I2RH01140180-01
Inspection
S5JB0A1426042
13) Install engine front mounting brackets (1). Tighten
bracket bolts to specified torque. Crankshaft
Tightening torque
Crankshaft runout
Engine front mounting bracket bolt (a): 55 N·m (
Using a dial gauge, measure runout at center journal.
5.5 kgf-m, 40.0 lb-ft)
Rotate crankshaft slowly. If runout exceeds its limit,
14) Install water pump (2) and heater outlet pipe (3). replace crankshaft.
Refer to “Water Pump Removal and Installation (For
Limit on runout
J20 Engine Model) in Section 1F”.
0.06 mm (0.0023 in.)

I2RH01140182-01

I2RH01140181-01

15) Install pistons and connecting rods. Refer to

“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation: For J20 Engine”.
16) Install oil pump. Refer to “Oil Pump Removal and
Installation: For J20 Engine in Section 1E”.
17) Install cylinder head assembly to cylinder. Refer to
“Valves and Cylinder Head Removal and Installation:
For J20 Engine”.
 Engine Mechanical: For J20 Engine 1D-123

Crankshaft thrust play Out-of-round and taper (uneven wear) of journals

Measure this play with crankshaft set in cylinder block in An unevenly worn crankshaft journal shows up as a
the normal manner, that is, with thrust bearing and lower difference in diameter at a cross section or along its
crankcase installed. Tighten crankcase bolts referring to length (or both). This difference, if any, is determined by
“Main Bearings, Crankshaft and Cylinder Block Removal taking micrometer readings. If any one of journals is
and Installation: For J20 Engine”. badly damaged or if amount of uneven wear in the sense
Use a dial gauge to read displacement in axial (thrust) exceeds its limit, regrind or replace crankshaft.
direction of crankshaft.
Limit on out-of-round and taper
If its limit is exceeded, replace thrust bearing with new
0.01 mm (0.0004 in.)
standard one or oversize one to obtain standard thrust
play. Out-of-round
“A” – “B”
Crankshaft Thrust Play
Standard: 0.10 – 0.35 mm (0.0039 – 0.0137 in.) Taper
Limit: 0.42 mm (0.0149 in.) “a” – “b”

I2RH01140185-01

Main Bearings
I2RH01140183-01

Thickness of crankshaft thrust bearing Main bearings general information

Standard 2.500 mm (0.0984 in.) • Service main bearings are available in standard size
Oversize: 0.125 mm and 0.25 mm (0.0098 in.) undersize, and standard
2.563 mm (0.1009 in.)
(0.0049 in.) size has 5 kinds of bearings differing in tolerance.
• Upper half of bearing (1) has oil groove (2) as shown
in figure.
Install this half with oil groove to cylinder block.
• Lower half of bearing does not have oil groove.

I2RH01140184-01

1. Thrust bearing 2. Oil groove

I2RH01140186-01

Main bearings inspection

Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and
lower halves. Never replace either half without replacing
the other half.
1D-124 Engine Mechanical: For J20 Engine

Main bearing clearance Selection of main bearings

Check clearance by using gauging plastic according to STANDARD BEARING:
the following procedure. If engine is under the following conditions, select a new
1) Remove lower crankcase. standard bearing as followings and install it.
2) Clean bearings and main journals. • Bearing is in malcondition.
3) Place a piece of gauging plastic (1) to full width of • Bearing clearance is cut of specification.
bearing (parallel to crankshaft) on journal, avoiding • Crankshaft or cylinder block is replaced.
oil hole. 1) First check journal diameter. As shown in figure,
crank web No.2 has stamped numbers.
Six kinds of numbers (“4” through “9”) represent the
following journal diameters.
Journal diameter
Stamped numbers Journal diameter
58.0030 – 58.0060 mm
4
(2.28358 – 2.28369 in.)
58.0000 – 58.0029 mm
5
(2.28346 – 2.28357 in.)
57.9970 – 57.9999 mm
6
(2.28334 – 2.28345 in.)
I2RH01140187-01
57.9940 – 57.9969 mm
4) Install lower crankcase to cylinder block referring to 7
(2.28323 – 2.28333 in.)
“Main Bearings, Crankshaft and Cylinder Block
57.9910 – 57.9939 mm
Removal and Installation: For J20 Engine”. 8
(2.28311 – 2.28322 in.)
NOTE 57.9880 – 57.9909 mm
9
(2.28299 – 2.28310 in.)
Do not rotate crankshaft while gauging
plastic is installed. Stamped numbers on crank web No.2 (3) represent
journal diameters marked with an arrow in figure
5) Remove lower crankcase and using scale (2) on
respectively. For example, stamped number “5”
gauging plastic envelop (1), measure gauging plastic
indicates that corresponding journal diameter is
width at its widest point. If clearance exceeds its
58.0000 – 58.0029 mm (2.28346 – 2.28357 in.).
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.
1 2
After selecting new bearing, recheck clearance.
Main Bearing Clearance
Standard: 0.032 – 0.050 mm (0.0013 – 0.0019 in.)
Limit: 0.063 mm (0.0024 in.) 3
I4RH01140047-01

