Engine Mechanical: Removal & Installation Suzuki Kizashi I

Air Cleaner Filter Removal and Installation

Reference: AIR CLEANER COMPONENTS

Scheme 19

1. Open air cleaner case (1) by unhooking the clamps (2).
2. Remove air cleaner filter from case.

Installation

Reference: AIR CLEANER FILTER INSPECTION AND CLEANING

Reverse removal procedure.

Air Cleaner Assembly Removal and Installation

Reference: AIR CLEANER COMPONENTS

Scheme 20

1. Disconnect negative (-) cable at battery.
2. Disconnect MAF and IAT sensor connector (1).
3. Remove air cleaner outlet hose (2).
4. Remove air cleaner bolts No. 1 (3) and No. 2 (4).
5. Remove air cleaner assembly (5).

Reverse removal procedure for installation noting the following points

Scheme 21

1. Align matchmark of air cleaner outlet hose and air cleaner suction hose when installing, see «AIR CLEANER COMPONENTS»(ref-585578-S28303824262013111200000) .
2. Install throttle body (1) side clamp bolt head (2) within specified range "a" shown below and tighten it to specified torque, see «AIR CLEANER COMPONENTS»(ref-585578-S28303824262013111200000) .
3. Tighten clamps and bolts to specified torque, see «AIR CLEANER COMPONENTS»(ref-585578-S28303824262013111200000) .

Scheme 22

Throttle Body Assembly Removal and Installation

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Scheme 23

Scheme 24

1. Disconnect negative (-) cable at battery.
2. Drain coolant, see «COOLING SYSTEM DRAINING»(ref-585577-S13391481082013111200000) .
3. Remove air cleaner outlet hose (1).
4. Disconnect engine coolant hoses (2) and connector (3) from throttle body assembly (1).
5. Remove throttle body bolts (4), and then remove throttle body assembly and gasket (5) from intake manifold.

Reference: THROTTLE BODY CLEANING

Scheme 25

Scheme 26

1. Clean mating surfaces and install new throttle body gasket (1) to intake manifold.
2. Install throttle body assembly (1) to intake manifold, and then tighten throttle body bolt (2) to specified torque. Tightening torque Throttle body bolt (a): 12 N.m (1.2 kg-m, 9.0 lbf-ft)
3. Connect connector (4) and coolant hoses (3) to throttle body assembly (1).
4. Install air cleaner outlet hose, see «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S10930133882013111200000) .
5. Refill cooling system with coolant, see «COOLING SYSTEM REFILLING»(ref-585577-S08150924882013111200000) .
6. Connect negative (-) cable at battery.
7. Check for coolant leaks, see «ENGINE COOLING SYSTEM INSPECTION»(ref-585577-S39475297722013111200000) .

Intake Manifold Removal and Installation

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Scheme 27

Scheme 28

Scheme 29

1. Disconnect negative (-) cable at battery.
2. Remove engine cover.
3. Remove throttle body assembly, see «THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S00015605662013111200000) .
4. Remove engine cover bolt (1).
5. Disconnect the following connectors and hoses. EVAP canister purge valve connector (2) Brake booster hose (3) PCV valve hose (4) Purge hose (5) IMT valve actuator connector (6) IMT valve actuator clamp (7) Engine harness bracket (8) Engine harness clamp (Intake manifold lower side) (9)
6. Remove intake manifold (1) and gasket (2) from cylinder head.

Reverse removal procedure for installation noting the following points

Scheme 30

1. Use New gaskets
2. The Intake manifold bolt No. 1 (1) is not reusable so use a new one.
3. Refill cooling system, see «COOLING SYSTEM REFILLING»(ref-585577-S08150924882013111200000) .
4. Check for coolant leaks, see «ENGINE COOLING SYSTEM INSPECTION»(ref-585577-S39475297722013111200000) .

Scheme 31

1. Disconnect negative (-) cable at battery.
2. Disconnect IMT valve actuator connector.
3. Remove IMT valve actuator (2) and gasket (3) from intake manifold (1).

Reverse removal procedure noting the following points

1. Use new gasket.
2. Check that IMT valve operates properly after installation.

Scheme 32

1. Disconnect negative (-) cable at battery.
2. Drain coolant, see «COOLING SYSTEM DRAINING»(ref-585577-S13391481082013111200000) .
3. Remove exhaust manifold cover.
4. Remove block heater protector, and then disconnect block heater harness connector.
5. Remove cylinder block heater (1).

