General Description: 2006 Suzuki Aerio Premium 2006 Suzuki Aerio Premium
General Description: 2006 Suzuki Aerio Premium 2006 Suzuki Aerio Premium
General Description: 2006 Suzuki Aerio Premium 2006 Suzuki Aerio Premium
2006-07 ENGINE
GENERAL DESCRIPTION
ENGINE CONSTRUCTION DESCRIPTION
The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead
camshaft) valve mechanism arranged for "V" type valve configuration consisting of 16 valves (4 valves/one
cylinder). The double overhead camshaft is mounted over the cylinder head; it is driven from crankshaft
through timing chains, and no push rods are provided in the valve train system.
This air cleaner element is dry type. Remember that it needs cleaning according to Air Cleaner Element
Inspection and Cleaning .
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
1. Warm up engine.
2. Stop engine after warming up.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
Special Tool
A. 09915-64510-001
B. 09915-64510-002
C. 09915-64530
D. 09915-67010
9. Disengage clutch (to lighten starting load on engine) for M/T vehicle, and depress accelerator pedal all
the way to make throttle fully open.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
10. Crank engine with fully charged battery, and read the highest pressure on compression gauge.
NOTE: For measuring compression pressure, crank engine at least 250 RPM by
using fully charged battery.
Compression pressure
Max. difference between any two cylinders: 100 kPa (1.0 kg/cm2 , 14.2 psi)
11. Carry out Steps 8), 9) and 10) on each cylinder to obtain 4 readings.
12. After checking, install spark plugs (2) and ignition coils (1).
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
The engine vacuum that develops in the intake line is a good indicator of the condition of the engine. The
vacuum checking procedure is as follows:
1. Warm up engine to normal operating temperature and make sure that engine idle speed is within
specification.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
"Neutral" (shift selector lever to "P" range for A/T model), and set parking
brake and block drive wheels.
2. Stop engine and remove engine cover referring to ENGINE COVER REMOVAL AND
INSTALLATION.
3. Disconnect vacuum hose between vacuum pipe (2) and intake manifold (1) from vacuum pipe.
4. Connect special tools (vacuum gauge and hose joint) to vacuum hose of intake manifold side.
Special Tool
A. 09915-67311
B. 09918-08210
C. 09355-35754-600 Hose, SUZUKI GENUINE PARTS
D. 09367-04002 3-way joint, SUZUKI GENUINE PARTS
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
5. Start engine and run engine at specified idle speed (Refer to IDLE SPEED / IDLE AIR CONTROL
(IAC) DUTY INSPECTION ), and read vacuum gauge. Vacuum should be within specification.
Vacuum specification
52.6 - 65.8 kPa (40 - 50 cmHg, 15.7 - 19.7 in.Hg) at specified idle speed
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
REPAIR INSTRUCTIONS
VALVE LASH ADJUSTER NOISE DIAGNOSIS
In case of the following, valve lash adjuster noise may be caused by air trapped into valve lash adjusters.
If noise from valve lash adjusters is suspected, perform the following checks.
If oil level is low, add oil up to Full level hole on oil level gauge.
Oil quality
If oil is discolored, or deteriorated, change it. For particular oil to be used, refer to ENGINE OIL
AND FILTER CHANGE .
Oil leaks
2. Run engine for about half an hour at about 2,000 to 3,000 RPM, and then air will be purge and tapping
sound will cease.
3. Should tapping sound not cease, it is possible that hydraulic valve lash adjuster is defective.
Replace it if defective.
a. Stop engine and remove cylinder head cover referring to CYLINDER HEAD COVER
REMOVAL AND INSTALLATION.
b. Push adjuster downward by hand (with less than 20 kg or 44 lbs. force) when cam crest is not on
adjuster to check if clearance exists between cam and adjuster.
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2006-07 ENGINE Engine Mechanical - Aerio
Removal
1. Disconnect MAF sensor coupler (3) and air cleaner outlet hose (4) from air cleaner upper case (1).
2. Remove air cleaner upper case (1) from lower case after hooking clamps (2) from upper case.
3. Remove air cleaner element.
Installation
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Inspection
Cleaning
Blow off dust by compressed air from air outlet side of element.
Removal
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Installation
1. Install air cleaner outlet hose (1) by aligning match marks (2) as shown in figure.
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2006-07 ENGINE Engine Mechanical - Aerio
Removal
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2006-07 ENGINE Engine Mechanical - Aerio
Installation
Tightening torque
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2006-07 ENGINE Engine Mechanical - Aerio
With accelerator pedal depressed fully, check clearance between throttle lever (2) and lever stopper (1) (throttle
body) which should be within the following specification.
Clearance between throttle lever and lever stopper (with pedal depressed fully) "b"
If measured value is out of specification, adjust it to specification with cable adjusting nut (4).
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2006-07 ENGINE Engine Mechanical - Aerio
Fig. 13: Checking Clearance Between Throttle Lever And Lever Stopper
Courtesy of SUZUKI OF AMERICA CORP.
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2006-07 ENGINE Engine Mechanical - Aerio
Fig. 14: Identifying Throttle Body And Intake Manifold Components (With Tightening Torques)
Courtesy of SUZUKI OF AMERICA CORP.
Check that throttle valve lever (2) and accelerator cable (1) moves smoothly.
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2006-07 ENGINE Engine Mechanical - Aerio
Removal
WARNING: To help avoid danger of being burned, do not remove drain plug (1)
and radiator cap while engine and radiator are still hot. Scalding
fluid and steam can be blown out under pressure if plug and cap are
taken off too soon.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
Fig. 17: Disconnecting Coolant Hoses And Breather Hose From Throttle Body
Courtesy of SUZUKI OF AMERICA CORP.
Installation
1. Clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket.
2. Install throttle body to intake manifold and tighten bolts and nuts.
3. Connect coolant hoses (6) and breather hose (7).
4. Connect couplers of TP sensor (3), IAC sensor (4) and ground terminal (5).
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2006-07 ENGINE Engine Mechanical - Aerio
Fig. 18: Connecting Couplers Of TP Sensor, IAC Sensor (4), And Ground Terminal (5)
Courtesy of SUZUKI OF AMERICA CORP.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
6. Install P/S pump to its bracket referring to P/S PUMP REMOVAL AND INSTALLATION .
7. Install generator drive belt referring to GENERATOR DRIVE BELT REMOVAL AND
INSTALLATION .
