Engine Mechanical: Removal & Installation Suzuki SX4 I

Air Cleaner Assembly Removal and Installation

Reference: AIR CLEANER COMPONENTS

Scheme 8

1. Remove air cleaner inlet hose (2) and outlet hose.
2. Disconnect MAF sensor connector (3).
3. Remove air cleaner case (1).

Scheme 9

1. Install air cleaner case (1).
2. Connect MAF sensor connector (3), and tighten hose clamp to specified torque. Tightening torque Air cleaner outlet hose clamp: 3 N.m (0.3 kg-m, 2.5 lb-ft)
3. Install air cleaner inlet hose (2) and outlet hose.

Scheme 10

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

Installation

Reference: AIR CLEANER FILTER INSPECTION AND CLEANING

Reverse removal procedure for installation.

Electric Throttle Body Assembly Removal and Installation

Reference: ELECTRIC THROTTLE BODY ON-VEHICLE INSPECTION

Reference: ELECTRIC THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Reference: ELECTRIC THROTTLE BODY CLEANING

Scheme 11

1. Disconnect negative (-) cable at battery.
2. Drain coolant.
3. Remove air cleaner assembly, referring to «REMOVAL»(ref-268922-S32478541502007102700000) .
4. Disconnect engine coolant hoses (1) from electric throttle body assembly (2).
5. Disconnect connector (3) from electric throttle body assembly.
6. Remove stiffener (4).
7. Remove electric throttle body assembly from intake manifold.

Scheme 12

1. Clean mating surfaces, and install new throttle body gasket to intake manifold.
2. Install electric throttle body assembly (2) with stiffener (4) to intake manifold.
3. Connect connector (3) to electric throttle body assembly securely.
4. Connect engine coolant hoses (1) to electric throttle body assembly (2).
5. Install air cleaner assembly, referring to «INSTALLATION»(ref-268922-S40663716002007102700000) .
6. Refill coolant, referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-268900-S38679149692007102700000) .
7. Connect negative (-) cable at battery.
8. Perform calibration of electric throttle body assembly, referring to «ELECTRIC THROTTLE BODY SYSTEM CALIBRATION»(ref-268895-S15400494952007102700000) if replaced.

Intake Manifold Removal and Installation

Reference: ELECTRIC THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Scheme 13

1. Disconnect negative (-) cable at battery.
2. Drain cooling.
3. Remove electric throttle body assembly, referring to «REMOVAL»(ref-268922-S20675339652007102700000) .
4. Disconnect the following electric lead wires: IMT connector (1)
5. Disconnect the following hoses: Brake booster hose (2) from intake manifold PCV hose (3) from PCV valve Vacuum hose (4) from EVAP canister purge valve Breather hose from intake manifold
6. Remove harness brackets (5) from intake manifold.
7. Remove intake manifold and O-ring from cylinder head.

Reverse removal procedure for installation noting the followings.

Scheme 14

1. Use new intake manifold O-ring.
2. Install intake manifold bolts (2) and nuts (1) (Scheme 14) Apply thread lock cement to intake manifold bolt. "A": Thread lock cement 99000-32110Thread Lock Cement Super 1322 ()
3. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
4. Refill cooling system, referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-268900-S38679149692007102700000).
5. Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
6. Finally, start engine and check for engine coolant leaks.

IMT Valve Actuator Removal and Installation

Reference: ELECTRIC THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Scheme 15

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

Reverse removal procedure noting the followings.

Scheme 16

1. Use new O-ring (1).
2. Tighten IMT valve actuator bolt (2) to specified torque. Tightening torque IMT valve actuator bolt a: 6 N.m (0.6 kg-m, 4.5 lb-ft)

Scheme 17

Cylinder Head Cover Removal and Installation

Reference: CYLINDER HEAD COVER COMPONENTS

Scheme 18

Scheme 19

1. Disconnect negative (-) cable at battery.
2. Remove ignition coils referring to «REMOVAL»(ref-268902-S29441137252007102700000).
3. Remove oil level gauge (1).
4. Disconnect CMP sensor connector (2) and then remove CMP sensor (7) from cylinder head cover.
5. Disconnect breather hose (3) and PCV hose (4) from cylinder head cover (5).
6. Remove harness bracket (6) from cylinder head cover (5).
7. Remove PCV valve from cylinder head cover.
8. Remove cylinder head cover nuts in such order as indicated in (Scheme 19).
9. Remove cylinder head cover from cylinder head.
10. Remove cylinder head side seals from cylinder head.

