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Crankshaft Disassembly and Assembly: Assembly

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2008 Suzuki Reno, 2008 Suzuki Forenza, 2007 Suzuki Reno, 2007 Suzuki Forenza, and 2006 Suzuki Reno. 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: Identifying Crankshaft Bearings
    G04716534Courtesy 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
    G04716535Courtesy 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 (Runout)
    G04716536Courtesy of SUZUKI OF AMERICA CORP.
  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° and 15°.

    Fig 4: Identifying Plastic Gauging Thread At Length Of Bearing Width
    G04716537Courtesy 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: Locating Bearing Clearance For Permissible Tolerance Ranges
    G04716538Courtesy 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° and 15°.

    Fig 6: Tightening Crankshaft Bearing Cap Bolts
    G04716539Courtesy of SUZUKI OF AMERICA CORP.
  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° plus 15°.

    Fig 7: Identifying Plastic Gauging Thread At Length Of Bearing Width
    G04716537Courtesy of SUZUKI OF AMERICA CORP.
  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 8: Locating Bearing Clearance For Permissible Tolerance Ranges
    G04716538Courtesy 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° plus 15°.

    Fig 9: Tightening Connecting Rod Bearing Cap Bolts
    G04716542Courtesy of SUZUKI OF AMERICA CORP.
  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 10: Identifying Oil Pump And Retaining Bolts
    G04716531Courtesy 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° 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° 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).

    Fig 11: Identifying Oil Suction Pipe And Support Bracket Bolts
    G04716544Courtesy of SUZUKI OF AMERICA CORP.
  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 12: Identifying Oil Pan Retaining Bolts
    G04716545Courtesy of SUZUKI OF AMERICA CORP.
  35. Rotate the engine on the engine overhaul stand KM-412.
    Fig 13: Identifying Engine On Engine Overhaul Stand (KM-412)
    G04716529Courtesy 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° plus 15° 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 14: Tightening Engine Mount Retaining Bolts
    G04716547Courtesy 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 15: Identifying Automatic Tensioner, Timing Belt And Pulley
    G04716424Courtesy of SUZUKI OF AMERICA CORP.
  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° and 15° 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° and 15° using the angular torque gauge KM-470-B.

    Fig 16: Identifying Exhaust Camshaft Gear
    G04716398Courtesy 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 17: Identifying Camshaft Cover Bolts Location
    G04716397Courtesy 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 18: Identifying Front Timing Belt Cover And Bolts
    G04716523Courtesy of SUZUKI OF AMERICA CORP.
  62. Install a new crankshaft rear oil seal using installer J-36792.
    Fig 19: Identifying Crankshaft Rear Oil Seal Using Installer (J-36792)
    G04716552Courtesy 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° plus 15°. 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 20: Identifying Flywheel Or Flexible Plate Bolts
    G04716553Courtesy of SUZUKI OF AMERICA CORP.
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