8. Install air cleaner outlet hose referring to AIR CLEANER OUTLET HOSE REMOVAL AND
INSTALLATION.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
CAUTION: IAC valve, TP sensor, or other components containing rubber must not be
placed in a solvent or cleaner both. A chemical reaction will cause these
parts to swell, harden or get distorted.
Don't put drills or wires into passages for cleaning. It causes damages in
passages.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
Removal
WARNING: To help avoid danger of being burned, do not remove drain plug (1)
and radiator cap while engine and radiator are still hot. Scalding
fluid and steam can be blown out under pressure if plug and cap are
taken off too soon.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
10. Remove rear stiffener (17), and disconnect coolant pipe (18) from intake manifold.
11. Remove intake manifold (2) with throttle body from cylinder head, and then its gasket (1).
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2006-07 ENGINE Engine Mechanical - Aerio
Fig. 25: Removing Intake Manifold With Throttle Body From Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.
Installation
Tightening torque
Intake manifold bolt and nut a: 25 N.m (2.5 kg-m, 18.0 lb-ft)
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
3. Connect coolant pipe (1) to intake manifold and install rear stiffener (2). Tighten bolts to specified torque.
Tightening torque
Intake manifold rear stiffener bolt a: 25 N.m (2.5 kg-m, 18.0 lb-ft)
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
4. Install intake manifold front stiffener (1). Tighten bolts to specified torque.
Tightening torque
Intake manifold front stiffener bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
8. Install air cleaner outlet hose referring to AIR CLEANER OUTLET HOSE REMOVAL AND
INSTALLATION.
9. Install engine cover referring to ENGINE COVER REMOVAL AND INSTALLATION.
10. Check to ensure that all removed parts are back in place.
11. Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
12. Connect negative cable at battery.
13. Start engine and check for engine coolant leaks.
Removal
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
8. Remove PCV valve (1) from cylinder head cover (4), if equipped.
Installation
1. Install PCV valve to cylinder head cover referring to PCV VALVE REMOVAL AND
INSTALLATION .
2. Remove oil, old sealant and dust from sealing surfaces on cylinder head and cover. After cleaning, apply
sealant "A" to cylinder head sealing surface area as shown in figure.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
3. Install new O-rings (3) and new cylinder head cover gasket (2) to cylinder head cover (1).
NOTE: Be sure to check each of these parts for deterioration or any damage
before installation and replace if found defective.
4. Install new cylinder head side seal (4) and cylinder head cover to cylinder head.
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2006-07 ENGINE Engine Mechanical - Aerio
Tightening torque
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2006-07 ENGINE Engine Mechanical - Aerio
Fig. 32: Connecting Breather Hose And PCV Hose To Cylinder Head Cover
Courtesy of SUZUKI OF AMERICA CORP.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
Fig. 33: Identifying Cylinder Block Heater Components (With Tightening Torques)
Courtesy of SUZUKI OF AMERICA CORP.
Removal
WARNING: To help avoid danger of being burned, do not remove drain plug (1)
and radiator cap while engine and radiator are still hot. Scalding
fluid and steam can be blown out under pressure if plug and cap are
taken off too soon.
3. Disconnect cylinder block heater connector and remove cylinder block heater (1).
Installation
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
Install cylinder block heater (1) in the direction as shown in the figure.
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2006-07 ENGINE Engine Mechanical - Aerio
Tightening torque
2. Check that there is no continuity between terminal "a" and "b" or "c" and "b".
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2006-07 ENGINE Engine Mechanical - Aerio
Removal
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
Installation
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2006-07 ENGINE Engine Mechanical - Aerio
Fig. 39: Fixing Cylinder Block Heater Harness To Engine Harness With Clamps
Courtesy of SUZUKI OF AMERICA CORP.
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2006-07 ENGINE Engine Mechanical - Aerio
WARNING: "A": Tighten mounting member to suspension frame nuts or bolts first,
and tighten mounting member to body bolts with specified torque.
"B": Tighten engine right mounting No.1 bracket bolts first, and tighten
engine left mounting bolts with specified torque.
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2006-07 ENGINE Engine Mechanical - Aerio
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2006-07 ENGINE Engine Mechanical - Aerio
Removal
1. Release fuel pressure in fuel feed line by referring to FUEL PRESSURE RELIEF PROCEDURE .
2. Disconnect negative cable at battery.
3. Remove engine hood after disconnecting windshield washer hose.
4. Drain cooling system.
WARNING: To help avoid danger of being burned, do not remove drain plug (1)
and radiator cap while engine and radiator are still hot. Scalding
fluid and steam can be blown out under pressure if plug and cap are
taken off too soon.
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2006 Suzuki Aerio Premium
2006-07 ENGINE Engine Mechanical - Aerio
7. Remove air cleaner outlet hose referring to AIR CLEANER OUTLET HOSE REMOVAL AND
INSTALLATION.
8. Disconnect MAF sensor coupler (1).
9. Remove air cleaner case assembly (2).
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2006-07 ENGINE Engine Mechanical - Aerio
11. Remove accelerator cable with its bracket from intake manifold.
12. Disconnect the following hoses: See HOSES. See Fig. 44
HOSES
Brake booster hose (1) from intake Heater outlet hose (5) from heater
manifold outlet pipe
Fuel feed hose (2) from delivery pipe Vacuum hose (6) from EVAP canister
purge valve
Fuel return hose (3) from return pipe P/S suction hose (7) and high pressure
pipe (8) from P/S pump
Heater inlet hose (4) from water outlet
cap
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2006-07 ENGINE Engine Mechanical - Aerio
13. Disconnect the following connectors and wires: See CONNECTOR & WIRE IDENTIFICATION
table. See Fig. 45.
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15. Remove clutch operating cylinder (1) from transmission with hose still attached (for M/T model).
NOTE: Suspend removed clutch operating cylinder at a place free from any
possible damage during removal and installation of engine assembly.
Fig. 46: Removing Clutch Operating Cylinder From Transmission With Hose Attached
Courtesy of SUZUKI OF AMERICA CORP.
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22. Remove A/C compressor from compressor bracket with hoses still attached, if equipped with A/C.
