Main Bearings, Crankshaft and Cylinder Block Removal and Installation - Suzuki Jimny Workshop Manual
1D
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
Removal
1)
Remove engine assembly from vehicle as previously outlined.
2)
Remove clutch cover, clutch disc and flywheel (drive plate for A/T) by using special tool.
3)
Remove the following parts from engine as previously outlined.
•
Oil pan and oil pump strainer
• Intake manifold and exhaust manifold
• Cylinder head cover
• Timing chain cover
• Timing chain guide, chain tensioner adjuster, chain tensioner, timing chain and crankshaft timing sprocket
• Camshaft, tappet and shim
• Cylinder head assembly
• Piston and connecting rod
• Intake manifold and exhaust manifold
• Cylinder head cover
• Timing chain cover
• Timing chain guide, chain tensioner adjuster, chain tensioner, timing chain and crankshaft timing sprocket
• Camshaft, tappet and shim
• Cylinder head assembly
• Piston and connecting rod
4)
Remove rear oil seal housing (1).
5)
Loosen main bearing cap No.1 and No.2 bolts in such order as indicated in the figure and remove them.
6)
Remove crankshaft from cylinder block.
Installation
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, bearing caps, connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb such combination and make sure that each part goes back to where it came from, when installing.
• Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores.
• Journal bearings, bearing caps, connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb such combination and make sure that each part goes back to where it came from, when installing.
1)
Install sensor plate (1) to crankshaft (2) and tighten bolts to specified torque.
NOTE:
When installing sensor plate, align spring pin (3) on crankshaft and hole of sensor plate.
2)
Install main bearings to cylinder block.
Upper half of bearing (1) has an oil groove (2).
Install it to cylinder block (3), and the other half without oil groove to bearing cap.
Make sure that two halves are painted in the same color.
Upper half of bearing (1) has an oil groove (2).
Install it to cylinder block (3), and the other half without oil groove to bearing cap.
Make sure that two halves are painted in the same color.
3)
Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to crank webs.
4)
Confirm that dowel pins (3) are installed to intake side of each journal.
5)
Install crankshaft to cylinder block.
6)
Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1 bolts ((1) – (10)) and main bearing cap No.2 bolts ((11) – (20)), tighten them gradually as follows.
After applying engine oil to main bearing cap No.1 bolts ((1) – (10)) and main bearing cap No.2 bolts ((11) – (20)), tighten them gradually as follows.
NOTE:
If bearing cap No.1 bolts are reused, check thread diameters of them for deformation according to previous mentioned “Main Bearing Cap No.1 Bolt” and replace them with new ones if thread diameter exceeds limit.
a)
Tighten bolts ((1) – (10)) to 30 N·m (3.0 kgf-m, 22.0 lbf-ft) according to numerical order as shown by using a 12 corner socket wrenches.
b)
In the same manner as in Step a), tighten them to 50 N·m (5.0 kgf-m, 36.5 lbf-ft).
c)
In the same manner as in Step a), retighten them to 60°.
d)
Tighten bolts ((11) – (20)) to 22 N·m (2.2 kgf-m, 16.0 lbf-ft) according to numerical order as shown.
Main bearing cap No.2 bolt ((11) – (20)) : 22 N·m ( 2.2 kg-m, 16.0 lb-ft)
Tightening torque
Main bearing cap No.1 bolt ((1) – (10))
:
50 N·m (5.0 kgf-m, 36.5 lbf-ft) and extra tightening 60°
Main bearing cap No.2 bolt ((11) – (20)) : 22 N·m ( 2.2 kg-m, 16.0 lb-ft)
CAUTION:
After tightening cap bolts, check to be sure that crankshaft rotates smoothly when turning it by 12 N·m (1.2 kgf-m, 9.0 lbf-ft) torque or below.
7)
If necessary, press-fit rear oil seal (1) to oil seal housing (2) by using special tool as shown in the figure.
Crank rear oil seal installing position (dimension)
“a”: 3 mm (0.12 in.)
8)
Apply sealant to mating surface of rear oil seal housing (1).
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
9)
Install rear oil seal housing (1) and tighten bolts to specified torque by using special tool.
| A: | Crankshaft side |
10)
Install flywheel (for M/T) or drive plate (for A/T).
Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts applied with sealant to specification.
Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts applied with sealant to specification.
11)
Install the following parts to engine as previously outlined.
•
Piston and connecting rod
• Cylinder head assembly
• Camshaft, tappet and shim
• Timing chain guide, chain tensioner adjuster, chain tensioner, timing chain and crankshaft timing sprocket
• Timing chain cover
• Cylinder head cover
• Intake manifold and exhaust manifold
• Oil pan and oil pump strainer
• Cylinder head assembly
• Camshaft, tappet and shim
• Timing chain guide, chain tensioner adjuster, chain tensioner, timing chain and crankshaft timing sprocket
• Timing chain cover
• Cylinder head cover
• Intake manifold and exhaust manifold
• Oil pan and oil pump strainer
12)
Install clutch to flywheel (vehicle with M/T) referring to
Clutch Cover, Clutch Disc, Flywheel and Release Bearings Removal and Installation:M13A Model
.
13)
Install engine assembly to vehicle referring to
Engine Assembly Removal and Installation:M13A
.