2002 Chevrolet Tracker

2002 ENGINES Tracker - 2.5L V6

2002 ENGINES

Tracker - 2.5L V6

ENGINE IDENTIFICATION
ENGINE IDENTIFICATION CODES
Application VIN
Tracker 4

ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT

Hydraulic lifters are used; no valve adjustments are required.

TROUBLE SHOOTING

NOTE: To trouble shoot engine mechanical components, see ENGINE MECHANICAL in

BASIC TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system.

When servicing vehicle, use care to avoid accidental air bag deployment.
SIR system-related components are located in various locations
throughout interior and exterior of vehicle, depending on application. Do
not use electrical test equipment on or near these circuits. If necessary,
deactivate SIR system before servicing components. See AIR BAG
SAFETY PRECAUTIONS and DISABLING & ACTIVATING AIR BAG
SYSTEM in AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.

CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.

NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.

NOTE: For reassembly reference, label electrical connectors, vacuum hoses and fuel
lines before removal. Place mating marks on engine hood and other major
assemblies before removal.

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FUEL PRESSURE RELIEF PROCEDURE

CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before
servicing the fuel system in order to reduce the risk of personal injury.
After you relieve the fuel system pressure, a small amount of fuel may be
released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel
system components with a shop towel before disconnection. This will
catch any fuel that may leak out. Place the towel in an approved container
when the disconnection is complete.

NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging
the catalytic converter.

1. Loosen the fuel filler cap in order to relieve any fuel tank pressure.
2. Remove the fuel pump relay from the junction box. See Fig. 1.
3. Crank the engine.
4. Allow the engine to start and stall.
5. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure.
6. Disconnect the negative battery cable in order to avoid repressurizing the fuel system.
7. Install the fuel pump relay to the junction box.
8. Tighten the fuel filler cap.

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Fig. 1: Removing Fuel Pump Relay

Courtesy of SUZUKI OF AMERICA CORP.

ENGINE

NOTE: Tools Required:

l J-36854 Heavy Duty Automotive Engine Stand

l J-35271 Flywheel Holder

Removal

1. Relieve fuel pressure. See FUEL PRESSURE RELIEF PROCEDURE.

2. Disconnect negative battery cables.
3. Remove the hood from vehicle.
4. Raise and support vehicle.
5. Remove front skid plate from vehicle, if equipped.
6. Drain engine oil.
7. Drain engine cooling system.
8. Remove automatic transmission fluid cooler lines from the radiator. Cap open lines to prevent leakage.

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9. Lower vehicle.
10. Remove the radiator. See RADIATOR.
11. Disconnect accelerator cable. See Fig. 2.
12. Disconnect the A/T throttle cable.

NOTE: The vehicle should be supported on a hoist prior to removing the strut
tower brace. This will facilitate removal and installation of the brace.

13. Remove the 6 bolts and the strut tower brace.

14. Remove the 4 screws and the surge tank cover.
15. Disconnect the Intake Air Temperature (IAT) sensor connector.
16. Remove the 4 nuts from the Surge Tank Pipe.
17. Remove the Air Cleaner Upper Case, Intake Air Hose, Intake Air Pipe, and Surge Tank Pipe as an
assembly.
18. Remove the one bolt and the engine oil level indicator and tube.
19. Remove the one bolt and the transmission fluid level indicator and tube.
20. Remove the ignition coil covers.
21. Disconnect the injector wire connector.
22. Disconnect the brake booster vacuum hose.
23. Disconnect the following electrical connectors:
l The Camshaft Position Sensor (CMP).

l The 6 ignition coils.

l The Throttle Position (TP) sensor.

l The Mass Air Flow (MAF) sensor.

l The Idle Air Control (IAC) valve.

l The ground wires from the surge tank.

24. Remove the clamp bracket.

25. Disconnect the following electrical connectors:
l EVAP canister purge valve.

l Exhaust Gas Recirculation (EGR) valve.

l Oxygen sensor.

l Coolant temperature sensor.

l Generator wires.

l Starter wires.

l Oil pressure switch wire.

l Power steering pressure switch wire.

l Ground wire from the generator bracket.

26. Remove clamp brackets.

27. Disconnect the following hoses:
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l Heater hose from the heater water pipe.

l Heater hose from the water outlet cap.

l EVAP canister hose from the canister pipe.

28. Remove the Idle Air Control (IAC) valve.

29. Remove the EVAP canister purge valve.
30. Disconnect the fuel feed hose from the fuel feed pipe.
31. Disconnect the fuel return hose from the fuel return pipe.
32. Remove the EVAP canister.
33. Remove the 3 bolts and the power steering pump from it's bracket, and position aside.

NOTE: Do not discharge the A/C system nor remove the refrigerant lines from the
compressor.

34. Remove the 3 bolts and the A/C compressor, if equipped, from it's bracket, and position aside.
35. Remove the 4 bolts and the A/C compressor bracket, if equipped.
36. Remove the lower steering shaft assembly.
37. Raise the vehicle.
38. On vehicles with 4WD, remove the front axle housing. See appropriate DIFFERENTIALS & AXLE
SHAFTS - TRACKER article.
39. Remove the front exhaust pipe.
40. Remove the exhaust manifold bracket from the transmission.
41. Remove the transmission fluid hose clamps from the engine mounting bracket.
42. Remove the flywheel cover.
43. Remove the torque converter bolts on automatic transmission equipped vehicles. Use a screwdriver in
order to lock the flywheel.
44. Remove the 2 bolts and the starter motor.
45. Lower the vehicle.
46. Support the transmission.
47. Remove the 4 bolts and 2 nuts that fasten the transmission to the cylinder block.
48. Install the engine hoist to the engine.
49. Remove the 2 nuts from the top side of the engine mounts.

NOTE: Before lifting the engine, ensure that all of the hoses, pipes, electrical
wires and cables are disconnected from the engine, and positioned aside.

50. Remove the engine assembly from the vehicle by sliding the assembly toward the front side of the engine
compartment. Carefully lift the engine assembly from the vehicle verifying clearance on all sides.

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Fig. 2: Removing & Installing Accelerator Cable

Courtesy of GENERAL MOTORS CORP.

Installation

1. Install the engine hoist.

2. Remove the engine assembly from the Heavy Duty Automotive Engine Stand (J-36854).

NOTE: Apply the proper amount of the sealant to the fastener when assembling
this component. Excessive use of the sealant can prohibit the component
from being assembled properly or allow the fastener to loosen. A
component or fastener that is not assembled properly can loosen of fall off
leading to extensive engine damage.

3. Align the flywheel-to-crankshaft marks and install the flywheel.

4. Apply threadlocker GM P/N 12345493, or the equivalent, to the flywheel retaining bolt threads.
5. Install the flywheel retaining bolts to the crankshaft. Use the Flywheel Holder (J-35271) to lock the
flywheel. Cross tighten the 8 flywheel retaining bolts. See TORQUE SPECIFICATIONS.
6. Install the engine assembly. Lower the engine into the front of the engine compartment. While ensuring

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clearance on all sides, slide the assembly rearward.

7. Install the engine mount nuts. Tighten the engine mount nuts. See TORQUE SPECIFICATIONS.
8. Remove the engine hoist.
9. Install the 4 bolts and 2 nuts that fasten the transmission to the cylinder block. Tighten the bolts and nuts.
10. Raise the vehicle.
11. Install the torque converter bolts. Use a screwdriver in order to lock the flywheel. Tighten the torque
converter bolts. See TORQUE SPECIFICATIONS.
12. Install the flywheel cover.
13. Install the starting motor.
14. Install the transmission fluid hose clamps to the engine mounting bracket.
15. Install the exhaust manifold bracket to the transmission.
16. Install the front exhaust pipe.
17. Install the front axle housing (on 4WD models only).
18. Install the lower steering shaft assembly.
19. Install the 4 bolts and the A/C compressor bracket, if equipped. Tighten the compressor bracket bolts. See
TORQUE SPECIFICATIONS.
20. Install the A/C compressor, if equipped. Secure with the 3 bolts. Tighten the compressor mounting bolts.
21. Install the power steering pump to its bracket. Secure with the 3 bolts. Tighten the power steering pump
mounting bolts. See TORQUE SPECIFICATIONS.
22. Install the power steering pump drive belt.
23. Install the EVAP canister.
24. Connect the fuel return hose to the fuel return pipe.
25. Connect the fuel feed hose to the fuel feed pipe.
26. Install the EVAP canister purge valve.
27. Install the Idle Air Control (IAC) valve.
28. Connect the following hoses:
l The EVAP canister hose to the canister pipe.

l The heater hose to the water outlet cap.

l The heater hose to the heater water pipe.

29. Connect the following electrical connectors:

l The EVAP canister purge valve.

l The Exhaust Gas Recirculation (EGR) valve.

l The oxygen sensor.

l The coolant temperature sensor.

l The generator wires.

l The starter wires.

l The oil pressure switch wire.

l The power steering pressure switch wire.

