Main Bearings, Crankshaft and Cylinder Block Removal and Installation
Main Bearings, Crankshaft and Cylinder Block Removal and InstallationCAUTION:
Keep the following parts in order. They must go back in the position from which they were removed.
^ Main bearing
^ Thrust bearing
Removal
1) Remove engine assembly.
2) Remove flywheel for 5 M/T model or drive plate for 4 A/T model.
3) Remove generator.
4) Remove water pump.
5) Remove P/S pump.
6) Remove engine front mounting brackets (1).
7) Remove piston and connecting rod.
8) Remove oil pump chain adjuster (1) from lower crank case.
9) Remove CKP sensor.
10) Loosen crank case bolt No.2s in numerical order ("1" - "12") evenly and gradually.
11) Loosen crank case bolt No.1s in numerical order ("1" - "10") evenly and gradually, and then remove lower crank case and rear oil seal.
NOTE:
Use 12-point socket wrench to crank case bolt No.1s.
12) Remove crankshaft and oil pump chain from cylinder block.
13) Remove sensor plate (2) from crankshaft (1), if necessary.
NOTE:
Use T-30 security TORX(R) to loosen sensor plate screws (3).
Installation
CAUTION:
^ Apply engine oil to the following parts.
^ Crankshaft journal
^ Main bearing
^ Thrust bearing
^ Oil pump chain adjuster
^ Do not apply engine oil to the following spots.
^ Contact surfaces between main bearing and cylinder block
^ Contact surfaces between main bearing and lower crank case
^ Contact surfaces between connecting rod bearing and connecting rod
^ Contact surfaces between connecting rod bearing and connecting rod cap
^ Install the following parts in the position from which they were removed.
^ Main bearing
^ Thrust bearing
1) Install sensor plate (1) according to the following procedure.
a) Attach spring pin (2) to crankshaft (3).
NOTE:
Use spring pin which is genuine SUZUKI part (09205-05006).
b) Install sensor plate to crankshaft.
CAUTION:
^ Align spring pin hole (4) on sensor plate with spring pin on crankshaft.
^ Inside edge (5) of sensor plate is bent. Install sensor plate properly.
Tightening torque
Sensor plate screw (a): 11 Nm (1.1 kg-m, 8.5 lbf-ft)
c) Detach spring pin from crankshaft.
2) Install main bearings to cylinder block and lower crankcase according to the following procedure.
NOTE:
^ Install main bearing halves with oil groove to cylinder block.
^ Install other main bearing halves to lower crankcase.
a) Fit the tab (1) on each bearing into recess (2) in cylinder block or lower crank case.
b) Press bearing end (3) until it fully seat in cylinder block or lower crankcase.
c) Apply engine oil to sliding surface (4) of main bearing halves.
CAUTION:
Do not apply engine oil between bearing halves (5) and cylinder block or lower crank case (5).
3) Install new O-rings (1) to cylinder block (3).
4) Install dowel pins (2) to cylinder block (3).
5) Apply engine oil to thrust bearings (1) and install them to cylinder block journal No.3, with oil grooves (2) facing outward.
6) Apply engine oil to sliding surface of main bearings and crankshaft.
7) Install crankshaft to cylinder block, with oil pump chain installed to oil pump drive sprocket on crankshaft.
8) Apply sealant to mating surface of lower crankcase (1) as shown in figure.
"A": Sealant 99000-31260 (SUZUKI Bond No.1217G)
Sealant bead size for lower crankcase
Width "a": 3 mm (0.12 in.)
Height "b": 2 mm (0.08 in.)
9) Install lower crank case to cylinder block and tighten crank case bolt No.1s according to the following procedure.
NOTE:
^ If crank case bolt No.1s are reused, check them for deformation.
^ Use 12-point socket wrench to crank case bolt No.1s.
a) Apply engine oil to bolt threads and seats of crank case bolt No.1 and tighten bolt to 50 Nm (5.1 kgf-m, 37.0 lbf-ft) in numerical order ("1" - "10") evenly and gradually.
b) Loosen all bolts in reverse numerical order until loosening torque becomes 0.
c) In the same manner as Step a), retighten them to 20 Nm (2.0 kgf-m, 15.0 lbf-ft).
d) In the same manner as Step a), retighten them to 35 Nm (3.6 kgf-m, 26.0 lbf-ft).
e) In the same manner as Step a), retighten them to 40 degrees.
f) In the same manner as Step a), retighten them to 40 degrees.
Tightening torque
Crank case bolt No.1* (a): 50 Nm -> 0 Nm -> 20 Nm -> 35 Nm -> 40 degrees -> 40 degrees (5.1 kgf-m -> 0 kgf-m -> 2.0 kgf-m -> 3.6 kgf-m -> 40 degrees -> 40 degrees, 37.0 lbf-ft -> 0 lbf-ft -> 15.0 lbf-ft -> 26.0 lbf-ft -> 40 degrees -> 40 degrees)
10) Tighten crank case bolt No.2s in numerical order ("1" - "12") evenly and gradually.
Tightening torque
Crank case bolt No.2* (a): 25 Nm (2.5 kg-m, 18.5 lbf-ft)
11) Check that crankshaft rotates smoothly when turning it by hand.
12) Apply engine oil to new rear oil seal (1) and install it to cylinder block (2) using special tools.
Special Tool
(A): 09911-97710
(B): 09911-97811
13) Install pistons and connecting rods.
14) Install oil pump chain adjuster (1).
Tightening torque
Oil pump chain adjuster bolt (a): 11 Nm (1.1 kg-m, 8.5 lbf-ft)
15) Install CKP sensor.
16) Install flywheel for 5 M/T model, or drive plate for 4 A/T model.
17) Install engine front mounting brackets (1).
Tightening torque
Engine front mounting bracket bolt (a): 55 Nm (5.6 kg-m, 40.5 lbf-ft)
18) Install P/S pump.
19) Install water pump.
20) Install generator.
21) Install engine assembly.