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Crankshaft Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Coat the crankshaft bearings with engine oil.
  2. If replacing the crankshaft, transfer the pulse pickup sensor disc to the new crankshaft.
    Fig 1: Coating Crankshaft Bearings With Engine Oil
    G04102815Courtesy of SUZUKI OF AMERICA CORP.
  3. Install the crankshaft.
  4. Install the lower crankshaft bearings in the bearing caps.
  5. Inspect the crankshaft end play with the crankshaft bearings installed.
  6. Check for permissible crankshaft end play. Refer to "ENGINE SPECIFICATIONS :".
    Fig 2: Inspecting Crankshaft End Play
    G04102816Courtesy of SUZUKI OF AMERICA CORP.
  7. With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to "ENGINE SPECIFICATIONS :".
    Fig 3: Checking Middle Crankshaft Journal For Permissible Out-Of-Round
    G04102817Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the crankshaft bearing caps are removed.
  8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
  9. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.
  10. Install the crankshaft bearing caps and the bolts.

    Tighten 

    Tighten the crankshaft bearing cap bolts to 50 N.m (37 lb-ft) plus 45 degrees and 15 degrees.

    Fig 4: Checking Crankshaft Bearing Oil Clearance
    G04102818Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove the crankshaft bearing cap bolts and the caps.
  12. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
  13. Inspect the bearing clearance for permissible tolerance ranges. Refer to "ENGINE SPECIFICATIONS :".
    Fig 5: Inspecting Bearing Clearance For Permissible Tolerance Ranges
    G04102819Courtesy of SUZUKI OF AMERICA CORP.
  14. Apply a bead of adhesive sealing compound to the grooves of the crankshaft bearing caps.
  15. Install the crankshaft bearing caps to the engine block.
  16. Tighten the crankshaft bearing caps using new bolts.

    Tighten 

    Tighten the crankshaft bearing cap bolts to 50 N.m (37 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the crankshaft bearings another 45 degrees and 15 degrees.

    Fig 6: Tightening Crankshaft Bearing Caps Bolt
    G04102820Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gauging thread does not tear when the connecting rod bearing caps are removed.
  17. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
  18. Cut the plastic gauging threads to the length of the connecting rod bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.
  19. Install the connecting rod bearing caps.

    Tighten 

    Tighten the connecting rod bearing cap bolts to 35 N.m (26 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the connecting rod bearing cap bolts another 45 degrees plus 15 degrees.

  20. Remove the connecting rod bearing caps.
  21. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
  22. Inspect the bearing clearance for permissible tolerance ranges. Refer to "ENGINE SPECIFICATIONS :".
    Fig 7: Inspecting Bearing Clearance For Permissible Tolerance Ranges
    G04102822Courtesy of SUZUKI OF AMERICA CORP.
  23. Install the connecting rod bearing caps to the connecting rods.
  24. Tighten the connecting rod bearing caps using new bolts.

    Tighten 

    Tighten the connecting rod bearing cap bolts to 35 N.m (26 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the connecting rod cap bolts another 45 degrees plus 15 degrees.

  25. Install the oil pump.
  26. Install the oil pump retaining bolts.

    Tighten 

    Tighten the oil pump retaining bolts to 10 N.m (89 lb-in).

    Fig 8: Installing Oil Pump Retaining Bolts
    G04102824Courtesy of SUZUKI OF AMERICA CORP.
  27. Install the crankshaft bearing bridge and bolts.

    Tighten 

    Tighten the crankshaft bearing bridge bolts to 20 N.m (15 lb-ft) plus 45 degrees using the angular torque gauge KM-470-B.

  28. Install the crankshaft bearing bridge and oil pan scraper bolts.

    Tighten 

    Tighten the crankshaft bearing bridge and oil scraper bolts to 20 N.m (15 lb-ft) plus 45 degrees using the angular torque gauge KM-470-B.

  29. Install the oil suction pipe.
  30. Install the oil suction pipe and support bracket bolts.

    Tighten 

    Tighten the oil suction pipe bolts to 8 N.m (81 lb-in) and oil suction pipe support bracket bolt to 6 N.m (53 lb-in).

  31. Coat the new oil pan gasket with sealant.
  32. Install the oil pan gasket to the oil pan.
  33. Install the oil pan.
  34. Install the oil pan retaining bolts.

    Tighten 

    Tighten the oil pan retaining bolts to 10 N.m (89 lb-in).