Reference: CYLINDER BLOCK HEATER INSPECTION (IF EQUIPPED)

Reverse removal procedure for installation noting the following points

Scheme 33

1. Use new cylinder block heater bolts.
2. Tighten cylinder block heater bolts (1) to specified torque. Tightening torque Cylinder block heater bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
3. Refill coolant, see «COOLING SYSTEM REFILLING»(ref-585577-S08150924882013111200000) .
4. Check for coolant leaks, see «ENGINE COOLING SYSTEM INSPECTION»(ref-585577-S39475297722013111200000) .

Cylinder Head Cover Removal and Installation

Reference: CYLINDER HEAD COVER COMPONENTS

Scheme 34

1. Disconnect negative (-) cable at battery.
2. Remove engine cover.
3. Remove ignition coil assemblies from cylinder head cover, see «IGNITION COIL ASSEMBLY REMOVAL AND INSTALLATION»(ref-585636-S11826904132013111200000) .
4. Disconnect IMT valve connector (1) and IMT valve harness clamp (2).
5. Disconnect PCV valve hose (1) and breather hose (2).
6. Detach engine harness clamps.
7. Remove engine harness bracket (3).
8. Remove cylinder head cover bolts.
9. Remove cylinder head cover with its gasket.
10. Remove PCV valve if necessary.

Scheme 35

Scheme 36

Scheme 37

Scheme 38

1. Tighten PCV valve to specified torque, if removed. Tightening torque PCV valve: 2.5 N.m (0.25 kg-m, 2.0 lbf-ft)
2. Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover.
3. Install new cylinder head cover gasket (1) to cylinder head cover (2) as shown in figure.
4. Apply sealant "A" to the designated area as shown in figure. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)
5. Install cylinder head cover to cylinder head. NOTE: Install cylinder head cover, making sure cylinder head cover gasket for proper fit in cylinder head cover.
6. Tighten cylinder head cover bolts using the following procedures: a) Tighten cylinder head cover bolts to 3.0 N.m (0.31 kgf-m, 2.5 lbf-ft) in numerical order ("1" - "16") evenly and gradually. Retighten them to 5.0 N.m (0.51 kgf-m, 4.0 lbf-ft). In the same manner as in Step a ). Retighten them to 7.5 N.m (0.76 kgf-m, 5.5 lbf-ft). In the same manner as in Step a ). Tightening torque Cylinder head cover bolt* (a): 3.0 N.m --> 5.0 N.m --> 7.5 N.m (0.31 kgf-m --> 0.51 kgf-m --> 0.76 kgf-m, 2.5 lbf-ft --> 4.0 lbf-ft --> 5.5 lbf-ft)
7. Install engine harness bracket (1).
8. Connect PCV valve hose (2) to PCV valve and breather hose (3) to cylinder head cover.
9. Connect IMT valve connector (1) and IMT valve harness clamp (2).
10. Install ignition coil assemblies, see «IGNITION COIL ASSEMBLY REMOVAL AND INSTALLATION»(ref-585636-S11826904132013111200000) .
11. Install engine cover.
12. Connect negative (-) cable at battery.

Scheme 39

Camshaft and Tappet Removal and Installation

Reference: CAMSHAFT AND TAPPET COMPONENTS

Scheme 40

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Scheme 47

Scheme 48

1. Remove cylinder head cover, see «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-585578-S04363068542013111200000) .
2. Remove accessory drive belt, see «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-585571-S19141351432013111200000) .
3. Turn crankshaft clockwise, and position piston No. 1 at TDC on the compression stroke using the following procedures: Align the timing mark (1) on the CMP actuator and the timing mark (2) on the exhaust camshaft timing sprocket with the matchmark (3) on the camshaft housing No. 1. Align notch mark (1) on the crankshaft pulley with "0" (2) on the timing chain cover.
4. Fix timing chain tensioner using the following procedures: Remove timing chain cover plug (1) and gasket (2). Insert fore-end of special tool into timing chain tensioner hole (1) from timing chain cover plug hole. NOTE: Make sure that special tool is inserted in timing chain tensioner hole, with mirrors or the like. Special Tool 09917-16710 Fix special tool by special tool fixing bolt (2) to specified torque. NOTE: Failure to observe the following cautions result in engine damage or incorrect installing of timing chain. Use the following bolt for special tool fixing bolt. Special tool fixing bolt BOLT LENGTH SPECIFICATION Bolt size M6 Pitch 1.0 mm (0.039 in.) Length "a" 15.0 mm (0.590 in.) Be sure to tighten specified tool fixing bolt (2) to specified torque. If bolt becomes loose, plunger of timing chain tensioner adjuster may extend, making it difficult to reinstall timing chain properly. Do not turn crankshaft after timing chain is fixed with special tool. Tightening torque Special tool fixing bolt (a): 8 N.m (0.82 kg-m, 6.0 lbf-ft)
5. Apply a dab of paint to two timing chain links (2) which meet timing marks (1) on CMP actuator and exhaust camshaft timing sprocket.
6. Remove exhaust camshaft timing sprocket using the following procedures: Hold the hexagonal section of exhaust camshaft using a wrench. Remove exhaust camshaft timing sprocket bolt, then remove sprocket (1). NOTE: Be careful not to drop dowel pin into the space between timing chain cover and cylinder block.
7. Remove dowel pin from exhaust camshaft.
8. Loosen camshaft housing bolts in numerical order ("1" - "21") evenly and gradually.
9. Remove intake camshaft and exhaust camshaft.
10. Remove camshaft bearings and tappets if necessary.
11. Remove CMP actuator from intake camshaft using the following procedures if necessary. Hold hexagonal section of intake camshaft using vice. Remove CMP actuator bolt, and then remove CMP actuator (1). CAUTION: The CMP actuator will lose its original performance if it is disassembled. Do not try to disassemble and repair the CMP actuator. If any faulty condition is found, replace the CMP actuator with a new one.