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l The ground wire to the generator bracket.

30. Install the clamp brackets.
31. Connect the following electrical connectors:
l The Camshaft Position Sensor (CMP).

l The 6 ignition coils.

l The Throttle Position (TP) sensor.

l The Mass Airflow (MAF) sensor.

l The Idle Air Control (IAC) valve.

l The ground wires to the surge tank.

32. Install the clamp bracket.

33. Connect the injector wire connector.
34. Connect the brake booster vacuum hose.
35. Install the engine oil level indicator and tube. Secure with the bolt. Tighten the oil level indicator tube
bolt. See TORQUE SPECIFICATIONS.
36. Install the transmission fluid level indicator and tube. Secure with the one bolt. Tighten the transmission
fluid level indicator tube bolt. See TORQUE SPECIFICATIONS.
37. Install the ignition coil covers.
38. Install the Air Cleaner Upper Case, the Intake Air Hose, the Intake Air Pipe and the Surge Tank Pipe as
an assembly to the throttle body and intake manifold.
39. Install the 4 nuts to the surge tank pipe. Tighten the surge tank pipe nuts. See TORQUE
SPECIFICATIONS.
40. Connect the Intake Air Temperature (IAT) sensor connector.
41. Install the surge tank cover.
42. Install the strut tower brace. Secure with the 6 bolts. Tighten the strut tower brace bolts. See TORQUE
SPECIFICATIONS.
43. Connect the A/T throttle cable.
44. Connect the accelerator cable.
45. Install the radiator.
46. Install the upper radiator hose.
47. Install the automatic transmission fluid cooler lines to the radiator.
48. Install the lower radiator hose.
49. Install the front skid plate to the vehicle, if equipped. Secure the front skid plate with the 4 bolts. Tighten
the front skid plate bolts. See TORQUE SPECIFICATIONS.
50. Install the engine oil drain plug with a NEW gasket. Tighten the engine oil drain plug. See TORQUE
SPECIFICATIONS.
51. Fill the crankcase with engine oil.
52. Fill the cooling system.
53. Fill the automatic transmission fluid as necessary.
54. Connect the negative battery cable.

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55. Run the engine and inspect for the following:

l Engine oil leaks.

l Transmission fluid leaks.

l Engine coolant leaks.

l Fuel leaks.

INTAKE MANIFOLD

Removal

1. Partially drain cooling system and relieve fuel pressure. Disconnect the water hoses from the throttle
body.
2. Disconnect the injector wire coupler.
3. Disconnect the following electrical connectors:
l The Throttle Position (TP) sensor.

l The Mass Airflow (MAF) sensor.

l The Idle Air Control (IAC) valve.

4. Disconnect the ground terminal from the intake collector.

5. Remove the clamp bracket from the intake collector.
6. Disconnect the following electrical connectors:
l The Manifold Differential Pressure (MDP) sensor.

l The EVAP canister purge valve.

l The Exhaust Gas Recirculation (EGR) valve.

7. Disconnect the following hoses:

l The PVC hose from the cylinder head cover.

l The breather hose from the throttle body.

l The EVAP canister purge valve hose.

l The water hose.

l The heater hoses.

8. Remove the EGR pipe.

9. Disconnect the following hoses:
l The heater hose.

l The EVAP canister hose.

l The fuel feed hose.

l The fuel return hose.

l The tank pressure control solenoid valve hose.

10. Disconnect the hose from the Idle Air Control (IAC) valve.
11. Remove the Idle Air Control (IAC) valve.
12. Remove the 4 nuts and 2 bolts on the intake collector.

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13. Remove the intake manifold rear crossover pipe and throttle body from the intake manifold as an
assembly.
14. If necessary, remove the 2 nuts and bolts and remove the throttle body from the intake manifold rear
crossover pipe.
15. Remove the 8 bolts and 4 nuts on the intake manifold.
16. Remove the intake manifold.

Installation

1. Install the NEW intake manifold gaskets onto the cylinder heads.
2. Install the intake manifold. Secure the intake manifold with the 8 bolts and 4 nuts. Tighten the bolts and
nuts. See TORQUE SPECIFICATIONS.
3. Install the NEW throttle body gasket to the intake collector.
4. Install the throttle body to the intake collector. Secure the throttle body with the 2 bolts and 2 nuts.
Tighten the nuts and bolts. See TORQUE SPECIFICATIONS table.
5. Install the intake collector and the throttle body as an assembly to the intake manifold with a NEW
gasket. Secure with the 4 nuts and 2 bolts. Tighten the nuts and bolts. See TORQUE
SPECIFICATIONS.
6. Install the Idle Air Control (IAC) valve with a NEW gasket.
7. Connect the following hoses:
l The heater hose.

l The EVAP canister hose.

l The fuel feed hose.

l The fuel return hose.

l The tank pressure control solenoid valve hose.

8. Install the Exhaust Gas Recirculation (EGR) pipe.

9. Connect the following hose:
l The PCV hose to the cylinder head cover.

l The breather hose to the throttle body.

l The EVAP canister purge valve hose.

l The water hose.

l The heater hoses.

10. Connect the following electrical connectors:

l The Manifold Differential Pressure (MDP) sensor.

l The EVAP canister purge valve.

l The exhaust gas recirculation (EGR) valve.

11. Install the clamp bracket to the intake collector.

12. Install the ground terminal to intake collector.
13. Connect the following electrical connectors:
l The Throttle Position (TP) sensor.

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The Mass Airflow (MAF) sensor.

l

l The Idle Air Control (IAC) valve.

14. Connect the injector wire coupler.

15. Connect the water hoses to the throttle body.

EXHAUST MANIFOLD

Removal (Left)

1. Remove exhaust manifold cover bolts and the cover.

2. Remove exhaust manifold reinforcement bracket.
3. Remove nuts and bolts from exhaust manifold.
4. Remove exhaust manifold and gasket.

Removal (Right)

1. Disconnect the EGR pipe from the exhaust manifold.

2. Remove the exhaust manifold cover bolts and the cover.
3. Remove the exhaust manifold reinforcement bracket.
4. Remove the nuts and bolts from the exhaust manifold.
5. Remove the exhaust manifold with the gasket.

Installation (Left)

NOTE: When installing a new exhaust system component, always use new gaskets and
seals.

1. Install exhaust manifold with a new gasket. Tighten the manifold nuts and bolts. See TORQUE
SPECIFICATIONS.
2. Install the exhaust manifold reinforcement bracket to the exhaust manifold and engine block. Tighten the
engine mount-to-exhaust bracket bolt and the exhaust bracket-to-exhaust manifold nut. See TORQUE
SPECIFICATIONS.
3. Install the exhaust manifold cover and the cover bolts. Tighten the exhaust manifold heat shield bolts. See
TORQUE SPECIFICATIONS.

Installation (Right)

NOTE: When installing a new exhaust system component, always use new gaskets and
seals.

1. Install the exhaust manifold with a new gasket. Tighten the manifold bolts and nuts. See TORQUE
SPECIFICATIONS.
2. Install the exhaust manifold reinforcement bracket following to the exhaust manifold and engine block.
Tighten the engine mount-to-exhaust bracket bolt and the exhaust bracket-to-exhaust manifold nut. See
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TORQUE SPECIFICATIONS.
3. Install the exhaust manifold cover and the cover bolts. Tighten the lower manifold heat shield bolts. See
TORQUE SPECIFICATIONS.
4. Connect the EGR pipe to the exhaust manifold.

VALVE COVERS

NOTE: Valve cover may also be referred to as camshaft cover.

Removal (Left & Right)

1. Remove ignition coil cover.

2. Remove ignition coils.
3. Remove the 4 nuts on the valve cover.
4. Remove valve cover.
5. Remove valve cover gasket.

Installation (Left & Right)

1. Clean sealing surfaces on valve cover and cylinder head.

2. Apply GM P/N 12346240 or equivalent to the cylinder head at the points indicated. See Fig. 3.
3. Install the NEW valve cover gasket to the valve cover.
4. Install the NEW cylinder head side seals to the cylinder head.
5. Install the valve cover to the cylinder head.
6. Using NEW seal washers, tighten the 4 nuts on the valve cover. See TORQUE SPECIFICATIONS.
7. Install the ignition coils.
8. Install the ignition coil cover.

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Fig. 3: Applying Valve Cover Sealant

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Courtesy of SUZUKI OF AMERICA CORP.

CYLINDER HEAD

Removal (Left & Right)

1. Remove the camshafts.

2. Remove the lifters.
3. Remove the exhaust manifold.
4. Remove the water crossover pipe.
5. Remove the hex bolt.
6. Remove the cylinder head bolts in the proper order. See Fig. 39.
7. Remove the cylinder heads.
8. Clean the cylinder head mating surface.
9. Clean the cylinder block mating surface.
10. Clean the cylinder head bolt threads and bolts. Replace any stretched or damaged bolts.
11. Clean the cylinder block bolt holes of all debris, threadlocker, sealant etc. Installing a bolt to a blocked
bolt hole will cause incorrect torque and may cause cylinder head/block damage.

