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Engine Unit: Disassembly and Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
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.
  1. 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 ].
  2. Remove both exhaust manifolds. Refer to EXHAUST MANIFOLD: REMOVAL AND INSTALLATION [VQ40DE]
  3. Remove pilot converter (A/T models) using Tool as necessary.
    Fig 1: Removing Pilot Converter (A/T Models)
    G06441068Courtesy of SUZUKI OF AMERICA CORP.

    Tool number: ST16610001 (J-23907) 

  4. Lift engine, and mount to engine stand.
    Fig 2: Lifting Engine And Mount To Engine Stand
    G06441069Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Before removing the hanging chains, make sure engine stand is stable and there is no risk of overturning.
    • A widely use engine stand can be used.
      Fig 3: Identifying Engine Stand
      G06441070Courtesy of SUZUKI OF AMERICA CORP.
      CAUTION: Use engine stand that has a load capacity [approximately 220 kg (441 lb) or more] large enough for supporting the engine weight.
  5. Drain engine oil. Refer to [CHANGING ENGINE OIL ]
  6. Drain engine coolant by removing the cylinder block drain plugs (A), (B), (C) and (D) from cylinder block as shown.
    Fig 4: Identifying Cylinder Block Drain Plugs And Washer
    G06441071Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: For Canada, (D) is not plug but block heater.
  7. Remove cylinder head. Refer to [CYLINDER HEAD: REMOVAL AND INSTALLATION ].
  8. Remove sub harness, and remove knock sensors.
    CAUTION: Carefully handle sensor avoiding shocks.
  9. 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 not to drop connecting rod bearing, and to scratch the surface.
  10. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
  11. Remove connecting rod bearing cap.
  12. Push piston and connecting rod assembly out to the cylinder head side using suitable tool.
    Fig 5: Pushing Piston And Connecting Rod Assembly
    G06441072Courtesy 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.
  13. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
    CAUTION: Identify installation position, and store them without mixing them up.
  14. 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 6: Removing Piston Rings Using Piston Ring Expander Or Suitable Tool
      G06441073Courtesy 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.
  15. Remove piston from connecting rod as follows:
    1. Remove snap ring using snap ring pliers.
      Fig 7: Removing Snap Ring Using Snap Ring Pliers
      G06441074Courtesy of SUZUKI OF AMERICA CORP.
    2. Heat piston to 60° to 70 °C (140° to 158 °F) with industrial use drier or equivalent.
      Fig 8: Heating Piston
      G06441075Courtesy of SUZUKI OF AMERICA CORP.
    3. Push out piston pin with stick of outer diameter approximately 20 mm (0.79 in).
      Fig 9: Pushing Piston Pin
      G06441076Courtesy of SUZUKI OF AMERICA CORP.
  16. Remove lower cylinder block bolts.
    • Before loosening lower cylinder block bolts, measure the 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 10: Lower Cylinder Block Bolts Loosening Sequence
      G06441077Courtesy of SUZUKI OF AMERICA CORP.
      NOTE: Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).
  17. Remove lower cylinder block.
    • Cut liquid gasket for removal. Refer to [PRECAUTION FOR LIQUID GASKET ].

      Tool number: KV10111100 (J-37228) 

      CAUTION: Be careful not to damage the mounting surfaces.
  18. Remove crankshaft.
  19. 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 pull the rear oil seal installed between crankshaft and cylinder block out.
    CAUTION: Be careful not to damage crankshaft and cylinder block.
  20. 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.
  21. Remove oil jet.
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