Engine Unit: Disassembly and Assembly: Disassembly

NOTE: Explained here is how to disassemble with engine stand supporting transmission surface. When using different type of engine stand, some steps may be different.

Remove the engine and the transmission assembly from the vehicle, and separate the transmission assembly from the engine. Refer to Engine Assembly: Removal and Installation .
Remove clutch cover and clutch disc (M/T models). Refer to [CLUTCH DISC, CLUTCH COVER: REMOVAL AND INSTALLATION [5M/T] ]
Remove flywheel (M/T models) or drive plate (A/T models) with power tool.

Fig 1: Removing Flywheel Using Power Tool
Courtesy of SUZUKI OF AMERICA CORP.
- Secure crankshaft with a stopper plate, and remove bolts.
- Loosen bolts using suitable tool.
  Flywheel (M/T models): size T55 (commercial service tool)
  
  Drive plate (A/T models): size E20
  
  CAUTION: Be careful not to damage or scratch drive plate (A/T models) and contact surface for clutch disc of flywheel (M/T models).
  
  NOTE: The flywheel, two block construction, allows movement in response to transmission side pressure, or when twisted in its rotational direction. Therefore, some amount of noise is normal.
Lift engine, and mount to engine stand.
CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
- A widely used engine stand can be used.
  
  Fig 2: Identifying Widely Used Engine Stand
  Courtesy of SUZUKI OF AMERICA CORP.
  
  CAUTION: Use engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough for supporting the engine weight.
Drain engine oil. Refer to [CHANGING ENGINE OIL ]
Drain engine coolant by removing water drain plug from side of the engine.

Fig 3: Identifying Water Drain Plug
Courtesy of SUZUKI OF AMERICA CORP.
Remove cylinder head. Refer to [CYLINDER HEAD: REMOVAL AND INSTALLATION ].
Remove knock sensor.
CAUTION: Carefully handle knock sensor avoiding shocks.
Remove crankshaft position sensor (POS).

Fig 4: Identifying Crankshaft Position Sensor, O-Ring And Mounting Bolt
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Avoid impacts such as a dropping.
- Do not disassemble.
- Keep it away from metal particles.
- Do not place the sensor in a location where it is exposed to magnetism.
Remove oil pressure switch using a suitable tool.
CAUTION: Do not drop or shock oil pressure switch.
Remove pilot converter (A/T models) or pilot bushing (M/T models) using Tool.

Fig 5: Removing Pilot Converter Or Pilot Bushing Using Tool
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: ST16610001 (J-23907)
Remove piston and connecting rod assembly as follows:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to [ENGINE UNIT: INSPECTION AFTER DISASSEMBLY ].
  CAUTION: Be careful no to drop connecting rod bearing, and to scratch the surface.
Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
Remove connecting rod bearing cap.
Push piston and connecting rod assembly out to the cylinder head side using suitable tool.

Fig 6: Pushing Piston And Connecting Rod Assembly Using Suitable Tool
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION: Identify installation position, and store them without mixing them up.
Remove piston rings from piston.
- Before removing piston rings, check the piston ring side clearance. Refer to [ENGINE UNIT: INSPECTION AFTER DISASSEMBLY ].
- Remove piston rings using piston ring expander or suitable tool.
  
  Fig 7: Removing Piston Rings Using Piston Ring Expander
  Courtesy of SUZUKI OF AMERICA CORP.
  CAUTION:
  - When removing piston rings, be careful not to damage piston.
  - Be careful not to damage piston rings by expanding them excessively.
Remove piston from connecting rod as follows:
1. Remove snap rings using snap ring pliers.
  
  Fig 8: Removing Snap Rings Using Snap Ring Plier
  Courtesy of SUZUKI OF AMERICA CORP.
2. Heat piston to 60° to 70°C (140° to 158°F) with an industrial use drier or equivalent.
  
  Fig 9: Heating Piston Using Industrial Use Drier
  Courtesy of SUZUKI OF AMERICA CORP.
3. Push out piston pin with stick of outer diameter approximately 19 mm (0.75 in).
  
  Fig 10: Pushing Out Piston Pin
  Courtesy of SUZUKI OF AMERICA CORP.
Remove lower cylinder block bolts.
- Before loosening lower cylinder block bolts, measure crankshaft end play. Refer to [ENGINE UNIT: INSPECTION AFTER DISASSEMBLY ].
- Loosen lower cylinder block bolts in reverse order as shown in several different steps.
  
  Fig 11: Tightening Order Of Lower Cylinder Block Bolts
  Courtesy of SUZUKI OF AMERICA CORP.
  
  NOTE: Use TORX socket (size E14) for bolts No. 1 to 10.
Remove lower cylinder block.
- Use Tool to cut liquid gasket for removal.
  Tool number: KV10111100 (J-37228)
  
  CAUTION: Be careful not to damage the mounting surfaces.
Remove crankshaft.
CAUTION:
- Be careful not damage or deform signal plate mounted on crankshaft.
  
  Fig 12: Identifying Crankshaft And Signal Plate
  Courtesy of SUZUKI OF AMERICA CORP.
- When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface.
- Do not remove signal plate unless it is necessary to do so.
NOTE: When removing or installing signal plate, use TORX socket (size T30).
Pull rear oil seal out from rear end of crankshaft.
NOTE: When replacing rear oil seal without removing lower cylinder block, use a suitable tool to remove the oil seal installed between crankshaft and cylinder block out.

CAUTION: Be careful not to damage crankshaft and cylinder block.
Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
- Do not drop main bearing, or scratch the surface.
- Identify installation positions, and store them without mixing them up.