Removal and Installation
Main Bearing, Crankshaft and Cylinder Block Removal and Installation
Main Bearing, Crankshaft and Cylinder Block Components
NOTE:
If any of the parts listed below is reinstalled into a position different from the original position, engine problems could occur.
If these parts are to be reused, keep them in numerical order so that they may be reinstalled in their original positions.
- Main bearing
- Thrust bearing
Removal
1) Remove engine assembly. Removal and Replacement
2) Remove flywheel for M/T model or drive plate for CVT model. Flywheel / Drive Plate Removal and Installation
3) Remove generator. Generator Removal and Installation
4) Remove water pump. Water Pump Removal and Installation
5) Remove engine front mounting bracket (1).
6) Remove piston and connecting rod. Removal and Installation
7) Remove oil pump chain adjuster (1) from lower crankcase.
8) Remove CKP sensor. CKP Sensor Removal and Installation
9) Loosen crankcase bolts No.2 in numerical order ("1" - "12") evenly and gradually.
10) Loosen crankcase bolts No.1 in numerical order ("1" - "10") evenly and gradually, and then remove lower crankcase and rear oil seal.
NOTE:
Use 12-point socket wrench for crankcase bolts No.1.
11) Remove crankshaft and oil pump chain from cylinder block.
12) Remove sensor plate (2) from crankshaft (1), if necessary.
NOTE:
Use T-30 security TORX� to loosen sensor plate screws (3).
Installation
Crankshaft Inspection
Main Bearing Inspection
Sensor Plate Inspection
Flywheel / Drive Plate Inspection
Cylinder Block Inspection
Oil Pump Drive Sprocket Inspection
Oil Pump Chain and Oil Pump Chain Adjuster Inspection
NOTE:
- The engine will seize up if it is operated when the parts listed below are not properly lubricated.
Be sure to lubricate all the friction surfaces of these parts with engine oil before installing them.
- Crankshaft journal
- Main bearing
- Thrust bearing
- Oil pump chain guide
- If oil is present between the bearing's outside surface and the cylinder block / lower crank case surface, the bearing could heat up to very high temperature, resulting in seizure.
Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface and the cylinder block / lower crank case surface.
1) Install sensor plate (1) using the following procedure.
a) Attach spring pin (2) to crankshaft (3).
NOTE:
Use spring pin of genuine SUZUKI part (09205-05006).
b) Install sensor plate to crankshaft, fitting pin (2) into hole (4) and facing inside edge (5) outward as shown in figure.
Tightening torque
Sensor plate screw (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
c) Detach spring pin from crankshaft.
2) Install main bearings to cylinder block or lower crankcase using the following procedures:
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 crankcase.
b) Press bearing end (3) until it is firmly seated on the cylinder block or lower crankcase.
c) Apply engine oil to sliding surface (4) of main bearing halves.
NOTE:
If oil is present between the bearing's outside surface and the camshaft housing / cylinder head surface, the bearing could heat up to very high temperature, resulting in seizure.
Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface (5) and the camshaft housing / cylinder head surface.
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.
NOTE:
- Before applying sealant, make sure mating surfaces are clean and dry.
- Install lower crankcase within 10 minutes after applying sealant.
"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)
Sealant bead size for lower crankcase
Width "a": 3 mm (0.11 in.)
Height "b": 2 mm (0.07 in.)
9) Install lower crankcase to cylinder block and tighten crankcase bolt No.1s using the following procedures:
NOTE:
- If crankcase bolt No.1 are reused, check them for deformation by referring to "Crankcase Bolt No.1 Inspection" under Main Bearing Inspection Main Bearing Inspection.
- Use 12-point socket wrench for crankcase bolts No.1.
a) Apply engine oil to bolt threads and seats of crankcase 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) Retighten them to 20 Nm (2.0 kgf-m, 15.0 lbf-ft) in the same manner as in Step a).
d) Retighten them to 35 Nm (3.6 kgf-m, 26.0 lbf-ft) in the same manner as in Step a).
e) Retighten them to 40° in the same manner as in Step a).
f) Retighten them to 40° in the same manner as in Step a).
Tightening torque
Crankcase bolt No.1* (a): (50 Nm -> 0 Nm -> 20 Nm -> 35 Nm -> 40� -> 40� (5.1 kgf-m -> 0 kgf-m -> 2.0 kgf-m -> 3.6 kgf-m -> 40� -> 40�, 37.0 lbf-ft -> 0 lbf-ft -> 15.0 lbf-ft -> 26.0 lbf-ft -> 40� -> 40�))
10) Tighten crankcase bolt No.2s in numerical order ("1" - "12") evenly and gradually.
Tightening torque
Crankcase bolt No.2* (a): 25 Nm (2.5 kgf-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. Removal and Installation
14) Install oil pump chain adjuster (1).
Tightening torque
Oil pump chain adjuster bolt (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
15) Install cylinder head. Removal and Replacement
16) Install timing chain cover. Timing Chain Cover Removal and Installation
17) Install cylinder head cover. Cylinder Head Cover Removal and Installation
18) Install oil pan. Oil Pan and Oil Pump Strainer Removal and Installation
19) Install CKP sensor. CKP Sensor Removal and Installation
20) Install flywheel for M/T model, or drive plate for CVT model. Flywheel / Drive Plate Removal and Installation
21) Install engine front mounting bracket (1).
Tightening torque
Engine front mounting bracket bolt (a): 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
22) Install water pump. Water Pump Removal and Installation
23) Install generator. Generator Removal and Installation
24) Install engine assembly. Removal and Replacement