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 flywheel (drive plate for A/T) by using special tool.
Special Tool (A):09924-17811
3. Remove pistons and connecting rods.
4. Remove CKP sensor (1).
5. Remove water pump (1) and heater outlet pipe (3).
6. Remove engine front mounting brackets (2).
7. Loosen crankcase bolts, in sequence shown in figure and remove them.
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 caps), connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb 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 another half without oil groove to lower crankcase.
Make sure that two halves are painted in the same color.
2. Install new O-ring (2) to cylinder block.
3. Install knock pins (5) to cylinder block.
4. Fit thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to crank webs.
5. Put crankshaft (1) with oil pump chain to cylinder block.
6. Apply sealant "A" to lower crankcase (1) mating surface area as shown in figure.
"A": Water tight sealant 99000-31250SUZUKI Bond No.1207F ()
Sealant amount for lower crankcase
Width "a": 3 mm (0.12 in.)
Height "b": 2 mm (0.08 in.)
7. Install lower crankcase (1) to cylinder block.
Apply engine oil to all crankcase bolts ((1) - (10)) and tighten them gradually as follows.
a) Tighten bolts ((1) - (10)) to 40 Nm (4.0 kgf-m, 29.0 ft. lbs.) according to numerical order in figure.
b) Loosen bolts ((1) - (10)) until tightening torque is reduced to 0 according to numerical order in figure.
c) Tighten bolts ((1) - (10)) to 40 Nm (4.0 kgf-m, 29.0 ft. lbs.) according to numerical order in figure.
d) In the same manner as in step c), retighten bolts ((1) - (10)) to 58 Nm (5.8 kgf-m, 42.0 ft. lbs.).
e) Tighten bolts ((11) - (22)) to specified torque according to numerical order in figure.
Tightening torque
Crankcase bolt with 10 mm thread diameter ((1) - (10)): Tighten 40 Nm (4.0 kgf-m, 29.0 ft. lbs.), 0 Nm (0 kgf-m, 0 ft. lbs.), 40 Nm (4.0 kgf-m, 29.0 ft. lbs.), 58 Nm (5.8 kgf-m, 42.0 ft. lbs.) by the specified procedure Crankcase bolt with 8 mm thread diameter ((11) - (22)): Tighten 26 Nm (2.6 kgf-m, 19.0 ft. lbs.) 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).
8. Pull out dowel pin (2) from crankshaft (1) and then install rear oil seal (3) until it becomes flush with cylinder block surface using special tools and plastic hammer.
Special Tool
(A): 09911-97710
(B): 09911-97811
9. Install dowel pin (2).
10. Install CKP sensor (1) and fix its wire harness with bracket.
Tightening torque
CKP sensor bolt a: 11 Nm (1.1 kgf-m, 8.0 ft. lbs.)
11. Install flywheel (drive plate for A/T). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts (1) to specified torque.
NOTE: Use new flywheel or drive plate bolt.
Special Tool (A): 09924-17811
Tightening torque
Flywheel or drive plate bolt a: 70 Nm (7.0 kgf-m, 51.0 ft. lbs.)
12. Install engine front mounting brackets (1). Tighten bracket bolts to specified torque.
Tightening torque
Engine front mounting bracket bolt a: 55 Nm (5.5 kgf-m, 40.0 ft. lbs.)
13. Install water pump (2) and heater outlet pipe (3).
14. Install pistons and connecting rods.
15. Install oil pump.
16. Install cylinder head assembly to cylinder.
17. Install camshafts and tappets and shims.
18. Check intake and exhaust valve lashes.
19. Install, timing chain sprockets, timing chains, timing chain tensioner, tensioner adjusters, timing chain guides, timing chain cover, crankshaft pulley, water pump pulley.
20. Install cylinder head cover.
21. Install oil pump strainer and oil pan.
22. Install clutch cover and clutch disc to flywheel (for M/T vehicle). For clutch installation, refer to Clutch Cover and Clutch Disc Removal and Installation.
23. Install engine assembly to vehicle.