NOTE: Suspend removed compressor at a place free from any possible damage
during removal and installation of engine assembly.
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29. Before removing engine with transaxle and transfer (for 4WD model) from vehicle body, recheck to make
sure all hoses, electric wires and cables are disconnected from engine and transaxle.
30. Lower engine with transaxle and transfer (for 4WD model) from vehicle body.
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2006-07 ENGINE Engine Mechanical - Aerio
through clearance made on engine crankshaft pulley side. At this time, use
care so that no excessive force is applied to hoses.
31. Disconnect transfer from transaxle referring to TRANSFER DISMOUNTING AND REMOUNTING
for 4WD model.
32. Disconnect transaxle from engine referring to MANUAL TRANSAXLE UNIT DISMOUNTING AND
REMOUNTING or AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING .
33. Remove clutch cover and clutch disk referring to CLUTCH COVER, CLUTCH DISC AND
FLYWHEEL REMOVAL AND INSTALLATION (for M/T model).
Installation
1. Install clutch cover and clutch disk referring to CLUTCH COVER, CLUTCH DISC AND
FLYWHEEL REMOVAL AND INSTALLATION (for M/T model).
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NOTE: Be sure to tighten engine right mounting No.1 bracket bolt (10)
previously, and tighten engine left mounting bolts (9).
Be sure to tighten mounting member to suspension frame bolts (12)
or nuts (12) previously, and tighten mounting member to body bolts
(11).
Tightening torque
Engine mounting bolts and nut a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
Engine front and rear mounting nut b: 45 N.m (4.5 kg-m, 32.5 lb-ft)
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12. For 4WD model, connect propeller shaft referring to PROPELLER SHAFT REMOVAL AND
INSTALLATION .
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13. Adjust gear shift control cable, referring to GEAR SHIFT LEVER AND CABLE REMOVAL AND
INSTALLATION .
14. Install generator belt (Power steering pump drive belt) referring to GENERATOR DRIVE BELT
REMOVAL AND INSTALLATION .
15. Refill transaxle with A/T fluid or gear oil, referring to AUTOMATIC TRANSAXLE FLUID
REPLACEMENT or MANUAL TRANSAXLE OIL CHANGE .
16. For 4WD model, refill transfer with transfer oil referring to TRANSFER OIL CHANGE .
17. Refill engine with engine oil, referring to ENGINE OIL AND FILTER CHANGE .
18. Refill cooling system, referring to COOLING SYSTEM FLUSH AND REFILL .
19. Upon completion of installation, check to make sure that there is no fuel leakage, coolant leakage,
transaxle oil leakage, transfer oil leakage or exhaust gas leakage at each connection.
20. Adjust accelerator cable play, referring to ACCELERATOR CABLE ADJUSTMENT.
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Removal
1. Remove engine assembly from vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
2. Remove oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION .
3. Remove cylinder head cover referring to CYLINDER HEAD COVER REMOVAL AND
INSTALLATION.
4. Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool (camshaft pulley holder) with it as shown in figure.
Special Tool
(a): 09917-68221
NOTE: Be sure to use the following bolts instead of pins for fixing special tool to
crankshaft pulley.
Bolt size: M8, P1.25 L = 25 mm (0.98 in.)
Strength: 7T
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To remove crankshaft pulley, use special tools (Steering wheel remover, Bearing puller attachment) with
it as shown in figure.
Special Tool
A. 09944-36011
B. 09926-58010
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7. Remove generator belt idler pulley (1), water pump pulley (2) and generator belt tensioner (3).
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8. Remove timing chain cover (1) bolts (3) and nut (2).
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Installation
Reverse removal sequence to install timing chain cover (1) noting the following points.
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2. Apply engine oil to oil seal lip, then install timing chain cover (1). Tighten bolts and nut to specified
torque.
NOTE: Before installing timing chain cover, check that pin is securely fitted.
Tightening torque
Timing chain cover bolt and nut a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
3. Install generator belt idler pulley (1). Tighten nut to specified torque.
Tightening torque
Generator belt idler pulley nut a: 42 N.m (4.2 kg-m, 30.5 lb-ft)
Tightening torque
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6. Install A/C compressor bracket (1) if equipped. Tighten bracket bolts to specified torque.
Tightening torque
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7. Install cylinder head cover referring to CYLINDER HEAD COVER REMOVAL AND
INSTALLATION.
8. Install oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
for installation.
9. Install crankshaft pulley. To lock crankshaft pulley (1), use special tool (camshaft pulley holder) with it as
shown in figure.
Special Tool
(A): 09917-68221
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NOTE: Be sure to use the following bolts instead of pins for fixing special tool to
crank pulley. Bolt size: M8, P1.25 L = 25 mm (0.98 in.)
Strength: 7T
Tightening torque
10. Install engine assembly to vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
Clean
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Clean sealing surface on timing chain cover, crank case, cylinder block and cylinder head.
Inspection
Check oil seal lip for fault or other damage. Replace as necessary.
NOTE: When installing new oil seal (2), drive it in until its surface is flash with edge of
timing chain cover (1).
To install oil seal, use special tool (bearing installer).
Special Tool
(A): 09913-75510
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Fig. 62: Identifying 2nd Timing Chain And Chain Tensioner Components (With Tightening Torques)
Courtesy of SUZUKI OF AMERICA CORP.
Removal
1. Remove engine assembly from vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
2. Remove oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION for removal.
3. Remove cylinder head cover. Refer to CYLINDER HEAD COVER REMOVAL AND
INSTALLATION for removal.
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4. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION
for removal.
5. Turn crankshaft to meet following conditions.
Key (I) on crankshaft is positioned as shown.
Arrow mark on idler sprocket (II) points upward.
Marks on sprockets (III) match with marks on cylinder head.
Note that this step must be followed for reinstallation of timing chain.
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6. Remove timing chain tensioner adjuster No.2 (1) and gasket. To remove them, slacken 2nd timing chain
by turning intake camshaft counterclockwise a little while pushing back pad.
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Fig. 64: Removing Timing Chain Tensioner Adjuster No. 2 And Gasket
Courtesy of SUZUKI OF AMERICA CORP.
7. Remove intake (1) and exhaust (2) camshaft timing sprocket bolts. To remove them, fit a spanner to
hexagonal part (3) at the center of camshaft to hold it stationary.
