XL-7 2006
XL-7 2006
XL-7 2006
2006 ENGINE
GENERAL DESCRIPTION
ENGINE GENERAL INFORMATION
The engine is a water-cooled, 60° V6 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead
camshaft) valve mechanism arranged for "V" type valve configuration. The double overhead camshaft is
mounted over the cylinder head; it is driven from crankshaft through timing chains, and no push rods are
provided in the valve train system.
This air cleaner element is of dry type. Note that it needs cleaning referring to AIR CLEANER ELEMENT
INSPECTION AND CLEANING.
1. Warm up engine.
2. Stop engine after warming up.
3. Remove ignition coil covers and disconnect ignition coil harness couplers.
4. Remove all ignition coils (1) and spark plugs (2) referring to SPARK PLUG REMOVAL AND
INSTALLATION.
Special Tool
(A): 09915-64510
(B): 09915-64530
(C): 09915-67010
8. Disengage clutch (to lighten starting load on engine) for M/T vehicle, and depress accelerator pedal all
the way to make throttle fully open.
9. Crank engine with fully charged battery, and read the highest pressure on compression gauge.
NOTE: For measuring compression pressure, crank engine at least 250 rpm by
using fully charged battery.
Compression pressure
Standard: 1400 - 1600 kPa (14.0 - 16.0 kg/cm2 , 199.0 - 227.5 psi)
Max. difference between any two cylinders: 100 kPa (1.0 kg/cm2 , 14.2 psi)
The engine vacuum that develops in the intake line is a good indicator of the condition of the engine. The
vacuum checking procedure is as follows:
1. Warm up engine to normal operating temperature and make sure that engine idle speed is within
specification.
2. Stop engine and disconnect vacuum hoses from fuel pressure regulator valve (1).
3. Connect special tools (Vacuum gauge and hose joint) and 3-way joint between vacuum hose and valve.
Special Tool
(A): 09915-67311
(B): 09918-08210
4. Start engine and run engine at specified idle speed, and read vacuum gauge. Vacuum should be within
specification.
59 - 79 kPa (450 - 600 mmHg, 17.7 - 23.7 in.Hg) at specified idle speed
REPAIR INSTRUCTIONS
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION
Removal
Installation
Inspection
Cleaning
When cleaning element, blow off dust by blowing compressed air from air outlet side of element (i.e., the side
facing up when installed in air cleaner case).
If measured value is out of specification, adjust accelerator cable (1) so as pedal play to be within
specification with cable adjusting nut (2). Then tighten lock nut (3).
Fig. 8: Identifying Accelerator Cable, Cable Adjusting Nut And Lock Nut
Courtesy of SUZUKI OF AMERICA CORP.
3. With accelerator pedal depressed fully, check clearance between throttle lever (2) and lever stopper (1)
(throttle body) which should be within the following specification.
If measured value is out of specification, adjust it to specification by changing height of pedal stopper
bolt (3).
Clearance between throttle lever and lever stopper (throttle body) (with accelerator pedal
depressed fully)
Fig. 9: Identifying Throttle Lever, Lever Stopper And Pedal Stopper Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Removal
Fig. 13: Identifying Intake Air Pipe, Surge Tank Pipe And Intake Control Valve
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 14: Identifying TP Sensor, IAC Valve, Intake Manifold, Terminal And Clamp Bracket
Courtesy of SUZUKI OF AMERICA CORP.
12. Disconnect connectors of EVAP canister purge valve (1) and EGR valve (5).
13. Disconnect PCV valve hose (6), ground terminal connector (7) and breather hose (3) from cylinder head
and EVAP canister purge valve hose (2).
14. Detach EGR pipe (4) from exhaust manifold.
Fig. 15: Identifying EVAP Canister Purge Valve, EGR Valve, PCV Valve Hose, Terminal
Connector, EVAP Canister Purge Valve Hose, EGR Pipe And Breather Hose
Courtesy of SUZUKI OF AMERICA CORP.
15. Remove throttle body (3) and intake collector (2) from intake manifold (1).
16. Disconnect hoses of PCV from throttle body.
17. Remove throttle body from intake collector.
Installation
1. Clean mating surfaces and install new throttle body gasket (2) to intake collector (1).
2. Install throttle body to intake collector and tighten bolts and nuts.
3. Connect PCV hose to throttle body.
4. Install throttle body and intake collector to intake manifold with new intake collector gaskets.
5. Install EGR pipe with new gaskets.
6. Connect breather hose, EVAP canister purge valve hose and PCV valve hose.
7. Connect connectors of EVAP canister purge valve and EGR valve.
Tightening torque
Strut tower bar mounting bolts a: 50 N.m (5.0 kg-m, 36.5 lb-ft)
Fig. 18: Identifying Strut Tower Bar And Strut Tower Bar Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION: l Do not blow compressed air through bypass air passage with IAC
valve installed to throttle body. This will cause IAC valve to
malfunction.
l TP sensor, idle air control valve or other components containing
rubber must not be places in a solvent or cleaner bath.
Clean throttle body bore and bypass air passages (1) by blowing compressed air.
Special Tool
(A): 09917-47011
2. Apply vacuum to intake control valve (1) and verify that throttle (2) fully closes within the specified
range.
CAUTION: Do not apply above 88 kPa of negative pressure. Damage may occur
to intake control valve (1).
3. Let the throttle (2) close for 15 seconds with no vacuum application and inspect throttle travel. If throttle
travel decreases, replace intake air valve (1).
Removal
1. Release fuel pressure in fuel feed line by referring to FUEL PRESSURE RELIEF PROCEDURE .
2. Disconnect negative (-) cable at battery.
3. Drain coolant referring to COOLANT DRAINING .
4. Detach fuse/relay box and remove strut tower bar (2).
5. Disconnect coupler from IAT sensor and MAF sensor.
6. Remove surge tank cover (1).
Fig. 22: Identifying Surge Tank Cover And Strut Tower Bar
Courtesy of SUZUKI OF AMERICA CORP.
7. Remove air cleaner upper case, MAF sensor, intake air hose, intake air pipe (1) and surge tank pipe (2) as
one component. Do not disassemble them, when removing and reinstalling.
8. Remove intake control valve (3).
Fig. 23: Identifying Intake Air Pipe, Surge Tank Pipe And Intake Control Valve
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 25: Identifying Injector Wire, Brake Booster Hose, Fuel Pressure Regulator Vacuum Hose And
Intake Control Valve Hose
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 26: Identifying TP Sensor, IAC Valve, Terminal And Clamp Bracket
Courtesy of SUZUKI OF AMERICA CORP.
16. Disconnect couplers from MAP sensor, EVAP canister purge valve (1), earth terminal (9) and EGR valve
(2).
17. Disconnect PCV hose (6) from cylinder head cover.
18. Disconnect breather hoses (8) from throttle body or cylinder head cover.
19. Disconnect EVAP canister purge valve hose (4), heater hose (5) and water hose (7).
20. Remove EGR pipe (3) and wire harness clamps.
Fig. 27: Identifying EVAP Canister Purge Valve, Terminal, EGR Valve, PCV Hose, EGR Pipe,
Breather Hoses, Water Hose And Heater Hose
Courtesy of SUZUKI OF AMERICA CORP.
21. Disconnect hoses of heater (1), EVAP canister purge (4), fuel feed (2) and fuel return (3).
Fig. 28: Identifying Heater Hose, EVAP Canister Purge, Fuel Feed And Fuel Return
Courtesy of SUZUKI OF AMERICA CORP.
22. Remove throttle body (1) and intake collector (2) from intake manifold (3).
Fig. 29: Identifying Throttle Body, Intake Collector And Intake Manifold
Courtesy of SUZUKI OF AMERICA CORP.
23. Disconnect hoses of PCV valve and EVAP canister purge valve from intake collector.
24. Remove throttle body (1) from intake collector.
Installation
2. Install intake manifold (1), and tighten bolts (2) and nuts (3).
3. Install throttle body (2) to intake collector (1) with new throttle body gasket.
4. Install IAC valve, EGR valve (1), EVAP canister purge valve (2), MAP sensor and each hoses to intake
collector and throttle body if removed.
