Engine Mechanical: Removal & Installation Suzuki SX4 I рестайлинг

Air Cleaner Filter Removal and Installation

Reference: AIR CLEANER COMPONENTS

Scheme 16

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

Installation

Reference: AIR CLEANER FILTER INSPECTION AND CLEANING

Reverse removal procedure for installation.

Air Cleaner Assembly Removal and Installation

Reference: AIR CLEANER COMPONENTS

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1. Disconnect negative (-) cable from battery.
2. Remove engine cover according to the following procedure. Disconnect engine cover hose (1) from air cleaner assembly. Disconnect engine cover front side hook (2) from engine cover pin. Disconnect engine cover rear side hook (3) from engine cover pin. CAUTION: When removing the engine cover, be careful not to hit it against the cowling front panel.
3. Remove air cleaner inlet hose (1).
4. Disconnect MAF and IAT sensor connector (2).
5. Remove air cleaner outlet hose (3).
6. Remove air cleaner assembly (4).
7. Remove air cleaner outlet hose according to the following procedure if necessary. Disconnect breather pipe (1) from air cleaner outlet hose (2). Remove air cleaner outlet hose with resonator (3) from electric throttle body assembly (4).

Reverse removal procedure for installation.

Scheme 20

Throttle Body Assembly Removal and Installation

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Scheme 21

1. Disconnect negative (-) cable from battery.
2. Drain coolant, see «COOLING SYSTEM DRAINING»(ref-514579-S15347634932012112100000) .
3. Remove air cleaner assembly, see «Air Cleaner Assembly Removal and Installation»(ref-514568-S42483472292012112100000) .
4. Disconnect engine coolant hoses (2) and electric connector (3) from throttle body assembly (1).
5. Remove throttle body assembly and its gasket from intake manifold.

Reference: THROTTLE BODY CLEANING

Scheme 22

1. Clean mating surfaces and install new throttle body gasket (1) to intake manifold.
2. Install throttle body assembly (1) to intake manifold.
3. Connect electric connector (3) and coolant hoses (2) to throttle body assembly (1).
4. Install air cleaner assembly, see «Air Cleaner Assembly Removal and Installation»(ref-514568-S42483472292012112100000) .
5. Refill cooling system, see «COOLING SYSTEM REFILLING»(ref-514579-S08553899402012112100000) .
6. Connect negative (-) cable to battery.
7. Check for coolant leaks, see «ENGINE COOLING SYSTEM INSPECTION»(ref-514579-S25640199602012112100000) .

Intake Manifold Removal and Installation

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

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1. Disconnect negative (-) cable from battery.
2. Remove windshield wiper arms with wiper blades, see «WINDSHIELD WIPER REMOVAL AND INSTALLATION»(ref-514618-S37358481902012112100000) .
3. Remove cowl top garnish and cowl top panel, see «COWL TOP AND FRONT LOWER CROSSMEMBER COMPONENTS»(ref-514563-S15462800572012112100000) .
4. Remove air cleaner assembly, see «Air Cleaner Assembly Removal and Installation»(ref-514568-S42483472292012112100000) .
5. Remove throttle body assembly, see «Throttle Body Assembly Removal and Installation»(ref-514568-S29497606742012112100000) .
6. Disconnect the following wiring harness connectors and hoses. EVAP canister purge valve connector (1) IMT valve actuator connector (2) Brake booster hose (3) PCV valve hose (4) Purge hose (5) Engine harness clamps
7. Remove intake manifold (1) and intake manifold gaskets (2) from cylinder head.

Reverse removal procedure for installation noting the following.

Scheme 25

1. Use new Intake manifold bolt for position (1) in figure, because it is not reusable.
2. Use new gaskets.
3. Refill cooling system, see «COOLING SYSTEM REFILLING»(ref-514579-S08553899402012112100000) .
4. Check for coolant leaks, see «ENGINE COOLING SYSTEM INSPECTION»(ref-514579-S25640199602012112100000) .

Scheme 26

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

Reference: IMT Valve Actuator Inspection

Reverse removal procedure noting the followings.

1. Use new gasket.
2. Check that IMT valve operates properly after installing IMT valve actuator to intake manifold.

Scheme 27

1. Disconnect negative (-) cable from battery.
2. Drain coolant, see «COOLING SYSTEM DRAINING»(ref-514579-S15347634932012112100000) .
3. Remove A/C condenser cooling fan. Manual A/C model: Refer to «CYLINDER BLOCK HEATER INSPECTION (IF EQUIPPED)»(ref-514568-S10300108622012112100000) . Auto A/C model: Refer to «CONDENSER COOLING FAN REMOVAL AND INSTALLATION»(ref-514569-S23888284222012112100000)
4. Remove exhaust manifold cover.
5. Remove engine block heater (1).