8. Remove camshaft timing sprockets and 2nd timing chain (4).
CAUTION: After 2nd timing chain is removed, never turn intake camshaft,
exhaust camshaft and crankshaft independently more than such an
extent as shown. If turned, interference may occur between piston
and valves and valves themselves, and parts related to piston and
valves may be damaged.
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Fig. 65: Removing Intake And Exhaust Camshaft Timing Sprocket Bolts
Courtesy of SUZUKI OF AMERICA CORP.
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Installation
1. Check that match mark (1) on crank timing sprocket is in match with timing mark (2) on lower crankcase
as shown in figure.
2. Check that arrow mark (1) on idler sprocket faces upward as shown in figure.
3. Check that knock pins of intake (2) and exhaust (3) camshafts are aligned with timing marks on cylinder
head as shown in figure.
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4. Install 2nd timing chain by aligning yellow plate (1) of 2nd timing chain and match marks on idler
sprocket.
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5. Install sprockets to intake and exhaust camshafts by aligning dark blue plate of 2nd timing chain, match
marks on intake sprocket and exhaust sprocket respectively.
NOTE: As an arrow mark is provided on both sides, camshaft timing sprocket has
no specific installation direction.
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6. Install intake (1) and exhaust (2) camshaft timing sprocket bolts. To install it, fit a spanner to hexagonal
part (3) at the center of camshaft to hold it stationary.
Tightening torque
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Fig. 71: Installing Intake And Exhaust Camshaft Timing Sprocket Bolts
Courtesy of SUZUKI OF AMERICA CORP.
7. Push back plunger (1) into tensioner body (2) and hold it at the position by inserting stopper (3) into
body.
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8. Install timing chain tensioner adjuster No. 2 (1) with new gasket.
Tightening torque
Timing chain tensioner adjuster No. 2 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
Timing chain tensioner adjuster No. 2 nut b: 45 N.m (4.5 kg-m, 33.0 lb-ft)
9. Pull out stopper (2) from timing chain tensioner adjuster No. 2.
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Fig. 73: Pulling Out Stopper From Timing Chain Tensioner Adjuster No. 2
Courtesy of SUZUKI OF AMERICA CORP.
10. Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on
cylinder block as shown in figure.
Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets
respectively.
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Fig. 74: Checking Timing Marks Of Cylinder Head And Cylinder Block
Courtesy of SUZUKI OF AMERICA CORP.
11. Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.
12. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION
for installation.
13. Install cylinder head cover. Refer to CYLINDER HEAD COVER REMOVAL AND
INSTALLATION for installation.
14. Install oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
for installation.
15. Install engine assembly to vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
Reference: 2nd Timing Chain and Chain Tensioner Removal and Installation
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Camshaft Sprocket
Timing Chain
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Check shoe (1) for wear or damage and latch functions properly.
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Fig. 78: Identifying 1st Timing Chain and Chain Tensioner Components (With Tightening Torques)
Courtesy of SUZUKI OF AMERICA CORP.
Removal
1. Remove engine assembly from vehicle referring to ENGINE ASSEMBLY REMOVAL AND
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INSTALLATION.
2. Remove oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION for removal.
3. Remove cylinder head cover. Refer to CYLINDER HEAD COVER REMOVAL AND
INSTALLATION for removal.
4. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION
for removal.
5. For reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and lower
crankcase match with those on sprockets as shown in figure.
6. Remove 2nd timing chain. Refer to 2nd Timing Chain and Chain Tensioner Removal and Installation
for removal.
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Installation
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1. Check that match mark (1) on crankshaft timing sprocket is in match with timing mark (2) on lower
crankcase.
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6. Bring yellow plate (4) of 1st timing chain (3) into match with match mark (2) on crankshaft timing
sprocket (1).
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7. Apply engine oil to sliding surface of timing chain tensioner (1) and then install it as shown in figure.
Tightening torque
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8. With latch of tensioner adjuster No.1 returned and plunger (1) pushed back into body, insert stopper (4)
into latch (2) and body (3).
After inserting it, check to make sure that plunger will not come out.
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Tightening torque
Timing chain tensioner adjuster No.1 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
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11. Apply engine oil to sliding surface of timing chain guide No.1 (1) and then install it.
Tightening torque
Timing chain guide No. 1 bolt a: 9 N.m (0.9 kg-m, 6.5 lb-ft)
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12. Check that dark blue and yellow plates of 1st timing chain are in match with match marks on sprockets
respectively.
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13. Install 2nd timing chain. Refer to 2nd Timing Chain and Chain Tensioner Removal and Installation
for installation.
14. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION
for installation.
15. Install cylinder head cover. Refer to CYLINDER HEAD COVER REMOVAL AND
INSTALLATION for installation.
16. Install oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
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for installation.
17. Install engine assembly to vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
Reference: 1st Timing Chain and Chain Tensioner Removal and Installation
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Idler Sprocket
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Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.
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Removal
1. Remove engine assembly from vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
2. Remove oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION for removal.
3. Remove cylinder head cover. Refer to CYLINDER HEAD COVER REMOVAL AND
INSTALLATION for removal.
4. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION
for removal.
5. Remove 2nd timing chain. Refer to 2nd Timing Chain and Chain Tensioner Removal and Installation
for removal.
6. Remove CMP sensor. Refer to CMP (CAMSHAFT POSITION) SENSOR REMOVAL AND
INSTALLATION for removal.
7. To secure work in the following steps, reinstall mounting member, engine front torque bush, rear
mounting and rear mounting No.2 bracket.
8. Set key on crankshaft in position as shown by turning crankshaft. This is to prevent interference between
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9. Loosen camshaft housing bolts in such order as indicated in figure and remove them.
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Immerse removed adjuster (2) in clean engine oil (1) and keep it there till
reinstalling it so as to prevent oil leakage. If it is left in air, place it with its
bucket body facing down. Don't place on its side or with bucket body
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facing up.
Installation
1. Before installing valve lash adjuster to cylinder head (1), fill oil passage of cylinder head with engine oil
according to following procedure.
Pour engine oil through oil holes (2) and check that oil comes out from oil holes in sliding part of valve
lash adjuster.
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Apply engine oil around valve lash adjuster and then install it to cylinder head.
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3. Match match mark (1) on crank timing sprocket and mating surface of cylinder block and lower
crankcase (2).