NOTE: Use new gasket when installing IAC valve and EGR valve.
Fig. 35: Identifying EGR Valve, EVAP Canister Purge Valve & EVAP Canister Purge Valve Hose
Courtesy of SUZUKI OF AMERICA CORP.
5. Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets.
6. Connect hoses of heater (1), EVAP canister (4), fuel feed (2) and fuel return (3).
Fig. 36: Identifying Heater Hose, EVAP Canister Hose, Fuel Feed Hose And Fuel Return Hose
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 37: Identifying EGR Pipe, EVAP Canister Purge Valve Hose, Heater Hose, PCV Hose,
Breather Hose, Water Hose, EVAP Canister Purge Valve, EGR Valve And Earth Terminal
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 38: Identifying Clamp Bracket, Earth Terminal, TP Sensor Coupler And IAC Valve Coupler
Courtesy of SUZUKI OF AMERICA CORP.
14. Connect brake booster hose (2), fuel pressure regulator vacuum hose (4) and intake control valve hose (3)
to intake manifold.
15. Connect injector wire (1) coupler.
Fig. 39: Identifying Brake Booster Hose, Fuel Pressure Regulator Vacuum Hose, Intake Control
Valve Hose & Injector Wire
Courtesy of SUZUKI OF AMERICA CORP.
18. Install surge tank pipe (2) and intake control valve (3) to intake manifold with new gaskets and intake air
pipe (1) to throttle body.
Fig. 41: Identifying Surge Tank Pipe, Intake Control Valve And Intake Air Pipe
Courtesy of SUZUKI OF AMERICA CORP.
Tightening torque
Strut tower bar mounting bolts a: 50 N.m (5.0 kg-m, 36.5 lb-ft)
Fig. 43: Identifying Strut Tower Bar And Strut Tower Bar Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.
25. Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
26. Connect negative cable (-) at battery.
27. Upon completion of installation, verify that there is no fuel leakage at each connection according to
FUEL LEAKAGE CHECK PROCEDURE .
Removal
1. Remove throttle body and intake manifold referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION.
2. Remove ignition coil covers.
3. Disconnect ignition coil couplers and remove ignition coils referring to IGNITION COIL ASSEMBLY
(IGNITER AND IGNITION COIL) REMOVAL AND INSTALLATION .
4. Remove cylinder head covers (1).
Fig. 44: Identifying Cylinder Head Cover, Nut, Seal Washer And Cylinder Head Cover Gasket
Courtesy of SUZUKI OF AMERICA CORP.
Installation
3. Install new cylinder head cover gaskets (4) to head covers (1).
4. Install cylinder head covers (1) to cylinder heads.
5. Using new seal washers (3), tighten nuts (2) to specified torque.
Tightening torque
Cylinder head cover nut a: 10.5 N.m (1.1 kg-m, 7.5 lb-ft)
Fig. 46: Identifying Cylinder Head Cover, Seal Washer, Nut And Cylinder Head Cover Gasket
Courtesy of SUZUKI OF AMERICA CORP.
6. Install ignition coils and connect ignition coil couplers referring to IGNITION COIL ASSEMBLY
(IGNITER AND IGNITION COIL) REMOVAL AND INSTALLATION .
7. Install ignition coil covers.
8. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
Fig. 47: Identifying Timing Chain Cover Components With Torque Specifications
Courtesy of SUZUKI OF AMERICA CORP.
Removal
Special Tool
(A): 09917-68221
Fig. 48: Identifying Crankshaft Pulley Bolt, Wrench And Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
NOTE: Be sure to use the following bolt for fixing special tool to crankshaft
pulley.
Bolt size: M8, P1.25 L=45 mm
Strength: 7T
If it is hard to remove, use special tools (Steering wheel remover, Bearing puller attachment) as shown in
figure.
If bolts of steering wheel remover are too long, replace them with those of suitable length.
Special Tool
(B): 09944-36011
(C): 09926-58010
15. Disconnect CKP sensor connector and remove CKP sensor if necessary.
16. Remove timing chain cover.
Installation
Reverse removal sequence to install timing chain cover noting the following points.
l Clean sealing surface on timing chain cover, crankcase, cylinder block and cylinder heads. Remove oil,
old sealant, and dust from sealing surface.
l Apply sealant "A" to timing chain cover sealing surface area as shown in figure.
l Apply sealant "B" to mating surfaces of cylinder head and cylinder block as shown.
Fig. 53: Identifying Cylinder Head And Cylinder Block Sealant Application Area
Courtesy of SUZUKI OF AMERICA CORP.
l Apply engine oil to new oil seal lip and water pump O-ring. Using special tool (bearing installer), install
new oil seal (2) with its surface is flash with edge of timing chain cover (1).
Special Tool
(D): 09913-75510
Fig. 54: Identifying Oil Seal, Timing Chain Cover & Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Tightening torque
l Apply engine oil to O-ring of CKP sensor and install CKP sensor (4) to timing chain cover.
Tightening torque
To lock crankshaft pulley, use special tool (camshaft pulley holder) with it at shown in figure.
Special Tool
(A): 09917-68221
Tightening torque
Fig. 55: Identifying CKP Sensor, Bolt, Wrench, Crankshaft Pulley And Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
NOTE: Be sure to use the following bolt for fixing special tool to crank pulley.
Bolt size: M8, P1.25 L=45 mm
Strength: 7T
Fig. 57: Identifying LH (No.1) Bank 2nd Timing Chain And Chain Tensioner Components With Torque
Specifications
Courtesy of SUZUKI OF AMERICA CORP.
l Arrow mark on idler sprocket No.2 (2) points the center of crankshaft.
To remove it, slacken LH bank 2nd timing chain by turning intake camshaft (2) counterclockwise a little
while pushing back pad.
Fig. 59: Identifying Timing Chain Tensioner Adjuster No. 3 And Intake Camshaft
Courtesy of SUZUKI OF AMERICA CORP.
To remove it, fit a spanner to hexagonal part (3) at the center of camshaft to hold it stationary.
CAUTION: Removing sprocket (1) from camshaft (2) may cause cam to turn,
resulting in damage to valve and piston. To prevent this, when
removing sprocket, hold camshaft stationary by using a spanner at
its hexagonal part.
Reference: LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Removal
Fig. 62: Identifying Shoe, Timing Chain Guide No. 4 And No. 5
Courtesy of SUZUKI OF AMERICA CORP.
Camshaft Sprocket
Timing Chain
l Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.
Reference: LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Components
Reference: LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Removal
Reference: LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Inspection
Fig. 67: Identifying Crank Timing Pulley Key And Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 68: Identifying Timing Mark On Idler Sprocket No. 2, Match Mark Of Idler Sprocket No. 2 &
Crankshaft
Courtesy of SUZUKI OF AMERICA CORP.
Tightening torque
Timing chain guide No.4 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
4. Check that knock-pins of intake and exhaust camshafts are aligned with match marks on cylinder head as
shown in figure.
Fig. 70: Identifying Knock-Pins Of LH Bank Intake And Exhaust Camshafts & Match Marks
Courtesy of SUZUKI OF AMERICA CORP.
5. Install by aligning match marks (2) on yellow plate (1) of LH bank 2nd timing chain and idler sprocket
No.2.
6. Install sprockets to intake and exhaust camshafts by aligning silver plate (1) of LH bank 2nd timing chain,
match marks on intake sprocket and exhaust sprocket respectively.
To install it, fit a spanner to hexagonal part at the center of camshaft to hold stationary.
Tightening torque
Fig. 72: Identifying Silver Plate, Arrow Mark On Intake And Exhaust Camshaft Timing Sprockets
& Sprocket Bolt
Courtesy of SUZUKI OF AMERICA CORP.
8. With latch (2) of tensioner adjuster No.3 returned and plunger (1) pushed back into body, insert stopper
(pin) (4) into set hole (3).
After inserting it, check to make sure that plunger will not come out.