Reference: CYLINDER BLOCK HEATER INSPECTION (IF EQUIPPED)

Reverse removal procedure for installation noting the following.

Scheme 28

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.
4. Check for coolant leaks.

Cylinder Head Cover Removal and Installation

Reference: CYLINDER HEAD COVER COMPONENTS

Removal

1. Disconnect negative (-) cable from battery.
2. Remove engine cover.
3. Remove ignition coil assemblies from cylinder head cover.
4. Disconnect PCV valve hose (1) and breather hose (2).
5. Detach engine harness clamps.
6. Loosen cylinder head cover bolts in numerical order ("1" - "16") evenly and gradually.
7. Remove cylinder head cover with its gasket.
8. Remove PCV valve if necessary.

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1. Install new cylinder head cover gasket (1) to cylinder head cover (2) as shown in figure.
2. Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning, apply sealant "A" to the designated area in figure. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)
3. Install cylinder head cover to cylinder head. NOTE: When installing cylinder head cover, use care so that cylinder head cover gasket does not get out of place or fall off.
4. Tighten cylinder head cover bolts according to the following procedure. 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. In the same manner as Step a ), retighten them to 5.0 N.m (0.51 kgf-m, 4.0 lbf-ft). In the same manner as Step a ), retighten them to 7.5 N.m (0.76 kgf-m, 5.5 lbf-ft). 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)
5. Connect PCV valve hose (1) to PCV valve and breather hose (2) to cylinder head cover.
6. Install ignition coil assemblies, see «IGNITION COIL ASSEMBLY REMOVAL AND INSTALLATION»(ref-514577-S21854623312012112100000) .
7. Install engine cover, see «Air Cleaner Assembly Removal and Installation»(ref-514568-S42483472292012112100000) .
8. Connect negative (-) cable to battery.

Scheme 32

Camshaft and Tappet Removal and Installation

Reference: CAMSHAFT AND TAPPET COMPONENTS

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

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1. Remove cylinder head cover, see «Cylinder Head Cover Removal and Installation»(ref-514568-S38533523692012112100000) .
2. Remove accessory drive belt, see «ACCESSORY DRIVE BELT INSPECTION»(ref-514576-S00367964672012112100000) .
3. Turn crankshaft clockwise with 19 mm wrench, and position piston No. 1 at TDC on the compression stroke according to the following procedure. Align the timing mark (1) on the CMP actuator and the timing mark (2) on the exhaust camshaft timing sprocket with the match marks (3) on the camshaft housing No. 1. Align notch (1) on the crankshaft pulley with "0" (2) on the timing chain cover.
4. Fix timing chain tensioner according to the following procedure. Remove timing chain cover plug (1) and gasket (2). Insert fore-end of special tool into timing chain tensioner hole (1) through 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 (A): 09917-16710 Fix special tool by tightening special tool fixing bolt (2) to specified torque. CAUTION: 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. 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 according to the following procedure. Hold hexagonal section of exhaust camshaft using wrench or the like. Loosen exhaust camshaft timing sprocket bolt and remove exhaust camshaft timing sprocket (1). CAUTION: Be careful not to drop dowel pin into the space between timing chain cover and cylinder block. Do not remove CMP actuator at this procedure.
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. NOTE: Be careful not to drop timing chain into timing chain cover.
10. Remove camshaft bearings and tappets as necessary.
11. Remove CMP actuator from intake camshaft according to the following procedure if necessary. Hold hexagonal section of intake camshaft using vice. Loosen CMP actuator bolt and remove CMP actuator (1). CAUTION: Do not disassemble CMP actuator.