Cleaning & Inspection

1. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by.
2. If the gasket has failed, determine the cause. Gasket failure may be caused by the following:
l Improper installation.

l Loose or warped cylinder head.

l Warped cylinder block surface.

l Missing, off location or not fully seated dowel pins.

l Corrosion in the seal area around the coolant passages.

l Chips or debris in the cylinder head bolt holes.

l Bolt holes in the cylinder block not drilled or tapped deep enough.

l Incorrect cylinder head bolt torque.

l Incorrect cylinder head bolt length.

3. Inspect the cylinder head gasket surface:

l Replace the cylinder head if the area between the valve seats is cracked.

l Replace the cylinder head if corrosion has been found inside a .375" (4 mm) band around each
combustion chamber.

NOTE: Do not use a wire brush on any gasket sealing surface. Do not
attempt to weld the cylinder head, replace it.

4. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.

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5. Clean the valve guides.

6. Inspect the valve guides for wear.
7. Inspect the valve seats for excessive wear and hot spots.
8. Inspect the valve seating surfaces.
9. Clean the threaded holes. Use a nylon bristle brush.
10. Clean the remains of the sealer from the plug holes.
11. Replace all suspect bolts.
12. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.
13. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
14. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
15. Inspect the intake, the exhaust and the cylinder head deck sealing surfaces.
16. Inspect the cylinder head deck surface for flatness. See CYLINDER HEAD under ENGINE
SPECIFICATIONS.
17. Inspect the cylinder head intake surface for flatness. See CYLINDER HEAD under ENGINE
SPECIFICATIONS.
18. Inspect the cylinder head exhaust surface for flatness. See CYLINDER HEAD under ENGINE
SPECIFICATIONS.
19. If the warpage is greater than the maximum in any measurement, replace the cylinder head.
20. Measure the free length of each valve spring using a Vernier caliper. See VALVES & VALVE
SPRINGS under ENGINE SPECIFICATIONS.
21. If the free length of any valve spring is not within specification, replace the valve spring.
22. Measure the tension of the valve spring at the specified installed height using a spring tester. See
VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS.
23. If the installed tension of any valve spring is not within specifications, replace the valve spring.
24. Measure the valve spring squareness deviation using a steel square. See VALVES & VALVE SPRINGS
under ENGINE SPECIFICATIONS.
25. If the deviation of any valve spring is greater than the specified maximum, replace the valve spring.
26. Inspect the valve spring seating surface of the valve spring seats for wear or gouging. Replace as
required.
27. Temporarily install the valves into the cylinder head.
28. Measure valve runout. Inspect valve face-to-valve seat contact pattern by performing the following:
l Apply a light coating of Prussian blue to the entire valve face. Seat the valve but do not rotate it.
The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve
seat.
l Clean all traces of Prussian blue.

l Apply a light coating of Prussian blue to the valve seat and repeat the check. The traces of Prussian
blue transferred to the valve face indicates valve face concentricity.
l Recondition the valve seat and/or replace the valves as necessary.

Installation

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1. Install the knockpin to the cylinder block if removed.

2. Apply sealant to the cylinder head gasket as shown.
3. Install the cylinder head gasket to the block with the 86FA mark facing up.
4. Install the cylinder head to the block.

NOTE: The cylinder head bolts must be tightened in 2 stages, loosened, and then
retightened in 3 stages in order to ensure against compression and
coolant leaks.

5. Apply clean engine oil to the bolt threads and install the cylinder head bolts.
6. Tighten the cylinder head bolts. See TORQUE SPECIFICATIONS.
7. Install the water crossover pipe.
8. Install the lifters.
9. Install the camshafts.

TIMING CHAIN COVER & FRONT OIL SEAL

Removal

1. Drain the engine oil.

2. Remove the throttle body and intake manifold.
3. Remove the left and right cylinder head covers.
4. Remove the water pump drive belt. See Fig. 4.
5. Remove the water pump pulley.
6. Remove the 3 bolts and the thermostat cap.
7. Remove the 3 bolts from the power steering pump bracket and remove bracket.
8. Remove the crankshaft balancer.
9. Remove the lower oil pan.
10. Remove the upper oil pan.
11. Disconnect the Crankshaft Position (CKP) sensor.
12. Remove the bolt and the (CKP) sensor.
13. Remove the bolts and the front cover.
14. Remove engine crankshaft balancer.

NOTE: To protect the crankshaft from damage, wrap the tip of the screwdriver
with tape.

15. Carefully pry out the crankshaft front oil seal using a screwdriver.

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Fig. 4: Identifying Coolant Fan & Pulley

Courtesy of GENERAL MOTORS CORP.

Installation

1. Lubricate the new crankshaft front oil seal with Chassis Grease GM P/N 1051344 or equivalent.

NOTE: Tap the oil seal in until its surface is flush with the crankshaft front oil seal
retainer edge.

2. Using a hammer and an appropriate driver, lightly tap the crankshaft front oil seal into place.
3. Install the crankshaft balancer.
4. Clean the sealing surfaces on the front cover, the crankcase, the cylinder block and the cylinder heads.
5. Apply GM P/N 12346240 or equivalent to the front cover. See Fig. 5.
6. Apply engine oil to the oil seal lip and the water pump "O" ring.

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7. Install the front cover and secure with the bolts. Tighten the bolts. See TORQUE SPECIFICATIONS.
8. Apply engine oil to the "O" ring of the Crankshaft Position (CKP) sensor.
9. Install the CKP sensor. Secure with the bolt. Tighten the bolt. See TORQUE SPECIFICATIONS.
10. Install the upper oil pan.
11. Install the lower oil pan.
12. Install the crankshaft balancer.
13. Install the power steering pump bracket. Secure with the 3 bolts. Tighten the bolts. See TORQUE
SPECIFICATIONS.
14. Install the thermostat cap.
15. Install the water pump pulley.
16. Install the left and right cylinder head covers.
17. Install the intake manifold and throttle body.

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Fig. 5: Applying Timing Chain Cover Sealant

Courtesy of SUZUKI OF AMERICA CORP.

LEFT (NO. 1) BANK 2ND TIMING CHAIN & CHAIN TENSIONER

Removal

1. Remove the engine front cover.

2. Remove the spark plugs.

NOTE: The timing marks must be correctly aligned before disassembly in order to
correctly install the timing chains. Avoid turning the camshafts and the
crankshaft once the timing chain is removed. Valve and piston damage
may occur.

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3. Rotate the crankshaft so that the following conditions are met:

l The keyway on the crankshaft is properly positioned.

l The arrow on the idler sprocket is pointing to the crankshaft.

l The marks on the sprockets match up with the marks on the cylinder head. See Fig. 6.

4. Remove the 3 bolt and the upper chain guide.

5. Remove the one nut and 2 bolts from the timing chain tensioner.
6. Remove the timing chain tensioner. It may be necessary to slacken the timing chain by turning the intake
camshaft counterclockwise a little while pushing back on the tensioner pad. See Fig. 7.
7. Hold the camshafts with a wrench and remove the camshaft sprocket bolts.
8. Remove the camshaft sprockets and timing chain.
9. Remove the 2 bolts and the side chain guide.

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Fig. 6: Aligning Marks For Left Bank 2nd Timing Chain

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Courtesy of SUZUKI OF AMERICA CORP.

Fig. 7: Removing Left Bank 2nd Timing Chain

Courtesy of SUZUKI OF AMERICA CORP.

Installation

1. Verify the keyway on the crankshaft is properly positioned.

2. Verify the timing mark on the idler sprocket is properly positioned.
3. Install the side chain guide. Secure with the 2 bolts. Tighten the bolts. See TORQUE
SPECIFICATIONS.
4. Verify that the knock-pin of the intake camshaft and knock-pin of the exhaust camshaft are aligned with
the match marks on the cylinder head. See Fig. 8
5. Install timing chain to idler sprocket by aligning Yellow link of the timing chain with the mark on the
idler sprocket. See Fig. 9.
6. Install the sprockets to the camshafts by aligning the Silver links with the mark on the intake sprocket and
the exhaust sprocket.
7. Secure the sprocket with the bolts while holding the camshafts with a wrench. Tighten the 2 bolts. See

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TORQUE SPECIFICATIONS.
8. With the latch of the tensioner adjuster returned and the plunger pushed back into the body, insert a
retainer (paper clip or similar tool) into the set hole. After inserting the pin, make sure the plunger will
not come out.
9. Install the timing chain tensioner. Secure with the bolt. Tighten the bolt. See TORQUE
SPECIFICATIONS.
10. Install tensioner nut. Tighten the nut. See TORQUE SPECIFICATIONS.
11. Remove the retainer from the tensioner.
12. Install the upper chain guide. Secure with the 3 bolts. Tighten the bolts. See TORQUE
SPECIFICATIONS.
13. Turn the crankshaft 2 revolutions clockwise.
14. Align the keyway on the crankshaft with the oil jet.
15. Verify that all the other timing marks are properly aligned.
16. Apply engine oil to the following:
l The timing chains.

l The tensioner.

l The guides.

l The sprockets.

17. Install the spark plugs.

18. Install the engine front cover.

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Fig. 8: Aligning Left Bank Camshaft Knock Pins

Courtesy of SUZUKI OF AMERICA CORP.

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Fig. 9: Locating Left Bank Camshaft Timing Chain Marks

Courtesy of SUZUKI OF AMERICA CORP.

1ST TIMING CHAIN & CHAIN TENSIONER

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Removal

1. Remove the engine front cover. See TIMING CHAIN COVER & FRONT OIL SEAL.
2. Remove the spark plugs.

NOTE: The timing marks must be correctly aligned before disassembly in order to
correctly install the timing chains. Avoid turning the camshafts and the
crankshaft once the timing chain is removed. Valve and piston damage
may occur.

3. Rotate the crankshaft so that timing marks are aligned.

4. Remove the secondary timing chain.
5. Remove the timing chain guides.
6. Remove the timing chain tensioner adjuster.
7. Remove the idler sprocket and the primary timing chain.
8. Remove the idler sprocket and the sprocket shaft.
9. Remove the timing chain tensioner.
10. Remove the right primary timing chain camshaft sprocket bolt while holding the right intake camshaft
with a wrench.
11. Remove the right primary sprocket from the intake camshaft.
12. Remove the primary timing chain crankshaft sprocket. See Fig. 10.

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Fig. 10: Exploded View Of Right Bank Timing Chain Components

Courtesy of SUZUKI OF AMERICA CORP.

Installation

1. Verify the keyway on the crankshaft is positioned properly.

2. Install the crankshaft sprocket to the crankshaft.
3. Verify that the knock-pin on the right intake camshaft is aligned with the match mark. See Fig. 11.
4. Install the right primary sprocket to the intake camshaft with the RH mark facing forward.
5. Secure the sprocket with the bolt while holding the intake camshaft with a wrench. Tighten the bolt. See
TORQUE SPECIFICATIONS.
6. Install the timing chain tensioner. Secure with the nut. Tighten the nut. See TORQUE
SPECIFICATIONS.
7. Install the primary timing chain to the primary right intake sprocket by aligning the right Silver link on
the chain with the mark on the sprocket.
8. Apply oil to the inside of the idler sprocket and install the sprocket by aligning the left Silver link with the
mark on the idler sprocket.

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9. Install the primary timing chain to the crankshaft sprocket by aligning the Yellow link on the chain with
the mark on the sprocket.
10. Apply oil to the bearing of the idler sprocket.
11. Install the primary timing chain to the idler sprocket and secure the sprocket to the engine block with the
bolt. Tighten the bolt. See TORQUE SPECIFICATIONS.
12. With the latch of the tensioner adjuster returned and the plunger pushed back into the body, insert a
retainer (paper clip or similar tool) into the set hole. After inserting the pin, make sure the plunger will
not come out.
13. Install the tensioner adjuster to the engine block and tensioner. Secure with the 2 bolts. Tighten the bolt.
See TORQUE SPECIFICATIONS.
14. Remove the retainer from the tensioner.
15. Install the timing chain guides. Tighten the bolts. See TORQUE SPECIFICATIONS.
16. Verify that each timing mark is aligned properly. See Fig. 12.
17. Install the left secondary timing chain and tensioner.
18. Install the engine front cover.
19. Install the spark plugs.

Fig. 11: Aligning Right Bank Intake Camshaft

Courtesy of SUZUKI OF AMERICA CORP.

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Fig. 12: Aligning Marks On Right 1st Timing Chain

Courtesy of SUZUKI OF AMERICA CORP.

RIGHT (NO. 2) BANK 2ND TIMING CHAIN & CHAIN TENSIONER

Removal

1. Remove the engine front cover.

2. Remove the left secondary timing chain.
3. Remove the primary timing chain.
4. Remove the 2 bolts and the timing chain guide.
5. Remove the camshaft bearing cap bolts in the proper sequence. See Fig. 13.
6. Remove the camshaft bearing caps.
7. Remove the camshafts and secondary timing chain as a set.
8. Remove the 2 bolts and the timing chain tensioner. See Fig. 14.

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Fig. 13: Right Camshaft Bearing Cap Bolt Removal Sequence

Courtesy of SUZUKI OF AMERICA CORP.

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Fig. 14: Exploded View Of Right Timing Chain & Camshafts

Courtesy of SUZUKI OF AMERICA CORP.

Installation

1. Verify that the keyway on the crankshaft is positioned properly.

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2. Apply oil to the secondary right timing chain tensioner.

3. Install the timing chain tensioner and secure with the 2 bolts. Tighten the bolts. See TORQUE
SPECIFICATIONS.
4. Apply oil to the camshafts lobes and journals.
5. Install the right timing chain to the camshaft sprockets by aligning the Silver or Yellow links with the
marks on the camshaft sprockets. See Fig. 15.
6. Install the camshaft bearing cap pins.
7. Install the camshafts with the timing chain to the cylinder head.
8. Apply oil to the camshaft bearing cap bolts.

NOTE: Cylinder head and camshaft damage may result if the bearing caps are
incorrectly installed.

9. Install the camshaft bearing caps. The caps are marked intake or exhaust, position away from the timing
chain, and direction toward the timing chain. See Fig. 16.
10. Tighten the camshaft bearing caps. See TORQUE SPECIFICATIONS. See Fig. 16 and Fig. 20 .
11. Install the right secondary timing chain guide. Secure with the 2 bolts. Tighten the bolts. See TORQUE
SPECIFICATIONS.
12. Install the primary timing chain.
13. Install the left secondary timing chain.
14. Install the engine front cover.

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Fig. 15: Aligning Right Bank Timing Chain & Camshaft Sprockets Marks
Courtesy of SUZUKI OF AMERICA CORP.

Fig. 16: Installing Right Camshaft Bearing Caps

Courtesy of SUZUKI OF AMERICA CORP.

CAMSHAFT

Removal (Left Exhaust)

1. Remove the Camshaft Position (CMP) sensor.

2. Loosen the camshaft bearing caps in sequence.

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3. Remove the camshaft bearing caps.

4. Remove the camshaft.

Removal (Left Intake)

1. Loosen the camshaft bearing caps in sequence.

2. Remove the camshaft bearing caps. See Fig. 17.
3. Remove the camshafts.

Fig. 17: Left Camshafts Bearing Cap Bolt Removal Sequence

Courtesy of SUZUKI OF AMERICA CORP.

Removal (Right Exhaust)

1. Remove the camshaft bearing cap bolts in the proper sequence. See Fig. 18.
2. Remove the camshaft bearing caps.
3. Remove the camshafts and secondary drive chain as a set.

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Fig. 18: Right Camshafts Bearing Cap Bolt Removal Procedure

Courtesy of GENERAL MOTORS CORP.

Removal (Right Intake)

1. Remove the camshaft bearing cap bolts in the proper sequence.

2. Remove the camshaft bearing caps.
3. Remove the camshafts and secondary drive chain as a set.

Inspection

NOTE: The following tools are required:

l J-26900-2 Micrometer
l J-8001 Dial Indicator Set
l J-26900-13 Magnetic Indicator Base

1. Measure the camshaft lobe height using the J-26900-2. Replace the camshaft if any lobe is below the
minimum. See CAMSHAFT under ENGINE SPECIFICATIONS.
2. Place the camshaft onto V-blocks. Measure the camshaft runout using the J-8001 with the J-26900-13.
Replace the camshaft if the runout exceeds specifications. See CAMSHAFT under ENGINE
SPECIFICATIONS.
3. Inspect the camshaft bearing caps for wear, cracks and scoring.
4. Inspect the camshaft bearing journals in the cylinder head for wear, cracks and scoring.
5. If excessive wear or scoring is present, or if the cylinder head is cracked, replace the cylinder head, with

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bearing caps.
6. Clean the journals of the camshaft and the cylinder head.
7. Do not install the valve lifters.
8. Install the camshafts. The rear end of the exhaust camshaft is slotted to mate with the camshaft position
sensor.

NOTE: Do not turn the camshafts while the plastic gauge is installed.

9. Place a piece of plastic gauge across the full width of each camshaft journal.

NOTE: Cylinder head and camshaft damage may result if the bearing caps are
incorrectly installed. The oil clearance measurement will also be incorrect.

10. Install the camshaft bearing caps. The caps are marked intake or exhaust, position away from the timing
chain, and direction toward the timing chain.
11. Use 3 progressive steps to tighten the camshaft bearing cap bolts in sequence. See TORQUE
SPECIFICATIONS.
12. Remove the camshaft bearing caps.
13. Measure the plastic gauge at it's widest point. See CAMSHAFT under ENGINE SPECIFICATIONS.
14. If the clearance is greater than the maximum perform the following:
l Remove the camshaft.

l Measure the camshaft journal outside diameter with the J-26900-2. See CAMSHAFT under
ENGINE SPECIFICATIONS.
l Install the camshaft bearing caps and torque to 97 INCH lbs (11 N.m).

l Measure the camshaft journal inside (bore) diameter. See CAMSHAFT under ENGINE
SPECIFICATIONS.
15. Replace the component, camshaft or cylinder head with caps, that has the greatest difference from
specification.

Installation (Left Exhaust)

1. Verify that the keyway on the crankshaft is properly positioned.

2. Apply engine oil to the camshaft journals and lobes.
3. Install the camshaft aligning the guide pin with the mark on the cylinder head. The exhaust camshaft rear
end is slotted to mate with the camshaft position sensor.
4. Install the dowel pins to the cylinder head.
5. Apply a bead of GM P/N 12346240, Canadian P/N 10953493 or equivalent to the exhaust camshaft end
housing sealing surface.

NOTE: Cylinder head and camshaft damage may result if the bearing caps are
incorrectly installed.

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6. Install the camshaft bearing caps. The caps are marked intake or exhaust, position away from the timing
chain, and direction toward the timing chain.
7. Apply oil to the camshaft bearing cap bolts.

NOTE: Both camshafts need to be installed and tightened together. See Fig. 19.

8. Tighten the camshaft bearing caps in sequence. See Fig. 19. Tighten to specification. See TORQUE
SPECIFICATIONS.
9. Install Camshaft Position (CMP) sensor.

Installation (Left Intake)

1. Verify the keyway on the crankshaft is properly positioned.

2. Apply engine oil to the camshaft journals and lobes.
3. Install the camshaft aligning the guide pin with the mark on the cylinder head.
4. Install the dowel pins to the cylinder head.

NOTE: Cylinder head and camshaft damage may result if the bearing caps are
incorrectly installed.

5. Install the camshaft bearing caps. The caps are marked intake or exhaust, position away from the timing
chain, and direction toward the timing chain.
6. Apply oil to the camshaft bearing cap bolts.
7. Tighten the camshaft bearing caps. See Fig. 19. See TORQUE SPECIFICATIONS.

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Fig. 19: Left Camshaft Bearing Cap Tightening Sequence

Courtesy of SUZUKI OF AMERICA CORP.

Installation (Right Exhaust)

1. Verify that the keyway on the crankshaft is properly positioned.

2. Apply oil to the camshaft lobes and journals.
3. Install the right timing chain to the camshaft sprockets by aligning the Silver or Yellow links with the
marks on the camshaft sprockets.
4. Install the camshafts with the timing chain to the cylinder head.
5. Install the dowel pins to the cylinder head.
6. Apply oil to the camshaft bearing cap bolts.

NOTE: Cylinder head and camshaft damage may result if the bearing caps are
incorrectly installed.

7. Install the camshaft bearing caps. The caps are marked intake or exhaust, position away from the timing
chain, and direction toward the timing chain. See Fig. 22.
8. Tighten the camshaft bearing caps. See Fig. 20. See TORQUE SPECIFICATIONS.
9. Install the right secondary timing chain guide. Secure with the 2 bolts. See TORQUE
SPECIFICATIONS.

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10. Install the right sprocket and primary timing chain.

11. Install the left secondary timing chain.
12. Install the engine front cover.

Fig. 20: Right Camshaft Bearing Cap Tightening Sequence

Courtesy of SUZUKI OF AMERICA CORP.

Installation (Right Intake)

1. Verify that the keyway on the crankshaft is properly positioned.

2. Apply oil to the camshaft lobes and journals.
3. Install the right timing chain to the camshaft sprockets by aligning the silver or yellow links with the
marks on the camshaft sprockets.
4. Install the camshafts with the timing chain to the cylinder head.
5. Install the dowel pins to the cylinder head.
6. Apply oil to the camshaft bearing cap bolts.

NOTE: Cylinder head and camshaft damage may result if the bearing caps are
incorrectly installed.

7. Install the camshaft bearing caps. The caps are marked intake or exhaust, position away from the timing
chain, and direction toward the timing chain.
8. Tighten the camshaft bearing caps. See Fig. 19.
9. Install the right secondary timing chain guide. Secure with the 2 bolts. See TORQUE
SPECIFICATIONS.

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10. Install the right sprocket and primary timing chain.

11. Install the left secondary timing chain.
12. Install the engine front cover.

VALVE LIFTER

NOTE: Store the valve lifters so that they can be installed in the same bore from which
they were removed. Do not disassemble the valve lifter. Do not apply force to
the body (valve side) of the valve lifter, this will force oil to leak out of the valve
lifter. Store the valve lifters submerged in clean engine oil camshaft side down
until installation. Store the valve lifters camshaft side up if left in air until
installation. Do not store in air with the camshaft side down or on the valve lifter
side.

Removal (Left & Right)

1. Disconnect the negative battery cable. Remove the engine front cover.
2. Remove the spark plugs.
3. Remove the left secondary timing chain. Remove the camshafts.
4. To remove the lifters:
l Store the valve lifters so that they can be installed in the same bore from which they were removed.

l Do not disassemble the valve lifter.

l Do not apply force to the body (valve side) of the valve lifter, this will force oil to leak out of the
valve lifter.
l Store the valve lifters submerged in clean engine oil camshaft side down until installation.

l Store the valve lifters camshaft side up if left in air until installation.

l Do not store in air with the camshaft side down or on the valve lifter side.

5. Remove the lifters. See Fig. 21.

Installation (Left & Right)

1. Pour engine oil into the oil feed hole in the valve lifter bore in order to flush any debris from the gallery
and to prelube the bore.

NOTE: l Do not turn the camshafts or start the engine (valves should not be
operated) for approximately 30 minutes after replacing the valve
lifters and camshafts.
l Allow approximately 30 minutes for the valves to settle in place.
Operating the valves before this time may cause valve or piston
damage.
l The valve(s) may make a tapping/ticking sound after replacement if
air is trapped in the valve lifter. Run the engine at 2000 RPM until the
air is purged from the lifter.

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l If the tapping/ticking does not stop, locate the defective lifter with a
stethoscope and replace. Or, remove the cylinder head cover with the
engine stopped and push the lifter down by hand with a force less
than 44 lbs (20 kg) when the camshaft is on the base circle. If
clearance exists between the camshaft and the lifter, the lifter is
defective and should be replaced.

2. Apply engine oil to the valve lifter and install the valve lifters in the same bore from which they were
removed. See Fig. 21.

Fig. 21: Removing & Installing Valve Lifters

Courtesy of GENERAL MOTORS CORP.

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Fig. 22: Installing Left Camshaft Bearing Caps

Courtesy of SUZUKI OF AMERICA CORP.

CRANKSHAFT REAR OIL SEAL

Removal

1. Mark the flywheel-to-crankshaft position.

2. Remove the flywheel from the crankshaft.

NOTE: To protect the crankshaft from damage, wrap the tip of the screwdriver
with tape.

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3. Carefully pry out the crankshaft rear oil seal using a screwdriver.

Installation

NOTE: The following tool is required: J-41172 Oil Seal Installer.

1. Apply GM P/N 1051344 Chassis Grease to the new crankshaft rear oil seal lip.

NOTE: The J-41172 will install the seal to the correct installed depth. Other sealer
installers may not seat the seal properly and oil leakage may result.

2. Position the new seal in place over the end of the crankshaft.
3. Lightly tap the crankshaft rear oil seal into place using a hammer and the Oil Seal Installer (J-41172).
4. Install the flywheel.

RADIATOR

1. Disconnect the negative battery cable.

2. Remove the radiator cap.
3. Raise and properly support the vehicle.
4. Remove the lower radiator shroud clips.
5. Open the drain plug.
6. Drain the cooling system.
7. Close the drain plug.
8. Remove the transmission oil cooler lines from the bottom of the radiator (automatic transmission only).
Cap the open lines to prevent leakage.
9. Remove the lower radiator hose.
10. Lower the vehicle then remove the radiator overflow hose.
11. Remove the upper radiator hose.
12. Remove the 2 upper radiator shroud clips.
13. Remove the bolts from each side of the radiator.

NOTE: Do not damage the radiator or the fan during removal.

14. Lean the fan shroud toward the engine and lift the radiator up and out of the vehicle.

THERMOSTAT REPLACEMENT

Removal Procedure

1. Drain the engine coolant.

2. Remove the lower radiator pipe bolt (1).

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Fig. 23: Lower Radiator Pipe Bolt

Courtesy of GENERAL MOTORS CORP.

3. Remove the thermostat cap bolts (1), cap (2) and the thermostat.

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Fig. 24: Thermostat Cap Bolts, Cap & Thermostat

Courtesy of GENERAL MOTORS CORP.