Fig. 73: Identifying Tensioner Adjuster No. 3 Latch, Plunger, Set Hole And Stopper Pin
Courtesy of SUZUKI OF AMERICA CORP.
9. Install timing chain tensioner adjuster No.3 (1) in tightening order below.
Tightening torque
Timing chain tensioner adjuster No.3 bolt c: Tighten 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified
procedure
Timing chain tensioner adjuster No.3 nut d: Tighten 55 N.m (5.5 kgf-m, 40.0 lb-ft) by the specified
procedure
"1"-->"2"-->"3"
Fig. 74: Identifying Timing Chain Tensioner Adjuster No. 3, Stopper Pin & Bolts Tightening
Sequence
Courtesy of SUZUKI OF AMERICA CORP.
11. Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on
cylinder block as shown in figure.
Check each other timing marks that align them shown in figure.
12. Apply oil to timing chains, tensioner adjusters sprockets and guides.
13. Install timing chain cover referring to TIMING CHAIN COVER REMOVAL AND
INSTALLATION.
14. Install oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
15. Install front differential referring to FRONT DIFFERENTIAL DISMOUNTING AND
REMOUNTING : Front.
16. Install P/S system referring to P/S PUMP REMOVAL AND INSTALLATION.
17. Install cooling system referring to COOLING FAN AND FAN CLUTCH REMOVAL AND
INSTALLATION. and RADIATOR REMOVAL AND INSTALLATION. .
18. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
19. Refill coolant referring to COOLING SYSTEM FLUSH AND REFILL .
20. Refill engine oil referring to ENGINE OIL AND FILTER CHANGE.
21. Refill P/S fluid and bleed air in P/S system referring to P/S SYSTEM AIR BLEEDING
PROCEDURE .
22. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
23. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.
Fig. 76: Identifying 1st Timing Chain And Chain Tensioner Components With Torque Specifications
6. Remove LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Removal.
7. Remove the following parts referring to 1ST TIMING CHAIN AND CHAIN TENSIONER
COMPONENTS.
l Timing chain guide No.1 and No.2.
8. Remove RH bank 1st timing chain intake camshaft sprocket bolt. To remove it, fit a spanner to hexagonal
part (3) at the center of camshaft (2) to hold it stationary.
Fig. 82: Identifying RH Bank 1st Timing Chain Intake Camshaft Sprocket
Courtesy of SUZUKI OF AMERICA CORP.
Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.
Fig. 86: Identifying Timing Chain Tensioner Adjuster No. 1 Latch And Tooth Surface
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 87: Identifying Crank Timing Pulley Key And Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.
2. Install 1st timing chain crankshaft sprocket (2) to crankshaft (1) as shown in figure.
Confirm that tooth for CKP sensor are free from metal particles and damage.
Fig. 88: Identifying 1st Timing Chain Crankshaft Sprocket, Lower Crankcase And Crankshaft
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 89: Identifying Knock Pin Of Intake Camshaft & Match Mark
Courtesy of SUZUKI OF AMERICA CORP.
4. Install RH bank 1st timing chain intake camshaft sprocket (1) noting the following points.
l The sprocket should be set in such way that its RH mark (4) can be seen.
l Camshaft (2) should be held stationary by using a spanner at its hexagonal parts (3) as shown in
figure.
Tightening torque
RH bank 1st timing chain intake camshaft sprocket bolt a: 80 N.m (8.0 kg-m, 58.0 lb-ft)
Fig. 90: Identifying RH Bank 1st Timing Chain Intake Camshaft Sprocket, Camshaft,
Hexagonal Part & RH Mark
Courtesy of SUZUKI OF AMERICA CORP.
Tightening torque
Fig. 91: Identifying Timing Chain Tensioner, Spacer & RH Bank Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.
6. Install 1st timing chain by aligning match marks (2) on RH silver plate (1) of 1st timing chain and RH
Fig. 92: Identifying Match Marks, RH Silver Plate & RH Bank Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 93: Identifying Match Marks, LH Silver Plate & RH Bank Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.
10. Install crankshaft sprocket by aligning match marks (2) on yellow plate (1) of 1st timing chain and
crankshaft timing sprocket.
To install it, fit a spanner to hexagonal part at the center of RH bank intake camshaft to turn a little.
Tightening torque
13. With latch of tensioner adjuster No.1 returned and plunger (1) pushed back into body, insert stopper (3)
into latch (2) and body.
After inserting it, check to make sure that plunger (1) will not come out.
Tightening torque
Timing chain tensioner adjuster No.1 bolt d: 11 N.m (1.1 kg-m, 8.0 lb-ft)
Fig. 97: Identifying Timing Chain Tensioner Adjuster No. 1, Stopper & Timing Chain Tensioner
Courtesy of SUZUKI OF AMERICA CORP.
16. Install timing chain guide No.1 (2) and No.2 (1).
Tightening torque
Timing chain guide No.1 and No.2 bolt e: 9 N.m (0.9 kg-m, 6.5 lb-ft)
Fig. 98: Identifying Timing Chain Guide No. 1 & No. 2 & Guide Bolts
Courtesy of SUZUKI OF AMERICA CORP.
18. Install LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Installation.
19. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
20. Install oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
21. Install front differential housing referring to FRONT DIFFERENTIAL DISMOUNTING AND
REMOUNTING : Front.
22. Install P/S system referring to P/S PUMP REMOVAL AND INSTALLATION.
23. Install cooling system referring to COOLING FAN AND FAN CLUTCH REMOVAL AND
INSTALLATION. and RADIATOR REMOVAL AND INSTALLATION. .
24. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
Fig. 100: Identifying RH (No. 2) Bank 2nd Timing Chain And Chain Tensioner Components With
Torque Specifications
Courtesy of SUZUKI OF AMERICA CORP.
Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Components
1. For reinstallation of timing chain, align 12 timing marks as shown in figure by turning crankshaft.
2. Remove LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Removal.
3. Remove 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Removal.
4. Remove timing chain guide No.3 referring to RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN
TENSIONER COMPONENTS.
5. Loosen camshaft housing bolts in such order ("1"-"17") as indicated in figure and remove them.
6. Remove camshaft housings.
7. Remove RH bank intake camshaft, RH bank exhaust camshaft, and RH bank 2nd timing chain as a set
referring to RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER COMPONENTS.
8. Remove timing chain tensioner adjuster No.2, referring to RH (NO.2) BANK 2ND TIMING CHAIN
AND CHAIN TENSIONER COMPONENTS.
Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Removal
Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Components
Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Removal
Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Inspection
Fig. 107: Identifying Crank Timing Pulley Key And Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.
Tightening torque
Timing chain tensioner adjuster No.2 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
Fig. 108: Identifying Timing Chain Tensioner Adjuster No. 2, Water Pump & Engine Front Side
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 109: Identifying Silver Plates & Match Marks Of RH Bank 2nd Timing Chain Intake &
Exhaust Camshaft Sprockets
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 110: Identifying Camshaft Housing Pins, RH Bank Intake Camshaft & RH Bank Exhaust
Camshaft
Courtesy of SUZUKI OF AMERICA CORP.
Embossed marks are provided on each camshaft housing, indicating position and direction for
installation. Install housings as indicated by these marks.
Then tighten them by following sequence ("1"-"17") as indicated in figure. Tighten a little at a time and
evenly among bolts and repeat tightening sequence 2 or 3 times before they are tightened to specified
torque below.
Tightening torque
Camshaft housing bolt: Tighten 12 N.m (1.2 kgf-m, 9.0 lb-ft) by the specified procedure
Tightening torque
Timing chain guide No.3 bolt c: 11 N.m (1.1 kg-m, 8.0 lb-ft)
10. Install 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Installation.
11. Install LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Installation.
12. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
13. Install oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
14. Install front differential housing referring to FRONT DIFFERENTIAL DISMOUNTING AND
REMOUNTING : Front.
15. Install P/S system referring to P/S PUMP REMOVAL AND INSTALLATION.
16. Install cooling system referring to RADIATOR REMOVAL AND INSTALLATION. .
17. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
18. Refill cooling system with coolant, front differential with gear oil, P/S system with specified fluid and
engine with engine oil.
19. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
20. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.
Fig. 114: Identifying Camshafts And Valve Lash Adjusters Components With Torque Specifications
Courtesy of SUZUKI OF AMERICA CORP.
Removal
NOTE: Immerse removed adjuster (2) in clean engine oil (1) and keep it there till
reinstalling it so as to prevent oil leakage. If it is left in air, place it with its
bucket body facing down. Don't place on its side or with bucket body facing up.
Installation
CAUTION: l Don't turn camshafts or start engine (i.e., valves should not be
operated) for about half an hour after reinstalling hydraulic valve lash
adjusters and camshafts. As it takes time for valves to settle in place,
operating engine within half an hour after their installation may cause
interference to occur between valves themselves or valves and
piston.
l If air is trapped in valve lash adjuster, valve may make tapping sound
when engine is operated after valve lash adjuster is installed. In such
a case, run engine for about half an hour at about 2000 to 3000 rpm,
and then air will be purged and tapping sound will cease. Should
tapping sound not cease, it is possible that valve lash adjuster is
defective. Replace it if defective.
1. Before installing valve lash adjuster to cylinder head, fill oil passage of cylinder head (1) with engine oil
according to the following procedure.
Pour engine oil through oil holes (2) and check that oil comes out from oil holes (2) in sliding part of
valve lash adjuster.
2. Apply engine oil around valve lash adjuster and then install it to cylinder head.
Fig. 120: Identifying Crank Timing Pulley Key & Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.
4. Install RH bank camshafts referring to RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN
TENSIONER INSTALLATION.
5. Install LH bank camshafts.
Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match
marks (4) on cylinder head (3) and LH bank camshafts as shown in figure.
Fig. 121: Identifying Match Marks, Cylinder Head And LH Bank Camshafts
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 122: Identifying LH Bank Intake & Exhaust Camshafts & Pin Installation Position
Courtesy of SUZUKI OF AMERICA CORP.
Embossed marks are provided on each camshaft housing, indicating position and direction for
installation. Install housings as indicated by these marks.
Fig. 123: Identifying Intake Side, Exhaust Side, Position From Timing Chain Side & Timing Chain
Side
Courtesy of SUZUKI OF AMERICA CORP.
Then tighten them by following sequence ("1"-"19") as indicated in figure. Tighten a little at a time and
evenly among bolts and repeat tightening sequence 2 or 3 times before they are tightened to specified
torque below.
Tightening torque
Camshaft housing bolt: Tighten 12 N.m (1.2 kgf-m, 9.0 lb-ft) by the specified procedure
10. Install 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Inspection.
11. Install LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Installation.
12. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
13. Install oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
14. Install front differential housing referring to FRONT DIFFERENTIAL DISMOUNTING AND
REMOUNTING : Front.
15. Install P/S system referring to P/S PUMP REMOVAL AND INSTALLATION.
16. Install cooling system referring to COOLING FAN AND FAN CLUTCH REMOVAL AND
INSTALLATION and RADIATOR REMOVAL AND INSTALLATION. .
17. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
18. Install CMP sensor referring to CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND
INSTALLATION .
19. Refill cooling system with coolant, front differential with gear oil, P/S system with specified fluid and
engine with engine oil.
20. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
21. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.
22. Check ignition timing, referring to IGNITION TIMING CHECK AND ADJUSTMENT .
Cam Wear
Using a micrometer, measure cam height "a". If measured height is below its limit, replace camshaft.
Camshaft Runout
Set camshaft between two "V" blocks, and measure its runout by using a dial gauge.
Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head
without replacing housings.
6. Remove housing, and using scale (2) on gauging plastic (1) envelop, measure gauging plastic (1) width at
its widest point.
If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside
diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the difference from
specification is greater.
Fig. 130: Measuring Journal (Housing) Bore And Outside Diameter Of Camshaft Journal
Courtesy of SUZUKI OF AMERICA CORP.
Measure cylinder head bore and adjuster outside diameter to determine cylinder head-to-adjuster clearance. If
clearance exceeds limit, replace adjuster or cylinder head.
Fig. 132: Measuring Cylinder Head Bore And Adjuster Outside Diameter
Courtesy of SUZUKI OF AMERICA CORP.
In case of the followings, valve lash adjuster noise may be caused by air trapped into valve lash adjusters.
If noise from valve lash adjusters is suspected, perform the following checks.
l Oil quality - If oil is discolored, or deteriorated, change it. For particular oil to be used, refer to
ENGINE OIL AND FILTER CHANGE.
l Oil leaks - If leak is found, repair it.
l Oil pressure (refer to OIL PRESSURE CHECK. ) - If defective pressure is found, repair it.
2. Run engine for about half an hour at about 2000 to 3000 rpm, and then air will be purge and tapping
sound will cease.
3. Should tapping sound not cease, it is possible that hydraulic valve lash adjuster is defective.
Replace it if defective. If defective adjuster can't be located by hearing among 16 of them. check as
follows.
Fig. 133: Identifying Valves And Cylinder Heads Components With Torque Specifications
Courtesy of SUZUKI OF AMERICA CORP.
Removal
Installation
1. Clean mating surface on cylinder head and cylinder block. Remove oil, old gasket and dust from mating
surface.
2. Install knock pin (4) to cylinder block.
3. Install new cylinder head gasket (1) to cylinder block as shown in figure. Carved lot number (5) on
cylinder head gasket (1) should face up (toward cylinder head side).
Fig. 135: Identifying Cylinder Head Gasket, Crankshaft Pulley Side, Flywheel Side, Knock Pin &
Lot Number
Courtesy of SUZUKI OF AMERICA CORP.
After applying oil to cylinder head bolts, tighten them gradually as follows.
a. Tighten cylinder head bolts (except hex hole bolt) to 53 N.m (5.3 kgf-m, 38.5 lb-ft) according to
numerical order in figure.
b. In the same manner as Step a, tighten them to 84 N.m (8.4 kgf-m, 61.0 lb-ft).
c. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
d. In the same manner as Step a, tighten them to 53 N.m (5.3 kgf-m, 38.5 lb-ft).
e. In the same manner as Step a again, tighten them to specified torque.
f. Tighten cylinder head bolts (hex hole bolt) to specified torque.
Tightening torque
Cylinder head bolt a: Tighten 53 N.m (5.3 kgf-m, 38.5 lb-ft), 84 N.m (8.4 kgf-m, 61.0 lb-ft), 0
N.m (0 kgf-m, 0 lb-ft), 53 N.m (5.3 kgf-m, 38.5 lb-ft) and 105 N.m (10.5 kgf-m, 76.0 lb-ft) by
the specified procedure
Cylinder head bolt (hex hole bolt) b: Tighten 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified
procedure
Fig. 136: Identifying Crankshaft Pulley Side, Flywheel Side & Hex Hole Bolts Tightening
Sequence
Courtesy of SUZUKI OF AMERICA CORP.
Fig. 137: Identifying Crank Timing Pulley Key & Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.
7. Install valve lash adjuster, camshaft, CMP sensor and RH bank 2nd timing chain.
Refer to CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION and
RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION. For CMP
sensor, refer to CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION .
8. Install 1st timing chain referring to 1st Timing Chain and Chain Tensioner Installation.
9. Install LH bank 2nd timing chain referring to LH (No.1) Bank 2nd Timing Chain and Chain
Tensioner Installation.
10. Install timing chain cover referring to TIMING CHAIN COVER REMOVAL AND
INSTALLATION.
11. Install oil pan and oil pump strainer referring to OIL PAN AND OIL PUMP STRAINER REMOVAL
AND INSTALLATION.
12. Install cylinder head cover referring to CYLINDER HEAD COVERS REMOVAL AND
INSTALLATION.
13. Install exhaust manifold referring to EXHAUST MANIFOLD REMOVAL AND INSTALLATION.
14. Install radiator outlet pipe, radiator, cooling fan and water hose.
15. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
16. Adjust water pump drive belt tension.
17. Adjust power steering pump drive belt tension referring to P/S PUMP DRIVE BELT INSPECTION
AND ADJUSTMENT. .