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4. Install camshafts.
Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match
marks on cylinder head and camshafts as shown in figure.
NOTE: Install camshaft in such direction that its end with groove for CMP sensor
installation comes to exhaust side.
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Embossed marks are provided on each camshaft housing, indicating position and direction for
installation. Install housings as indicated by these marks.
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7. Apply sealant "A" to exhaust camshaft end housing (1) sealing surface area as shown in figure.
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8. After applying oil to housing bolts, tighten them temporarily first. Then tighten them by following
numerical order in figure.
Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before
they are tightened to specified torque.
Tightening torque
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9. Install CMP sensor. Refer to CMP (CAMSHAFT POSITION) SENSOR REMOVAL AND
INSTALLATION for installation.
10. Install 2nd timing chain. Refer to 2nd Timing Chain and Chain Tensioner Removal and Installation
for installation.
11. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION
for installation.
12. Install cylinder head cover. Refer to CYLINDER HEAD COVER REMOVAL AND
INSTALLATION for installation.
13. Install oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
for installation.
14. Install engine assembly to vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
CAUTION: Don't turn camshafts or start engine (i.e., valves should not be
operated) for about half an hour after reinstalling hydraulic
valve lash adjusters and camshafts. As it takes time for valves
to settle in place, operating engine within half an hour after their
installation may cause interference to occur between valves
themselves or valves and piston.
If air is trapped in valve lash adjuster, valve may make tapping
sound when engine is operated after valve lash adjuster is
installed. In such a case, run engine for about half an hour at
about 2,000 to 3,000 RPM, and then air will be purged and
tapping sound will cease. Should tapping sound not cease, it is
possible that valve lash adjuster is defective. Replace it if
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Cam Wear
Using a micrometer, measure cam height. If measured height is below its limit, replace camshaft.
Cam height
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Camshaft Runout
Set camshaft between two "V" blocks, and measure its runout by using a dial gauge.
Runout limit
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Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head
without replacing housings.
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Tightening torque
6. Remove housing, and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its
widest point.
Journal clearance
STANDARD LIMIT
Standard Limit
0.020 - 0.074 mm (0.0008 - 0.0029 in.) 0.12 mm (0.0047 in.)
If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of
camshaft journal.
Replace camshaft or cylinder head assembly whichever the difference from specification is greater.
Camshaft journal
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STANDARD ITEM
Item Standard
Camshaft journal bore diameter. (IN & EX) 26.000 - 26.033 mm (1.0236 - 1.0249 in.)
Camshaft journal O.D. (IN & EX) 25.959 - 25.980 mm (1.0221 - 1.0228 in.)
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Measure cylinder head bore and adjuster outside diameter to determine cylinder head-to-adjuster clearance. If
clearance exceeds limit, replace adjuster or cylinder head.
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Check oil relief valve for clogging and ball for being stuck.
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Removal
1. Remove engine assembly from vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
2. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION
for removal.
3. Remove 2nd timing chain and 1st timing chain. Refer to 2nd Timing Chain and Chain Tensioner
Removal and Installation and 1ST TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND
INSTALLATION for removal.
4. Remove camshafts and valve lash adjuster. Refer to CAMSHAFTS AND VALVE LASH ADJUSTERS
REMOVAL AND INSTALLATION for removal.
5. Remove intake manifold rear stiffener (1).
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9. Loosen cylinder head bolts in such order as numbered in figure and remove them.
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10. Check all around cylinder head for any other parts required to be removed or disconnected and remove or
disconnect whatever necessary.
11. Remove cylinder head with intake manifold, exhaust manifold and water outlet cap. Use lifting device, if
necessary.
Installation
1. Match match mark (1) on crank timing sprocket and mating surface (2) of cylinder block and lower
crankcase.
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2. Clean mating surface of cylinder head and cylinder block (2). Remove oil, old gasket and dust from
mating surface.
3. Install knock pins (3) to cylinder block.
4. Install new cylinder head gasket (1) to cylinder block. Top mark (6) provided on gasket comes to
crankshaft pulley side (4), facing up (toward cylinder head side).
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Fig. 123: Installing Cylinder Head Gasket With TOP Mark Facing Upward
Courtesy of SUZUKI OF AMERICA CORP.
Apply engine oil to cylinder head bolts and tighten them gradually as follows.
a. Tighten all bolts to 53 N.m (5.3 kgf-m, 38.5 lb-ft) according to numerical order in figure.
b. In the same manner as in step a), retighten them to 84 N.m (8.4 kgf-m, 61.0 lb-ft).
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c. Loosen all bolts until tightening torque is reduced to 0 according to numerical order in figure.
d. Tighten all bolts to 53 N.m (5.3 kgf-m, 38.5 lb-ft) according to numerical order in figure.
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Tightening torque
Cylinder head bolt (hex hole bolt) b: 11 N.m (1.1 kg-m, 8.0 lb-ft)
Tightening torque
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Disassembly
1. When servicing cylinder head, remove intake manifold, injectors, exhaust manifold and water outlet cap
from cylinder head.
2. Using special tools, compress valve springs and then remove valve cotters (1) also by using special tool.
Special Tool
A. 09916-14510
B. 09916-16510
C. 09919-28610
D. 09916-84511
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3. Release special tool, and remove spring retainers and valve springs.
4. Remove valve from combustion chamber side.
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5. Remove valve stem seal (1) from valve guide, and then valve spring seat (2).
NOTE: Do not reuse seal once disassembled. Be sure to use new seal when
assembling.
6. Using special tool (Valve guide remover), drive valve guide out from combustion chamber side to valve
spring side.
Special Tool
(A): 09916-46020
NOTE: Do not reuse valve guide once disassembled. Be sure to use new valve
guide (oversize) when assembling.
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7. Place disassembled parts except valve stem seal and valve guide in order so that they can be installed in
their original positions.
Assembly
1. Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as
to remove burrs and make it truly round.
Special Tool
A. 09916-34542
B. 09916-38210
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Heat cylinder head uniformly at a temperature of 80 to 100 °C (176 to 212 °F) so that head will not be
distorted, and drive new valve guide into hole with special tools.
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Drive in new valve guide until special tool (Valve guide installer) contacts cylinder head.
After installing, make sure that valve guide protrudes by 13.5 mm (0.53 in.) from cylinder head.