Installation Procedure

IMPORTANT: Align the thermostat air bleed valve (1) to the recession on the thermostat case
(2).

1. Position the new thermostat and O-ring on the thermostat case.

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Fig. 25: Positioning New Thermostat & O-Ring On Thermostat Case

Courtesy of GENERAL MOTORS CORP.

2. Secure the thermostat housing cap (2) with two bolts (1).

Tighten

Tighten the thermostat housing bolts to 16 N.m (12 lb ft).

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Fig. 26: Installing Thermostat Housing Cap With Bolts

Courtesy of GENERAL MOTORS CORP.

3. Install the lower radiator pipe bolt.

4. Fill the radiator with an approved coolant.

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Fig. 27: Lower Radiator Pipe Bolt

Courtesy of GENERAL MOTORS CORP.

WATER PUMP

Removal

Remove the negative battery cable. Drain the engine oil. Drain the engine coolant. Remove the engine front
cover. See TIMING CHAIN COVER & FRONT OIL SEAL. Remove the water pump bolts and the water
pump. See Fig. 28.

Installation

Install NEW "O" rings to the water pump. See Fig. 29. Insert the water pump to the cylinder block. Tighten the
bolts to 20 ft. lbs. (27 N.m). Refill the engine coolant. Refill the engine oil. Connect the negative battery cable.
Check the systems for leaks.

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Fig. 28: Identifying Water Pump Bolts

Courtesy of GENERAL MOTORS CORP.

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Fig. 29: Replacing Water Pump "O" Rings

Courtesy of GENERAL MOTORS CORP.

OIL PAN

Removal (Lower)

1. Drain the engine oil.

2. Remove the 2 nuts and 8 bolts from the lower oil pan. See Fig. 30.

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3. Separate the lower oil pan from the upper oil pan.

Removal (Upper)

1. Remove the lower oil pan.

2. Remove the 2 bolts and the oil strainer bracket.
3. Remove the radiator outlet pipe from the upper oil pan.
4. Remove the upper oil pan bolts and lower the oil pan.
5. Remove the 2 bolts that secure the oil pump pipe to the oil.
6. Remove the upper oil pan and oil strainer together.

Installation (Upper)

1. Install a NEW "O" ring to the lower crankcase.

2. Install NEW "O" rings to the oil pump pipe.
3. Apply sealant to the upper oil pan.
4. Place the upper oil pan with the oil pump pipe and screen assembly beneath the crankcase.
5. Install the oil pump pipe and screen assembly and secure with the 2 bolts.
6. Install the upper oil pan to the crankcase and secure with the bolts. Tighten the bolts to 97 INCH. lbs. (11
N.m). See Fig. 31.
7. Install the bracket to the oil strainer. Tighten the bolts to 97 INCH lbs. (11 N.m)
8. Attach the radiator outlet pipe to the upper oil pan.

Installation (Lower)

1. Apply a bead of sealant to the lower oil pan.

2. Install the lower oil pan to the upper oil pan and secure with the 2 nuts and 8 bolts. SeeTORQUE
SPECIFICATIONS.
3. Install the drain plug to the oil pan. See TORQUE SPECIFICATIONS.
4. Fill the engine with oil.

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Fig. 30: Identifying Oil Pan Components

Courtesy of GENERAL MOTORS CORP.

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Fig. 31: Installing Upper Oil Pan

Courtesy of SUZUKI OF AMERICA CORP.

OVERHAUL

NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.

CYLINDER HEAD

WARNING: Compressed valve springs have high tension against the valve spring
compressor. Valve springs that are not properly compressed by or
released from the valve spring compressor can be ejected from the valve
spring compressor with intense force. Use care when compressing or
releasing the valve spring with the valve spring compressor and when
removing or installing the valve stem keys. Failing to use care may cause
personal injury.

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NOTE: The following tools are required:

l J-8062 Valve Spring Compressor

l J-37979 Valve Spring Compressor Adaptor
l J-36017 Valve Guide Seal Remover

Disassembly

NOTE: Keep the valve train components together and identified in order for proper
installation in their original position.

1. Compress the valve spring using the Valve Spring Compressor (J-8062) and the Valve Spring
Compressor Adaptor (J-37979).
2. Remove the valve keepers using a magnet or small screwdriver.
3. Slowly release the Valve Spring Compressor (J-8062) from the valve spring assembly.
4. Remove the retainer and the inner and the outer valve springs. Both the inner and outer valve spring have
a top, large-pitch, and bottom, small-pitch, end. The small-pitch end is installed toward the valve spring
seat.

NOTE: Do not damage the valve guide. Remove any burrs that have formed at the
key groove by chamfering the valve stem with an oil stone or a file.

5. Remove the valve seal using the Valve Guide Seal (J-36017).
6. Remove the spring seat.
7. Remove the valve.
8. Remove the remaining valve springs and valves.

Cleaning & Inspection

1. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by.
2. If the gasket has failed, determine the cause. Gasket failure may be caused by the following:
l Improper installation.

l Loose or warped cylinder head.

l Warped cylinder block surface.

l Missing, off location or not fully dowel pins.

l Corrosion in the seal area around the coolant passages.

l Chips or debris in the cylinder block not drilled or tapped deep enough.

l Incorrect cylinder head bolt torque.

l Incorrect cylinder head bolt length.

3. Inspect the cylinder head gasket surface:

l Cylinder head may be reused if corrosion is found only outside a .375 in (44 mm) band around each
combustion chamber.

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l Replace the cylinder head if the area between the valve seats is cracked.
l Replace the cylinder head if corrosion has been found inside a .375 in (44 mm) band around each
combustion chamber.

NOTE: Do not use a wire brush on any gasket sealing surface. Do not attempt to
weld the cylinder head, replace it.

4. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.
5. Clean the valve guides.
6. Inspect the valve guides for wear.
7. Inspect the valve seats for excessive wear and hot spots.
8. Inspect the valve seating surfaces.
9. Clean the threaded holes. Use a nylon bristle brush.
10. Clean the remains of the sealer from the plug holes.
11. Replace all suspect bolts.
12. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.
13. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
14. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
15. Inspect the intake, the exhaust and the cylinder head deck sealing surfaces.
16. Inspect the cylinder head deck surface for flatness. See CYLINDER HEAD.
17. Inspect the cylinder head intake surface for flatness. See CYLINDER HEAD.
18. Inspect the cylinder head exhaust surface for flatness. See CYLINDER HEAD.
19. If the warpage is greater than the maximum in any of the above measurements, replace the cylinder head.
20. Measure the free length of each valve spring using a Vernier caliper. See VALVES & VALVE
SPRINGS under ENGINE SPECIFICATIONS.
21. If the free length of any valve spring is not within specifications, replace the valve spring.
22. Measure the tension of the valve spring at the specified installed height using a spring tester. See
VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS.
23. If the installed tension of any valve spring is not within specifications, replace the valve spring.
24. Measure the valve spring squareness deviation using a steel square. See VALVES & VALVE SPRINGS
under ENGINE SPECIFICATIONS.
25. If the deviation of any valve spring is greater than the specified maximum, replace the valve spring.
26. Inspect the valve spring seating surface of the valve spring seats for wear or gouging. Replace as
required.
27. Temporarily install the valves into the cylinder head.
28. Measure valve runout, valve face-to-valve seat contact pattern, by performing the following:
l Apply a light coating of Prussian blue to the entire valve face. Seat the valve but do not rotate it.
The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve
seat.
l Clean all traces of Prussian blue.

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l Apply a light coating of Prussian blue to the valve seat and repeat the check. The traces of Prussian
blue transferred to the valve face indicates valve face concentricity.
l Recondition the valve seat and/or replace the valves as necessary.

Reassembly

CAUTION: Compressed valve springs have high tension against the valve spring
compressor. Valve springs that are not properly compressed by or
released from the valve spring compressor can be ejected from the valve
compressor with intense force. Use care when compressing or releasing
the valve spring with the valve spring compressor and when removing or
installing the valve stem keys. Failing to use care may cause personal
injury.

NOTE: The following tools are required:

l J-8062 Valve Spring Compressor

l J-37979 Valve Spring Compressor Adaptor
l J-38232 Valve Guide Seal Installer

1. Install the spring seat to the cylinder head.

2. Install the new valve seals using the Valve Guide Seal Installer (J-38232). Fully seat the seals on the
valve guides.
3. Apply engine oil to the valve stem. Install the valve.

NOTE: Both the inner and outer valve springs have a top, large-pitch, and bottom,
small-pitch end. Install the small-pitch end toward the valve spring seat.

4. Install the springs.

5. Install the retainer.
6. Compress the valve spring using the J-8062 and the J-37979.
7. Install the valve keepers.
8. Slowly release the J-8062 from the valve spring assembly.
9. Lightly tap the valve stem tip with a plastic faced hammer and inspect for proper valve keeper seating.

Valve Springs

Check valve springs for damage. Using a square and flat surface plate, check spring squareness. Using valve
spring tester, check valve spring pre-load pressure. See VALVES & VALVE SPRINGS under ENGINE
SPECIFICATIONS. Replace any weak or out-of-square springs.