1. Crankshaft pulley side 2. Flywheel side

I2RH01140188-01
 Engine Mechanical: For J20 Engine 1D-125

2) Next, check journal bore diameter. On lower 3) There are 5 kinds of standard bearings differing in
crankcase five alphabets are stamped as shown in thickness. To distinguish them, they are painted (1)
figure. in the following colors at the position as indicated in
Three kinds of alphabets (“A”, “B” and “C”) represent figure.
the following journal bore diameters. Each color indicates the following thickness at the
center of bearing.
Journal bore diameter
Stamped alphabet Journal bore diameter Standard size main bearing thickness
62.0000 – 62.0060 mm Color painted Bearing thickness
A
(2.44094 – 2.44117 in.) 1.9910 – 1.9940 mm
Green
62.0061 – 62.0120 mm (0.07839 – 0.07850 in.)
B
(2.44118 – 2.44141 in.) 1.9940 – 1.9970 mm
Black
62.0121 – 62.0180 mm (0.07851 – 0.07862 in.)
C
(2.44142 – 2.44164 in.) 1.9970 – 2.0000 mm
Colorless (no painted)
(0.07863 – 0.07874 in.)
Stamped alphabets on lower crankcase represent 2.0000 – 2.0030 mm
Yellow
journal diameter marked with an arrow in figure (0.07874 – 0.07885 in.)
respectively. 2.0030 – 2.0060 mm
Blue
For example, stamped alphabet “A” at No.2 journal (0.07886 – 0.07897 in.)
indicates that (journal) bore diameter of No.2 journal
is 62.0000 – 62.0060 mm (2.44094 – 2.44117 in.).

2 3 4

6 7

I2RH01140191-01

I4RH01140048-01

1. No.1 journal 5. No.5 journal

2. No.2 journal 6. Crankshaft pulley side
3. No.3 journal 7. Flywheel side
4. No.4 journal
1D-126 Engine Mechanical: For J20 Engine

4) From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard
bearing to be installed to journal by referring to table shown.
For example, if number stamped on crank web No.2 is “5” and alphabet stamped on lower crankcase is “A”, install
new standard bearings painted in “Green” to cylinder block side journal and “Black” to lower crankcase side
journal.

NOTE
The meaning of “Upper” and “Lower” described in below table are the following.
• Upper: It is instruction of main bearing installed in cylinder block side journal.
• Lower: It is instruction of main bearing installed in lower crankcase side journal.

Main bearing cross-reference table (new standard bearing)

Standard number on crank web No.2
4 5 6 7 8 9
Upper: Green Upper: Black Upper: Colorless
A Green Black Colorless
Lower: Black Lower: Colorless Lower: Yellow
Standard
Upper: Black Upper: Colorless Upper: Yellow
alphabet on B Black Colorless Yellow
Lower: Colorless Lower: Yellow Lower: Blue
lower crankcase
Upper: Colorless Upper: Yellow
C Colorless Yellow Blue Blue
Lower: Yellow Lower: Blue

5) Check main bearing clearance with newly selected standard bearing referring to “Main Bearing Clearance”.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance.

UNDERSIZE BEARING (0.25 mm):

• 0.25 mm undersize bearing is available, in five kinds varying in thickness.
To distinguish them, each bearing is painted (1) in the following colors at such position as indicated in figure.
Each color represents the following thickness at the center of bearing.
Undersize main bearing thickness
Color painted Bearing thickness
Green & Red 2.1160 – 2.1190 mm (0.08331 – 0.08342 in.)
Black & Red 2.1190 – 2.1220 mm (0.08343 – 0.08354 in.)
Red only 2.1220 – 2.1250 mm (0.08355 – 0.08366 in.)
Yellow & Red 2.1250 – 2.1280 mm (0.08367 – 0.08377 in.)
Blue & Red 2.1280 – 2.1310 mm (0.08378 – 0.08389 in.)

