Downloaded from www.Manualslib.com manuals search engine General Information: 0A-6
When Using Floor Jack
WARNING!
If the vehicle to be jacked up only at the front
or rear end, be sure to block the wheels on
ground in order to ensure safety.
After the vehicle is jacked up, be sure to
support it on stands. It is extremely
dangerous to do any work on the vehicle
raised on jack alone.
CAUTION!
• Never apply jack against rear suspension parts (i.e., stabilizer, etc.) or vehicle floor,
or it may get deformed.
• When jacking up the front end, be sure to use an air type floor jack with the following
specified height or a manual type floor jack
of the following size. Otherwise, the jack
may cause the bumper or vehicle body
panel a damage.
Jack size
Height “h”: under 145 mm (under 5.71 in.)
Length “l”: above 900 mm (above 35.4 in.) In raising front or rear vehicl
e end off the floor by jacking,
be sure to put the jack a gainst front suspension frame
(1) or rear jacking bracket (2).
To perform service with either front or rear vehicle end
jacked up, be sure to place safety stands (1) under body
mounting stay (2) so that vehicle body is securely
supported. And then check to ensure that body mounting
stay (2) does not slide on safety stands (1) and the
vehicle is held stable for safety’s sake.
“h”
“l”
I4RS0A010002-01
[A]: Front
[B]: Rear
2
1
I4RS0A010003-01
1
1
2
2
[B] [A]
I4RS0A010004-01
Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-22
Installation1) Clean sealing surface on timing chain cover, cylinder block and cylinder head.
Remove oil, old sealant and dust from sealing
surface.
2) Install oil seal (1) to timi ng chain cover, if removed.
NOTE
When installing new oil seal, press fit to
timing chain cover (2) by using special tool
(bearing installer) as shown in figure.
Drive in dimension
“a”: 1.5 mm (0.06 in.)
Special tool
(A): 09913–75810
3) Install oil control valve to timing chain cover referring to “Oil Control Valve Removal and Installation”.
4) Apply sealant “A” to mating surface of cylinder and cylinder head and “B” to mating surface of timing
chain cover as shown in figure.
“A”: Water tight sealant 99000–31140 (SUZUKI
Bond No.1207B)
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount 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 (1). Tighten bolts and nut to specified
torque.
NOTE
Before installing timing chain cover, check
that pin is securely fitted.
Tightening torque
Timing chain cover bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Timing chain cover nut (b): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
6) Apply engine oil to new O-rings (2) and install them to cap (3).
7) Install cap (3) to ti ming chain cover (1).
Tighten bolts to specified torque.
Tightening torque
Cap bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
I2RH0B140058-01
I3RH0B140025-01
(a)
(b)
(c)
1
2
3
I4RS0B140011-02
Downloaded from www.Manualslib.com manuals search engine 1D-31 Engine Mechanical:
7) Install camshaft housing.
8) Tighten camshaft housing bolts as follows.a) Apply engine oil to camshaft housing bolts.
b) Tighten camshaft housing bolts by hand.
c) Tighten camshaft housing bolts to 5 N ⋅m (0.5 kgf-
m, 4.0 lb-ft) according to numerical order (“1”
through “21”) as shown in figure.
d) Retighten them by turning through 11 N⋅ m (1.1
kgf-m, 8.0 lb-ft) in same manner as Step c).
Tightening torque
Camshaft housing bolt (a): 5 N ⋅m (0.5 kgf-m,
4.0 lb-ft) and 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft) by
the specified procedure
9) With hexagonal section (1) of intake camshaft (2) held stationary with spanner or the like, tighten bolt
of intake cam timing sp rocket assembly (3) to
specification.
Tightening torque
Intake cam timing sprocket bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)
10) Install timing chain with cr ankshaft sprocket referring
to “Timing Chain and Chain Tensioner Removal and
Installation”.
11) Install timing chain cover referring to “Timing Chain Cover Removal and Installation”.
12) Check valve lashes referring to “Valve Lash (Clearance) Inspection”.
13) Perform Steps 9) to 14) of “Installation” of “Timing Chain Cover Removal and Installation”.Camshaft, Tappet and Shim InspectionS7RS0B1406022
Intake Cam Timing Sprocket Assembly
Fit intake cam timing sprocket assembly to camshaft (2)
and hold hexagonal section of camshaft by using
spanner or the like.