18. Adjust accelerator cable play referring to ACCELERATOR CABLE ADJUSTMENT
19. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not
been reinstalled.
20. Refill engine with engine oil referring to ENGINE OIL AND FILTER CHANGE.
21. Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
22. Refill front differential housing with gear oil if drained referring to FRONT DIFFERENTIAL GEAR
OIL INSPECTION AND CHANGE : Front.
23. Connect negative (-) cable at battery.
24. Check ignition timing and adjust as necessary referring to IGNITION TIMING CHECK AND
ADJUSTMENT .
25. Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each
connection.
26. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
Disassembly
1. Using special tools (A), (B) and (C), compress valve springs and then remove valve cotters (1) by using
special tool (D).
2. Release special tool, and remove spring retainer and valve spring.
Special Tool
(A): 09916-14510
(B): 09916-14910
(C): 09919-28610
(D): 09916-84511
NOTE: Do not reuse seal once disassembled. Be sure to use new seal when
assembling.
Fig. 139: Identifying Valve Stem Seal And Valve Spring Seat
Courtesy of SUZUKI OF AMERICA CORP.
5. Using special tool (E) (Valve guide remover), drive valve guide out from combustion chamber side to
Special Tool
(E): 09916-44910
NOTE: Do not reuse valve guide once disassembled. Be sure to use new valve
guide (Oversize) when assembling.
Fig. 140: Driving Out Valve Guide Using Valve Guide Remover
Courtesy of SUZUKI OF AMERICA CORP.
6. Place disassembled parts except valve stem seal and valve guide in order so that they can be installed in
their original positions.
Assembly
1. Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as
to remove burrs and make it truly round.
Special Tool
(E): 09916-34542
(F): 09916-38210
Heat cylinder head uniformly at a temperature of 80 to 100°C (176 to 212°F) so that head will not be
distorted, and drive new valve guide into hole with special tools. Drive in new valve guide until special
tool (Valve guide installer) contacts cylinder head.
After installing, make sure that valve guide protrusions (1) by specified height from cylinder head.
Special Tool
(G): 09916-58210
(H): 09917-87810
NOTE: l Do not reuse valve guide once disassembled. Install new valve guide
(Oversize).
l Intake and exhaust valve guides are identical.
3. Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore.
Special Tool
(E): 09916-34542
(I): 09916-37810
After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to
spindle, and then install seal to valve guide by pushing special tool by hand.
After installing, check to be sure that seal is properly fixed to valve guide.
Special Tool
(J): 09917-98221
(K): 09916-58210
NOTE: l Do not reuse seal once disassembled. Be sure to install new seal.
l When installing, never tap or hit special tool with a hammer or else.
Install seal to guide only by pushing special tool by hand. Tapping or
hitting special tool may cause damage to seal.
Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem.
Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Be sure to
position spring in place with its bottom end (valve spring retainer side (3)) facing the bottom (valve
spring seat side (4)).
Fig. 145: Identifying Top End And Bottom End Of Valve Spring
Courtesy of SUZUKI OF AMERICA CORP.
8. Using special tool (Valve lifter), compress valve spring and fit 2 valve cotters (1) into groove in valve
stem.
Special Tool
(A): 09916-14510
(B): 09916-14910
(C): 09916-84511
(D): 09919-28610
Valve Guides
Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance. Be sure to take reading at more than one place along the length of each stem and guide.
Valves
Valve specifications
VALVE SPECIFICATIONS
Item Standard Limit
Intake 1.0 mm (0.039 in.) 0.6 mm (0.024 in.)
Exhaust 1.2 mm (0.047 in.) 0.7 mm (0.028 in.)
l Inspect valve stem end face for pitting and wear. If pitting or wear is found, valve stem end may be
resurfaced. But do not grind its taper excessively. When valve is excessively worn out too much or its
taper is gone, replace it.
l Check each valve for radial runout with a dial gauge and "V" block.
To check runout, rotate valve slowly. If runout exceeds its limit, replace valve.
Create contact pattern on each valve in the usual manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotatingly tapping seat with valve head. Valve lapper (tool used in valve
lapping) must be used.
Pattern produced on seating face of valve must be a continuous ring without any break, and the width of
pattern must be within specified range.
A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out
of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Use valve seat cutters (1) to make two cuts as illustrated in figure. Two cutters must be used: the
1st for making 15° angle, and the 2nd for making 45° angle. The 2nd cut must be made to produce
desired seat width.
Use valve seat cutters (1) to make three cuts as illustrated in figure. Three cutters must be used: the
1st for making 15° angle, the 2nd for making 60° angle, and the 3rd for making 45° angle. The 3rd
cut (45°) must be made to produce desired seat width.
c. Valve lapping
Lap valve on seat in two steps, first with coarse size lapping compound applied to face and the
second with fine-size compound, each time using valve lapper according to usual lapping method.
NOTE: Do not use any sharp-edged tool to scrape off carbon. Be careful not to
scuff or nick metal surfaces when decarboning. The same applies to
valves and valve seats, too.
l Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface.
Using straightedge (1) and thickness gauge (2), check flatness of gasketed surface at a total of 6 locations.
If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive
paper of about #400 (Waterproof silicon carbide abrasive paper): Place abrasive paper on and over
surface plate, and rub gasketed surface against paper to grind off high spots. Should this fail to reduce
thickness gauge readings to within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint is often due to warped gasketed surface: such
leakage results in reduced power output.
Fig. 155: Checking Flatness Of Gasketed Surface Using Straightedge & Thickness Gauge
Courtesy of SUZUKI OF AMERICA CORP.
Check seating faces of cylinder head for manifolds, using a straightedge (1) and thickness gauge (2), in
order to determine whether these faces should be corrected or cylinder head replaced.
Fig. 156: Checking Seating Faces Of Cylinder Head Using Straightedge & Thickness Gauge
Courtesy of SUZUKI OF AMERICA CORP.
l Referring to data given below, check to be sure that each spring is in sound condition, free of any
evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention
possibility of reducing power output due to gas leakage caused by decreased seating pressure.
l Spring squareness
Use a square and surface plate to check each spring for squareness in terms of clearance between end of
valve spring and square. Valve springs found to exhibit a larger clearance than limit given below must be
replaced.
Fig. 159: Identifying Pistons, Piston Rings, Connecting Rods And Cylinders Components With Torque
Specifications
Courtesy of SUZUKI OF AMERICA CORP.
INSTALLATION
Removal
9. Clean carbon from top of cylinder bore before removing piston from cylinder.
10. Push piston and connecting rod assembly out through the top of cylinder bore.
Installation
1. Apply engine oil to pistons, 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.
These guide hoses (1) protect crank pin and threads of rod bolt from damage during installation of
connecting rod and piston assembly.
3. When installing piston and connecting rod assembly into cylinder bore, point mark (1) on piston head to
crankshaft pulley side (2).
Fig. 162: Identifying Mark On Piston Head & Crankshaft Pulley Side
Courtesy of SUZUKI OF AMERICA CORP.
4. 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
Point mark (1) on cap to crankshaft pulley side (2). Tighten cap nuts to specification.
Tightening torque
Connecting rod bearing cap nut a: 45 N.m (4.5 kg-m, 32.5 lb-ft)
Fig. 164: Identifying Mark On Connecting Rod Bearing Cap, Connecting Rod Bearing Cap Nuts &
6. Install cylinder heads to cylinder block referring to VALVES AND CYLINDER HEADS REMOVAL
AND INSTALLATION.
7. Install oil pump to cylinder block referring to OIL PUMP REMOVAL AND INSTALLATION.
8. Install valve lash adjusters and camshafts referring to CAMSHAFTS AND VALVE LASH
ADJUSTERS REMOVAL AND INSTALLATION.
9. Install RH bank 2nd timing chain referring to RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN
TENSIONER INSTALLATION.