Reference: CAMSHAFT AND TAPPET INSPECTION

Scheme 49

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Scheme 60

Scheme 61

1. Install CMP actuator (1) to intake camshaft. Tightening torque CMP actuator bolt (a): 60 N.m (6.1 kg-m, 44.5 lbf-ft)
2. Apply engine oil to contact surface of tappets (hatched area), and then Install tappets (1) to cylinder head.
3. Install camshaft bearings using the following procedures: CAUTION: The camshaft upper bearing (1) is different in shape from the camshaft lower bearing (2). If these bearings are installed in the wrong (reverse) positions, the VVT system will have operational problems and/or the camshaft could seize up. Be sure to install the bearings in the specified positions. Fit tab (1) of camshaft bearing to groove (2) of cylinder head or camshaft housing. Press camshaft bearing end (3) until it is firmly seated on the cylinder head or camshaft housing. Apply engine oil to sliding surface (4) of camshaft bearing halves. CAUTION: If oil is present between the bearing's outside surface and the camshaft housing / cylinder head surface, the bearing could heat up to very high temperature, resulting in seizure. Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface and the camshaft housing / cylinder head surface.
4. Apply engine oil to sliding surfaces of camshafts, and then install camshafts to cylinder head using the following procedures: Align the timing chain link (2), which is painted in Step 5 ) of "Removal" under this section, with timing mark (1) on CMP actuator and install intake camshaft. Install the exhaust camshaft so that the dowel pin hole (3) is positioned downwards.
5. Install camshaft housings (1) to proper places distinguished by letter (2), number (3) and arrow direction (4) on each camshaft housing.
6. Tighten camshaft housing bolts using the following procedures: Install camshaft housing No. 1 (1). Install camshaft housing bolts, and tighten them by hand. Tighten camshaft housing bolts in numerical order ("1" - "21") evenly and gradually. Tightening torque Camshaft housing bolt*: 11 N.m (1.1 kg-m, 8.5 lbf-ft)
7. Install dowel pin to exhaust camshaft. CAUTION: Be careful not to drop dowel pin into the space between timing chain cover and cylinder block.
8. Install exhaust camshaft timing sprocket (3) to exhaust camshaft using the following procedures. Align the timing chain link (1), which is painted in Step 5 ) of "Removal", with timing mark (2) on exhaust camshaft timing sprocket (3), and loop timing chain up over exhaust camshaft timing sprocket. Install exhaust camshaft timing sprocket (3) with timing chain to the exhaust camshaft.
9. Tighten exhaust camshaft timing sprocket bolt (1) using special tool. Special Tool 09911-05120 Tightening torque Exhaust camshaft timing sprocket bolt (a): 60 N.m (6.1 kg-m, 44.5 lbf-ft) CAUTION: If the bolt is tightened using the extension special tool until the torque wrench reads the specified torque, the bolt will actually be tightened to a torque much more than the specified torque. This could cause damage to the related components. Use the formula shown below to determine the correct reading of the torque wrench for its length. Then tighten the bolt until the torque wrench indicates the value thus determined. Formula for reading value of torque wrench . M = T X L/(L + "a") M: Reading value using extension special tool T: Specified torque L: Torque wrench length "a": Dimension of special tool
10. Confirm that painted timing chain links (2) are aligned with timing marks (1) on CMP actuator and exhaust camshaft timing sprocket.
11. Remove special tool from timing chain cover.
12. Install timing chain cover plug (1) with new gasket (2), and tighten it to specified torque. Tightening torque Timing chain cover plug (a): 27 N.m (2.8 kg-m, 20.0 lbf-ft)
13. Check that camshaft and timing chain are properly installed as follows: a) Check that timing mark (1) on CMP actuator and timing mark (2) on exhaust camshaft timing sprocket are aligned with matchmark (3) on camshaft housing No. 1. b) Check that notch mark (1) on crankshaft pulley is aligned with "0" (2) on timing chain cover. Turn crankshaft clockwise 720° twice and repeat Step a ) and b ). NOTE: Be sure to turn crankshaft 720°. If it is turned only 360°, the timing marks on CMP actuator and exhaust camshaft timing sprockets will not meet matchmark on camshaft housing No. 1. After turning crankshaft 720°, the painted links of the timing chain will not be aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but this is normal.
14. Check valve clearance, see «VALVE CLEARANCE INSPECTION AND ADJUSTMENT»(ref-585578-S03989302782013111200000) .
15. Install cylinder head cover, see «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-585578-S04363068542013111200000) .