I2RH01140192-01
 Engine Mechanical: For J20 Engine 1D-127

• If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows.
a. Regrind journal to the following finished diameter.
Finished journal diameter
57.7380 – 57.7560 mm (2.27315 – 2.27385 in.)
b. Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
c. Using journal diameter measured and alphabets stamped on lower crankcase, select an undersize bearing by
referring to the following table.
Check bearing clearance with newly selected undersize bearing.

I2RH01140193-01

Undersize bearing specification

Measured journal diameter
57.7500 – 57.7560 mm 57.7440 – 57.7499 mm 57.7380 – 57.7439 mm
(2.27362 – 2.27385 in.) (2.27338 – 2.27361 in.) (2.27315 – 2.27337 in.)
A Green & Red Black & Red Red only
Alphabets stamped
B Black & Red Red only Yellow & Red
on lower crankcase
C Red only Yellow & Red Blue & Red

Crankshaft Position Sensor Plate Oil Pump Sprocket

Check teeth of plate for damage. Check teeth of sprocket for wear or damage.
If any damage is found, replace crankshaft (1). If any damage or wear is found, replace crankshaft (1).

I2RH01140194-01 I2RH01140195-01

2. Crankshaft position sensor plate 2. Oil pump sprocket

1D-128 Engine Mechanical: For J20 Engine

Oil Pump Chain 2) Using micrometer, measure piston diameter.

Check oil pump chain for wear or damage. 3) Calculate cylinder bore diameter to be rebored as
follows.
D=A+B–C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
I2RH01140196-01 B: Piston clearance = 0.02 – 0.04 mm (0.0008 –
0.0015 in.)
Flywheel C: Allowance for honing = 0.02 mm (0.0008 in.)
• If ring gear is damaged, cracked or worn, replace 4) Rebore and hone cylinder to calculated dimension.
flywheel.
• If the surface contacting clutch disc is damaged, or NOTE
excessively worn, replace flywheel. Before reboring, install lower crankcase and
• Check flywheel for face runout with a dial gauge. tighten to specification to avoid distortion of
If runout exceeds its limit, replace flywheel. bearing bores.
Limit on runout 5) Measure piston clearance after honing.
0.2 mm (0.0078 in.)

I2RH01140198-01

Cylinder Block
• Distortion of gasketed surface
• Using straightedge and thickness gauge, check
gasketed surface for distortion and, if flatness
exceeds its limit, correct It.
Flatness Limit
0.06 mm (0.0024 in.)

I5JB0A142059-01

“e”: 50 mm (1.96 in.) “g”: 26.5 mm (1.04 in.)

“f”: 95 mm (3.74 in.)
I2RH01140199-01

Check Valve
Honing or reboring cylinders
Check check valve for clogging and ball for being stuck.
1) When any cylinder needs reboring, all other
cylinders must also be rebored at the same time.
Oversize piston specification
Size Piston diameter
STD 83.970 – 83.990 mm (3.3059 – 3.3067 in.)
O/S 0.50 84.470 – 84.490 mm (3.3256 – 3.3264 in.)