Special Tool
A. 09916-57350
B. 09916-57340
NOTE: Do not reuse valve guide once disassembled. Install new valve
guide (Oversize).
Intake and exhaust valve guides are identical.
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3. Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore.
Special Tool
A. 09916-34542
B. 09916-37810
4. Install valve spring seat to cylinder head.
5. Install new valve stem seal (1) to valve guide.
After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to
spindle, and then install seal to valve guide by pushing special tool by hand.
After installing, check to be sure that seal is properly fixed to valve guide.
Special Tool
A. 09917-98221
B. 09916-57350
NOTE: Do not reuse seal once disassembled. Be sure to install new seal.
When installing, never tap or hit special tool with a hammer or else. Install
seal to guide only by pushing special tool by hand. Tapping or hitting
special tool may cause damage to seal.
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Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem.
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Special Tool
A. 09916-14510
B. 09916-16510
C. 09919-28610
D. 09916-84511
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9. Install intake manifold, injectors, exhaust manifold and water outlet cap to cylinder head.
Valve Guides
Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance.
Be sure to take reading at more than one place along the length of each stem and guide.
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Valves
Valve specification
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Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be
resurfaced, but not so much as to grind off its chamber. When it is worn out so much that its chamber is
gone, replace valve.
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Check each valve for radial runout with a dial gauge and "V" block. To check runout, rotate valve slowly.
If runout exceeds its limit, replace valve.
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Create contact pattern on each valve in the usual manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotatingly tapping seat with valve head. Valve lapper (tool used in valve
lapping) must be used.
Pattern produced on seating face of valve must be a continuous ring without any break, and the width of
pattern must be within specified range.
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A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out
of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
a. VALVE SEAT: Use valve seat cutters (1) to make three cuts as illustrated in figure. Three cutters
must be used: the 1st for making 30° angle, the 2nd for making 60° angle, and 3rd for making 45°
angle. The 3rd cut (45°) must be made to produce desired seat width.
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b. VALVE LAPPING: Lap valve on seat in two steps, first with coarse size lapping compound
applied to face and the second with fine-size compound, each time using valve lapper according to
usual lapping method.
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Cylinder Head
NOTE: Do not use any sharp-edged tool to scrape off carbon. Be careful not to
scuff or nick metal surfaces when decarbonizing. The same applies to
valves and valve seats, too.
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Check cylinder head for cracks in intake and exhaust ports, combustion chambers, and head surface at a
total of 6 locations. If distortion limit is exceeded, correct gasketed surface with a surface plate and
abrasive paper of about #400 (Waterproof silicon carbide abrasive paper):
Place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
Should this fail to reduce thickness gauge readings to within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint is often due to warped gasketed surface: such
leakage results in reduced power output.
Limit of distortion
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Check seating faces of cylinder head for manifolds, using a straightedge and thickness gauge, in order to
determine whether these faces should be corrected or cylinder head replaced.
Limit of distortion
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Valve Springs
Referring to data, check to be sure that each spring is in standard condition, free of any evidence of
breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention possibility
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of reducing power output due to gas leakage caused by decreased seating pressure.
Spring squareness:
Use a square and surface plate to check each spring for squareness in terms of clearance between end of
valve spring and square.
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Valve springs found to exhibit a larger clearance than limit must be replaced.
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Removal
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1. Remove engine assembly from vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
2. Remove oil pump with oil pump strainer. Refer to OIL PUMP REMOVAL AND INSTALLATION for
removal.
3. Remove cylinder head. Refer to VALVES AND CYLINDER HEAD REMOVAL AND
INSTALLATION for removal.
4. Mark cylinder number on all pistons, connecting rods and connecting rod caps.
5. Remove connecting rod bearing caps.
6. Clean carbon from top of cylinder bore before removing piston from cylinder.
7. Push piston and connecting rod assembly out through the top of cylinder bore.
Installation
1. Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins.
NOTE: Do not apply oil between connecting rod and bearing or between bearing
cap and bearing.
2. When installing piston and connecting rod assembly into cylinder bore, point front mark (3) on piston
head to crankshaft pulley side (1).
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3. Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to
compress rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor firmly against
cylinder block until all piston rings have entered cylinder bore.
Special Tool
(A): 09916-77310
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Tightening torque
Connecting rod bolt a: 15 N.m (1.5 kgf-m, 11.0 lb-ft) 45° and 45° by the specified procedure
NOTE: If connecting rod bolt is reused, make sure to check connecting rod
bolt for deformation referring to "CONNECTING ROD BOLT
DEFORMATION (PLASTIC DEFORMATION TIGHTENING BOLT)"
under PISTONS, PISTON RINGS, CONNECTING RODS AND
CYLINDERS INSPECTION AND CLEANING.
5. Install cylinder head. Refer to VALVES AND CYLINDER HEAD REMOVAL AND
INSTALLATION for installation.
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6. Install oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
for installation.
7. Install engine assembly to vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION
Disassembly
1. Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston.
2. Remove piston pin from connecting rod.
Ease out piston pin circlips (1), as shown.
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Assembly
Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS INSPECTION AND
CLEANING
NOTE: Two sizes of piston are available as standard size spare part so as to ensure
proper piston-to-cylinder clearance. When installing a standard size piston,
make sure to match piston with cylinder as follows.
1. Each piston (1) has stamped number 1 or 2 as shown. It represents outer diameter of piston.
2. There are also painted color (3) of red and blue on cylinder block (2) as shown.
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3. Stamped number on piston and stamped mark on cylinder block should correspond. That is, install
number 2 stamped piston to cylinder which is identified with mark blue and a number 1 piston to cylinder
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Also, a letter A or B is stamped on piston head but ordinarily it is not necessary to discriminate each
piston by this letter.
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After applying engine oil to piston pin and piston pin holes in piston and connecting rod, fit connecting
rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install piston pin
circlips.
NOTE: Circlip (4) should be installed so that circlip end gap comes within such
range as indicated by arrow.
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When installing oil ring (3), install spacer first and then two rails.
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6. After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.
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Inspection
Cylinder
Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore
is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston.
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Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions as shown in
figure. If any of following conditions is noted, rebore cylinder.
NOTE: If any one of four cylinders has to be rebored, rebore all four to the same
next oversize. This is necessary for the sake of uniformity and balance.