    Fig 9: Installing Oil Pan Retaining Bolts
    G04102826Courtesy of SUZUKI OF AMERICA CORP.
  35. Rotate the engine on the engine overhaul stand KM-412.
    Fig 10: Rotating Engine On Engine Overhaul Stand
    G04102827Courtesy of SUZUKI OF AMERICA CORP.
  36. Install the rear timing belt cover.
  37. Install the rear timing belt cover bolts.

    Tighten 

    Tighten the rear timing belt cover bolts to 7 N.m (62 lb-in).

  38. Install the crankshaft gear and bolt.

    Tighten 

    Tighten the crankshaft gear bolt to 145 N.m (107 lb-ft) plus 30 degrees plus 15 degrees using the angular torque gauge KM-470-B.

  39. Install the engine mount and retaining bolts.

    Tighten 

    Tighten the engine mount retaining bolts to 45 N.m (33 lb-ft).

    Fig 11: Tightening Crankshaft Gear Bolt
    G04102828Courtesy of SUZUKI OF AMERICA CORP.
  40. Install the timing belt automatic tensioner.
  41. Install the timing belt automatic tensioner bolts.

    Tighten 

    Tighten the timing belt automatic tensioner bolts to 25 N.m (18 lb-ft).

  42. Install the timing belt idler pulley.
  43. Install the timing belt idler pulley bolt and nut.

    Tighten 

    Tighten the timing belt idler pulley nut to 25 N.m (18 lb-ft).

    Fig 12: Installing Timing Belt Idler Pulley
    G04102829Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Take extreme care to prevent any scratches, nicks or damage to the camshafts.
  44. Install the intake camshaft gear.
  45. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.

    Tighten 

    Tighten the intake camshaft gear bolt to 50 N.m (37 lb-ft) plus 60 degrees and 15 degrees using the angular torque gauge KM-470-B.

  46. Install the exhaust camshaft gear.
  47. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.

    Tighten 

    Tighten the exhaust camshaft gear bolt to 50 N.m (37 lb-ft) plus 60 degrees and 15 degrees using the angular torque gauge KM-470-B.

    Fig 13: Installing Exhaust Camshaft Gear
    G04102830Courtesy of SUZUKI OF AMERICA CORP.
  48. Install the timing belt. Refer to "TIMING BELT REMOVAL AND INSTALLATION :".
  49. Adjust the timing belt tension. Refer to "TIMING BELT CHECK AND ADJUST :".
  50. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover to cylinder head seal.
  51. Install the camshaft cover and the camshaft cover gasket.
  52. Install the camshaft cover washers.
  53. Install the camshaft cover bolts.

    Tighten 

    Tighten the camshaft cover bolts to 8 N.m (71 lb-in).

    Fig 14: Installing Camshaft Cover Bolts
    G04102831Courtesy of SUZUKI OF AMERICA CORP.
  54. Connect the ignition wires to the spark plugs.
  55. Install the spark plug cover.
  56. Install the spark plug cover bolts.

    Tighten 

    Tighten the spark plug cover bolts to 8 N.m (71 lb-in).

  57. Connect the breather tube to the camshaft cover.
  58. Install the front timing belt cover.
  59. Install the front timing belt cover bolts.

    Tighten 

    Tighten the front timing belt cover bolts to 8 N.m (71 lb-in).

  60. Install the engine lifting device.
  61. Remove the engine from the engine overhaul stand KM-412.
    Fig 15: Tightening Front Timing Belt Cover Bolts
    G04102832Courtesy of SUZUKI OF AMERICA CORP.
  62. Install a new crankshaft rear oil seal using installer J-36792.
    Fig 16: Installing Crankshaft Rear Oil Seal
    G04102833Courtesy of SUZUKI OF AMERICA CORP.
  63. Install the flywheel or flexible plate.
  64. Install the flywheel or the flexible plate bolts.

    Tighten 

    Tighten the flywheel bolts to 65 N.m (48 lb-ft). Use the angular torque gauge KM-470-B to tighten the flywheel bolts another 30 degrees plus 15 degrees. For the automatic transmission, tighten the flexible plate bolts to 45 N.m (33 lb-ft).

  65. Install the engine. Refer to "ENGINE REMOVAL AND INSTALLATION :".
    Fig 17: Installing Flywheel Or Flexible Plate Bolts
    G04102834Courtesy of SUZUKI OF AMERICA CORP.
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