Main Bearings, Crankshaft and Cylinder Block Removal and Installation
Main Bearings, Crankshaft and Cylinder Block Removal and InstallationRemoval
1) Remove engine assembly from vehicle.
2) Remove drive plate.
3) Remove piston and connecting rod.
4) Remove oil pan.
5) Remove engine rear crankshaft oil seal housing (1).
6) Remove main bearing cap bolt and crank bearing cap side bolt in numerical order ("1" -"24") as indicated in figure.
7) Using special tool, remove main bearing caps (1).
Special Tool
(A): 09912-36510
(B): 09912-36520
8) Remove crankshaft from cylinder block.
9) Remove oil jets from cylinder block, if necessary.
Installation
CAUTION:
^ Be sure to apply oil to crankshaft journals, journal bearings, thrust bearings, crank pins, connecting rod bearings, pistons, piston rings and cylinder bores.
^ Main bearings, bearing caps, connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb such combination and make sure that each part goes back to where it came from, when installing.
1) Install oil jets (1) to cylinder block and tighten oil jet bolts (2) to specified torque.
Tightening torque
Oil jet bolt (a): 10 Nm (1.0 kg-m, 7.5 lbf-ft)
2) Install new main bearings (1) to cylinder block. Upper half of bearing has an oil groove (2). Install it to cylinder block (3), and the other half without oil groove to bearing cap.
CAUTION:
Do not apply engine oil between main bearing and main bearing cap, between main bearing and cylinder block.
a) Fit tab (4) of crankshaft upper and lower bearing to groove (5) of cylinder block or bearing cap.
b) Press bearing end (6) until bearing end surface becomes flush with surface of cylinder block or bearing cap.
3) Apply engine oil to new thrust bearings (1), install thrust bearings to cylinder block between No.4 and No.5 cylinders.
NOTE:
Be sure to face oil groove (2) side to crank web.
4) Apply engine oil to main bearings and sliding surface of crankshaft, install crankshaft to cylinder block.
5) Install bearing caps (1) to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order, 1, 2, 3 and 4, starting from pulley side.
6) Tighten main bearing cap bolts and main bearing cap side bolts as follows.
CAUTION:
^ Do not apply engine oil to main bearing cap bolts and main bearing cap side bolts.
^ After tightening cap bolts, check that crankshaft rotates smoothly.
a) Tighten new main bearing cap bolts No.1 to 20 Nm (2.0 kgf-m, 14.5 lbf-ft) in numerical order ("1" - "8") shown in figure evenly and gradually.
b) In the same manner as Step a), retighten them by +80 degrees.
c) Tighten new main bearing cap bolts No.2 to 15 Nm (1.5 kgf-m, 11.0 lbf-ft) in numerical order ("9" - "16") shown in figure evenly and gradually.
d) In the same manner as Step c), retighten them by +110 degrees.
e) Tighten new main bearing cap side bolts No.1 and new main bearing cap side bolts No.2 to 30 Nm (3.1 kgf-m, 22.5 lbf-ft) in numerical order ("17" - "24") shown in figure evenly and gradually.
f) In the same manner as Step e), retighten them by +60 degrees.
Tightening torque
Main bearing cap bolt No.1* (a): 20 Nm -> +80 degrees (2.0 kgf-m -> +80 degrees, 15.0 lbf-ft -> +80 degrees)
Main bearing cap bolt No.2* (a): 15 Nm -> +110 degrees (1.5 kgf-m -> +110 degrees, 11.0 lbf-ft -> +110 degrees)
Main bearing cap side bolt No.1* (a): 30 Nm -> +60 degrees (3.1 kgf-m -> +60 degrees, 22.5 lbf-ft -> +60 degrees)
Main bearing cap side bolt No.2* (a): 30 Nm -> +60 degrees (3.1 kgf-m -> +60 degrees, 22.5 lbf-ft -> +60 degrees)
7) Clean sealing surface between oil seal housing and cylinder block.
8) Install special tool to cylinder block.
Special Tool
(A): Engine front cover installation guide pins (EN-46109)
9) Install special tool to cylinder block.
Special Tool
(A): 09919-87800
(B): 09913-57820
10) Apply sealant to mating surface of new rear oil seal housing as shown in figure.
"A": Sealant 99000-31290 (SUZUKI Bond No.1217F)
Sealant bead size for rear oil seal housing
Width: "a": 3 mm (0.12 in.)
Height: "b": 2.5 mm (0.10 in.)
11) Install oil seal housing to cylinder block.
NOTE:
Do not apply engine oil to oil seal housing.
12) Tighten oil seal housing bolt in numerical order ("1" - "5") shown in figure evenly and gradually.
CAUTION:
Confirm that engine rear crankshaft oil seal lip is not turned over after engine rear crankshaft oil seal housing is installed.
Tightening torque
Oil seal housing bolt* (a): 10 Nm (1.0 kg-m, 7.5 lbf-ft)
13) Install piston and connecting rod.
14) Install drive plate.
15) Install cylinder head.
16) Install 2nd timing chain (bank 2).
17) Install 1st timing chain.
18) Install 2nd timing chain (bank 1).
19) Install timing chain cover.
20) Install cylinder head cover.
21) Install engine assembly to vehicle.