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Crankshaft Disassembly and Assembly: Disassembly

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. 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: Identifying Flywheel Or Flexible Plate With Bolts
    G04716521Courtesy 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
    G04716522Courtesy 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: Identifying Front Timing Belt Cover And Bolts
    G04716523Courtesy 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.
  15. Remove the engine mount retaining bolts.
  16. Remove the engine mount.
    Fig 4: Identifying Timing Belt, Idler Pulleys, Automatic Tensioner, Associated Nuts and Bolts
    G04716427Courtesy of SUZUKI OF AMERICA CORP.
  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: Identifying Camshaft Cover Bolts Location
    G04716397Courtesy of SUZUKI OF AMERICA CORP.
  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: Identifying Exhaust Camshaft Gear
    G04716398Courtesy of SUZUKI OF AMERICA CORP.
  28. Remove the crankshaft timing belt gear.
    Fig 7: Identifying Crankshaft Timing Belt Gear
    G04716409Courtesy of SUZUKI OF AMERICA CORP.
  29. Remove the rear timing belt cover bolts and cover.
    Fig 8: Identifying Rear Timing Belt Cover Bolts And Cover
    G04716455Courtesy of SUZUKI OF AMERICA CORP.
  30. Rotate the engine on the engine overhaul stand KM-412.
    Fig 9: Identifying Engine On Engine Overhaul Stand KM-412
    G04716529Courtesy 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.
    Fig 10: Identifying Crankshaft Bearing Bridge
    G04716530Courtesy of SUZUKI OF AMERICA CORP.
  39. Remove the oil pump retaining bolts.
  40. Remove the oil pump.
    Fig 11: Identifying Oil Pump And Retaining Bolts
    G04716531Courtesy 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 12: Identifying Connecting Rod Bearing Cap Bolts
    G04716532Courtesy 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 13: Identifying Crankshaft Bearing Caps And Lower Crankshaft Bearings
    G04716533Courtesy of SUZUKI OF AMERICA CORP.
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