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. Install PCV valve to cylinder head cover, referring to «INSTALLATION»(ref-268901-S25439105902007102700000).
2. Remove oil, old sealant and dust from sealing surfaces on cylinder head and cover.
3. Install new cylinder head side seals (1) to cylinder head.
4. Apply sealant "A" to cylinder head sealing surface area (Scheme 20) "A": Water tight sealant 99000-31250SUZUKI Bond No.1207F
5. Apply engine oil to new O-rings.
6. Install new O-rings (3) and new cylinder head cover gasket (2) to cylinder head cover (1). NOTE: Be sure to check each of these parts for deterioration or any damage before installation and replace if found defective.
7. Install cylinder head cover to cylinder head.
8. Tighten cylinder head cover nuts in such order as indicated in (Scheme 22) a little at a time till they are tightened to specified torque. Use new seal washers. Tightening torque Cylinder head cover nut a: Tighten 11 N.m (1.1 kgf-m, 8.0 lb-ft) by the specified procedure
9. Install oil level gauge (1).
10. Install CMP sensor (5) to cylinder head cover, referring to «INSTALLATION»(ref-268895-S12173727212007102700000).
11. Connect CMP sensor connector (4).
12. Connect breather hose (2) and PCV hose (3) to cylinder head cover.
13. Install harness bracket (6) to cylinder head cover.
14. Install ignition coils, referring to «INSTALLATION»(ref-268902-S02014904302007102700000).
15. Install air cleaner case, referring to «INSTALLATION»(ref-268922-S40663716002007102700000).
16. Connect negative (-) cable at battery.

Scheme 24

Engine Assembly Removal and Installation

Reference: ENGINE MOUNTINGS COMPONENTS

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

1. Relieve fuel pressure according to «FUEL PRESSURE RELIEF PROCEDURE»(ref-268903-S34756322792007102700000).
2. Disconnect negative and positive cables at battery.
3. Disconnect ECM connectors.
4. Remove battery and battery tray with ECM.
5. Remove right and left side engine under covers.
6. Remove water pump and generator drive belt, referring to «REMOVAL»(ref-268900-S26599150592007102700000).
7. Drain engine oil.
8. Drain transaxle oil.
9. Drain transfer oil (4WD model).
10. Drain coolant.
11. Remove air cleaner assembly, referring to «REMOVAL»(ref-268922-S32478541502007102700000).
12. With hose connected, detach A/C compressor from its bracket, referring to «REMOVAL»(ref-268947-S00195578412007102700000). CAUTION: Suspend removed A/C compressor at a place where no damage will be caused during removal and installation of engine assembly.
13. Remove condenser cooling fan from radiator, referring to «CONDENSER COOLING FAN REMOVAL AND INSTALLATION»(ref-268947-S38423821942007102700000).
14. Drain P/S fluid.
15. Disconnect P/S fluid reservoir hose (1) and then remove P/S fluid reservoir (2) from bracket.
16. Disconnect the following electric wires/connectors and each clamps. Electric throttle body (1) ECT sensor (2) CMP sensor (3) Ignition coil assembly (4) Injector (5) HO2S (6) A/F sensor (7) Engine oil pressure switch (8) CKP sensor (9) Knock sensor (10) Generator (11) Starting motor (12) Ground terminal (13) from cylinder block Ground terminal (14) from exhaust manifold Battery ground cable (15) from transaxle Back-up light switch (16) (M/T model) Torque sensor (17) (electric P/S model) P/S motor (18) (electric P/S model) P/S pump (19) (hydraulic P/S model) Output shaft speed sensor (VSS) (20) (A/T model) Solenoid valve (21) (A/T model) Transmission range sensor (22) (A/T model) Input shaft speed sensor (23) (A/T model) IMT sensor (24)
17. Disconnect the following cables, and remove control cable bracket (25) Gear select control cable (26) (M/T model) Gear shift control cable (27) (M/T model) A/T select cable with select cable bracket (28) (A/T model)
18. Disconnect the following hoses. Brake booster hose (29) from intake manifold Radiator inlet and outlet hoses from radiator Heater inlet and outlet hoses (31) from heater core Fuel feed hose (32) from fuel feed pipe Purge hose (33) from purge valve Clutch hose (30) from transaxle (M/T model) A/T fluid cooler hoses (A/T model)
19. Disconnect right and left drive shaft joints from differential gear, referring to «REMOVAL»(ref-268926-S03101398532007102700000).
20. Remove exhaust center pipe, referring to «EXHAUST SYSTEM COMPONENTS»(ref-268927-S08603264792007102700000).
21. Disconnect propeller shaft from transfer, referring to «REMOVAL»(ref-268928-S00394535432007102700000) (4WD model).
22. Disconnect steering lower shaft from pinion shaft, referring to «REMOVAL»(ref-268929-S01258097892007102700000).
23. Fix radiator to body with rope in order to avoid the radiator fall off when front lower cross member lowered.
24. Fix transaxle to suspension frame with rope in order to avoid the engine assembly inclines when engine assembly lowered.
25. Support front suspension frame and front lower cross member using jack at hatched parts (1) indicated in (Scheme 28).
26. Remove engine right mounting (1), engine right mounting No.1 bracket (2) and engine left mounting bracket bolt and nuts (3).
27. Remove suspension frame mounting bolts (1) and front lower cross member bolts (2).
28. Lower engine with transaxle, front suspension frame, front lower cross member, transfer (4WD model) and steering gear case. CAUTION: Before lowering engine, in order to avoid damage to A/C compressor, make clearance by rising it.
29. Disconnect steering gear case from suspension frame, referring to «STEERING GEAR CASE ASSEMBLY COMPONENTS»(ref-268943-S34378515302007102700000), if necessary.
30. Disconnect transfer.
31. Disconnect transaxle from engine.
32. Remove clutch cover and clutch disk, referring to «REMOVAL»(ref-268907-S39901706682007102700000), if necessary (M/T model).

