11300-93843-01J Suzuki Cylinder/Crankcase Assembly

Table 1
Required Tools
Tool Part Number Part Description Qty
A 238-9586 Camshaft Drive Group 1
C 125-0200 Camshaft Pilot As 2
D 125-0201 Camshaft Guide As 1
E 8T-3169 Crank Assembly 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The following steps are for the installation of a camshaft in the 3512 Engines and 3516 Engines. The camshaft is in two pieces. Note: Ensure that the camshafts are assembled and installed according to the marks on the ends of the camshafts.
Illustration 1 g02051533
Install Tooling (D) on the flywheel housing. Do not tighten the bolts on Tooling (D).
Install Tooling (C) on the end of the front camshaft.
Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings.
Attach a suitable lifting device to the camshaft. The weight of one-half of the camshaft for 3512 Engines is approximately 32 kg (70 lb). The weight of one-half of the camshaft for 3516 Engines is approximately 41 kg (90 lb).
Position front camshaft (13) in the engine until Tooling (C) is in the first camshaft bearing.
Rotate front camshaft (13) and tighten the bolts for Tooling (D).
Rotate front camshaft (13) and insert the camshaft until the camshaft is slightly protruding from Tooling (D).
Illustration 2 g02051554
Illustration 3 g02050937
If the dowel was removed from front camshaft (13), install the dowel. Install the dowel to 22.0 0.5 mm (0.87 0.02 inch) from the surface of the camshaft.
Attach a suitable lifting device to rear camshaft (14). The weight of one-half of the camshaft for 3512 Engines is approximately 32 kg (70 lb). The weight of one-half of the camshaft for 3516 Engines is approximately 41 kg (90 lb). Install spacer (16) and rear camshaft (14) onto front camshaft (13). Install bolts (15) and tighten to a torque of 55 7 N m (41 5 lb ft).
Install Tooling (C) and Tooling (E) on rear camshaft (14).
Rotate rear camshaft (14) and insert the camshaft into the engine.
Remove all Tooling. Repeat Steps 1.a through 1.k for the camshaft on the opposite side of the engine. Go to Step 3.
The following steps are for the installation of the camshaft in 3508 Engines. The camshaft is one piece.
Install Tooling (D) on the flywheel housing. Do not tighten the bolts on Tooling (D).
Install Tooling (C) on the end of the camshaft.
Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings. Note: Ensure that the camshafts are installed according to the marks on the ends of the camshafts.
Attach a suitable lifting device to the camshaft. The weight of the camshaft is approximately 45 kg (100 lb). Insert the camshaft in the engine until Tooling (C) is in the first camshaft bearing.
Install Tooling (E). Rotate the camshaft and tighten the bolts on Tooling (D).
Rotate the camshaft and insert the camshaft into the engine.
Repeat Steps 2.a through 2.f for the camshaft on the opposite side of the engine. Go to Step 3.
Illustration 4 g02050934
Install thrust washers (12) and bolts (11) that fasten the camshaft to the engine.
If the camshaft is out of time more than 18 degrees (approximately 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, "Camshaft Timing" for more information.
Illustration 5 g02051674
Remove timing pin (17) from the storage position on the side of the engine.
Turn the camshaft until timing pin (17) can be installed through the cylinder block and into groove (18) that is in the camshaft.
Repeat Steps 4 and 5 for the camshaft on the opposite side of the engine.
Illustration 6 g02051678
Remove bolts (21), cover (20), and plug (19).
Install one bolt (21) into the flywheel housing through the hole for plug (19). Use Tooling (A) and a ratchet to turn the flywheel until bolt (21) can be installed through the hole and into the flywheel. Doing so will position the No. 1 cylinder at the top center. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston" for more information.