Timing Chain Cover Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

Scheme 62

Scheme 63

1. Remove engine assembly from vehicle, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .
2. Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool as shown in the following figure. Special Tool 09917-68221
3. Remove crankshaft pulley (1). Use special tools as shown in figure if it is hard to remove. Special Tool 09944-36011 09926-58010
4. Remove cylinder head cover, see «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-585578-S04363068542013111200000) .
5. Remove oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-585579-S20387956532013111200000) .
6. Remove tensioner pulley and idler pulley, see «TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(ref-585571-S34416445112013111200000) .
7. Remove timing chain cover bolts, then remove timing chain cover with engine hook.
8. Remove crankshaft oil seal from timing chain cover using flat-end screwdriver or the like, if necessary.
9. Remove oil control valve from timing chain cover if necessary, see «OCV REMOVAL AND INSTALLATION»(ref-585578-S27634798392013111200000) .

Reference: TIMING CHAIN COVER INSPECTION

Scheme 64

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Scheme 68

1. Install oil control valve if removed, see «OCV REMOVAL AND INSTALLATION»(ref-585578-S27634798392013111200000) .
2. Clean mating surface of timing chain cover, cylinder block and cylinder head by removing old sealant and oil.
3. Check oil seal (1) for any damage. Replace oil seal if any abnormalities are found. NOTE: When installing new oil seal, press it into timing chain cover (2) using special tool as shown in figure. Special Tool 09913-75510
4. Install dowel pins (1) to cylinder block.
5. Apply sealant "A" as follows: Fill sealant "A" to mating clearance of cylinder block and cylinder head. Apply sealant "A" to mating surface of timing chain cover as specified. NOTE: Before applying sealant, make sure mating surfaces are clean and dry. Install timing chain cover within 2 minutes after applying sealant. Wipe off excessive sealant of upper and lower end of the cover. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) Sealant bead size for timing chain cover Width "a": 3 mm (0.11 in.) Height "b": 2 mm (0.07 in.)
6. Apply engine oil to oil seal lip, and then install timing chain cover with engine hook. Tighten timing chain cover bolts to specified torque in numerical order ("1" - "17") evenly and gradually. NOTE: Before installing timing chain cover, check that dowel pins are securely fitted. Tightening torque Timing chain cover bolt* (M8 bolt) (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft) Timing chain cover bolt* (M10 bolt) (b): 55 N.m (5.6 kg-m, 40.5 lbf-ft)
7. Install tensioner pulley and idler pulley, see «TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(ref-585571-S34416445112013111200000) .
8. Install cylinder head cover, see «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-585578-S04363068542013111200000) .
9. Install oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-585579-S20387956532013111200000) .
10. Install crankshaft pulley (1) and tighten crankshaft pulley bolt to specified torque. To lock crankshaft pulley, use special tool as shown in figure. Special Tool 09917-68221 Tightening torque Crankshaft pulley bolt (a): 150 N.m (15.3 kg-m, 111.0 lbf-ft)
11. Install engine assembly to vehicle, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .

OCV Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

Removal

Remove OCV (2) and O-ring (3) from timing chain cover (1).

Scheme 69

Reverse removal procedure noting the following point

1. Tighten OCV bolt to specified torque. Tightening torque OCV bolt: 11 N.m (1.1 kg-m, 8.5 lbf-ft)

Scheme 70

1. Remove transmission assembly. M/T model: «MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-585624-S15424779752013111200000) . CVT model: «CVT ASSEMBLY DISMOUNTING AND REMOUNTING»(ref-585587-S29986396022013111200000) .
2. Wedge a special tool in ring gear teeth to lock flywheel or drive plate as shown in figure. Special Tool 09924-17811
3. Remove flywheel or drive plate from engine assembly.