Scheme 31

Scheme 32

Scheme 33

1. Install clutch cover and clutch disk, referring to «INSTALLATION»(ref-268907-S15758787282007102700000) , if necessary (M/T model).
2. Connect transaxle to engine, referring to «MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-268911-S34224283822007102700000) or «AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-268912-S17398199982007102700000) , if removed.
3. Connect transfer to suspension frame, referring to «TRANSFER DISMOUNTING AND REMOUNTING»(ref-268913-S35006675332007102700000) , if removed (4WD model).
4. Connect steering gear case to suspension frame, referring to «STEERING GEAR CASE ASSEMBLY COMPONENTS»(ref-268943-S34378515302007102700000) , if removed.
5. Lift engine with transaxle, front suspension frame, front lower cross member, transfer (4WD model) and steering gear case into engine compartment with jack. CAUTION: Before lifting engine, in order to avoid damage to A/C compressor, make clearance by rising it.
6. Tighten suspension frame mounting bolts and front lower cross member bolts, and then tighten bolts to specified torque. Tightening torque Suspension frame mounting bolt a: 150 N.m (15.0 kg-m, 108.5 lb-ft) Front lower cross member bolt b: 55 N.m (5.5 kg-m, 40.0 lb-ft)
7. Install engine right mounting, engine right mounting No.1 bracket and engine left mounting bracket, and then tighten bolts and nuts to specified torque referring to «ENGINE MOUNTINGS COMPONENTS»(ref-268922-S37147437342007102700000) .
8. Remove jack.
9. Connect steering lower shaft to pinion shaft, referring to «INSTALLATION»(ref-268929-S32797792102007102700000) .
10. Connect propeller shaft, referring to «INSTALLATION»(ref-268928-S40964378982007102700000) (4WD model).
11. Install exhaust center pipe, referring to «EXHAUST SYSTEM COMPONENTS»(ref-268927-S08603264792007102700000) .
12. Connect right and left drive shaft joints to differential gear, referring to «INSTALLATION»(ref-268926-S06492682462007102700000) .
13. Reverse disconnected hoses, cables and electric wires for connection noting the following. Tighten bolts and nuts to specified torque. Tightening torque Starting motor terminal nut a: 11 N.m (1.1 kg-m, 8.0 lb-ft) Generator terminal nut b: 5 N.m (0.5 kg-m, 4.0 lb-ft) Battery ground bolt c: 25 N.m (2.5 kg-m, 18.0 lb-ft) Ground terminal bolt d: 11 N.m (1.1 kg-m, 8.0 lb-ft)
14. Connect P/S fluid reservoir hose (1) and then install P/S fluid reservoir (2) to bracket.
15. Refill P/S fluid, referring to «P/S FLUID CHANGE»(ref-268943-S12821627242007102700000) .
16. Install condenser cooling fan to radiator, referring to «INSTALLATION»(ref-268947-S04094464322007102700000) .
17. Install A/C compressor to its bracket (if removed), referring to «INSTALLATION»(ref-268947-S26315308782007102700000) .
18. Install air cleaner assembly, referring to «INSTALLATION»(ref-268922-S40663716002007102700000) .
19. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
20. Refill coolant, referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-268900-S38679149692007102700000) .
21. Refill transfer oil, referring to «TRANSFER OIL CHANGE»(ref-268913-S23420868992007102700000) (4WD model).
22. Refill transaxle oil, referring to «MANUAL TRANSAXLE OIL CHANGE»(ref-268911-S34240057862007102700000) or «A/T FLUID CHANGE»(ref-268912-S10487220472007102700000) .
23. Refill engine oil, referring to «ENGINE OIL AND FILTER CHANGE»(ref-268898-S30295650402007102700000) .
24. Install water pump and generator drive belt, referring to «INSTALLATION»(ref-268900-S26156678352007102700000) .
25. Install right and left side engine under covers.
26. Install battery and battery tray with ECM.
27. Connect ECM connectors.
28. Connect negative and positive cable at battery.
29. Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection.