Valve Stem Oil Seals

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NOTE: Do not reuse old valve stem oil seals.

Place new lubricated stem seal on valve guide. Using Valve Stem Seal Installer (J-38232), press oil seal onto
valve guide using hand pressure only. When installer bottoms on head, seal is properly positioned. DO NOT
twist seals during installation. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS.

Valve Guides

NOTE: The following tools are required:

l J-37968 Valve Guide Seal/Installer Kit.

l J-37972 11 mm Reamer.
l J-43842 Valve Guide Installer.
l J-38342 (6 mm) Reamer.

1. Tap out the valve guide from the combustion chamber side of the cylinder head using a hammer and the
Valve Guide Seal/Installer Kit (J-37968).

NOTE: Clean the valve guides before reaming. Packing of chips or carbon may
result in the reamer jamming into the valve guide or broken reamer flutes.

2. Ream the valve guide bore with a 11 mm reamer (J-37972).

3. Gradually heat the cylinder head to 176-212°F (80-100°C).

NOTE: Intake and exhaust valve guides are identical. The new valve guide is
0.0012 in (0.03 mm) oversize. Intake and exhaust valve guides should
protrude 0.53 in (13.5 mm) above the cylinder head surface.

4. Tap the new (oversize) valve guide into the cylinder head from the camshaft side using the J-37968, the J-
43842 and a hammer.
5. Install the valve guide to the specified protrusion. See VALVES & VALVE SPRINGS under ENGINE
SPECIFICATIONS. The J-43842 should bottom out on the cylinder head when the specified protrusion
height is reached.
6. Ream the new valve guide with the J-38342.

Valve Seat

NOTE: Proper reconditioning of the valve seats is very important. Because the valve
guide serves to support and center the valve grinder, it is essential that the
valve guide is cleaned properly. If the valve guide requires reaming, this must
be done first.

1. Use the following as a general guideline when reconditioning the cylinder head:
l Ream the valve guide bores first and then recondition the valve seats.

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l Inspect the valve seats for excessive wear and burned spots. Valve seats may be reconditioned by
grinding. If grinding results in the new seat being too wide, it may be narrowed by using a 20
degree or 70 degree stone. The 20 degree stone will lower the seat and the 70 degree stone will
raise the seat.
l The valves must seat perfectly for the engine to deliver optimum power and performance.

l Cooling the valve heads is another important factor. Good contact between each valve and its seat
in the cylinder head is necessary to ensure that the heat in the valve head is properly carried away.
l Regardless of what type of equipment is used, it is essential that the valve guide bores are free from
carbon or dirt to ensure the proper centering of the pilot in the guide.
l The valve seats should be concentric to within .031 in (.05 mm) total indicator reading.

l Replace any valve that is not in serviceable condition.

l Several different types of equipment are available for reconditioning valves and valve seats. Use
the manufacturers recommendations to obtain proper results.
2. Grind the exhaust valve seat first with a 15 degree stone, and then with a 45 degree stone. See VALVES
& VALVE SPRINGS under ENGINE SPECIFICATIONS.
3. Grind the intake valve seat first with a 15 degree stone, then with a 60 degree stone and then with a 45
degree. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS.
4. Lap the valves and seats with a coarse compound and then with a fine compound.
5. Clean all traces of the grinding compound from the valve components before final assembly.

Valves

NOTE: Excessive valve stem to guide clearance may cause a noisy valve train,
premature valve stem oil seal wear, component damage, and/or excessive oil
consumption. Insufficient valve stem to guide clearance will result in noisy or
sticking valves. Valves that are too tight may disturb engine smoothness or
lead to component damage.

1. Inspect for excessive valve stem to guide clearance.

NOTE: Do not scratch the valve stem with the wire brush.

2. Clean the valves of carbon, oil and varnish. Carbon can be removed with a wire brush, varnish can be
removed by soaking in Parts Immersion Solvent GM P/N 12345368 or equivalent.
3. Clean the deposits from the valve face.
4. Inspect the valve face for the following:
l Worn of no margin.

l Pitting.

l Burnt or eroded areas.

l Grooving.

l Deposits.

5. If any of the above conditions exist, replace the valve.

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6. Clean the valve guides with a rifle brush and a suitable solvent.
7. Inspect the valves for the following:
l Burnt or eroded areas.

l A worn margin.

l A bent stem.

l A worn or scored stem.

l A worn or chipped valve keeper groove.

l A worn stem end.

l A bent valve head.

8. If the valves are worn or damaged, replace the valve.

9. Burrs and minor scratches on the valve stem may be removed with an oil stone.
10. The valve stem end may be reconditioned by grinding. Follow the grinder manufacturer's instructions.
11. If the valve face had pieces broken off, inspect the corresponding piston and cylinder head area for
damage.
12. The valves may be lightly lapped to the valve seats.

CYLINDER BLOCK ASSEMBLY

Piston, Connecting Rod, & Bearing Installation

NOTE: The following tool is required: J-8037 Ring Compressor.

NOTE: Install pieces of hose over the threads of the rod bolts. This is to prevent
damage to the bearing journal, the cylinder walls, or the rod bolt threads when
removing the connecting rod. Remove the hose after the connecting rod is in
place.

1. Lubricate the following components with engine oil:

l The Pistons

l The Rings

l The Cylinder Walls

l The Connecting Rod Bearings

l The Crankshaft Journals

2. Ensure that the piston ring end gaps are staggered equally around the piston. See Fig. 33.
3. Install the piston so that the mark on the top of the piston faces the front of the engine.
4. Install the upper connecting rod bearing to the connecting rod.
5. Install a J-8037 over the piston, ensuring it sits firmly against the cylinder block until all of the piston
rings have entered the cylinder bore.

NOTE: Guide the lower connecting rod end carefully to avoid damaging the
crankshaft journal. See Fig. 32.

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6. Install the piston assembly into its matching cylinder bore.

7. Guide the connecting rod into place on the crankshaft.
8. Gently tap the piston into its cylinder bore with a hammer handle.
9. Install the lower connecting rod bearing to the connecting rod cap.
10. Install the connecting rod cap to its matching connecting rod with the arrow pointing towards the front of
the engine. Secure with 2 connecting rod cap nuts. See TORQUE SPECIFICATIONS.
11. Pry the connecting rod back and forth in order to inspect for binding.

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Fig. 32: Locating Stamped Numbers On Cylinder Block & Pistons

Courtesy of SUZUKI OF AMERICA CORP.

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Fig. 33: Positioning Piston Rings

Courtesy of SUZUKI OF AMERICA CORP.

Crankshaft & Main Bearings Removal

1. Remove the 8 mm bolts.

2. Remove the 10 mm bolts in the proper sequence.

NOTE: Do not gouge the sealing surfaces of the 2 halves of the cylinder block
during disassembly.

3. Carefully pry the lower crankcase apart from the cylinder block using a screwdriver.
4. Carefully remove the lower crankcase with the lower bearing inserts.

NOTE: Remove the crankshaft carefully in order to avoid damaging the crankshaft
journals, the rod, the main bearing inserts, or the connecting rods.

5. Remove the crankshaft from the cylinder block.

6. Remove the bearing inserts from the block.

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Crankshaft & Main Bearings Installation

NOTE: The upper main bearings have an oil groove and oil holes, the lower bearings
do not have oil grooves or oil holes.

1. Install the upper main bearings into the cylinder block and lubricate with engine oil.
2. Install the lower main bearings into the lower crankcase and lubricate with engine oil.

NOTE: Install the upper thrust bearing washers with the oil groove facing
outward.

3. Install the 2 upper thrust bearing washers into the cylinder block and lubricate with engine oil.
4. Carefully place the crankshaft on to the main bearings in the cylinder block.
5. Thoroughly clean and remove any oil residue from the cylinder block mating surfaces.

NOTE: Avoid applying an excessive amount of sealant to the surface.

6. Apply a continuous bead of GM P/N 12345997 or equivalent sealant to the cylinder block mating rails.
7. Carefully place the lower crankcase assembly on to the cylinder block.
8. Gently tap the lower crankcase into place with a suitable tool.

NOTE: Gradual and uniform tightening is important for the lower crankcase bolts.

9. Install the long 8 mm bolt finger tight.

10. Install the 8 mm bolts finger tight.
11. Install the 10 mm bolts finger tight.
12. Progressively tighten the 10 mm main bearing cap bolts using 2 steps in the sequence shown. See
TORQUE SPECIFICATIONS.

Undersize Main Bearing Selection

1. If new standard bearings do not produce the correct oil clearance, regrind the crankshaft to a finished
diameter of 2.5485-2.5492 in. (64.732-64.750 mm) and install .0098 in (.25 mm) undersized bearings.
Undersized bearings are available in 5 sizes/tolerances, differing in thickness in the center of the bearing.
2. Undersized bearings are distinguished from standard size bearings by a double paint mark. See COLOR
CODE FOR UNDERSIZE BEARINGS.

