Main Bearings, Crankshaft and Cylinder Block Removal and Installation
Main Bearings, Crankshaft and Cylinder Block Removal and InstallationReference: Main Bearing, Crankshaft and Cylinder Block Components
CAUTION:
Parts must go back in the position where they were. Keep them in the following order:
^ Main bearing
^ Thrust bearing
Removal
1) Remove engine assembly.
2) Remove flywheel for M/T model or drive plate for CVT model.
3) Remove generator.
4) Remove water pump.
5) Remove engine front mounting bracket (1).
6) Remove piston and connecting rod.
7) Remove oil pump chain adjuster (1) from lower crankcase.
8) Remove CKP sensor.
9) Loosen crankcase bolt No.2s in numerical order ("1" - "12") evenly and gradually.
10) Loosen crankcase bolt No.1s 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 bolt No.1s.
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(R) to loosen sensor plate screws (3).
Installation
Reference: Crankshaft Inspection
Reference: Main Bearings Inspection
Reference: Sensor Plate Inspection
Reference: Flywheel/Drive Plate Inspection
Reference: Cylinder Block Inspection
Reference: Oil Pump Drive Sprocket Inspection
Reference: Oil Pump Chain and Oil Pump Chain Adjuster Inspection
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 crankcase
- 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 where they were:
- Main bearing
- Thrust bearing
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.
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 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.
CAUTION:
Do not apply engine oil between bearing halves (5) and cylinder block or lower crankcase (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.
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 Bearings Inspection.
^ Use 12-point socket wrench for crankcase bolt No.1s.
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 degrees in the same manner as in Step a).
f) Retighten them to 40 degrees 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 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 cylinder head.
16) Install timing chain cover.
17) Install cylinder head cover.
18) Install oil pan.
19) Install CKP sensor.
20) Install flywheel for M/T model, or drive plate for CVT model.
21) Install engine front mounting bracket (1).
Tightening torque
Engine front mounting bracket bolt (a): 55 Nm (5.6 kg-m, 40.5 lbf-ft)
22) Install water pump.
23) Install generator.
24) Install engine assembly.