Scheme 34

Timing Chain Cover Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

Scheme 35

Scheme 36

Scheme 37

Scheme 38

1. Remove engine assembly from vehicle referring to «REMOVAL»(ref-268922-S35350275592007102700000).
2. Remove oil pan, referring to «REMOVAL»(ref-268923-S15712258552007102700000).
3. Remove cylinder head cover, referring to «REMOVAL»(ref-268922-S19545546592007102700000).
4. Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool (camshaft pulley holder) (Scheme 35) Special Tool (A): 09917-68221 NOTE: Be sure to use the following bolts instead of pins in order to fix crankshaft pulley by special tool. Bolt size: M8, P1.25 L = 25 mm (0.98 in.) Strength: 7T
5. Remove crankshaft pulley (1). To remove crankshaft pulley, use special tools (Steering wheel remover, Bearing puller attachment) with it (Scheme 36) Special Tool 09944-36011 09926-58010
6. Remove idler pulley (1), water pump pulley (2) and belt tensioner (3).
7. Remove timing chain cover bolts (2) and nut (1).
8. Remove timing chain cover (3).

Reference: TIMING CHAIN COVER CLEANING AND INSPECTION

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

1. Clean sealing surfaces on timing chain cover, cylinder block and cylinder head. Remove oil, old sealant and dust from sealing surface.
2. Install new oil seal (2) to timing chain cover using special tool, if removed. NOTE: When installing new oil seal (2), drive it until its surface is flash with edge of timing chain cover (1). Special Tool (A): 09913-75510
3. Apply sealant "A" and "B" to specific area (Scheme 40) "A": Sealant 99000-31260SUZUKI Bond No.1217G "B": Water tight sealant 99000-31140SUZUKI Bond No.1207B Sealant amount for timing chain cover "a": 3 mm (0.12 in.) "b": 2 mm (0.08 in.) "c": 4 mm (0.16 in.) "d": 16 mm (0.63 in.) "e": 14 mm (0.55 in.) "f": 65 mm (2.56 in.) "g": 73 mm (2.87 in.)
4. Apply engine oil to oil seal lip, then install timing chain cover (1). Tighten bolts and nut to specified torque. NOTE: Before installing timing chain cover, check that pin is securely fitted. Tightening torque Timing chain cover bolt and nut a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
5. Install belt idler pulley (1). Tighten nut to specified torque. Tightening torque Idler pulley nut a: 42 N.m (4.2 kg-m, 30.5 lb-ft)
6. Install belt tensioner (2). Tighten bolts to specified torque. Tightening torque Generator belt tensioner bolt b: 25 N.m (2.5 kg-m, 18.5 lb-ft)
7. Install water pump pulley (3).
8. Install cylinder head cover, referring to «INSTALLATION»(ref-268922-S19355082212007102700000).
9. Install oil pan. Refer to «INSTALLATION»(ref-268923-S00689869272007102700000).
10. Install crankshaft pulley. To lock crankshaft pulley (1), use special tool (camshaft pulley holder) (Scheme 43) Special Tool (A): 09917-68221 NOTE: Be sure to use the following bolts instead of pins in order to fix crank pulley by special tool. Bolt size: M8, P1.25 L = 25 mm (0.98 in.) Strength: 7T Tightening torque Crankshaft pulley bolt a: 150 N.m (15.0 kg-m, 108.5 lb-ft)
11. Install engine assembly to vehicle, referring to «INSTALLATION»(ref-268922-S20714470302007102700000).

2nd Timing Chain and Chain Tensioner Removal and Installation

Reference: 2nd TIMING CHAIN AND CHAIN TENSIONER COMPONENTS

Scheme 44

Scheme 45

Scheme 46

1. Remove timing chain cover. Refer to «REMOVAL»(ref-268922-S09604998132007102700000) .
2. Turn crankshaft clockwise to meet the following conditions. Mark on crank sprocket match with mark on lower crankcase (I). Arrow mark on idler sprocket points upward (II). Marks on cam sprockets match with marks on cylinder head (III).
3. Remove timing chain tensioner adjuster No.2 (1) and gasket. To remove them, slacken 2nd timing chain by turning intake camshaft counterclockwise a little while pushing back pad.
4. Remove intake and exhaust camshaft timing sprocket bolts (1). To remove them, fit a spanner (4) to hexagonal part (3) at the center of camshaft to hold it stationary.
5. Remove camshaft timing sprockets and 2nd timing chain (2).