Reference: CAMSHAFT AND TAPPET INSPECTION

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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 (arrow), and then Install tappets (1) to cylinder head.
3. Install camshaft bearings according to the following procedure. CAUTION: Camshaft upper bearing half (1) is different in shape from lower bearing half (2). Distinguish upper and lower bearing halves certainly when installing. Fit tab (1) of camshaft bearing to groove (2) of cylinder head or camshaft housing. Press camshaft bearing end (3) until it fully seats in cylinder head or camshaft housing. Apply engine oil to sliding surface (4) of camshaft bearing halves. CAUTION: Do not apply engine oil between bearing halves (5) and camshaft housing or cylinder head (5).
4. Apply engine oil to sliding surfaces of camshafts, and then install camshafts to cylinder head according to the following procedure. Align the timing chain link (2), which is painted in removal procedure under this service information, with timing mark (1) on CMP actuator and install intake camshaft. Install exhaust camshaft and position dowel pin hole (3) of exhaust camshaft downward.
5. Install camshaft housings (1) to proper places distinguished by character (2), number (3) and arrow direction (4) on each camshaft housing.
6. Tighten camshaft housing bolts according to the following procedure. Apply engine oil to bolt thread and seat of camshaft housing bolts. 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 according to the following procedure. Align timing chain link (1), which is painted in "removal" under this service information, 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 (A): 09911-05120 Tightening torque Exhaust camshaft timing sprocket bolt (a): 60 N.m (6.1 kg-m, 44.5 lbf-ft) CAUTION: In case of using extension special tool combined with torque wrench, reading value of torque wrench is smaller than actual value. When using extension special tool, reading value should be calculated according to formula below. 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 wench 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 installed properly as follows. Check that timing mark (1) on CMP actuator and timing mark (2) on exhaust camshaft timing sprocket are aligned with match marks (3) on camshaft housing No. 1. Check that notch (1) on crankshaft pulley is aligned with "0" (2) on timing chain cover. Turn crankshaft clockwise twice and repeat Step a ) and b ). NOTE: Be sure to turn crankshaft fully twice. If it is once, timing marks on CMP actuator and exhaust camshaft timing sprockets do not meet match marks on camshaft housing No. 1. After turning crankshaft twice, the painted links of timing chain are not aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but it is normal.
14. Check valve clearance, see «Valve Clearance Inspection and Adjustment»(ref-514568-S40233411322012112100000) .
15. Install cylinder head cover, see «Cylinder Head Cover Removal and Installation»(ref-514568-S38533523692012112100000) .

Engine Assembly Removal and Installation

Reference: ENGINE MOUNTINGS COMPONENTS

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1. Relieve fuel pressure, see «FUEL PRESSURE RELIEF PROCEDURE»(ref-514581-S08070904532012112100000) .
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 accessory drive belt, see «ACCESSORY DRIVE BELT INSPECTION»(ref-514576-S00367964672012112100000) .
7. Remove front bumper, see «FRONT BUMPER AND REAR BUMPER COMPONENTS»(ref-514563-S19474663122012112100000) .
8. Drain the following oils and fluids if necessary. Engine oil, see «ENGINE OIL AND FILTER CHANGE»(ref-514576-S20298855722012112100000) . Manual transaxle oil (M/T model), see «MANUAL TRANSAXLE OIL CHANGE»(ref-514589-S09420238092012112100000) . CVT fluid (CVT model), see «CVT FLUID CHANGE»(ref-514590-S30269455542012112100000) . P/S fluid (Hydraulic P/S model), see «P/S FLUID CHANGE»(ref-514593-S16031016792012112100000) . Transfer oil (4WD model), see «TRANSFER OIL CHANGE»(ref-514591-S06780539672012112100000) .
9. Remove air cleaner assembly.
10. Remove radiator, see «RADIATOR REMOVAL AND INSTALLATION»(ref-514579-S42585031912012112100000) .
11. With hose connected, detach A/C compressor from its bracket. Manual A/C model, see «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(ref-514570-S23914577822012112100000) . Auto A/C model, see «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(ref-514569-S34350673702012112100000) . CAUTION: Suspend removed A/C compressor at a place where no damage will be caused during removal and installation of engine assembly.
12. Disconnect P/S fluid reservoir hose (1) and P/S gear low pressure hose (2) (Hydraulic P/S model).
13. Disconnect the following electric wires/connectors and each clamp. Connectors (1) in main fuse box Connector (2) in fuse box No. 1 Ground terminal (3) from vehicle body Battery ground cable (4) from transaxle Ground terminal (5) from exhaust manifold Torque sensor (6) (EPS model) P/S motor (7) (EPS model)
14. Disconnect TCM connectors (1), and then pull out engine harness to engine compartment.
15. Disconnect the following cables, and remove control cable bracket (1). Gear select control cable (2) (M/T model) Gear shift control cable (3) (M/T model) Select cable with select cable bracket (4) (CVT model)
16. Disconnect the following hoses. Brake booster hose (1) from brake booster Heater inlet and outlet hoses (2) from water outlet cap and heater outlet pipe Fuel feed hose (3) from fuel feed pipe Purge hose (4) from purge valve Clutch hose (5) from clutch fluid pipe (6) (M/T model)
17. Remove right and left drive shaft, see «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-514599-S06713669722012112100000) .
18. Remove exhaust No. 1, No. 2 and center pipe. See «EXHAUST SYSTEM COMPONENTS»(ref-514571-S15888920782012112100000) .
19. Disconnect propeller shaft from transfer (4WD model), see «PROPELLER SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-514596-S37517394492012112100000) .
20. Disconnect steering lower shaft from pinion shaft, see «STEERING LOWER SHAFT REMOVAL AND INSTALLATION»(ref-514559-S08895917722012112100000) .
21. Fix A/C condenser to vehicle body with rope so that A/C condenser does not fall off while lowering engine front mounting member.
22. Fix transaxle to suspension frame with rope so that engine assembly does not incline while lowering engine assembly.
23. Support front suspension frame and engine front mounting member putting jack at hatched parts (1) indicated in figure.
24. Remove engine right mounting nuts (1) and engine left mounting bracket bolt and nuts (2).
25. Remove suspension frame mounting bolts (1) and engine front mounting member No. 1 and No. 2 bolts (2).
26. Lower engine with transaxle, transfer (4WD model), steering gear case, CVT fluid cooler, front suspension frame and engine front mounting member. CAUTION: When lowering engine, in order to avoid damage to A/C compressor, make clearance by raising A/C compressor.
27. Disconnect steering gear case from suspension frame, if necessary. Hydraulic P/S model, see «STEERING GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION»(ref-514593-S29348040192012112100000) . EPS model, see «STEERING GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION»(ref-514598-S25558557552012112100000) .
28. Remove engine with transaxle, transfer (4WD model) from front suspension frame and front lower cross member.
29. Remove engine harness.
30. Disconnect transfer (4WD model).
31. Disconnect transaxle from engine.
32. Remove clutch cover and clutch disk, if necessary (M/T model), see «CLUTCH COVER AND CLUTCH DISC REMOVAL AND INSTALLATION»(ref-514586-S26008298312012112100000) .

