11301-95531-02M Suzuki Cylinder, Crankcase Assembly

Table 1
Required Tools
Tool Part Number Part Description Qty
A 364-9107 Fuel Injection Pump Timing Pin 1
B 230-6284 Timing Pin (Camshaft) 1
C 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
D 298-5564 T40 Torx Socket 1
E 7H-1942 Dial Indicator 1
- Magnetic Base and Stand 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01996476
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Ensure that Tooling (C) is installed in Hole (Y) in the cylinder block. Use Tooling (C) to lock the crankshaft in the correct Position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Ensure that Tooling (B) is installed into Hole (X) in camshaft gear (3).
Use Tooling (A) to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.
Illustration 3 g01996477
Illustration 4 g02196594
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Clean idler gear (4) and inspect the idler gear for wear and damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the idler gear.
Clean hub (9) and inspect the hub for wear and damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the hub.
Lubricate hub (9) with clean engine oil. Install hub (9) into the recess in the front housing. Ensure that oil Hole (Z) is position as shown in the Illustration 4.
Install idler gear (4) onto hub (9). Ensure that the timing marks are toward the front of the idler gear.
Align the timing mark on idler gear (4) with the timing mark on camshaft gear (3), fuel injection pump gear (10), and crankshaft gear (11). Refer to the Illustration 5. Install the assembly of idler gear (4) to hub (9).
Clean plate (8) and inspect the plate for wear and damage. If necessary, replace the plate.
Lubricate plate (8) with clean engine oil. Align the holes in plate (8) with the holes in hub (9). Install the plate in the original orientation.Note: Ensure that the identification mark TOP is upward.
Install bolts (7). Tighten the bolts to a torque of 44 N m (32 lb ft).
Remove Tooling (A), Tooling (B), and Tooling (C).Note: Ensure that timing marks are aligned, before removing the Tooling (A), Tooling (B) and Tooling (C).
Illustration 6 g01996554
Position a new O-ring seal (1) onto plug (2). Install the plug to the cylinder block and tighten the plug to a torque of 21 N m (186 lb in).
Use Tooling (E) to check the end play for the idler gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (E) to check the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (E) to check the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (E) to check the backlash between the idler gear and the fuel injection pump gear. Refer to Specifications, "Gear Group (Front)" for more information.
Lightly lubricate all the gears with clean engine oil.
Illustration 7 g01994556
Use Tooling (D) to tighten threaded inserts (4) on all rocker arms (5). Tighten the threaded inserts to a torque of 30 N m (266 lb in).Note: When the threaded insert is tightened, the threaded insert must be seated correctly into the cup for the pushrod.
The engine, should not be operated for a period 30 minutes after the threaded inserts on all the rocker arms have been tightened. This period will allow the force from the valve springs to purge off excessive engine oil from the hydraulic lifters.End By:
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.