Scheme 47

Reference: 2nd TIMING CHAIN AND CHAIN TENSIONER INSPECTION

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Check that match mark (1) on crank timing sprocket is in match with timing mark (2) on lower crankcase (Scheme 48)
2. Check that arrow mark (1) on idler sprocket faces upward.
3. Check that knock pins of intake (2) and exhaust (3) camshafts are aligned with timing marks on cylinder head.
4. Install 2nd timing chain by aligning yellow plate (1) of 2nd timing chain and match marks on idler sprocket.
5. Install sprockets to intake and exhaust camshafts by aligning dark blue plate of 2nd timing chain, match marks on intake sprocket and exhaust sprocket respectively. CAUTION: Do not turn more than allowable turning range. If turned excessively, valve and piston may be damaged. NOTE: As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.
6. Tighten intake and exhaust camshaft timing sprocket bolts (1) to specified torque. To tighten it, fit a spanner (2) to hexagonal part (3) at the center of camshaft to hold it stationary. Tightening torque Camshaft timing sprocket bolt a: 80 N.m (8.0 kg-m, 57.5 lb-ft)
7. Push back plunger (1) into tensioner body (2), and hold it at the position by inserting stopper (3) into body.
8. Install timing chain tensioner adjuster No.2 (1) with new gasket. Tightening torque Timing chain tensioner adjuster No.2 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft) Timing chain tensioner adjuster No.2 nut b: 45 N.m (4.5 kg-m, 33.0 lb-ft)
9. Pull out stopper (2) from timing chain tensioner adjuster No.2.
10. Turn crankshaft two rotations clockwise, and then align timing mark (1) on crankshaft and timing mark (2) on cylinder block (Scheme 55) At this time, check timing marks (3, 5 and 7) of sprockets are in match with timing marks (4, 6 and 8) of cylinder head, cylinder block and lower crank case.
11. Apply oil to timing chains, tensioner, tensioner adjusters, sprockets and guides.
12. Install timing chain cover. Refer to «INSTALLATION»(ref-268922-S20234545222007102700000).
13. Install cylinder head cover. Refer to «INSTALLATION»(ref-268922-S19355082212007102700000).
14. Install oil pan. Refer to «INSTALLATION»(ref-268923-S00689869272007102700000).
15. Install engine assembly to vehicle, referring to «INSTALLATION»(ref-268922-S20714470302007102700000).

1st Timing Chain and Chain Tensioner Removal and Installation

Reference: 1st TIMING CHAIN AND CHAIN TENSIONER COMPONENTS

Scheme 56

1. Remove 2nd timing chain. Refer to «REMOVAL»(ref-268922-S27177680252007102700000) for removal.
2. Remove timing chain guide No.1 (1).
3. Remove timing chain tensioner adjuster No.1 (2).
4. Remove timing chain tensioner (3).
5. Remove idler sprocket (6) and 1st timing chain (5).
6. Remove crankshaft timing sprocket (4).

Reference: 1st TIMING CHAIN AND CHAIN TENSIONER INSPECTION

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Install crankshaft timing sprocket (2).
2. Check that match mark (1) on crankshaft timing sprocket is in match with timing mark (2) on lower crankcase.
3. Apply engine oil to idler sprocket shaft and bush of idler sprocket (1).
4. Install idler sprocket and idler sprocket shaft.
5. Install 1st timing chain by aligning dark blue plate (4) of 1st timing chain (3) and match mark (2) on idler sprocket (1).
6. Bring gold plate (4) of 1st timing chain (3) into match with match mark (2) on crankshaft timing sprocket (1).
7. Apply engine oil to sliding surface of timing chain tensioner (1) and then install it (Scheme 61) Tighten tensioner nut to specified torque. Tightening torque Timing chain tensioner nut a: 25 N.m (2.5 kg-m, 18.0 lb-ft)
8. With latch of tensioner adjuster No.1 returned and plunger (1) pushed back into body, insert stopper (4) into latch (2) and body (3). After inserting it, check to make sure that plunger will not come out.
9. Install timing chain tensioner adjuster No.1 (1). Tightening torque Timing chain tensioner adjuster No.1 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
10. Pull out stopper (2) from timing chain tensioner adjuster No.1.
11. Apply engine oil to sliding surface of timing chain guide No.1 (1) and then install it. Tighten guide bolts to specified torque. Tightening torque Timing chain guide No.1 bolt a: 9 N.m (0.9 kg-m, 6.5 lb-ft)
12. Check that dark blue and gold plates of 1st timing chain are in match with match marks on sprockets respectively.
13. Install 2nd timing chain. Refer to «INSTALLATION»(ref-268922-S25577701882007102700000).
14. Install timing chain cover. Refer to «INSTALLATION»(ref-268922-S20234545222007102700000).
15. Install cylinder head cover. Refer to «INSTALLATION»(ref-268922-S19355082212007102700000).
16. Install oil pan. Refer to «INSTALLATION»(ref-268923-S00689869272007102700000).
17. Install engine assembly to vehicle, referring to «INSTALLATION»(ref-268922-S20714470302007102700000).