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1. Install clutch cover and clutch disk, if removed (M/T model), see «CLUTCH COVER AND CLUTCH DISC REMOVAL AND INSTALLATION»(ref-514586-S26008298312012112100000) .
2. Connect transaxle to engine, if removed. M/T model, see «MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-514589-S20630626792012112100000) . CVT model, see «CVT ASSEMBLY DISMOUNTING AND REMOUNTING»(ref-514590-S24258684402012112100000) .
3. Connect transfer to transaxle, if removed (4WD model). See «TRANSFER DISMOUNTING AND REMOUNTING»(ref-514591-S33495817022012112100000) .
4. Install engine harness, and then tighten bolts and nuts to specified torque. Tightening torque Starting motor terminal nut (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft) Generator terminal nut (b): 11 N.m (1.1 kg-m, 8.5 lbf-ft) Ground terminal bolt (c): 11 N.m (1.1 kg-m, 8.5 lbf-ft) Ground terminal bolt (d): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
5. Install engine with transaxle, transfer (4WD model) to front suspension frame and engine front mounting member.
6. Connect steering gear case to suspension frame, if removed. Hydraulic P/S model, see «STEERING GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION»(ref-514593-S29348040192012112100000) . EPS model, see «STEERING GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION»(ref-514598-S25558557552012112100000) .
7. Lift engine with transaxle, transfer (4WD model), steering gear case, CVT fluid cooler, front suspension frame and engine front mounting member into engine compartment with jack. CAUTION: When lifting engine, in order to avoid damage to A/C compressor, make clearance by raising A/C compressor.
8. Tighten suspension frame mounting bolts and engine front mounting member bolts, and then tighten bolts to specified torque. Tightening torque Suspension frame mounting bolt (a): 95 N.m (9.7 kg-m, 70.0 lbf-ft) Engine front mounting member No. 1 bolt (b): 55 N.m (5.6 kg-m, 40.5 lbf-ft) Engine front mounting member No. 2 bolt (c): 59 N.m (6.0 kg-m, 43.5 lbf-ft)
9. Tighten engine right mounting nuts, engine left mounting bolts and nuts to specified torque. See «Engine Mountings Components»(ref-514568-S26650602902012112100000) .
10. Remove jack.
11. Connect steering lower shaft to pinion shaft, see «STEERING LOWER SHAFT REMOVAL AND INSTALLATION»(ref-514559-S08895917722012112100000) .
12. Connect propeller shaft (4WD model), see «PROPELLER SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-514596-S37517394492012112100000) .
13. Install exhaust No. 1, No. 2 and center pipe. See «EXHAUST SYSTEM COMPONENTS»(ref-514571-S15888920782012112100000) .
14. Install right and left drive shafts , see «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-514599-S06713669722012112100000) .
15. Reverse disconnection of hoses, cables and electric wires for connection noting the following. Tighten bolts and nuts to specified torque. Tightening torque Battery ground bolt (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft) ((M/T model)) Battery ground bolt (b): 55 N.m (5.6 kg-m, 40.5 lbf-ft) ((CVT model))
16. Connect P/S fluid reservoir hose (1) and P/S gear low pressure hose (2) (Hydraulic P/S model).
17. Install A/C compressor to cylinder block. Manual A/C model: Auto A/C model
18. Install radiator, radiator outlet hose, CVT fluid cooler inlet and outlet hoses.
19. Install A/C condenser cooling fan to radiator. Manual A/C model, see «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(ref-514570-S23914577822012112100000) . Auto A/C model, see «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(ref-514569-S34350673702012112100000) .
20. Install radiator cooling fan assembly and radiator inlet hose, see «RADIATOR REMOVAL AND INSTALLATION»(ref-514579-S42585031912012112100000) .
21. Install air cleaner assembly, see «Air Cleaner Assembly Removal and Installation»(ref-514568-S42483472292012112100000) .
22. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
23. Install accessory drive belt, see «ACCESSORY DRIVE BELT INSPECTION»(ref-514576-S00367964672012112100000) .
24. Install front bumper, see «FRONT BUMPER AND REAR BUMPER COMPONENTS»(ref-514563-S19474663122012112100000) .
25. Install battery and battery tray with ECM.
26. Connect ECM connectors.
27. Connect negative and positive cable at battery.
28. Refill cooling system with coolant, see «COOLING SYSTEM REFILLING»(ref-514579-S08553899402012112100000) .
29. Fill all drained oils and fluids. Engine oil, see «ENGINE OIL AND FILTER CHANGE»(ref-514576-S20298855722012112100000) . Manual transaxle oil (M/T model), see «MANUAL TRANSAXLE OIL CHANGE»(ref-514589-S09420238092012112100000) . CVT fluid (CVT model), see «CVT FLUID CHANGE»(ref-514590-S30269455542012112100000) . P/S fluid (Hydraulic P/S model), see «P/S FLUID CHANGE»(ref-514593-S16031016792012112100000) . Transfer oil (4WD model), see «TRANSFER OIL CHANGE»(ref-514591-S06780539672012112100000) .
30. Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection.
31. Install right and left side engine under covers.

