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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 164 (Engine Mechanical) >> 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 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: Installing O-Ring To Cylinder Block
    G02256869Courtesy 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 No. 2 & No. 3 Cylinders
    G02256870Courtesy of SUZUKI OF AMERICA CORP.
  4. Put crankshaft to cylinder block.
  5. Apply sealant "A" to crankcase mating surface area as shown in figure.

    "A": Water tight sealant 99000-31250 

    Fig 3: Applying Sealant "A" To Crankcase Mating Surface
    G02256871Courtesy 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 the figure.
    2. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
    3. In the same manner as in Step a), tighten them to 42 N.m (4.2 kg-m, 30.5 lb-ft).
    4. In the same manner as in Step a) again, tighten them to 60 N.m (6.0 kg-m, 43.5 lb-ft).
    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 (following the order ("1" - "16") shown in Fig 4), then tighten 8 mm (0.31 in.) thread diameter bolts.

    Tightening torque 

    Crankcase bolt (10 mm (0.39 in.) thread diameter) (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 Crankcase bolt (8 mm (0.31 in.) thread diameter) (b): Tighten 27 N.m (2.7 kg-m, 19.5 lb-ft) by the specified procedure 

    NOTE: After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand.
    Fig 4: Tightening Bolts In Sequence
    G02256872Courtesy of SUZUKI OF AMERICA CORP.
  7. Using special tools (Oil seal installer and oil seal guide), install rear oil seal (1).

    Special tool 

    (A): 09911-97811 

    (B): 09911-97710 

    Fig 5: Installing Rear Oil Seal Using Special Tool
    G02256873Courtesy of SUZUKI OF AMERICA CORP.
  8. Install clutch and flywheel (M/T vehicle) or drive plate (A/T vehicle).

    For clutch and flywheel installation, refer to "CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION " For drive plate installation, refer to "AUTOMATIC TRANSMISSION (WITH TRANSFER IF EQUIPPED) DISMOUNTING AND REMOUNTING "

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