Camshafts, Tappet and Shim Removal and Installation

Reference: CAMSHAFTS, TAPPET AND SHIM COMPONENTS

Scheme 66

1. Remove 2nd timing chain. Refer to «REMOVAL»(ref-268922-S27177680252007102700000).
2. Loosen camshaft housing bolts in such order as indicated in (Scheme 66) and remove them.
3. Remove camshaft housings.
4. Remove camshafts.
5. Remove tappets with shims.

Reference: CAMSHAFT, TAPPET AND SHIM INSPECTION

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Apply engine oil around tappet (1) and shim, and then install tappets with shims to cylinder head. NOTE: When installing shim, make sure to direct shim No. side toward tappet.
2. Match mark (1) on crank timing sprocket and mating surface of cylinder block (3) and lower crankcase (2). At this time, make sure that arrow mark (4) on idler sprocket (5) at the position.
3. Install camshafts. Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match marks on cylinder head and camshafts (Scheme 69)
4. Install camshaft housing pins (3).
5. Check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housings as indicated by these marks.
6. After applying oil to housing bolts, tighten them temporarily first. Then tighten them by following numerical order in (Scheme 72). Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to specified torque. Tightening torque Camshaft housing bolt a: Tighten 11 N.m (1.1 kgf-m, 8.0 lb-ft) by the specified procedure
7. Turn crankshaft clockwise then align crankshaft timing sprocket key (1) with timing mark (2).
8. Install 2nd timing chain. Refer to «INSTALLATION»(ref-268922-S25577701882007102700000).
9. Install timing chain cover. Refer to «INSTALLATION»(ref-268922-S20234545222007102700000).
10. Install cylinder head cover. Refer to «INSTALLATION»(ref-268922-S19355082212007102700000).
11. Install oil pan. Refer to «INSTALLATION»(ref-268923-S00689869272007102700000).
12. Install engine assembly to vehicle, referring to «INSTALLATION»(ref-268922-S20714470302007102700000).
13. Check valve lashes, referring to «VALVE LASH (CLEARANCE) INSPECTION»(ref-268922-S37139088612007102700000).

Valves and Cylinder Head Removal and Installation

Reference: VALVES AND CYLINDER HEAD COMPONENTS

Scheme 73

1. Remove camshafts, tappets and shims. Refer to «REMOVAL»(ref-268922-S21708239352007102700000).
2. Loosen cylinder head bolts in such order as numbered in (Scheme 74) and remove them. NOTE: Don't forget to remove cylinder head bolt (M6) (3).
3. Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary.
4. Remove cylinder head with intake manifold, exhaust manifold and water outlet cap. Use lifting device, if necessary.

Reference: VALVES AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

1. Match mark (1) on crank timing sprocket and mating surface (2) of cylinder block and lower crankcase.
2. Clean mating surface of cylinder head and cylinder block (2). Remove oil, old gasket and dust from mating surface.
3. Install knock pins (3) to cylinder block.
4. Install new cylinder head gasket (1) to cylinder block. Identification number (6) provided on gasket comes to crankshaft pulley side (4), facing up (toward cylinder head side).
5. Install cylinder head to cylinder block. Apply engine oil to cylinder head bolts and tighten them gradually as follows. Tighten cylinder head bolts (M10) to 52 N.m (5.2 kgf-m, 38.0 lb-ft) according to numerical order in (Scheme 77). In the same manner as in step a ), retighten cylinder head bolts (M10) to 82 N.m (8.2 kgf-m, 59.5 lb-ft). Loosen cylinder head bolts (M10) until tightening torque is reduced to 0 according to numerical order in (Scheme 78). Tighten cylinder head bolts (M10) to 52 N.m (5.2 kgf-m, 38.0 lb-ft) according to numerical order in see scheme 115. In the same manner as in step b ), retighten cylinder head bolts (M10) to 103 N.m (10.3 kgf-m, 74.5 lb-ft). Tighten cylinder head bolt (M6) to specified torque. Tightening torque Cylinder head bolt (M10) a: Tighten 52 N.m (5.2 kgf-m, 38.0 lb-ft), 82 N.m (8.2 kgf-m, 59.5 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 52 N.m (5.2 kgf-m, 38.0 lb-ft) and 103 N.m (10.3 kgf-m, 74.5 lb-ft) by the specified procedure Cylinder head bolt (M6) b: 11 N.m (1.1 kg-m, 8.0 lb-ft)
6. Install camshafts, tappets and shims. Refer to «INSTALLATION»(ref-268922-S33903895212007102700000).
7. Install 1st timing chain. Refer to «INSTALLATION»(ref-268922-S31545025882007102700000).
8. Install 2nd timing chain. Refer to «INSTALLATION»(ref-268922-S25577701882007102700000).
9. Install timing chain cover. Refer to «INSTALLATION»(ref-268922-S20234545222007102700000).
10. Check intake and exhaust valve lashes by referring to «VALVE LASH (CLEARANCE) INSPECTION»(ref-268922-S37139088612007102700000).
11. Install cylinder head cover by referring to «INSTALLATION»(ref-268922-S19355082212007102700000).
12. Install oil pan by referring to «INSTALLATION»(ref-268923-S00689869272007102700000).
13. Install engine assembly to vehicle by referring to «INSTALLATION»(ref-268922-S20714470302007102700000).

Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS COMPONENTS

Removal

1. Remove oil pump with oil pump strainer. Refer to «REMOVAL»(ref-268923-S20785760262007102700000) .
2. Remove cylinder head. Refer to «REMOVAL»(ref-268922-S14154087082007102700000) .
3. Mark cylinder number on all pistons, connecting rods and connecting rod caps.
4. Remove connecting rod bearing caps.
5. Clean carbon from top of cylinder bore before removing piston from cylinder.
6. Push piston and connecting rod assembly out through the top of cylinder bore.

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY AND REASSEMBLY

Scheme 79

Scheme 80

Scheme 81

1. Apply engine oil to pistons, piston rings, cylinder walls, connecting rod bearings and crank pins. NOTE: Do not apply oil between connecting rod and bearing or between bearing cap and bearing.
2. When installing piston and connecting rod assembly into cylinder bore, point front mark (3) on piston head to crankshaft pulley side (1).
3. Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings. Guide connecting rod into place on crankshaft. Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore. Special Tool (A): 09916-77310
4. Install connecting rod bearing cap (1) as follows. NOTE: If connecting rod bolt is reused, make sure to check connecting rod bolt for deformation referring to "Connecting Rod Bolt Deformation (Plastic Deformation Tightening Bolt)" under «PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS INSPECTION AND CLEANING»(ref-268922-S38657426232007102700000) . Point arrow mark (2) on cap to crankshaft pulley side. Apply engine oil to new connecting rod bolts (3). Tighten all connecting rod bolts to 15 N.m (1.5 kgf-m, 11.0 lb-ft). Retighten them by turning through 45°. Repeat step d once again. Tightening torque Connecting rod bolt a: Tighten 15 N.m (1.5 kgf-m, 11.0 lb-ft), 45° and 45° by the specified procedure
5. Install cylinder head. Refer to «INSTALLATION»(ref-268922-S38670837682007102700000) .
6. Install oil pan. Refer to «INSTALLATION»(ref-268923-S00689869272007102700000) .
7. Install camshafts and tappets and shims. Refer to «INSTALLATION»(ref-268922-S33903895212007102700000) .
8. Install 1st timing chain. Refer to «INSTALLATION»(ref-268922-S31545025882007102700000) .
9. Install 2nd timing chain. Refer to «INSTALLATION»(ref-268922-S25577701882007102700000) .
10. Install timing chain cover. Refer to «INSTALLATION»(ref-268922-S20234545222007102700000) .
11. Check intake and exhaust valve lashes by referring to «VALVE LASH (CLEARANCE) INSPECTION»(ref-268922-S37139088612007102700000) .
12. Install cylinder head cover by referring to «INSTALLATION»(ref-268922-S19355082212007102700000) .
13. Install engine assembly to vehicle by referring to «INSTALLATION»(ref-268922-S20714470302007102700000) .

Reference: CYLINDER BLOCK HEATER INSPECTION (IF EQUIPPED)

Reverse removal procedure for installation, noting the following.

Scheme 82

Scheme 83

1. Install cylinder block heater (1) in the direction (Scheme 83)
2. Tighten cylinder block heater mounting bolt (1) to specified torque. Tightening torque Cylinder block heater mounting bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
3. Refill coolant by referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-268900-S38679149692007102700000).
4. Finally, start engine and check for engine coolant leaks and exhaust gas leakage.

Main Bearings, Crankshaft and Cylinder Block Removal and Installation

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Scheme 84

Scheme 85

Scheme 86

Scheme 87

1. Remove engine assembly from vehicle. Refer to «REMOVAL»(ref-268922-S35350275592007102700000).
2. Remove flywheel (drive plate for A/T) by using special tool. Special Tool (A): 09924-17811
3. Remove pistons and connecting rods by referring to «REMOVAL»(ref-268922-S30932875092007102700000).
4. Remove CKP sensor (1).
5. Remove water pump (1) and heater outlet pipe (3).
6. Remove engine front mounting brackets (2).
7. Loosen crankcase bolts, in sequence (Scheme 88)and remove them.
8. Remove crankshaft from cylinder block.