Scheme 68

Timing Chain Cover Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

Note. If the crankshaft pulley bolt is loosened and tightened without crankshaft locked using the special tool, the timing chain, sprocket and their related parts may receive undue forces, which could cause damage to these components. When loosening and tightening the crankshaft pulley bolt, be sure to use the special tool, which should be securely installed to the crankshaft pulley using a bolt of the following specifications: Bolt size: M8 Pitch: 1.25 mm Length: 25 mm (0.98 in.) Strength: 7T

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1. Remove engine assembly from vehicle, see «Engine Assembly Removal and Installation»(ref-514568-S18932907842012112100000) .
2. Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool as shown in figure. CAUTION: Use special tool to avoid applying unnecessary load to timing chain, sprockets and any other related parts. Use specified bolts (2) to install special tool to crankshaft pulley. Bolt size: M8 Pitch: 1.25 mm Length: 25 mm (0.98 in.) Strength: 7T Special Tool (A): 09917-68221
3. Remove crankshaft pulley (1). If it is hard to remove, use special tools as shown in figure. Special Tool 09944-36011 09926-58010
4. Remove cylinder head cover, see «Cylinder Head Cover Removal and Installation»(ref-514568-S38533523692012112100000) .
5. Remove oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-514578-S29412339732012112100000) .
6. Remove tensioner pulley and idler pulley, see «ACCESSORY DRIVE BELT TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(ref-514555-S25998186482012112100000) .
7. Remove timing chain cover by loosing timing chain cover bolts in numerical order ("1" - "17") evenly and gradually.
8. Remove crankshaft oil seal from timing chain cover using flat-head screwdriver or the like, if necessary.
9. Remove oil seal from timing chain cover if necessary.

