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Crankshaft Disassembly and Assembly: Disassembly

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. Remove the engine. Refer to "ENGINE REMOVAL AND INSTALLATION :".
  2. Remove the flywheel or flexible plate bolts.
  3. Remove the flywheel or the flexible plate.
    Fig 1: Removing Flywheel Or Flexible Plate
    G04102802Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove the crankshaft rear oil seal.
  5. Mount the engine assembly on the engine overhaul stand KM-412.
    Fig 2: Removing Crankshaft Rear Oil Seal
    G04102803Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove the front timing belt cover bolts.
  7. Remove the front timing belt cover.
  8. Remove the crankshaft pulley bolts.
  9. Remove the crankshaft pulley.
    Fig 3: Removing Crankshaft Pulley Bolts
    G04102804Courtesy of SUZUKI OF AMERICA CORP.
  10. Loosen the timing belt automatic tensioner bolt.
  11. Rotate the timing belt automatic tensioner hex-key clockwise to release the tension.
  12. Remove the timing belt idler pulley bolt and nut.
  13. Remove the timing belt idler pulleys.
  14. Remove the timing belt.
    Fig 4: Removing Timing Belt
    G04102805Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove the engine mount retaining bolts.
  16. Remove the engine mount.
  17. Disconnect the breather tubes from the camshaft cover.
  18. Remove the spark plug cover bolts.
  19. Remove the spark plug cover.
  20. Disconnect the ignition wires from the spark plugs.
  21. Remove the camshaft cover bolts.
  22. Remove the camshaft cover washers.
  23. Remove the camshaft cover and the camshaft cover gasket.
    Fig 5: Removing Camshaft Cover And Camshaft Cover Gasket
    G04102806Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Take extreme care to prevent any scratches, nicks or damage to the camshafts.
  24. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
  25. Remove the intake camshaft gear.
  26. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt.
  27. Remove the exhaust camshaft gear.
    Fig 6: Removing Exhaust Camshaft Gear
    G04102807Courtesy of SUZUKI OF AMERICA CORP.
  28. Remove the crankshaft timing belt gear.
    Fig 7: Removing Crankshaft Timing Belt Gear
    G04102808Courtesy of SUZUKI OF AMERICA CORP.
  29. Remove the rear timing belt cover bolts and cover.
    Fig 8: Removing Rear Timing Belt Cover Bolts
    G04102809Courtesy of SUZUKI OF AMERICA CORP.
  30. Rotate the engine on the engine overhaul stand KM-412.
    Fig 9: Rotating Engine On Engine Overhaul Stand
    G04102810Courtesy of SUZUKI OF AMERICA CORP.
  31. Remove the oil pan retaining bolts.
  32. Remove the oil pan.
  33. Remove the oil suction pipe and support bracket bolts.
  34. Remove the oil suction pipe.
  35. Remove the crankshaft bearing bridge and oil pan scraper bolts.
  36. Remove the oil pan scraper.
  37. Remove the crankshaft bearing bridge bolts.
  38. Remove the crankshaft bearing bridge.
  39. Remove the oil pump retaining bolts.
  40. Remove the oil pump.
    Fig 10: Removing Oil Pump Retaining Bolts
    G04102812Courtesy of SUZUKI OF AMERICA CORP.
  41. Mark the order of the connecting rod bearing caps.
  42. Remove the connecting rod bearing cap bolts for all of the pistons.
  43. Remove the connecting rod bearing caps and the lower connecting rod bearings.
    Fig 11: Removing Connecting Rod Bearing Cap Bolts
    G04102813Courtesy of SUZUKI OF AMERICA CORP.
  44. Mark the order of the crankshaft bearing caps.
  45. Remove the crankshaft bearing cap bolts.
  46. Remove the crankshaft bearing caps and the lower crankshaft bearings.
  47. Remove the crankshaft.
  48. Clean the parts, as needed.
    Fig 12: Identifying Crankshaft And Bearings
    G04102814Courtesy of SUZUKI OF AMERICA CORP.
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