10. Install 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Installation.
11. Install LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Installation.
12. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
13. Install oil pan and pump strainer. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
14. Install cylinder head cover. Refer to CYLINDER HEAD COVERS REMOVAL AND
INSTALLATION.
15. Install exhaust manifold. Refer to EXHAUST MANIFOLD REMOVAL AND INSTALLATION.
16. Install radiator outlet pipe, radiator, cooling fan and water hose.
17. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
18. Adjust water pump drive belt tension. Refer to COOLING FAN / GENERATOR BELT TENSION
CHECK AND ADJUSTMENT
19. Adjust power steering pump drive belt tension. Refer to DRIVE BELT INSPECTION AND
ADJUSTMENT.
20. Adjust accelerator cable play referring to ACCELERATOR CABLE ADJUSTMENT
21. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not
been reinstalled.
22. Refill engine with engine oil referring to ENGINE OIL AND FILTER CHANGE.
23. Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
24. Refill front differential housing with gear oil if drained, referring to FRONT DIFFERENTIAL GEAR
OIL INSPECTION AND CHANGE : Front.
25. Connect negative cable at battery.
26. Check ignition timing and adjust as necessary, referring to IGNITION TIMING CHECK AND
ADJUSTMENT .
27. Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each
connection.
28. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION
Disassembly
1. Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston.
2. Remove piston pin from connecting rod.
a. Ease out piston pin circlips (1) as shown in figure.
Assembly
1. 2 sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder
clearance. When installing a standard size piston, make sure to match piston with cylinder as follows.
a. Each piston has stamped number (1 or 2) on its piston head. It represents outer diameter of piston.
b. There are also stamped numbers of 1 and 2 on the cylinder block as shown in figure.
c. Stamped number on piston and cylinder block must correspond. That is, install number "2" stamped
piston to cylinder which is stamped also number "2" and a number "1" piston to cylinder with
number "1".
Piston-to-cylinder clearance
After applying engine oil to piston pin and piston pin holes in piston (1) and connecting rod (3), fit
connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install
piston pin circlips.
NOTE: "86F" mark on connecting rod must face toward crankshaft pulley side.
NOTE: l Install circlip with its cut part facing as shown in figure.
l Install so that circlip end gap comes within such range as indicated
by arrow "A".
Fig. 169: Identifying Circlip End Gap Range, Piston, Arrow Mark,
Connecting Rod, Oil Hole, Crankshaft Pulley Side & Circlip
Courtesy of SUZUKI OF AMERICA CORP.
l When installing oil ring (3), install spacer first and then 2 rails.
4. After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.
Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION
NOTE: Before the following inspection, clean carbon from piston head and ring
grooves, using a suitable tool.
Cylinders
l Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore
is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston.
l Using a cylinder gauge, measure cylinder bore in thrust and axial directions at 2 positions (1, 2) as shown
in figure. If any of the following condition is noted, rebore cylinder.
¡ Cylinder bore via. exceeds limit.
NOTE: If any one of six cylinders has to be rebored, rebore all six to the
same oversize. This is necessary for the sake of uniformity and
balance.
Pistons
l Piston diameter:
As shown in figure, piston diameter should be measured at a position 26.5 mm (1.04 in.) ("a") from piston
skirt end in the direction perpendicular to piston pin.
Piston diameter
l Piston clearance:
Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance.
Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder
and use oversize piston.
Piston-to-cylinder clearance
Before checking, piston grooves must be clean, dry and free of carbon.
Fit new piston ring (1) into piston groove, and measure clearance between ring and ring land by using
thickness gauge (2). If clearance is out of specification, replace piston.
Piston Rings
To measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge.
NOTE: Clean carbon and any other dirt from top of cylinder bore before inserting
piston ring.
Fig. 176: Identifying Cylinder Block, Feeler Gauge, Piston Ring & 120 MM
Courtesy of SUZUKI OF AMERICA CORP.
Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION
Piston Pins
l Check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular
attention to condition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly
worn or damaged, replace pin, connecting rod or piston.
l Piston pin clearance:
Check piston pin clearance in small end. Replace connecting rod if its small end is badly worn or
damaged or if measured clearance exceeds limit.
Small-end bore
Fig. 177: Measuring Piston Pin Diameter, Small-End Bore & Piston Pin Clearance In Small End
Courtesy of SUZUKI OF AMERICA CORP.
Connecting Rods
Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the
normal manner. If measured clearance is found to exceed its limit, replace connecting rod.
Mount connecting rod on aligner to check it for bow and twist. If limit is exceeded, replace it.
Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION
l Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a
micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crankshaft or regrind
crank pin then inspect rod bearing clearance referring to "Rod bearing clearance".
Fig. 179: Measuring Crank Pin For Out-Of-Round Or Taper With Micrometer
Courtesy of SUZUKI OF AMERICA CORP.
Service connecting rod bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and
standard size bearing has 5 kinds of bearings differing in tolerance. For identification of undersize
bearing, it is painted red at the position as indicated in figure, undersize bearing thickness is 1.605 - 1.615
mm (0.0632 - 0.0635 in.) at the center of it.
Inspect bearing shells for signs of fusion, pitting, burn or flaking and observe contact pattern. Bearing
shells found in defective condition must be replaced.
When installing cap, be sure to point arrow mark on cap to crankshaft pulley side, as shown in
figure.
After applying engine oil to rod bolts, tighten cap nuts to specified torque.
Tightening torque
Connecting rod bearing cap nut a: 45 N.m (4.5 kg-m, 32.5 lb-ft)
e. Remove cap and using a scale (2) on gaging plastic (1) envelope, measure gaging plastic (1) width
at the widest point (clearance).
If clearance exceed its limit, use a new standard size bearing referring to "Selection of Connecting
Rod Bearings" in this section.
Bearing clearance
f. If clearance can not be brought to within its limit even by using a new standard size bearing,
martes, 26 de mayo de 2020 08:21:51 p. m. Page 125 © 2011 Suzuki
2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7
Finished crank pin dia. = Measured big end bore dia. (including under-size bearing) - 0.054
mm (0.0021 in.)
Three kinds of numbers ("1", "2" and "3") represent the following connecting rod big end inside
diameters.
For example, stamped number "1" indicates that corresponding connecting rod big end inside
diameter is 53.0000 - 53.0060 mm (2.0867 - 2.0868 in.).
Fig. 184: Identifying Weight Indication Mark And Connecting Rod Big End Inside Diameter
Number
Courtesy of SUZUKI OF AMERICA CORP.
b. Next, check crankshaft pin diameter. On crank web No.3, six alphabets are stamped as shown in
figure. Three kinds of alphabet ("A", "B" and "C") represent the following crankshaft pin diameter
respectively. For example, stamped "A" indicates that corresponding crankshaft pin diameter is
49.9940 - 50.0000 mm (1.9683 - 1.9685 in.).
c. There are five kinds of standard bearings differing in thickness. To distinguish them, they are
painted in the following colors at the position as indicated in figure.
d. From number stamped on connecting rod and its cap and alphabets stamped on crank web No.3,
determine new standard bearing to be installed to connecting rod big end inside, by referring to
table. For example, if number stamped on connecting rod and its cap is "1" and alphabet stamped
on crank web No.3 is "B", install a new standard bearing painted in "Black" to its connecting rod
big end inside.
e. Check bearing clearance with newly selected standard bearing referring to "Selection of Connecting
Rod Bearing" under "Connecting Rod Bearings" in this section.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance.
Removal
1. Release fuel pressure in fuel feed line referring to FUEL PRESSURE RELIEF PROCEDURE .
2. Disconnect negative (-) cable at battery.
3. Remove engine hood.
4. Drain engine oil.
5. Drain coolant referring to COOLANT DRAINING .
6. Remove radiator, radiator fan shroud, cooling fan and radiator reservoir. Refer to COOLING FAN AND
FAN CLUTCH REMOVAL AND INSTALLATION.
7. Disconnect accelerator cable (1) from throttle body.
8. Detach fuse/relay box, then remove strut tower bar and surge tank cover.
9. Disconnect IAT sensor coupler and MAF sensor coupler then remove air cleaner upper case, intake air
hose, intake air pipe and surge tank pipe as a component.