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK INSPECTION

Note. All parts 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 (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 lower crankcase, remove oil, old sealant and dust from mating surface.

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

1. Fit main bearings to cylinder block (1). One of two halves of main bearing (4) has oil groove (3). Install this half with oil groove to cylinder block and another half without oil groove to lower crankcase. Make sure that two halves are painted in the same color.
2. Install new O-ring (2) to cylinder block.
3. Install knock pins (5) to cylinder block.
4. Fit thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to crank webs.
5. Put crankshaft (1) with oil pump chain to cylinder block.
6. Apply sealant "A" to lower crankcase (1) mating surface area (Scheme 91) "A": Water tight sealant 99000-31250SUZUKI Bond No.1207F () Sealant amount for lower crankcase Width "a": 3 mm (0.12 in.) Height "b": 2 mm (0.08 in.)
7. Install lower crankcase (1) to cylinder block. Apply engine oil to all crankcase bolts ((1) - (10)) and tighten them gradually as follows. Tighten bolts ((1) - (10)) to 40 N.m (4.0 kgf-m, 29.0 lb-ft) according to numerical order in (Scheme 92). Loosen bolts ((1) - (10)) until tightening torque is reduced to 0 according to numerical order in (Scheme 93). Tighten bolts ((1) - (10)) to 40 N.m (4.0 kgf-m, 29.0 lb-ft) according to numerical order in (Scheme 94). In the same manner as in step c ), retighten bolts ((1) - (10)) to 58 N.m (5.8 kgf-m, 42.0 lb-ft). Tighten bolts ((11) - (22)) to specified torque according to numerical order in (Scheme 94). Tightening torque Crankcase bolt with 10 mm thread diameter ((1) - (10)): Tighten 40 N.m (4.0 kgf-m, 29.0 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 40 N.m (4.0 kgf-m, 29.0 lb-ft), 58 N.m (5.8 kgf-m, 42.0 lb-ft) by the specified procedure Crankcase bolt with 8 mm thread diameter ((11) - (22)): Tighten 26 N.m (2.6 kgf-m, 19.0 lb-ft) by the specified procedure NOTE: After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand. Use new crankcase bolt (10 mm thread diameter).
8. Pull out dowel pin (2) from crankshaft (1) and then install rear oil seal (3) until it becomes flush with cylinder block surface using special tools and plastic hammer. Special Tool 09911-97710 09911-97811
9. Install dowel pin (2).
10. Install CKP sensor (1) and fix its wire harness with bracket. Tightening torque CKP sensor bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
11. Install flywheel (drive plate for A/T). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts (1) to specified torque. NOTE: Use new flywheel or drive plate bolt. Special Tool (A): 09924-17811 Tightening torque Flywheel or drive plate bolt a: 70 N.m (7.0 kg-m, 51.0 lb-ft)
12. Install engine front mounting brackets (1). Tighten bracket bolts to specified torque. Tightening torque Engine front mounting bracket bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
13. Install water pump (2) and heater outlet pipe (3). Refer to «INSTALLATION»(ref-268900-S26156678352007102700000).
14. Install pistons and connecting rods. Refer to «INSTALLATION»(ref-268922-S01829245522007102700000).
15. Install oil pump. Refer to «INSTALLATION»(ref-268923-S22454343442007102700000).
16. Install cylinder head assembly to cylinder. Refer to «INSTALLATION»(ref-268922-S38670837682007102700000).
17. Install camshafts and tappets and shims. Refer to «INSTALLATION»(ref-268922-S33903895212007102700000).
18. Check intake and exhaust valve lashes by referring to «VALVE LASH (CLEARANCE) INSPECTION»(ref-268922-S37139088612007102700000).
19. Install, timing chain sprockets, timing chains, timing chain tensioner, tensioner adjusters, timing chain guides, timing chain cover, crankshaft pulley, water pump pulley. Refer to «INSTALLATION»(ref-268922-S20234545222007102700000), «INSTALLATION»(ref-268922-S25577701882007102700000) and «INSTALLATION»(ref-268922-S31545025882007102700000).
20. Install cylinder head cover referring to «INSTALLATION»(ref-268922-S19355082212007102700000).
21. Install oil pump strainer and oil pan by referring to «INSTALLATION»(ref-268923-S00689869272007102700000).
22. Install clutch cover and clutch disc to flywheel (for M/T vehicle). For clutch installation, refer to «INSTALLATION»(ref-268907-S15758787282007102700000).
23. Install engine assembly to vehicle. Refer to «INSTALLATION»(ref-268922-S20714470302007102700000).