Check if sprocket (1) is not turned by hand.
If moved, replace intake ca m timing sprocket assembly.
Cam Wear
Using a micrometer, measure cam height “a”. If
measured height underruns its limit, replace camshaft.
Cam height “a”
“10”“9” “2” “1”,(a) “6” “5” “14” “13”
“20”
“17” “19”
“18”
“21”
“12”“11”
“4” “3” “8” “7” “16” “15”
I3RH0B140041-01
1
2
3
(a)
I3RH0B140042-01
Cam height Standard Limit
Intake cam 45.424 – 45.584 mm
(1.789 – 1.794 in.) 45.30 mm
(1.783 in.)
Exhaust cam 45.030 – 45.190 mm
(1.773 – 1.779 in.) 44.91 mm
(1.768 in.)
2
1
I3RH0B140043-01
I2RH0B140080-01
Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-56
5) Install crankshaft to cylinder block.
6) Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to
crank webs.
7) 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 (a) and main bearing cap No.2 bolts (b), tighten
them gradually as follows.
a) Tighten bolts (“1” through “10”) to 30 N ⋅m (3.0
kgf-m, 22.0 lb-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 lb-ft).
c) In the same manner as in Step a), retighten them to 60 °.
d) Tighten bolts (“11” through “18”) to 25 N ⋅m (2.5
kgf-m, 18.0 lb-ft) according to numerical order as
shown.
Tightening torque
Main bearing cap No.1 bolt (a): 30 N ⋅m (3.0
kgf-m, 22.0 lb-ft), 50 N ⋅m (5.0 kgf-m, 36.5 lb-ft)
and then retighten by turning through 60 °
Main bearing cap No.2 bolt (b): 25 N·m (2.5
kgf-m, 18.0 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 lb-ft)
torque or below.
8) If necessary, press-fit rear oil seal (1) to oil seal housing (2) by using special tool as shown in figure.
Special tool
(A): 09911–97821
Crank rear oil seal installing position
(dimension)
“a”: 2 mm (0.08 in.) 9) Apply sealant to mating surface of rear oil seal
housing (1).
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
10) Install rear oil seal housing (1) and tighten bolts to specified torque by using special tool.
Special tool
(A): 09911–97720
Tightening torque
Rear oil seal housing bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
I6RS0C140027-01
A: Crankshaft side
I4RS0A140017-01
I4RS0A140018-01
I4RS0A140019-01
Downloaded from www.Manualslib.com manuals search engine 1E-6 Engine Lubrication System:
Installation1) Install new O-rings (2) in the position as shown in figure and install o il pump strainer (1).
Tighten strainer bolt (3) first and then bracket bolt (4)
to specified torque.
Tightening torque
Oil pump strainer bolt (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
Oil pump strainer bracket bolt (b): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
2) Install dowel pin (1) to oil pan. 3) Apply sealant continuously to oil pan mating surface
as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for oil pan
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
4) Install oil pan to cy linder block temporarily.
5) Insert dowel pin (1) in hole (2) of oil pan in order to
locate oil pan precisely.
NOTE
Dowel pin is available as a spare part (part
number: 04211–13189).
I2RH0B150012-01
I4RS0A150005-01
I4RS0A150006-01
21I4RS0A150007-01
Downloaded from www.Manualslib.com manuals search engine 1F-11 Engine Cooling System:
Water Pump Removal and InstallationS7RS0B1606014
Removal1) Disconnect negative cable at battery.
2) Drain coolant.
3) Remove water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1J”.
4) Remove water pump assembly (1).
Installation 1) Apply sealant to mating surface of water pump (1) as shown in the figure.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant quantity (to mating surface of water
pump)
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 2) Install water pump assemb
ly (1) to cylinder block
and tighten bolts and nut to specified torque.
Tightening torque
Water pump bolt and nut (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
3) Install water pump pulley.
4) Install water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
5) Install A/C compressor belt (if equipped) referring to “Compressor Drive Belt Inspection and Adjustment
in Section 7B” or “Compressor Drive Belt Inspection
and Adjustment in Section 7B”.
6) Refill cooling system referri ng to Step 7) to 22) of
“Cooling System Flush and Refill”.
7) Connect negative cable at battery.
8) Check each part for leakage.
Water Pump InspectionS7RS0B1606015
CAUTION!
Do not disassemble water pump.
If any repair is requir ed on pump, replace it
as assembly.
Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
I2RH0B160016-01
I3RM0A160016-01
I2RH0B160018-01
I2RH0B160019-01
Downloaded from www.Manualslib.com manuals search engine 2A-1 Suspension General Diagnosis:
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS7RS0B2104001
ConditionPossible cause Correction / Reference Item
Vehicle pulls (Leads) Mismatched or uneven tires Replace tires.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging coil springs Replace coil springs.
Radial tire lateral force Replace tire.
Disturbed wheel alignment Check and adjust wheel alignment.
Brake dragging in one road wheel Repair brake.
Loose, bent or broken front or rear
suspension parts Tighten or replace related suspension parts.
Abnormal or excessive
tire wear Sagging or broken coil spring
Replace coil spring.
Tire out of balance Adjust balance or replace tire.
Disturbed wheel alignment Check and adjust wheel alignment.
Faulty strut (shock absorber) Replace strut (shock absorber).
Hard driving Replace tires.
Overloaded vehicle Replace tires and check suspension parts.
Not rotated tires Replace or rotate tires.
Worn or loose wheel bearing Replace wheel bearing.
Wobbly wheel or tire Replace wheel or tire.
Tires not adequately inflated Adjust tire pressure.
Wheel tramp Blister or bump on tire Replace tire.
Improper strut (shock absorber) action Replace strut (shock absorber).
Shimmy, shake or
vibration Tire or wheel out of balance
Balance wheel or replace tire and/or wheel.
Loosen wheel bearings Replace wheel bearings.
Worn tie-rod ends Replace tie-rod ends.
Worn lower ball joints Replace front suspension control arm.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire /
wheel assembly Replace tire or wheel.
Disturbed wheel alignment Check and adjust wheel alignment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear case bolts Tighten steering gear case bolts.
Abnormal noise, front end Worn, sticky or loose tie-rod ends, lower
ball joints, tie-rod in side ball joints or
drive shaft joints Replace tie-rod end, su
spension arm, tie-rod
or drive shaft joint.
Damaged struts or mountings Repair or replace struts or mountings.
Worn suspension arm bushings Replace suspension arm bushings.
Loose stabilizer bar Tighten bolts or nuts and/or replace bushes.
Loose wheel nuts Tighten wheel nuts.
Loose suspension bolts or nuts Tighten suspension bolts or nuts.
Broken or damaged wheel bearings Replace wheel bearings.
Broken suspension springs Replace suspension springs.
Poorly lubricated or worn strut bearings Replace strut bearing.
Malfunction of Power Steering System Check and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.
Broken or sagging coil springs Replace coil springs.
Over loaded Check loading.
Incorrect coil springs Replace coil spring.
Tires not adequately inflated Adjust tire pressure.
Ride too soft Faulty strut (shock absorber) Replace strut (shock absorber).
Suspension bottoms Overloaded Check loading.
Faulty strut (shock absorber) Replace strut (shock absorber).
Incorrect, broken or sagging coil springs Replace coil spring.
Downloaded from www.Manualslib.com manuals search engine Suspension General Diagnosis: 2A-2
NOTE
*1: Right-to-left trim height (“H”) difference should be within 15 mm (0.6 in.) with curb weight. (same
with rear side.)
Body leans or sways in
corners Loose stabilizer bar
Tighten stabilizer bar bolts or nuts, or replace
bushes.
Faulty strut (shock absorber) or
mounting Replace strut (shock absorber) or tighten
mounting.
Broken or sagging coil springs Replace coil springs.
Overloaded Check loading.
Cupped tires Front struts defective Replace struts.
Worn wheel bearings Replace wheel bearings.
Excessive tire or wheel run-out Replace tire and/or wheel.
Worn ball joints Replace front suspension control arm.
Tire out of balance Adjust tire balance.
Condition Possible cause Correction / Reference Item
“H”
I2RH01210001-01