I2RH01140201-01
 Engine Mechanical: For J20 Engine 1D-129

Specifications
Tightening Torque Specifications
S5JB0A1427001
Tightening torque
Fastening part Note
N˜m kgf-m lb-ft
Camshaft housing bolts 11 N˜m (1.1 kgf-m, 8.0 lb-ft) for tightening of )
special tool
Camshaft housing bolt 11 1.1 8.0 )/)/)
Cylinder head cover nut 11 1.1 8.0 )
Starting motor terminal nut 11 1.1 8.0 )
Generator terminal nut 7 0.7 5.0 )
Timing chain cover bolt and nut 11 1.1 8.0 )
Idler pulley nut 42 4.2 30.5 )
Generator belt tensioner bolt 25 2.5 18.5 )
Crankshaft pulley bolt 150 15.0 108.5 )
Camshaft timing sprocket bolt 80 8.0 57.5 )
Timing chain tensioner adjuster No.2 bolt 11 1.1 8.0 )
Timing chain tensioner adjuster No.2 nut 45 4.5 33.0 )
Timing chain tensioner nut 25 2.5 18.0 )
Timing chain tensioner adjuster No.1 bolt 11 1.1 8.0 )
Timing chain guide No.1 bolt 9 0.9 6.5 )
Cylinder head bolt (M10) Tighten 52 N˜m (5.2 kgf-m, 38.0 lb-ft), 82 )
N˜m (8.2 kgf-m, 59.5 lb-ft), 0 N˜m (0 kgf-m,
0 lb-ft), 52 N˜m (5.2 kgf-m, 38.0 lb-ft) and
103 N˜m (10.3 kgf-m, 74.5 lb-ft) by the
specified procedure.
Cylinder head bolt (M6) 11 1.1 8.0 )
Connecting rod bolt Tighten 15 N˜m (1.5 kgf-m, 11.0 lb-ft), 45q )/)
and 45q by the specified procedure.
Crankcase bolt with 10 mm thread diameter ((1) Tighten 40 N˜m (4.0 kgf-m, 29.0 lb-ft), 0 )
– (10)) N˜m (0 kgf-m, 0 lb-ft), 40 N˜m (4.0 kgf-m,
29.0 lb-ft) and 58 N˜m (5.8 kgf-m, 42.0 lb-ft)
by the specified procedure.
Crankcase bolt with 8 mm thread diameter ((11) Tighten 26 N˜m (2.6 kgf-m, 19.0 lb-ft) by the )
– (22)) specified procedure.
CKP sensor bolt 11 1.1 8.0 )
Flywheel bolt 70 7.0 51.0 )
Drive plate bolt 65 6.5 47.0 )
Engine front mounting bracket bolt 55 5.5 40.0 )

NOTE
The specified tightening torque is also described in the following.
“Engine Mountings Components: For J20 Engine”
“Timing Chain Cover Components: For J20 Engine”
“2nd Timing Chain and Chain Tensioner Components: For J20 Engine”
“1st Timing Chain and Chain Tensioner Components: For J20 Engine”
“Camshafts, Tappet and Shim Components: For J20 Engine”
“Valves and Cylinder Head Components: For J20 Engine”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components: For J20 Engine”
“Main Bearings, Crankshaft and Cylinder Block Components: For J20 Engine”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.
1D-130 Engine Mechanical: For J20 Engine

Special Tools and Equipment

Recommended Service Material
S5JB0A1428001
Material SUZUKI recommended product or Specification Note
Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 )
SUZUKI Bond No.1207F P/No.: 99000–31250 )/)/)

NOTE
Required service material is also described in the following.
“Timing Chain Cover Components: For J20 Engine”
“2nd Timing Chain and Chain Tensioner Components: For J20 Engine”
“1st Timing Chain and Chain Tensioner Components: For J20 Engine”
“Camshafts, Tappet and Shim Components: For J20 Engine”
“Valves and Cylinder Head Components: For J20 Engine”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components: For J20 Engine”
“Main Bearings, Crankshaft and Cylinder Block Components: For J20 Engine”

Special Tool
S5JB0A1428002
09355–35754–600 09367–04002
Hose 3-way joint
) )

09911–97710 09911–97811
Oil seal guide Oil seal installer
) )

09913–75510 09915–64512
Bearing installer Compression gauge
) )

09915–64530 09915–67010
Compression gauge hose Compression gauge
attachment (C)
) )

09915–67311 09916–14510
Vacuum gauge Valve lifter
) )/)
 Engine Mechanical: For J20 Engine 1D-131

09916–16510 09916–34542
Valve lifter attachment Reamer handle
)/) )/)

09916–37810 09916–38210
Valve guide reamer (6 mm) Valve guide reamer (11 mm)
) )

09916–46020 09916–57340
Valve guide remover Valve guide installer
attachment
) )

09916–57350 09916–66510
Valve guide installer handle Tappet holder
(6 mm)
)/) )/)

09916–77310 09916–84511
Piston ring compressor (50- Forceps
125 mm)
) )/)

09917–68221 09917–98221
Camshaft pulley holder Valve guide stem
attachment
)/) )

09918–08210 09919–28610
Vacuum gauge hose joint Protector sleeve
) )/)

09924–17810 09926–58010
Flywheel holder (drive plate Bearing remover attachment
stopper)
)/) )
1D-132 Engine Mechanical: For J20 Engine

09944–36011
Steering wheel remover
)