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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 129 (2.5L V6) >> Repair Instructions >> Main Bearings, Crankshaft And Cylinder Block Removal And Installation >> Installation

Main Bearings, Crankshaft And Cylinder Block Removal And Installation: Installation

WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • All parts to be installed must be perfectly clean.
  • Be sure to oil crankshaft journals, journal bearings, thrust bearings, crank pins, connecting rod bearings, pistons, piston rings and cylinder bores.
  • Journal bearings, crankcase (bearings caps), connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb combination and try to see that each part goes back to where it came from, when installing.
  • Clean mating surface of cylinder block and crankcase, remove oil, old sealant and dust from mating surface.
  1. Fit main bearings (4) to cylinder block (1).

    One of two halves of main bearing, has oil groove (3). Install this half with oil groove to cylinder block, and another half without oil groove to crankcase.

    Make sure that two halves are painted in the same color.

  2. Install O-ring (2) to cylinder block.
    Fig 1: Fitting Main Bearings & O-Ring To Cylinder Block
    G02264081Courtesy of SUZUKI OF AMERICA CORP.
  3. Fit thrust bearings (1) to cylinder block between No. 2 and No. 3 cylinders. Face oil groove (2) sides to crank webs.
    Fig 2: Fitting Thrust Bearings To Cylinder Block
    G02264082Courtesy of SUZUKI OF AMERICA CORP.
  4. Put crankshaft to cylinder block.
  5. Apply sealant "A" to crankcase mating surface area as shown in the figure.

    "A":  Water tight sealant 99000-31250

    Fig 3: Applying Sealant To Crankcase Mating Surface Area
    G02264083Courtesy of SUZUKI OF AMERICA CORP.
  6. Install crankcase to cylinder block. Apply oil to crankcase bolts before installing them. Tighten crankcase bolts gradually as follows.
    1. Tighten crankcase bolts (10 mm (0.39 in.) thread diameter) to 42 N. m (4.2 kg-m, 30.5 lb-ft) according to numerical order in figure.
    2. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
    3. In the same manner as Step  A, tighten them to 42 N. m (4.2 kg-m, 30.5 lb-ft).
    4. In the same manner as Step  A again, tighten them to specified torque.
    5. Tighten crankcase bolts (8 mm (0.31 in.) thread diameter) to specified torque.
    NOTE: Tighten 10 mm (0.39 in.) thread diameter bolts first (the following the order shown in figure), then tighten 8 mm (0.31 in.) thread diameter bolts.

    Tightening torque 

    Crankcase bolt (a):  Tighten 42 N. m (4.2 kg-m, 30.5 lb-ft), 0 N. m (0 kg-m, 0 lb-ft), 42 N. m (4.2 kg-m, 30.5 lb-ft) and 60 N. m (6.0 kg-m, 43.5 lb-ft) by the specified procedure (10 mm (0.39 in.) thread diameter)

    Crankcase bolt (b):  Tighten 27 N. m (2.7 kg-m, 19.5 lb-ft) by the specified procedure (8 mm (0.31 in.) thread diameter)

    NOTE: After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand.
    Fig 4: Identifying Crankcase Bolts & Torque Sequence
    G02264084Courtesy of SUZUKI OF AMERICA CORP.
  7. Using special tools (Oil seal installer and oil seal guide), install rear oil seal (1).

    Special tool 

    (A):  09911-97710

    (B):  09911-97811

    Fig 5: Installing Rear Oil Seal
    G02264085Courtesy of SUZUKI OF AMERICA CORP.
  8. Install flywheel (M/T vehicle) or drive plate (A/T vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts to specification.

    "A":  Sealant 99000-31110

    Special tool 

    (A):  09924-17811

    Tightening torque 

    Flywheel (or drive plate) bolt (c):  70 N.m (7.0 kg-m, 51.0 lb-ft)

    Fig 6: Installing Flywheel (M/T) Or Drive Plate (A/T)
    G02264086Courtesy of SUZUKI OF AMERICA CORP.
  9. Install oil pump referring to OIL PUMP REMOVAL & INSTALLATION .
  10. Install pistons and connecting rods referring to PISTONS, PISTON RINGS, CONNECTING RODS & CYLINDERS REMOVAL & INSTALLATION  .
  11. Install oil pump strainer and oil pan referring to OIL PAN & OIL PUMP STRAINER REMOVAL & INSTALLATION .
  12. Install cylinder heads assembly to cylinder block referring to VALVES & CYLINDER HEADS REMOVAL & INSTALLATION  .
  13. Install oil pump chain referring to OIL PUMP CHAIN REMOVAL & INSTALLATION .
  14. Install RH bank 2nd timing chain and tensioner referring to RH (NO. 2) BANK 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION  .
  15. Install 1st timing chain and tensioner referring to 1ST TIMING CHAIN & CHAIN TENSIONER INSTALLATION  .
  16. Install LH bank 2nd timing chain and tensioner referring to LH (NO. 1) BANK 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION  .
  17. Install timing chain cover and crankshaft pulley referring to TIMING CHAIN COVER REMOVAL & INSTALLATION  .
  18. Install cylinder head covers referring to CYLINDER HEAD COVERS REMOVAL & INSTALLATION  .
  19. Install exhaust manifold referring to EXHAUST MANIFOLD REMOVAL & INSTALLATION .
  20. Install intake manifold with throttle body. Refer to THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION (H25 ENGINE)  .
  21. Install clutch to flywheel (for M/T vehicle). For clutch installation, refer to CLUTCH COVER, CLUTCH DISC & FLYWHEEL REMOVAL & INSTALLATION .
  22. Install engine assembly to vehicle referring to ENGINE ASSEMBLY REMOVAL & INSTALLATION  .
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