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Pistons
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Piston diameter:
As indicated in figure, piston diameter should be measured at a position 27.5 mm (1.08 in.) ("a") from
piston skirt end in the direction perpendicular to piston pin.
Piston diameter
Piston clearance:
Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance.
Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and
use oversize piston.
Piston clearance
NOTE: Cylinder bore diameters used here are measured in thrust direction at two
positions.
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Before checking, piston grooves must be clean, dry and free of carbon.
Fit new piston ring (1) into piston groove, and measure clearance between ring and ring land by using
thickness gauge (2).
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Piston pin
Check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular
attention to condition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly
worn or damaged, replace pin, connecting rod or piston.
Piston pin clearance: Check piston pin clearance in small end.
Replace connecting rod if its small end is badly worn or damaged or if measured clearance exceeds limit.
Small-end bore
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Piston rings
To measure end gap, insert piston ring (2) into cylinder bore and then measure the gap by using thickness gauge
(1).
NOTE: Clean carbon and any other dirt from top of cylinder bore before inserting
piston ring.
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Connecting rod
Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the
normal manner. If measured clearance is found to exceed its limit, replace connecting rod.
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Mount connecting rod on aligner to check it for bow and twist. If limit is exceeded, replace it.
Limit on bow
Limit on twist
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Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a
micrometer. If crank pin is damaged, or out-of round or taper is out of limit, replace crankshaft or regrind
crank pin referring to the following step 6).
Out-of-round
"A"-"B"
Taper
"a"-"b"
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Inspect bearing shells for signs of fusion, pitting, burn or flaking and observe contact pattern. Bearing
shells found in defective condition must be replaced.
Two kinds of connecting rod bearings are available; standard size bearing and 0.25 mm (0.0098 in.)
undersize bearing. For identification of undersize bearing, it is painted red (1) at the position as indicated
in the figure, undersize bearing thickness is 1.605 - 1.615 mm (0.0632 - 0.0635 in.) at the center of it.
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Tightening torque
Connecting rod bolt a: 15 N.m (1.5 kgf-m, 11.0 lb-ft) 45° and 45° by the specified
procedure
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e. Remove connecting rod bearing cap, and using a scale (2) on gauging plastic envelope, measure
gauging plastic (1) width at the widest point (clearance).
If clearance exceeds its limit, select connecting rod bearing referring to PISTONS, PISTON
RINGS, CONNECTING RODS AND CYLINDERS INSPECTION AND CLEANING below
mentioned item.
Bearing clearance
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f. If clearance can not be brought to within its limit even by using a new standard size bearing,
replace crankshaft or regrind crankpin to undersize as follows.
Install 0.25 mm undersize bearing to connecting rod big end.
Measure bore diameter of connecting rod big end.
Regrind crankpin to the following finished diameter.
Finished crankpin diameter = Measured big end bore diameter (including undersize bearing -
0.054 mm (0.0021 in.)
NOTE: After checking the connecting rod bearing clearance, make sure
that checking for "Connecting rod bolt deformation".
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Three kinds of numbers ("1", "2" and "3") represent the following connecting rod big end inside
diameters.
For example, stamped number "1" indicates that corresponding connecting rod big-end inside
diameter is 53.0000 - 53.0060 mm (2.0867 - 2.0868 in.).
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b. Next, check crank pin diameter. On crank web of No. 3 cylinder, four alphabets are stamped as
shown in the figure. Three kinds of alphabet ("A", "B" and "C") represent the following crank pin
diameter respectively.
For example, stamped "A" indicates that corresponding crank pin diameter is 49.9940 - 50.0000
mm (1.9683 - 1.9685 in.).
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c. There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted
in the following colors at the position as indicated in the figure.
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d. From number stamped on connecting rod and its cap and alphabet stamped on crank web No. 3
cylinder, determine new standard bearing to be installed to connecting rod big-end inside, by
referring to the table.
For example, if number stamped on connecting rod and its cap is "1" and alphabet stamped on
crank web No. 3 cylinder is "B", install a new standard bearing painted in "Black" to its connecting
rod big-end inside.
e. Check bearing clearance with newly selected standard bearing referring to CRANK PIN AND
CONNECTING ROD BEARINGS.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance.
Measure each thread diameter of connecting rod bolts (1) at "A" on 28.5 mm (1.12 in.) from bolt
mounting surface and "B" on 42.0 mm (1.65 in.) from bolt mounting surface by using a micrometer (2).
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Cleaning
Clean carbon from piston head and ring grooves, using a suitable tool.
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Removal
1. Remove engine assembly from vehicle. Refer to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
2. Remove clutch and flywheel (M/T) or drive plate (A/T). For clutch removal, refer to CLUTCH COVER,
CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION .
Special Tool
(A): 09924-17810
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14. Loosen crankcase bolts, in sequence shown in figure and remove them.
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Installation
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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.
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4. Fit thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to
crank webs.
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Fig. 184: Putting Crankshaft With Oil Pump Chain To Cylinder Block
Courtesy of SUZUKI OF AMERICA CORP.
6. Apply sealant "A" to lower crankcase (1) mating surface area as shown in figure.
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After applying engine oil to all crankcase bolts ((1) - (22)), tighten them gradually as follows.
a. Tighten bolts ((1) - (10)) to 40 N.m (4.0 kgf-m, 29.0 lb-ft) according to numerical order as shown.
b. Loosen bolts ((1) - (10)) until tightening torque is reduced to 0 (zero) in reverse order of tightening.
c. In the same manner as in step a), tighten them to 40 N.m (4.0 kgf-m, 29.0 lb-ft).
d. In the same manner as in step a), tighten them to the specified torque.
e. Tighten bolts ((11) - (22)) to the specified torque according to numerical order as shown.
Tightening torque
Crankcase bolt with 10 mm thread diameter ((1) - (10)): 58 N.m (5.8 kg-m, 42.0 lb-ft)
Crankcase bolt with 8 mm thread diameter ((11) - (22)): 25 N.m (2.5 kg-m, 18.0 lb-ft)
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8. Pull out dowel pin (2) from crankshaft (1) and then install rear oil seal (3) by using special tools and
plastic hammer.
Special Tool
A. 09911-97710
B. 09911-97810
9. Install dowel pin.
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10. Install CKP sensor (1) and fix its wire harness with bracket.
