LEMON Manuals: Even more car manuals for everyone
Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 131 (2.0L 4-Cylinder) >> Repair Instructions >> Main Bearings, Crankshaft And Cylinder Block Installation

Main Bearings, Crankshaft And Cylinder Block Installation

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • All ports to be installed must be perfectly clean.
  • Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores.
  • Journal bearings, crankcase (bearing caps), connecting rods, rod bearing, 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 lower crankcase, remove oil, old sealant and dust from mating surface.
  1. Fit main bearing to cylinder block.

    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 (3) to lower crankcase.

    Make sure that 2 halves are painted in the same color.

  2. Install O-ring (2) to cylinder block (1).
    Fig 1: Identifying Main Bearing & Knock Pin
    G01352027Courtesy 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: Identifying Thrust Bearing Oil Grooves
    G01352028Courtesy of SUZUKI OF AMERICA CORP.
  4. Put crankshaft (1) with oil pump drive chain to cylinder block.

    Check to make sure that CKP sensor plate (2) is free from metal particles and damage.

    Fig 3: Identifying Crankshaft & CKP Sensor Plate
    G01352029Courtesy of SUZUKI OF AMERICA CORP.
  5. Apply sealant "A" to lower crankcase mating surface area as shown in the figure.
    1. "A":  Sealant 99000-31250
    Fig 4: Identifying Lower Crankcase Sealant Application Area
    G01352030Courtesy of SUZUKI OF AMERICA CORP.
  6. Install lower crankcase (1) to cylinder block. Apply oil to crankcase bolts before installing them. Tighten crankcase bolts to 70% torque of specified torque, the following sequence in the figure and then tighten crankshaft bolts to specified torque according to numerical order in the figure.

    Tightening Torque 

    1. Crankcase bolt (10 mm thread diameter) (a):  60 N.m (6.0 kg-m, 43.5 lb-ft)
    2. Crankcase bolt (8 mm thread diameter) (b):  27 N.m (2.7 kg-m, 19.5 lb-ft)
    NOTE: After tightening crankcase bolts, check to be sure that crankshaft, rotates smoothly when turned by hand.
    Fig 5: Identifying Crankcase Bolts Tightening Sequence
    G01352031Courtesy of SUZUKI OF AMERICA CORP.
  7. Install rear oil seal (1) by using plastic hammer and special tools.

    Special tool 

    1. (A):  099911-97710
    2. (B):  099911-97810
    Fig 6: Identifying Rear Oil Seal Configuration
    G01352032Courtesy of SUZUKI OF AMERICA CORP.
  8. Install CKP sensor (1) and fix its wire harness with bracket.

    Tightening torque 

    1. CKP sensor bolt (a):  6 N.m (0.6 kg-m, 4.5 lb-ft)
    Fig 7: Identifying CKP Sensor & Bolt
    G01352033Courtesy of SUZUKI OF AMERICA CORP.
  9. 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 (1) applied with thread lock cement to specification.

    1. "A":  Threat lock cement 99000-32110

    Special tool 

    1. (A):  09924-17810

    Tighten torque 

    1. Flywheel (or drive plate) bolt (c):  70 N.m (7.0 kg-m, 51.0 lb-ft)
    Fig 8: Identifying Flywheel (Or Drive Plate) Bolt & Special Tool
    G01352034Courtesy of SUZUKI OF AMERICA CORP.
  10. Install engine side mounting brackets (right and left (1).

    Tighten bracket bolts to specified torque.

    Tightening torque 

    1. Engine side mounting bracket bolt (d):  50 N.m (5.0 kg-m, 36.5 lb-ft)
  11. Install water pump (2) and heater outlet pipe (3). See INSTALLATION .
    Fig 9: Identifying Water Pump, Heater Outlet Pipe & Left Side Engine Mounting Bracket
    G01352035Courtesy of SUZUKI OF AMERICA CORP.
  12. Install pistons and connecting rods. See PISTONS, PISTON RINGS, CONNECTING RODS & CYLINDERS REMOVAL AND INSTALLATION .
  13. Install oil pump. See INSTALLATION .
  14. If Oil pump chain guide is reinstalled or new oil pump chain in installed, adjust clearance between oil pump chain and oil pump chain guide as follow:
    1. Install oil pump chain guide (1) and nuts (2) temporarily.
    2. To take up slack of chain, insert 0.5 mm (0.020 in.) thickness gauge (3) between chain guide (1) and chain and pull chain guide (1) in arrow direction with a force of 20 to 30 N (2-3 kg. 4.4-6.6 lb).
    3. With pulling chain guide (1) in Step b), tighten oil pump chain guide nuts (2) and pull out thickness gauge (3).
    Fig 10: Identifying Thickness Gauge, Oil Pump Chain Guide & Oil Pump Chain Guide Nuts
    G01352036Courtesy of SUZUKI OF AMERICA CORP.
  15. Install cylinder head assembly to cylinder block. See VALVES & CYLINDER HEAD INSTALLATION .
  16. Install 1st and 2nd timing chains. See 1ST TIMING CHAIN & CHAIN TENSIONER INSTALLATION  and 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION .
  17. Install timing chain cover. See TIMING CHAIN COVER REMOVAL & INSTALLATION .
  18. Install cylinder head cover. See CYLINDER HEAD COVER REMOVAL & INSTALLATION .
  19. Install oil pump strainer and oil strainer. See OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION .
  20. Install clutch to flywheel (for M/T vehicle). See INSTALLATION .
  21. Install engine assembly to vehicle. See INSTALLATION .
scientia non olet · About LEMON Manuals