10. Remove intake control valve, referring to THROTTLE BODY REMOVAL AND INSTALLATION.
11. Remove engine oil level gauge guide and A/T fluid level gauge guide (for A/T vehicle).
12. Remove ignition coil covers.
13. Disconnect the following electric lead wires:
l Injector wire coupler
l Generator wires
l Starter wires
Fig. 188: Identifying TP Sensor, IAC Valve, Wire, EVAP Canister Purge Valve, EGR Valve,
Brackets And Heater Hose
Courtesy of SUZUKI OF AMERICA CORP.
18. Remove P/S pump assembly referring to P/S PUMP REMOVAL AND INSTALLATION.
19. Remove A/C compressor assembly referring to COMPRESSOR ASSEMBLY REMOVAL AND
INSTALLATION : Manual Type, Compressor Assembly Removal and Installation: Automatic Type.
20. Remove steering shaft lower assembly referring to STEERING LOWER SHAFT ASSEMBLY
REMOVAL AND INSTALLATION .
21. Raise vehicle.
22. Remove front differential housing with differential from chassis if equipped. Refer to FRONT
DIFFERENTIAL DISMOUNTING AND REMOUNTING : Front.
23. Remove exhaust No.1 pipe referring to EXHAUST MANIFOLD REMOVAL AND
INSTALLATION.
24. Remove exhaust manifold stiffener from transmission.
25. Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle)
Fig. 190: Identifying A/T Fluid Hose Clamps And Engine Mounting Bracket
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION: Do not support A/T by placing a jacking equipment under oil pan. If
may damage to A/T.
31. Remove bolts and nuts fastening cylinder block and transmission.
Fig. 192: Identifying Engine Side Mounting Brackets, Engine Mountings & Nuts
Courtesy of SUZUKI OF AMERICA CORP.
34. Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
35. Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist
engine assembly.
Installation
Tightening torque
Engine side mounting bracket nut a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
Tightening torque
Transmission case bolt and nut b: 85 N.m (8.5 kg-m, 61.5 lb-ft) (for M/T vehicle)
Transmission case bolt and nut b: 80 N.m (8.0 kg-m, 58.0 lb-ft) (for A/T vehicle)
Tightening torque
l Tighten bolts and nuts of exhaust No.1 pipe (1) to specified torque.
Tightening torque
Exhaust No.1 pipe bolt and nut d: 50 N.m (5.0 kg-m, 36.5 lb-ft)
l Install front differential housing with differential to chassis referring to FRONT DIFFERENTIAL
DISMOUNTING AND REMOUNTING : Front, if necessary.
l Install steering shaft lower assembly referring to STEERING LOWER SHAFT ASSEMBLY
REMOVAL AND INSTALLATION .
l Install A/C compressor assembly, referring to COMPRESSOR ASSEMBLY REMOVAL AND
INSTALLATION : Manual Type, COMPRESSOR ASSEMBLY REMOVAL AND
INSTALLATION : Automatic Type.
l Install P/S pump assembly referring to P/S PUMP REMOVAL AND INSTALLATION.
l Adjust accelerator cable play referring to ACCELERATOR CABLE ADJUSTMENT
l Refill engine with engine oil referring to ENGINE OIL AND FILTER CHANGE.
l Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
l Check to ensure that all fasteners and clamps are tightened.
l Upon completion of installation, verify that there is no fuel leakage, coolant leakage, P/S fluid leakage or
exhaust gas leakage at each connection.
Fig. 197: Identifying Main Bearings, Crankshaft And Cylinder Block Components With Torque
Specifications
Courtesy of SUZUKI OF AMERICA CORP.
Removal
1. Remove engine assembly from vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
2. Remove clutch and flywheel (for M/T vehicle) or drive plate (for A/T vehicle). For clutch removal, refer
to CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION.
Using special tool (flywheel holder), remove flywheel (M/T vehicle) or drive plate (A/T vehicle).
Special Tool
(A): 09924-17811
Fig. 198: Identifying Special Tool (Flywheel Holder) And Flywheel Bolt
Courtesy of SUZUKI OF AMERICA CORP.
3. Remove throttle body with intake manifold and exhaust manifold referring to THROTTLE BODY AND
INTAKE MANIFOLD REMOVAL AND INSTALLATION. and EXHAUST MANIFOLD
REMOVAL AND INSTALLATION.
4. Remove oil pans (lower and upper) and oil pump strainer. Refer to OIL PAN AND OIL PUMP
STRAINER REMOVAL AND INSTALLATION.
5. Remove cylinder head cover referring to CYLINDER HEAD COVERS REMOVAL AND
INSTALLATION.
6. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
7. Remove LH bank 2nd timing chain and tensioner referring to LH (No.1) Bank 2nd Timing Chain and
Chain Tensioner Removal.
8. Remove 1st timing chain and tensioner referring to 1st Timing Chain and Chain Tensioner Removal.
9. Remove RH bank 2nd timing chain and tensioner referring to RH (No.2) Bank 2nd Timing Chain and
Chain Tensioner Removal.
10. Remove cylinder head assembly referring to VALVES AND CYLINDER HEADS REMOVAL AND
INSTALLATION.
11. Remove pistons and connecting rods referring to PISTONS, PISTON RINGS, CONNECTING RODS
AND CYLINDERS REMOVAL AND INSTALLATION.
12. Remove oil pump referring to OIL PUMP REMOVAL AND INSTALLATION.
13. Remove oil pump chain referring to OIL PUMP CHAIN REMOVAL AND INSTALLATION .
14. Loosen crankcase bolts, following sequence in figure and remove them.
NOTE: Loosen 8 mm (0.31 in.) thread diameter bolts first, then loosen 10 mm (0.39
in.) thread diameter bolts following the order shown in figure.
Installation
One of two halves of main bearing, has oil groove (3). Install this half with oil groove to cylinder block,
and another half without oil groove to crankcase.
Make sure that two halves are painted in the same color.
Fig. 200: Identifying Main Bearing, Cylinder Block, O-Ring, Oil Groove And Knock Pin
Courtesy of SUZUKI OF AMERICA CORP.
3. Fit thrust bearings (1) to cylinder block between No.2 and No.3 cylinders.
Fig. 202: Identifying Lower Crankcase, Bearing & Sealant Application Area
Courtesy of SUZUKI OF AMERICA CORP.
6. Install crankcase to cylinder block. Apply oil to crankcase bolts before installing them. Tighten crankcase
bolts gradually as follows.
a. Tighten crankcase bolts (10 mm (0.39 in.) thread diameter) to 42 N.m (4.2 kgf-m, 30.5 lb-ft)
according to numerical order in figure.
b. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
c. In the same manner as Step a, tighten them to 42 N.m (4.2 kgf-m, 30.5 lb-ft).
d. In the same manner as Step a again, tighten them to specified torque.
e. Tighten crankcase bolts (8 mm (0.31 in.) thread diameter) to specified torque.
NOTE: Tighten 10 mm (0.39 in.) thread diameter bolts first (the following the
order shown in figure), then tighten 8 mm (0.31 in.) thread diameter
bolts.
Tightening torque
Crankcase bolt a: Tighten 42 N.m (4.2 kgf-m, 30.5 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 42 N.m (4.2
kgf-m, 30.5 lb-ft) and 60 N.m (6.0 kgf-m, 43.5 lb-ft) by the specified procedure (10 mm (0.39
in.) thread diameter)
Crankcase bolt b: Tighten 27 N.m (2.7 kgf-m, 19.5 lb-ft) by the specified procedure (8 mm
(0.31 in.) thread diameter)
7. Using special tools (Oil seal installer and oil seal guide), install rear oil seal (1).
Special Tool
(A): 09911-97710
(B): 09911-97811
Fig. 204: Identifying Rear Oil Seal, Crankshaft Side, Oil Seal Side & Special Tools
Courtesy of SUZUKI OF AMERICA CORP.
