09440-50002 Suzuki SPRING

Weights of the guards are:943 engine guard - 66 kg (146 lb.)953 engine guard - 75 kg (166 lb.)943 or 953 transmission guard - 78 kg (172 lb.)2. Steam clean engine.3. Disconnect the batteries.4. Remove the plug from the flywheel housing, and look for oil. Continue to Step 5 if no oil is present. Remove the engine if a rear engine seal or transmission seal replacement is necessary.5. Drain the oil.6. Drain the coolant.7. Remove the oil filter. Cut it open to examine for foreign material.Crankshaft And Bearing Inspection
8. Remove the oil pan. Inspect it for foreign material.9. Remove the suction tube.10. Turn the crankshaft until a journal is at the lowest position. Remove the rod cap from the journal. Inspect the bearing according to Reusability Guidelines, Form No. SEBF8009. Inspect the crankshaft journal for damage or unusual wear. Install the rod cap, turn the crankshaft to remove another rod cap. Do this procedure again until all rod journals and lower rod bearings have been inspected.11. Remove number 2, 4 and 5 main bearing caps. Inspect the bearings and crankshaft as above. Install number 2, 4 and 5 bearing caps. Remove number 1 and 3 main bearing caps, and inspect them. Install number 1 and 3 main bearing caps. Continue to Step 12 if the crankshaft is not damaged. Remove the engine if the crankshaft must be removed for grinding or replacement.Cylinder Bore Inspection
12. Remove air cleaner/piping and the, turbocharger. Check to see if dirt or oil is present inside the piping. The turbocharger must be built again (reconditioned) if the turbocharger leaks oil. See Analyzing Turbocharger Failures, Form No. FEG45138 and Guideline For Reusable Parts For Turbochargers, Form No. SEBF8018.13. Tilt the cab. See the Vehicle Systems Disassembly And Assembly section.14. Remove the muffler, hood and exhaust manifold.15. Remove the fuel injection lines.16. Remove the valve cover, rocker shaft assembly and push rods.17. Remove the fuel injection nozzles.18. Remove the cylinder head assembly.19. Remove the carbon build-up from the cylinder walls. Measure cylinder bore wear.Disassembly
20. Turn the crankshaft until a rod cap is at bottom.21. Remove the nuts and connecting rod cap from the connecting rod that is at the bottom. Remove the piston.22. Do Steps 20 and 21 again, and remove the remainder of the pistons.Component Inspection
23. Inspect the pistons. See Guidelines For Reusable Parts, Form No. SEBF8001 Pistons And Liners.24. Remove the lifters one at a time. Inspect the lifters and camshaft lobes for unusual wear. Install the lifters in their original locations.25. Inspect the cylinder head assembly for necessary reconditioning.26. Recondition other components, such as the alternator, fuel pump, starter, water pump, etc., if necessary.27. Check for minor engine repairs or replacements such as gaskets, seals, belts, hoses, etc.28. Make a replacement of the front crankshaft seal only if necessary.29. Order the necessary parts as early as possible to avoid delays during assembly.Reconditioning
30. Disassemble the pistons from the rods. Put identification marks on the pistons as to their location in the cylinder block.31. Clean the pistons. Install new rings.32. Install the pistons on the rods.33. Flex-hone the cylinder walls.34. Test fuel injection nozzles for reconditioning or replacement.Assembly
35. Remove numbers 1, 3 and 4 main bearings. Clean the crankshaft journals.36. Put lubricant on number 1, 3 and 4 main bearings, and install the bearings, caps and bolts. Check the bearing clearance.37. Remove number 2 and 5 main bearing caps. Remove the upper main bearings, and clean the crankshaft journals.38. Put lubricant on number 2 and 5 main bearings, and install the bearings, caps and bolts. Check the bearing clearance.39. Torque-turn all main bearing bolts.40. Check the crankshaft for free rotation. Measure crankshaft end play.41. Put lubricant on the piston and rod assemblies, and install them in the cylinder block.42. Install connecting rod bearings, cap and nuts. Check the bearing clearance.43. Torque-turn all rod nuts.44. Check the crankshaft for free rotation.45. Install the suction tube.46. Install the cylinder head assembly. Tighten the bolts to the correct torque.47. Install the fuel injection nozzles.48. Install the rocker shaft assembly and push rods. Adjust the valves.49. Install the valve cover.50. Install the fuel injection lines.51. Install the exhaust manifold and turbocharger.52. Install the oil pan.53. Install the muffler and hood.54. Install the air cleaner/piping.55. Lower the cab. See the Vehicle Systems Disassembly And Assembly section.56. Install new oil and fuel filters.57. Fill the engine with oil to the correct level. See the Maintenance Guide.58. Fill the engine with coolant. See the Maintenance Guide.59. Connect the batteries.60. Install the guards below the engine and transmission.Test After Repair
61. Remove the air from (prime) the fuel system with the hand priming pump. Loosen the fuel line nuts to remove the air from the fuel lines.62. Start the engine, and check the systems.Literature References
Guideline For Reusable Parts, Form No. SEBF8001-01, Piston And Cylinder LinersGuidelines For Reusable Parts, Form No. SEBF8009, Main And Connecting Rod BearingsGuidelines For Reusable Parts, Form No. SEBF8002, Valves And Valve SpringsGuidelines For Reusable Parts, Form No. SEBF8018, TurbochargersGuidelines For Reusable Parts, Form No. SEBF8020, Wear Sleeves For ShaftsSpecial Publication, Form No. FEG45138, Analyzing Turbocharger Failures