Reverse removal procedure noting the following points

Scheme 71

1. Install new flywheel bolts or drive plate bolts.
2. Wedge a special tool in ring gear teeth to lock flywheel or drive plate as shown in figure. Special Tool 09924-17811
3. Tighten flywheel bolts or drive plate bolts to specified torque. Tightening torque Flywheel bolt (a): 70 N.m (7.1 kg-m, 52.0 lbf-ft) Drive plate bolt (a): 70 N.m (7.1 kg-m, 52.0 lbf-ft)

Timing Chain and Chain Tensioner Removal and Installation

Reference: TIMING CHAIN AND CHAIN TENSIONER COMPONENTS

Scheme 72

Note. If it is necessary to rotate the camshaft after removing timing chain, turn crankshaft counterclockwise and position the key (1) within an angle of 30 to 90° from TDC before rotating the camshaft as shown in the following figure and keep the valves from coming in contact with the pistons.

Scheme 73

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Scheme 75

1. Remove timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-585578-S36979470282013111200000)
2. Align camshafts and crankshaft by turning the crankshaft at specific position as follows: Align timing marks on CMP actuator (1) and timing mark (2) on exhaust camshaft timing sprocket with matchmark (3) on camshaft housing No. 1. Align timing mark (1) on crankshaft timing sprocket with matchmark (2) on lower crankcase.
3. Remove timing chain tensioner adjuster (3).
4. Remove timing chain tensioner (4).
5. Remove timing chain guide (5).
6. Remove timing chain (6) and crankshaft timing sprocket (7).

Reference: TIMING CHAIN AND CHAIN TENSIONER INSPECTION

Scheme 76

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Scheme 81

1. Turn camshaft position key slot (1) within specified range (30 - 90°) (2) in counterclockwise direction from top as shown in figure.
2. Align timing mark (3) on CMP actuator with matchmark (4) on camshaft housing No. 1.
3. Align timing mark (5) on exhaust camshaft timing sprocket with matchmark (4) on camshaft housing No. 1.
4. Install key (6) to key slot (1) of crankshaft. Align key slot of crankshaft timing sprocket (7) with key, and then Install crankshaft timing sprocket to crankshaft. Align timing mark (8) on crankshaft timing sprocket with matchmark (9) on lower crankcase.
5. Install timing chain while aligning two blue plates (2) with timing marks (1) on CMP actuator and exhaust camshaft timing sprockets.
6. Install timing chain while aligning blue plate (2) with timing mark (1) on crankshaft timing sprocket.
7. Install timing chain guide (1) and tighten timing chain guide bolts (2) to specified torque. Tightening torque Timing chain guide bolt (a): 9.0 N.m (0.92 kg-m, 7.0 lbf-ft)
8. Apply engine oil to sliding surface of timing chain guide.
9. Attach spacer (4) to timing chain tensioner (3).
10. Install timing chain tensioner (3) and tighten timing chain tensioner bolt (5) to specified torque. Tightening torque Timing chain tensioner bolt (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
11. Apply engine oil to sliding surface of timing chain tensioner.
12. Make sure that all blue plates (6) are aligned with timing marks (7) on corresponding timing sprockets.
13. Screw in plunger (2) of timing chain tensioner adjuster (1) clockwise and install a retainer (3) (1.4 mm (0.055 in.) diameter wire or the like) to hold plunger in place.
14. Install timing chain tensioner adjuster (1) with a retainer. Tighten timing chain tensioner adjuster bolts (2) to specified torque, and then remove a retainer from timing chain tensioner adjuster. Tightening torque Timing chain tensioner adjuster bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
15. Apply engine oil to timing chain, turn crankshaft clockwise 720°, and confirm that the following conditions have been met: Timing mark (4) on CMP actuator is aligned with matchmark (3) on camshaft housing No. 1. Timing mark (5) on exhaust camshaft timing sprocket is aligned with matchmark (3) on camshaft housing No. 1. Timing mark (6) on crankshaft timing sprocket is aligned with matchmark (7) on lower crankcase. NOTE: Be sure to turn crankshaft 720°. If it is turned only 360°, the timing marks on CMP actuator and exhaust camshaft timing sprockets will not meet matchmark on camshaft housing No. 1. After turning crankshaft 720°, the painted links of the timing chain will not be aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but this is normal.
16. Install timing chain cover, see «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-585578-S36979470282013111200000) .
17. Install cylinder head cover, see «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-585578-S04363068542013111200000) .
18. Install oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-585579-S20387956532013111200000) .
19. Install engine assembly, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .

Valve and Cylinder Head Removal and Installation

Reference: VALVE AND CYLINDER HEAD COMPONENTS

Scheme 82

Scheme 83

1. Remove timing chain, see «TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION»(ref-585578-S22981027752013111200000) .
2. Remove spark plugs, see «SPARK PLUG REMOVAL AND INSTALLATION»(ref-585636-S00540436802013111200000) .
3. Remove intake camshaft and exhaust camshaft, see «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(ref-585578-S27345590882013111200000) .
4. Remove camshaft bearings.
5. Remove heater outlet pipe bolt (1) from cylinder head (2).
6. Remove cylinder head bolt No. 2 (1).
7. Loosen cylinder head bolts No. 1 (2) in numerical order ("1" - "10") evenly and gradually. NOTE: Use 12-point socket wrench for cylinder head bolts No. 1.
8. Remove cylinder head with gasket, intake manifold and exhaust manifold from cylinder block.
9. Remove following components of cylinder head if necessary. Intake manifold: «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-585578-S19761653732013111200000) . Exhaust manifold: «EXHAUST MANIFOLD REMOVAL AND INSTALLATION»(ref-585626-S29038953912013111200000) . Fuel injector: «FUEL INJECTOR REMOVAL AND INSTALLATION»(ref-585580-S33863010272013111200000) . Water outlet cap: «COOLING SYSTEM COMPONENTS»(ref-585577-S18818441622013111200000) . Oil venturi plug: «VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY»(ref-585578-S23391128792013111200000) .

Reference: VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Reference: CYLINDER HEAD INSPECTION

Reference: CYLINDER HEAD BOLT NO. 1 INSPECTION

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1. Clean mating surface of cylinder head and cylinder block removing old gasket, dust and oil.
2. Install dowel pins (1) to cylinder block.
3. Install new cylinder head gasket (2) to cylinder block.
4. Install cylinder head to cylinder block as follows: NOTE: Before Installing the cylinder head to the cylinder block, turn crankshaft counterclockwise and position the key (1) within an angle of 30 to 90° from TDC before rotating the camshaft as shown in the following figure and keep the valves from coming in contact with the pistons. Install cylinder head to cylinder block. Apply engine oil to cylinder head bolts No. 1 threads. Tighten cylinder head bolts No. 1 to 20 N.m (2.0 kgf-m, 15.0 lbf-ft) in numerical order ("1" - "10") evenly and gradually. NOTE: Use 12-point socket wrench for cylinder head bolts No. 1. Retighten them to 40 N.m (4.1 kgf-m, 29.5 lbf-ft) in the same manner as in Step c ). Retighten them to 60° in the same manner as in Step c ). Retighten them to 80° in the same manner as in Step c ). Tightening torque Cylinder head bolt No. 1* (a): 20 N.m --> 40 N.m --> +60° --> +80° (2.0 kgf-m --> 4.1 kgf-m --> +60° --> +80°, 15.0 lbf-ft --> 29.5 lbf-ft --> +60° --> +80°) Tighten cylinder head bolt No. 2 (2) to specified torque. Tightening torque Cylinder head bolt No. 2 (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
5. Install oil venturi plug if removed, see «VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY»(ref-585578-S23391128792013111200000) .
6. Install intake camshaft and exhaust camshaft, see «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(ref-585578-S27345590882013111200000) .
7. Install timing chain, see «TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION»(ref-585578-S22981027752013111200000) .
8. Install timing chain cover, see «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-585578-S36979470282013111200000) .
9. Install cylinder head cover, see «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-585578-S04363068542013111200000) .
10. Install oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-585579-S20387956532013111200000) .
11. Install water outlet cap if removed, see «COOLING SYSTEM COMPONENTS»(ref-585577-S18818441622013111200000) .
12. Install heater outlet pipe bolt to cylinder head, see «COOLING SYSTEM COMPONENTS»(ref-585577-S18818441622013111200000) .
13. Install spark plugs, see «SPARK PLUG REMOVAL AND INSTALLATION»(ref-585636-S00540436802013111200000) .
14. Install exhaust manifold if removed, see «EXHAUST MANIFOLD REMOVAL AND INSTALLATION»(ref-585626-S29038953912013111200000) .
15. Install intake manifold if removed, see «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-585578-S19761653732013111200000) .
16. Install fuel injectors if removed, see «FUEL INJECTOR REMOVAL AND INSTALLATION»(ref-585580-S33863010272013111200000) .
17. Install engine assembly, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .

Piston, Piston Ring and Connecting Rod Removal and Installation

Reference: PISTON, PISTON RING AND CONNECTING ROD COMPONENTS

1. Remove engine assembly from vehicle, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .
2. Remove cylinder head, see «VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION»(ref-585578-S06301699882013111200000) .
3. Remove oil pump, see «OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION»(ref-585579-S33918550922013111200000) .
4. Mark cylinder number on all pistons, connecting rods and connecting rod bearing caps using silver pencil or quick drying paint.
5. Remove connecting rod bearing caps.
6. Remove carbon deposits from tops of cylinder bores before removing pistons from cylinder.
7. Push piston and connecting rod assembly out through the top of cylinder bore.
8. Remove connecting rod bearings from connecting rod and connecting rod bearing cap, if necessary.

Reference: PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY

Reference: CRANKSHAFT PIN AND CONNECTING ROD BEARINGS INSPECTION

Scheme 87

Scheme 88

Scheme 89

Scheme 90

1. Apply engine oil to pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft pins. NOTE: If oil is present between the bearing's outside surface and the connecting rod surface, the bearing could heat up to very high temperature, resulting in seizure. Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface and the connecting rod surface.
2. Install connecting rod bearing to connecting rod or bearing cap as follows: Fit tab (1) of connecting rod bearing to groove (2) of connecting rod or bearing cap. Press bearing end (3) until it fully seats in connecting rod or bearing cap.
3. When installing piston and connecting rod assembly into cylinder bore, direct front mark (1) on piston head to crankshaft pulley side (2).
4. Install piston and connecting rod assembly into cylinder bore. Use special tool to compress rings. Guide connecting rod into place on crankshaft. Tap piston head with a hammer handle to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered in cylinder bore. Special Tool 09916-77310
5. Install connecting rod bearing cap (1) as follows: CAUTION: Using connecting rod bolts that are deformed exceeding the service limit could lead to engine problems. Before installing connecting rod bearing cap, make sure that connecting rod bolts are not deformed exceeding the service limit. Refer to "Connecting rod bolt deformation" under «PISTON PINS AND CONNECTING RODS INSPECTION»(ref-585578-S04401668572013111200000) . NOTE: Tighten connecting rod bearing cap bolt (3) gradually. Direct arrow mark (2) on connecting rod bearing cap (1) to crankshaft pulley side. Apply engine oil to bolt thread and seat of connecting rod bearing cap bolt. c) Tighten all connecting rod bearing cap bolts to 15 N.m (1.5 kgf-m, 11.0 lbf-ft) evenly and gradually. Retighten them to 45° in the same manner as in Step c ). Retighten them to 45° in the same manner as in Step c ). Tightening torque Connecting rod bolt* (a): 15 N.m --> +45° --> +45° (1.5 kgf-m --> +45° --> +45°, 11.0 lbf-ft --> +45° --> +45°
6. Install oil pump, see «OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION»(ref-585579-S33918550922013111200000) .
7. Install cylinder head, see «VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION»(ref-585578-S06301699882013111200000) .
8. Install engine assembly, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .

Main Bearings, Crankshaft and Cylinder Block Removal and Installation

Reference: MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

1. Remove engine assembly, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .
2. Remove flywheel for M/T model or drive plate for CVT model, see «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(ref-585578-S07998687232013111200000) .
3. Remove generator, see «GENERATOR REMOVAL AND INSTALLATION»(ref-585571-S40517405292013111200000) .
4. Remove water pump, see «WATER PUMP REMOVAL AND INSTALLATION»(ref-585577-S38809000952013111200000) .
5. Remove engine front mounting bracket (1).
6. Remove piston and connecting rod, see «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(ref-585578-S31019673882013111200000) .
7. Remove oil pump chain adjuster (1) from lower crankcase.
8. Remove CKP sensor, see «CKP SENSOR REMOVAL AND INSTALLATION»(ref-585630-S16560259732013111200000) .
9. Loosen crankcase bolt No. 2s in numerical order ("1" - "12") evenly and gradually.
10. Loosen crankcase bolt No. 1s in numerical order ("1" - "10") evenly and gradually, and then remove lower crankcase and rear oil seal. NOTE: Use 12-point socket wrench for crankcase bolt No. 1s.
11. Remove crankshaft and oil pump chain from cylinder block.
12. Remove sensor plate (2) from crankshaft (1), if necessary. NOTE: Use T-30 security TORX® to loosen sensor plate screws (3).