8. Install flywheel (M/T vehicle) or drive plate (A/T vehicle). Using special tool, lock flywheel or drive
plate, and tighten flywheel or drive plate bolts to specification.
Special Tool
(A): 09924-17811
Tightening torque
Flywheel (or drive plate) bolt c: 70 N.m (7.0 kg-m, 51.0 lb-ft)
Fig. 205: Identifying Flywheel Bolt, Sealant Application Area & Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
CRANKSHAFT INSPECTION
Crankshaft Runout
Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit,
replace crankshaft.
Crankshaft runout
Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and
journal bearing caps installed. Tighten crankcase bolts gradually as follows.
1. Tighten crankcase bolts (10 mm (0.39 in.) thread diameter) to 42 N.m (4.2 kgf-m, 30.5 lb-ft) according to
numerical order in figure.
2. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
3. In the same manner as Step a), tighten them to 42 N.m (4.2 kgf-m, 30.5 lb-ft).
4. In the same manner as Step a) again tighten them to specified torque.
5. Tighten crankcase bolts (8 mm (0.31 in.) thread diameter) to specified torque.
NOTE: Tighten 10 mm (0.394 in.) thread diameter bolts first (following the order
shown in figure), then tighten 8 mm (0.315 in.) thread diameter bolts.
Tightening torque
Crankcase bolt a: Tighten 42 N.m (4.2 kgf-m, 30.5 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 42 N.m (4.2 kgf-
m, 30.5 lb-ft) and 60 N.m (6.0 kgf-m, 43.5 lb-ft) by the specified procedure (10 mm (0.39 in.) thread
diameter)
Crankcase bolt b: Tighten 27 N.m (2.7 kgf-m, 19.5 lb-ft) by the specified procedure (8 mm (0.31 in.)
thread diameter)
If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard
thrust play.
An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length
(or both). This difference, if any, is determined by taking micrometer readings. If any one of journals is badly
damaged or if amount of uneven wear in the sense explained above exceeds its limit, regrind or replace
crankshaft.
l Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of
them has 5 kinds of bearings differing in tolerance.
l Upper half of bearing (1) has oil groove (2) as shown in figure. Install this half with oil groove toward
cylinder block.
Visual Inspection
If any malcondition is found, replace both upper and lower halves. Never replace either half without replacing
the other half.
Check clearance by using gauging plastic (1) according to the following procedure.
4. Install lower crankcase to cylinder block without applying sealant referring to MAIN BEARINGS,
CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION.
5. Remove lower crankcase, and using scale (2) on gauging plastic (1) envelop, measure gauging plastic (1)
width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and
lower inserts as a unit.
A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft
journal for use of 0.25 mm undersize bearing.
Standard bearing
NOTE: The meaning of "Upper" and "Lower" described in this procedure are the
following.
If engine is under one of the following conditions, select a new standard bearing as follow, and install it.
l Bearing is in malcondition.
l Bearing clearance is out of specification.
l Crankshaft or cylinder block is replaced.
1. First check journal diameter. As shown in figure, crank web has stamped numbers and alphabet at the
center.
Six kinds of numbers ("4" through "9") represent the following journal diameters.
Journal diameter
Three kinds of alphabets (A, B and C) represent the following journal bore diameters.
Fig. 215: Identifying Crankshaft Pulley Side, Stamped Alphabets & Bearings
Courtesy of SUZUKI OF AMERICA CORP.
3. There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the
following colors at the position as indicated in figure.
NOTE: The following bearing are not supplied because they are unnecessary in
this selection procedure.
4. From number stamped on crank webs at its center and alphabets stamped on cylinder block lower side,
determine new standard bearing to be installed to journal referring to cross-reference table below. For
example, if number stamped on crank webs is "5" and alphabet stamped on cylinder block is "A", install
new standard bearing painted in "Black" to cylinder block side journal and "Colorless" to lower crankcase
side journal.
5. Using gauging plastic, check bearing clearance with newly selected standard bearing referring to MAIN
BEARING CLEARANCE.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance.
0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness.
To distinguish them, each bearing is painted in the following colors at such position as indicated in figure. Each
color represents the following thickness at the center of bearing.
l If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows.
a. Regrind journal to the following finished diameter.
Measurement should be taken in two directions perpendicular to each other in order to check for
out-of-round.
c. Using journal diameter measured and alphabets stamped on cylinder block, select undersize bearing
referring to cross-reference table below.
Check bearing clearance with newly selected undersize bearing referring to MAIN BEARING
CLEARANCE.
Carefully inspect oil seal for wear or damage. If lip portion is worn or damaged, replace oil seal.
Flywheel
Flywheel runout
Using straightedge and thickness gauge, check gasketed surface for distortion. If flatness exceeds its limit,
correct or replace it.
1. When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
2. Select oversized piston according to amount of cylinder wear.
D=A+B-C
NOTE: Before reboring, install all main bearing caps in place and tighten to
specification to avoid distortion of bearing bores.
Removal
3. Remove strut tower bar. if equipped. Refer to STRUT DAMPER REMOVAL AND
INSTALLATION .
4. Remove right side exhaust manifold. Refer to EXHAUST MANIFOLD REMOVAL AND
INSTALLATION.
5. Disconnect engine block heater and remove engine block heater (1).
Installation
"A": Thread lock cement 99000-32020 Thread Lock Cement Super 1333B
Tightening torque
Engine block heater mounting bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
l Check continuity between terminal "a" and "c". If there is no continuity, replace it.
l Check that there is no continuity between terminal "a" or "b" and "c". If there is continuity, replace it.
l Check continuity between terminal "c" and engine block heater body. If there is no continuity, replace it.
SPECIFICATIONS
TIGHTENING TORQUE SPECIFICATIONS
bolt
Timing chain 11 1.1 8.0
tensioner adjuster
No.1 bolt
Timing chain guide 9 0.9 6.5
No.1 and No.2 bolt
Timing chain 11 1.1 8.0
tensioner adjuster
No.2 bolt
Camshaft housing Tighten 12 N.m (1.2 kgf-m, 9.0 lb-ft) by the specified
bolt procedure
Timing chain guide 11 1.1 8.0
No.3 bolt
Cylinder head bolt Tighten 53 N.m (5.3 kgf-m, 38.5 lb-ft), 84 N.m (8.4 kgf-m,
61.0 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 53 N.m (5.3 kgf-m, 38.5
lb-ft) and 105 N.m (10.5 kgf-m, 76.0 lb-ft) by the specified
procedure
Cylinder head bolt Tighten 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified
(hex hole bolt) procedure
Connecting rod 45 4.5 32.5
bearing cap nut
Engine side 55 5.5 40.0
mounting bracket nut
Transmission case 85 8.5 61.5 for M/T vehicle
bolt and nut
Transmission case 80 8.0 58.0 for A/T vehicle
bolt and nut
Torque converter bolt 65 6.5 47.0
Exhaust No.1 pipe 50 5.0 36.5
bolt and nut
Crankcase bolt Tighten 42 N.m (4.2 kgf-m, 30.5 lb-ft), 0 N.m (0 kgf-m, 0 lb- 10 mm (0.39 in.)
ft), 42 N.m (4.2 kgf-m, 30.5 lb-ft) and 60 N.m (6.0 kgf-m, thread diameter
43.5 lb-ft) by the specified procedure
Crankcase bolt Tighten 27 N.m (2.7 kgf-m, 19.5 lb-ft) by the specified 8 mm (0.31 in.)
procedure thread diameter
Flywheel (or drive 70 7.0 51.0
plate) bolt
Engine block heater 11 1.1 8.0
mounting bolt
Reference:
For the tightening torque of fastener not specified in this section, refer to Fastener Information.
SPECIAL TOOL
09911-97710 09911-97811
09913-75510 09915-64510
09915-64530 09915-67010
09915-67311 09916-14510
09916-14910 09916-34542
09916-37810 09916-38210
09916-44910 09916-58210
09916-77310 09916-84511
09917-47011 09917-68221
09917-87810 09917-98221
09918-08210 09919-28610
09924-17811 09926-58010
09944-36011
Steering wheel
remover