Reference: TIMING CHAIN COVER INSPECTION

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1. Clean mating surface of timing chain cover, cylinder block and cylinder head. Remove oil, old sealant and dust from mating surface.
2. Check oil seal (1) for any damage. If abnormality is found, replace oil seal. NOTE: When installing new oil seal, press it into timing chain cover (2) using special tool as shown in figure. Special Tool (A): 09913-75510
3. Install dowel pins (1) to cylinder block.
4. Apply sealant "A" to mating surface of cylinder, cylinder head and timing chain cover as shown in figure. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) Sealant bead size for timing chain cover Width "a": 3 mm (0.12 in.) Height "b": 2 mm (0.08 in.)
5. Apply engine oil to oil seal lip, then install timing chain cover. 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)
6. Install tensioner pulley and idler pulley, see «ACCESSORY DRIVE BELT TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(ref-514555-S25998186482012112100000) .
7. Install cylinder head cover, see «Cylinder Head Cover Removal and Installation»(ref-514568-S38533523692012112100000) .
8. Install oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-514578-S29412339732012112100000) .
9. Install crankshaft pulley (1) and tighten crankshaft pulley bolt to specified torque. To lock crankshaft pulley, use special tool as shown in figure. CAUTION: Use special tool to avoid being applying unnecessary load to timing chain, sprockets and any other related parts. Use specified bolts (2) to install special tool to crankshaft pulley. Bolt size: M8 Pitch: 1.25 mm Length: 25 mm (0.98 in.) Strength: 7T Special Tool (A): 09917-68221 Tightening torque Crankshaft pulley bolt (a): 150 N.m (15.3 kg-m, 111.0 lbf-ft)
10. Install engine assembly to vehicle, see «Engine Assembly Removal and Installation»(ref-514568-S18932907842012112100000) .

OCV (Oil Control Valve) Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

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

Scheme 77

Reverse removal procedure noting the following.

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

Scheme 78

1. Remove transaxle assembly. M/T model: Refer to «MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-514589-S20630626792012112100000) . CVT model: Refer to «CVT ASSEMBLY DISMOUNTING AND REMOUNTING»(ref-514590-S24258684402012112100000) .
2. Wedge a special tool in ring gear teeth to lock flywheel or drive plate as shown in figure. Special Tool (A): 09924-17811
3. Remove flywheel or drive plate from engine assembly.

Reverse removal procedure noting the following.

Scheme 79

1. Install new drive plate bolts or flywheel bolts.
2. Wedge a special tool in ring gear teeth to lock flywheel or drive plate as shown in figure. Special Tool (A): 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)

Scheme 80

Timing Chain and Chain Tensioner Removal and Installation

Reference: TIMING CHAIN AND CHAIN TENSIONER COMPONENTS

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

Scheme 81

Note. If it is necessary to rotate the camshaft after removing timing chain, turn crankshaft counterclockwise and position key (1) within specified range (30 - 90°) as shown in figure before rotating camshaft.

Scheme 82

Scheme 83

Scheme 84

1. Remove timing chain cover, see «Timing Chain Cover Removal and Installation»(ref-514568-S25686873032012112100000) .
2. By turning crankshaft, align camshafts and crankshaft at specific position as follows. Align timing marks on CMP actuator (1) and timing mark (2) on exhaust camshaft timing sprocket with match marks (3) on camshaft housing No. 1. Align timing mark (1) on crankshaft timing sprocket with match mark (2) on lower crank case.
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 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

1. Turn crankshaft 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 match marks (4) on camshaft housing No. 1.
3. Align timing mark (5) on exhaust camshaft timing sprocket with match marks (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 match mark (9) on lower crank case.
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 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 plated (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-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, and then turn crankshaft clockwise fully twice, and make sure the following items. Timing mark (4) on CMP actuator is aligned with match mark (3) on camshaft housing No. 1. Timing mark (5) on exhaust camshaft timing sprocket is aligned with match mark (3) on camshaft housing No. 1. Timing mark (6) on crankshaft timing sprocket is aligned with match mark (7) on lower crank case. NOTE: Be sure to turn crankshaft fully twice. If it is once, timing marks on CMP actuator and exhaust camshaft timing sprocket do not meet match marks on camshaft housing No. 1. After turning crankshaft twice, the discrimination links of timing chain are not aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but it is normal.
16. Install timing chain cover, see «Timing Chain Cover Removal and Installation»(ref-514568-S25686873032012112100000) .
17. Install cylinder head cover, see «Cylinder Head Cover Removal and Installation»(ref-514568-S38533523692012112100000) .
18. Install oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-514578-S29412339732012112100000) .
19. Install engine assembly, see «Engine Assembly Removal and Installation»(ref-514568-S18932907842012112100000) .