Reference: CRANKSHAFT INSPECTION

Reference: MAIN BEARINGS INSPECTION

Reference: SENSOR PLATE INSPECTION

Reference: FLYWHEEL/DRIVE PLATE INSPECTION

Reference: CYLINDER BLOCK INSPECTION

Reference: OIL PUMP DRIVE SPROCKET INSPECTION

Reference: OIL PUMP CHAIN AND OIL PUMP CHAIN ADJUSTER INSPECTION

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

1. Install sensor plate (1) using the following procedure: Attach spring pin (2) to crankshaft (3). NOTE: Use spring pin of genuine SUZUKI part (09205-05006). Install sensor plate to crankshaft, fitting pin (2) into hole (4) and facing inside edge (5) outward as shown in figure. Tightening torque Sensor plate screw (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft) Detach spring pin from crankshaft.
2. Install main bearings to cylinder block or lower crankcase using the following procedures: NOTE: Install main bearing halves with oil groove to cylinder block. Install other main bearing halves to lower crankcase. Fit the tab (1) on each bearing into recess (2) in cylinder block or lower crankcase. Press bearing end (3) until it is firmly seated on the cylinder block or lower crankcase. Apply engine oil to sliding surface (4) of main bearing halves. CAUTION: If oil is present between the bearing's outside surface and the camshaft housing / cylinder head surface, the bearing could heat up to very high temperature, resulting in seizure. Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface (5) and the camshaft housing / cylinder head surface.
3. Install new O-rings (1) to cylinder block (3).
4. Install dowel pins (2) to cylinder block (3).
5. Apply engine oil to thrust bearings (1) and install them to cylinder block journal No. 3, with oil grooves (2) facing outward.
6. Apply engine oil to sliding surface of main bearings and crankshaft.
7. Install crankshaft to cylinder block, with oil pump chain installed to oil pump drive sprocket on crankshaft.
8. Apply sealant to mating surface of lower crankcase (1) as shown in figure. NOTE: Before applying sealant, make sure mating surfaces are clean and dry. Install lower crankcase within 10 minutes after applying sealant. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) Sealant bead size for lower crankcase Width "a": 3 mm (0.11 in.) Height "b": 2 mm (0.07 in.)
9. Install lower crankcase to cylinder block and tighten crankcase bolt No. 1s using the following procedures: NOTE: If crankcase bolt No. 1 are reused, check them for deformation by referring to "crankcase bolt no. 1 inspection" under «MAIN BEARINGS INSPECTION»(ref-585578-S33914285772013111200000) . Use 12-point socket wrench for crankcase bolt No. 1. a) Apply engine oil to bolt threads and seats of crankcase bolt No. 1 and tighten bolt to 50 N.m (5.1 kgf-m, 37.0 lbf-ft) in numerical order ("1" - "10") evenly and gradually. Loosen all bolts in reverse numerical order until loosening torque becomes 0. Retighten them to 20 N.m (2.0 kgf-m, 15.0 lbf-ft) in the same manner as in Step a ). Retighten them to 35 N.m (3.6 kgf-m, 26.0 lbf-ft) in the same manner as in Step a ). Retighten them to 40° in the same manner as in Step a ). Retighten them to 40° in the same manner as in Step a ). Tightening torque Crankcase bolt No. 1* (a): 50 N.m --> 0 N.m --> 20 N.m --> 35 N.m --> 40° --> 40° (5.1 kgf-m --> 0 kgf-m --> 2.0 kgf-m --> 3.6 kgf-m --> 40° --> 40°, 37.0 lbf-ft --> 0 lbf-ft --> 15.0 lbf-ft --> 26.0 lbf-ft --> 40° --> 40°)
10. Tighten crankcase bolt No. 2s in numerical order ("1" - "12") evenly and gradually. Tightening torque Crankcase bolt No. 2* (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
11. Check that crankshaft rotates smoothly when turning it by hand.
12. Apply engine oil to new rear oil seal (1) and install it to cylinder block (2) using special tools. Special Tool 09911-97710 09911-97811
13. Install pistons and connecting rods, see «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(ref-585578-S31019673882013111200000) .
14. Install oil pump chain adjuster (1). Tightening torque Oil pump chain adjuster bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
15. Install cylinder head, see «VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION»(ref-585578-S06301699882013111200000) .
16. Install timing chain cover, see «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-585578-S36979470282013111200000) .
17. Install cylinder head cover, see «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-585578-S04363068542013111200000) .
18. Install oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-585579-S20387956532013111200000) .
19. Install CKP sensor, see «CKP SENSOR REMOVAL AND INSTALLATION»(ref-585630-S16560259732013111200000) .
20. Install flywheel for M/T model, or drive plate for CVT model, see «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(ref-585578-S07998687232013111200000) .
21. Install engine front mounting bracket (1). Tightening torque Engine front mounting bracket bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft)
22. Install water pump, see «WATER PUMP REMOVAL AND INSTALLATION»(ref-585577-S38809000952013111200000) .
23. Install generator, see «GENERATOR REMOVAL AND INSTALLATION»(ref-585571-S40517405292013111200000) .
24. Install engine assembly, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .