08211-30451 Suzuki Thrust Washer

Table 1
Required Tools
Tool Part Number Part Description Qty
C 138-7573 Link Bracket 2
D - Guide Stud
5/8 - 11 by 6 inch 2
F 185-3984(1)
or
4C-5300 Gasket Sealant -
(1) EAME
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.
Note: Refer to Engine News, 27, March 2006, "Sealing and Installing the Flywheel Housing" for more information.
Ensure that the mating surface of the flywheel housing and the engine block are clean. Both mating surfaces must be clean, dry, and free of any oil before Tooling (F) is applied.
Illustration 1 g01317446
Apply a 6.0 mm (0.25 inch) bead of Tooling (F) to the mating surface of the flywheel housing. Refer to Illustration 1.
Illustration 2 g02380149
Install Tooling (D) into the cylinder block.
Install Tooling (C) and a suitable lifting device on flywheel housing (14). The weight of flywheel housing (14) is approximately 235 kg (518 lb).
Lift the flywheel housing into position onto Tooling (D).
Install bolts (15) and the hard washers that secure the flywheel housing to the cylinder block. Remove Tooling (D) and install remaining bolts (15) and the hard washers. Note: Refer to Parts Manual for the correct positions for bolts that secure the flywheel housing to the cylinder block.
Tighten bolts (15) evenly. Tighten the 1/2 - NC bolts to a torque of 135 20 N m (100 15 lb ft). Tighten the 5/8 - NC bolts to a torque of 270 40 N m (200 30 lb ft).
Tighten plugs (13) to a torque of 70 15 N m (50 11 lb ft).
Install the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Install".
Illustration 3 g01140296
Install timing bolt (5) in the flywheel. Ensure that timing pin (2) is installed in each camshaft. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
Illustration 4 g02380357
Illustration 5 g02380358
Use the following procedure in order to install camshaft drive gear (9) and camshaft drive gear (12).
Clean the taper of the camshaft and clean the tapered bore of the camshaft gear with a lint free cloth that is saturated with a solvent in order to remove any excess oil. Clean the parts again with a lint free alcohol wipe in order to remove any residue. If the alcohol wipe is dirty after cleaning the parts, clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe. Note: It is critical that the taper of the camshaft and the tapered bore of the camshaft gear are clean, dry, and free of residue before assembly.
Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.
Place camshaft drive gear (9) and camshaft drive gear (12) in position. Remove the backlash by rotating the gears in the opposite direction of engine rotation. Note: For "Standard Rotation" engines, turn the camshaft drive gears CLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE.
Install bolt (7) and plate (8).
Install bolt (10) and ring (11). Ensure that the hole in the ring is properly seated on the locating pin.
Tighten the bolt to a torque of 360 N m (265 lb ft).
Place a mark on the bolt.
Place a driver against the retaining plate of the camshaft drive gear. Strike the driver with a hammer, three or four times.
Tighten the bolt again to a torque of 360 N m (265 lb ft).
Repeat Steps 11.h and 11.i until the mark has turned at least 90 degrees.
Illustration 6 g01126909
Remove the timing pin from the camshafts. Install timing pin (2) in the storage position. Install rear camshaft covers (1).
Remove the timing bolt from the flywheel. Install plug (4) in the timing hole. Install cover (3) and timing bolt (5) in the storage position on the flywheel housing.
Illustration 7