Valve and Cylinder Head Removal and Installation

Reference: VALVE AND CYLINDER HEAD COMPONENTS

Scheme 91

Scheme 92

1. Remove timing chain, see «Timing Chain and Chain Tensioner Removal and Installation»(ref-514568-S02503377372012112100000) .
2. Remove spark plugs, see «SPARK PLUG REMOVAL AND INSTALLATION»(ref-514577-S39604449802012112100000) .
3. Remove intake camshaft with CMP actuator and exhaust camshaft with timing sprocket, see «Camshaft and Tappet Removal and Installation»(ref-514568-S02835718742012112100000) .
4. Remove camshaft bearings.
5. Remove heater outlet pipe bolt (1) from cylinder head (2).
6. Remove cylinder head No. 2 bolt (1).
7. Loosen cylinder head No. 1 bolts (2) in numerical order ("1" - "10") evenly and gradually. NOTE: Use 12-point socket wrench to cylinder head No. 1 bolts.
8. Remove cylinder head with its gasket, intake manifold and exhaust manifold from cylinder block.
9. Remove the following components cylinder head if necessary. Intake manifold, see «Intake Manifold Removal and Installation»(ref-514568-S10412990452012112100000) . Exhaust manifold, see «EXHAUST MANIFOLD REMOVAL AND INSTALLATION»(ref-514571-S27114578642012112100000) . Fuel injector, see «FUEL INJECTOR REMOVAL AND INSTALLATION»(ref-514581-S00231229152012112100000) . Water outlet cap, see «COOLING SYSTEM COMPONENTS»(ref-514579-S22664361332012112100000) . Oil venture plug, see «Valve and Cylinder Head Disassembly and Reassembly»(ref-514568-S31825482552012112100000) .

Reference: VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Reference: CYLINDER HEAD INSPECTION

Reference: CYLINDER HEAD NO. 1 BOLT INSPECTION

Scheme 93

Scheme 94

Scheme 95

1. Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface.
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 cylinder head to cylinder block, turn crankshaft and position key (1) within specified range (30 - 90°) in counterclockwise direction from top as shown in figure. Install cylinder head to cylinder block. Apply engine oil to cylinder head No. 1 bolts (1) threads. Tighten cylinder head No. 1 bolts 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 to cylinder head No. 1 bolts. In the same manner as in Step c ), retighten them to 40 N.m (4.1 kgf-m, 29.5 lbf-ft). In the same manner as Step c ), retighten them to 60°. In the same manner as Step c ), retighten them to 80°. Tightening torque Cylinder head No. 1 bolt * (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 No. 2 bolt (2) to specified torque. Tightening torque Cylinder head No. 2 bolt (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
5. Install intake camshaft and exhaust camshaft, see «Camshaft and Tappet Removal and Installation»(ref-514568-S02835718742012112100000) .
6. Install timing chain, see «Timing Chain and Chain Tensioner Removal and Installation»(ref-514568-S02503377372012112100000) .
7. Install timing chain cover, see «Timing Chain Cover Removal and Installation»(ref-514568-S25686873032012112100000) .
8. Install cylinder head cover, see «Cylinder Head Cover Removal and Installation»(ref-514568-S38533523692012112100000) .
9. Install oil pan, see «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-514578-S29412339732012112100000) .
10. Install water outlet cap if removed, see «COOLING SYSTEM COMPONENTS»(ref-514579-S22664361332012112100000) .
11. Install heater outlet pipe bolt to cylinder head, see «COOLING SYSTEM COMPONENTS»(ref-514579-S22664361332012112100000) .
12. Install spark plugs, see «SPARK PLUG REMOVAL AND INSTALLATION»(ref-514577-S39604449802012112100000) .
13. Install exhaust manifold if removed, see «EXHAUST MANIFOLD REMOVAL AND INSTALLATION»(ref-514571-S27114578642012112100000) .
14. Install intake manifold if removed, see «Intake Manifold Removal and Installation»(ref-514568-S10412990452012112100000) .
15. Install fuel injectors if removed, see «FUEL INJECTOR REMOVAL AND INSTALLATION»(ref-514581-S00231229152012112100000) .
16. Install engine assembly, see «Engine Assembly Removal and Installation»(ref-514568-S18932907842012112100000) .

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-514568-S18932907842012112100000) .
2. Remove cylinder head, see «Valve and Cylinder Head Removal and Installation»(ref-514568-S41345558772012112100000) .
3. Remove oil pump, see «OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION»(ref-514578-S26360733272012112100000) .
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 96

Scheme 97

Scheme 98

Scheme 99

1. Apply engine oil to pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft pins. NOTE: Do not apply engine oil between connecting rod and bearing, between connecting rod bearing cap and bearing.
2. Install connecting rod bearing to connecting rod bearing cap and connecting rod 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 and bearing cap.
3. When installing piston and connecting rod assembly into cylinder bore, point 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. 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 in cylinder bore. Special Tool (A): 09916-77310
5. Install connecting rod bearing cap (1) as follows. NOTE: Before installing connecting rod bearing cap, check connecting rod bearing cap bolts for deformation. Refer to " «CONNECTING ROD BOLT DEFORMATION»(ref-514568-S18378384662012112100000) " under «PISTON PINS AND CONNECTING RODS INSPECTION»(ref-514568-S12426603562012112100000) . Tighten connecting rod bearing cap bolt (3) gradually. Point 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. Tighten all connecting rod bearing cap bolt to 15 N.m (1.5 kgf-m, 11.0 lbf-ft) evenly and gradually. In the same manner as Step c ), retighten them to 45°. In the same manner as Step c ), retighten them to 45°. 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-514578-S26360733272012112100000) .
7. Install cylinder head, see «Valve and Cylinder Head Removal and Installation»(ref-514568-S41345558772012112100000) .
8. Install engine assembly, see «Engine Assembly Removal and Installation»(ref-514568-S18932907842012112100000) .