Tightening torque
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Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts (1) applied with
sealant to specification.
Special Tool
(A): 09924-17810
Tightening torque
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12. Install engine front mounting bracket (1). Tighten bracket bolts to specified torque.
Tightening torque
Engine front mounting bracket bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
13. Install water pump (2) and heater outlet pipe (3). Refer to WATER PUMP REMOVAL AND
INSTALLATION .
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14. Install pistons and connecting rods. Refer to PISTONS, PISTON RINGS, CONNECTING RODS
AND CYLINDERS REMOVAL AND INSTALLATION.
15. Install oil pump. Refer to OIL PUMP REMOVAL AND INSTALLATION .
16. Install cylinder head assembly to cylinder. Refer to VALVES AND CYLINDER HEAD REMOVAL
AND INSTALLATION.
17. Install, timing chain sprockets, timing chains, timing chain tensioners, tensioner adjusters, timing chain
guides, timing chain cover, crankshaft pulley, water pump pulley. Refer to TIMING CHAIN COVER
REMOVAL AND INSTALLATION, 2nd TIMING CHAIN AND CHAIN TENSIONER
REMOVAL AND INSTALLATION and 1ST TIMING CHAIN AND CHAIN TENSIONER
REMOVAL AND INSTALLATION.
18. Install oil pump strainer and oil pan.
19. Install clutch to flywheel (for M/T vehicle). For clutch installation, refer to CLUTCH COVER,
CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION .
20. Install engine assembly to vehicle. Refer to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
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INSTALLATION
Crankshaft
Crankshaft runout
Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit,
replace crankshaft.
Limit on runout
Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and
lower crankcase installed.
Tighten crankcase bolts referring to MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION.
If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard thrust
play.
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An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length
(or both). This difference, if any, is determined by taking micrometer readings. If any one of journals is badly
damaged or if amount of uneven wear in the sense exceeds its limit, regrind or replace crankshaft.
Out-of-round
"A"-"B"
Taper
"a"-"b"
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Main Bearings
Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and standard
size has 5 kinds of bearings differing in tolerance.
Upper half of bearing (1) has oil groove (2) as shown in figure.
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If any malcondition is found, replace both upper and lower halves. Never replace either half without replacing
the other half.
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3. Place a piece of gauging plastic (1) to full width of bearing (parallel to crankshaft) on journal, avoiding
oil hole.
4. Install lower crankcase to cylinder block referring to MAIN BEARINGS, CRANKSHAFT AND
CYLINDER BLOCK REMOVAL AND INSTALLATION.
5. Remove lower crankcase and using scale (2) on gauging plastic envelop (1), measure gauging plastic
width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and
lower inserts as a unit.
A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft
journal for use of 0.25 mm undersize bearing.
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STANDARD BEARING:
If bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing
according to the following procedure and install it.
1. First check journal diameter. As shown in figure, crank web No.2 has stamped numbers.
Three kinds of numbers ("1", "2" and "3") represent following journal diameters.
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Journal diameter
Stamped numbers on crank web No.2 (3) represent journal diameters marked with an arrow in figure
respectively. For example, stamped number "1" indicates that corresponding journal diameter is 58.0000 -
58.0060 mm (2.2835 - 2.2837 in.).
2. Next, check crankcase (bearing cap) bore diameter without bearing. On lower crankcase five alphabets
are stamped as shown in figure.
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Three kinds of alphabets ("A", "B" and "C") represent the following cap bore diameters.
Stamped alphabets on lower crankcase represent crankcase bore diameter marked with an arrow in figure
respectively.
For example, stamped alphabet "A" at bearing cap No.2 indicates that bearing cap bore diameter of
bearing cap No.2 is 61.9940 - 62.0000 mm (2.4407 - 2.4409 in.).
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3. There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted (1) in
the following colors at the position as indicated in figure.
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4. From number stamped on crank web No. 2 and alphabets stamped on lower crankcase, determine new
standard bearing to be installed to journal, by referring to table shown.
For example, if number stamped on crank web No. 2 is "1" and alphabet stamped on lower crankcase is
"B", install a new standard bearing painted in "Black" to its journal.
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5. Using gauging plastic (1) and scale (2), check bearing clearance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance.
6. When replacing crankshaft or cylinder block and lower crank case due to any reason, select new standard
bearings to be installed by referring to number stamped on new crankshaft or alphabets stamped on new
lower crankcase.
To distinguish them, each bearing is painted (1) in the following colors at such position as indicated in
figure.
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If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows.
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Measurement should be taken in two directions perpendicular to each other in order to check for
out-of-round.
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Flywheel
Limit on runout
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Cylinder Block
Flatness Limit
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1. When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
D=A+B-C
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Check Valve
Check check valve for clogging and ball for being stuck.
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Fig. 209: Checking Check Valve For Clogging And Ball For Being Stuck
Courtesy of SUZUKI OF AMERICA CORP.
SPECIFICATIONS
TIGHTENING TORQUE SPECIFICATIONS
Reference:
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For the tightening torque of fasteners not specified in this section, refer to FASTENERS INFORMATION .
SPECIAL TOOL
SPECIAL TOOLS
Tool Name Part No.
Hose 09355-35754-600
3-Way Joint 09367-04002
Oil Seal Guide 09911-97710
Oil Seal Installer 09911-97810
Bearing Installer 09913-75510
Compression Gauge 09915-64510-001
Connector 09915-64510-002
Compression Gauge Hose 09915-54530
Compression Gauge Attachment 09915-67010
Vacuum Gauge 09915-67311
Valve Lifter 09916-14510
Valve Lifter Attachment 09916-16510
Reamer Handle 09916-34542
Valve Guide Reamer (6 mm) 0916-37810
Valve Guide Reamer (11 mm) 09916-38210
Valve Guide Remover 09916-46020
Valve Guide Installer Attachment 09916-57340
Valve Guide Installer Handle (6 mm) 09916-57350
Piston Ring Compressor 09916-77310
Forceps 09916-84511
Camshaft Pulley Holder 09917-68221
Valve Guide Stem Attachment 09917-98221
Vacuum Gauge Hose Joint 09918-08210
Protector Sleeve 0991928610
Flywheel Holder (Drive Plate Stopper) 09924-17810
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