Main Bearings, Crankshaft and Cylinder Block Removal and Installation

Reference: MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

1. Remove engine assembly. Refer to «Engine Assembly Removal and Installation»(ref-514568-S18932907842012112100000) .
2. Remove flywheel for M/T model or drive plate for CVT model. Refer to «Flywheel/Drive Plate Removal and Installation»(ref-514568-S00093579772012112100000) .
3. Remove generator. Refer to «GENERATOR REMOVAL AND INSTALLATION»(ref-514555-S30150571592012112100000) .
4. Remove P/S pump. Refer to «P/S PUMP REMOVAL AND INSTALLATION»(ref-514593-S25101454622012112100000) .
5. Remove engine front mounting bracket (1).
6. Remove piston and connecting rod. Refer to «Piston, Piston Ring and Connecting Rod Removal and Installation»(ref-514568-S30615370172012112100000) .
7. Remove oil pump chain guide (1) from lower crank case.
8. Remove CKP sensor. Refer to «CRANKSHAFT POSITION (CKP) SENSOR REMOVAL AND INSTALLATION»(ref-514553-S21404304062012112100000) .
9. Loosen crank case bolt No. 2s in numerical order ("1" - "12") evenly and gradually.
10. Loosen crank case bolt No. 1s in numerical order ("1" - "10") evenly and gradually, and then remove lower crank case and rear oil seal. NOTE: Use 12-point socket wrench to crank case 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 INSPECTION

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

1. Install sensor plate (1) according to the following procedure. Attach spring pin (2) to crankshaft (3). NOTE: Use spring pin which is 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. CAUTION: Align spring pin hole (4) on sensor plate with spring pin on crankshaft. Inside edge (5) of sensor plate is bent. Install sensor plate properly. 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 and lower crankcase according to the following procedure. 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 crank case. Press bearing end (3) until it fully seat in cylinder block or lower crankcase. Apply engine oil to sliding surface (4) of main bearing halves. CAUTION: Do not apply engine oil between bearing halves (5) and cylinder block or lower crank case (5).
3. Install new O-ring (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. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) Sealant bead size for lower crankcase Width "a": 3 mm (0.12 in.) Height "b": 2 mm (0.08 in.)
9. Install lower crank case to cylinder block and tighten crank case bolt No. 1s according to the following procedure. NOTE: If crank case bolt No. 1s are reused, check them for deformation referring to " «CRANK CASE BOLT NO. 1 INSPECTION»(ref-514568-S28685581262012112100000) " under «Main Bearings Inspection»(ref-514568-S41506207812012112100000) . Use 12-point socket wrench to crank case bolt No. 1s. Apply engine oil to bolt threads and seats of crank case 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. In the same manner as Step a ), retighten them to 20 N.m (2.0 kgf-m, 15.0 lbf-ft). In the same manner as Step a ), retighten them to 35 N.m (3.6 kgf-m, 26.0 lbf-ft). In the same manner as Step a ), retighten them to 40°. In the same manner as Step a ), retighten them to 40°. Tightening torque Crank case 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 crank case bolt No. 2s in numerical order ("1" - "12") evenly and gradually. Tightening torque Crank case 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-514568-S30615370172012112100000) .
14. Install oil pump chain guide (1). Tightening torque Oil pump chain guide bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
15. Install CKP sensor, see «CRANKSHAFT POSITION (CKP) SENSOR REMOVAL AND INSTALLATION»(ref-514553-S21404304062012112100000) .
16. Install flywheel for M/T model, or drive plate for CVT model. See «Flywheel/Drive Plate Removal and Installation»(ref-514568-S00093579772012112100000) .
17. 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)
18. Install P/S pump. Refer to «P/S PUMP REMOVAL AND INSTALLATION»(ref-514593-S25101454622012112100000) .
19. Install water pump. Refer to «WATER PUMP REMOVAL AND INSTALLATION»(ref-514579-S42213960222012112100000) .
20. Install generator. Refer to «GENERATOR REMOVAL AND INSTALLATION»(ref-514555-S30150571592012112100000) .
21. Install engine assembly. Refer to «Engine Assembly Removal and Installation»(ref-514568-S18932907842012112100000) .