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Fig. 34: Identifying Standard & Undersize Bearing Color Marks

Courtesy of SUZUKI OF AMERICA CORP.

3. Measure the reground crankshaft journals for out-of-round. The maximum out-of-round is .0004 in (.01
mm).
4. Measure the reground crankshaft journals for taper. The maximum taper is .0004 in (.01 mm).
5. Measure the reground crankshaft journals for size.
6. Using the intersection of the measured journal size and the letters on the lower crankcase select the
correct sized bearing from the table. Measure the oil clearance. If the oil clearance is incorrect, install the
next thicker bearing and recheck the oil clearance.

COLOR CODE FOR UNDERSIZE BEARINGS

Paint Color Bearing Thickness - In. (mm)
Green & Red .1031-.1032 (2.619-2.621)
Black & Red .1032-.1033 (2.621-2.625)
Red Only .1033-.1034 (2.624-2.628)
Yellow & Red .1034-.1035 (2.627-2.631)
Blue & Red .1035-.1036 (2.630-2.634)
Pink & Red .1037-.1038 (2.633-2.637)

UNDERSIZE JOURNAL BEARING APPLICATION

Letters Stamped 2.5489-2.5492 " (64.742- 2.5487-2.5489" (64.737- 2.5485-2.5487"(64.732-
On Lower 64.750 mm) Diameter 64.742 mm) Diameter 64.737 mm) Diameter

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Crankcase Bearing Color Bearing Color Bearing Color

A Green & Black Black & Red Red
B Black & Red Red Yellow & Red
C Red Yellow & Red Blue & Red

Thrust Bearing

The crankshaft thrust bearing is available in standard and oversize. Standard thrust bearing thickness .984 in
(2.500 mm). Oversize thrust bearing thickness is .1009 in (2.563 mm). If the end play exceeds the maximum
replace the thrust bearing with a new standard size thrust bearing. If the end play still exceeds the maximum
replace the thrust bearing with a new oversize thrust bearing.

Cylinder Block Cleaning & Inspection

NOTE: The following tool is required: J-8087 Cylinder Bore Gage

1. Clean the sealing material from the gasket mating surfaces.

2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or stream.
4. Clean the oil passages.
5. Clean the coolant passages.
6. Clean the blind holes.
7. Spray the cylinder bores and the machined surfaces with engine oil.
8. Inspect the threaded holes. Clean the threaded holes with a rifle brush.
9. Measure the deck surface for flatness using a straightedge and a feeler gage. Carefully machine minor
irregularities. Replace the block if warpage exceeds .0024 in (.06 mm).
10. Inspect the lower crankcase rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill
file to remove any nicks.
11. Inspect the cylinder block for any cracks.
12. Visually inspect the cylinder bores for excessive wear or excessive ridging.
13. Measure the cylinder bore taper, out-of-round and size using the Cylinder Bore Gage (J-8087):
l The maximum cylinder taper is .004 in (.10 mm)

l Maximum cylinder out-of-round is .004 in (.10 mm)

l Maximum cylinder bore diameter is 3.3090 in (84.050 mm)

14. Measure the pistons. Pistons are available in 2 standard and 2 oversizes.
A. Standard size piston diameter:
l 3.3059-3.3062 in (83.970-83.980 mm)

l 3.3063-3.3067 in (83.980-83.990 mm)

B. .0098 in (.25 mm) oversize piston diameter:

l 3.3157-3.3156 in (84.220-84.240 mm)

C. .0196 in (.50 mm) oversize piston diameter:

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l 3.3256-3.32634 in (84.470-84.490 mm)

15. Subtract the piston diameter from the cylinder bore diameter. The piston-to-cylinder bore clearance
should be .0008-.0015 in (.02-.04 mm) for each piston cylinder.

NOTE: If the bore is worn beyond the limits, rebore all 6 cylinders and fit with
oversized pistons. Select the smallest available oversize piston.

16. Leave sufficient material to allow honing when fitting the piston.
17. Calculate the cylinder bore diameter to be rebored. D = A+B-C when:
l D = The cylinder bore diameter to be rebored.

l A = The measured piston diameter.

l B = The piston clearance: .0008-.0015 in (.02-.04 mm).

l C = The allowance for honing: .0008 in (.02 mm).

18. Install the lower crankcase and torque to specifications before boring or honing. This will avoid distortion
of the cylinder block.
19. Bore and hone the cylinders to the calculated dimension.
20. Measure the piston clearance after the honing is completed.

ENGINE OILING
ENGINE LUBRICATION SYSTEM

The oil pump is of a trochoid type, and is mounted under the crankshaft. Oil is drawn up through the oil pump
strainer and passed through the pump the oil filter. The filtered oil flows into 3 paths in the cylinder block. In
one path, the oil reaches the crankshaft journal bearings. Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting passages drilled in the crankshaft, and then injected from
the big end of the connecting rod to lubricate the piston, rings, and cylinder wall. In other paths oil goes up to
the cylinder heads and lubricates valves and camshafts after passing through the internal oilway of camshafts.
An oil relief valve is provided on the oil pump. This valve starts relieving oil pressure when the pressure
exceeds about 61.1 psi (430 kPa).

Crankcase Capacity

1. Install the oil filter.

2. Install the oil pan drain plug bolt. Tighten the oil pan drain bolt. See TORQUE SPECIFICATIONS.
3. Lower the vehicle.
4. Fill the engine with oil to the appropriate mark.

NOTE: Oil capacity with oil and filter change is 3.9 quarts (3.7 liters). Oil capacity
with oil change only is 3.7 quarts (3.5 liters).

5. Start the engine and check for leaks.

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Oil Pressure

1. Remove the oil pressure switch from the engine block.

2. Install a pressure gage in place of the oil pressure switch.
3. Start the engine and run at idle until normal operating temperature is reached.
4. Raise the engine speed to 4000 RPM and measure the oil pressure. Normal oil pressure is 47-61 psi (330-
430 kPa) at 4000 RPM.
5. Stop the engine.
6. Remove the pressure gage.
7. Install the oil pressure switch. Tighten the oil pressure switch. See TORQUE SPECIFICATIONS.
8. Run the engine and inspect for oil leaks from the oil pressure switch.

OIL PUMP

NOTE: Do not remove the oil pump sprocket or sprocket bolt.

NOTE: If the oil pump is found to be damaged or worn excessively replace the oil pump
as an assembly.

Removal

1. Remove the front engine cover. Refer to TIMING CHAIN COVER & FRONT OIL SEAL.
2. Remove the lower oil pan. Refer to REMOVAL (LOWER).
3. Remove the upper oil pan. Refer to REMOVAL (UPPER).
4. Loosen the 2 bolts (1) that secure the oil pump chain guide.

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Fig. 35: Loosening Bolts Securing Oil Pump Chain Guide

Courtesy of GENERAL MOTORS CORP.

5. Remove the 3 bolts and the oil pump (1).

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Fig. 36: Bolts & Oil Pump

Courtesy of GENERAL MOTORS CORP.

Disassembly

1. Remove the 5 bolts and separate the oil pump halves.

2. Remove the retainer, the spring and the relief valve.
3. Apply light air pressure to the oil jet. Inspect the oil jet for damage or clogging.
4. Remove and inspect the relief valve. Coat the relief valve with oil and check that it falls smoothly into the
valve hole by it's own weight.

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Cleaning & Inspection

NOTE: If the oil pump is found to be damaged or excessively worn replace the oil pump
as an assembly.

1. Inspect the following for excessive wear or damage:

l The oil pump outer gear.

l The oil pump inner gear.

l The oil pump cover.

l The oil pump body.

2. Measure the radial clearance between the oil pump outer gear and the oil pump body using a feeler gage.
Replace the oil pump if the clearance exceeds .0043 in (.15 mm).
3. Measure the side clearance between the oil pump gears and a straightedge using a feeler gage. Replace
the oil pump if the clearance exceeds .0043 in (.11 mm).
4. Measure the free length of the oil pressure relief spring. Replace the spring if the free length is less than
2.5 in (63.5 mm).
5. Measure the oil pressure relief spring tension. Replace the spring if the tension is less than 62 lbs at 2.05
in (86.0 Newtons at 52 mm).

OIL PUMP SPECIFICATIONS

Application Specification
Rotor
Radial Clearance .0059" (.150 mm)
Side Clearance .0043" (.109 mm)
Relief Spring
Free Length 2.5" (63.5 mm)
Spring Preload 19 lbs. @ 2.05" (8.6 kg. @ 52.07
mm)

Reassembly

1. Lubricate the following with clean engine oil:

l The oil pump inner gear.

l The oil pump outer gear.

l The inside surface of the oil pump body.

2. Install the oil pump outer and inner gears to the oil pump body.

NOTE: Fill oil pump cavities with petroleum jelly prior to installation. This will
ensure that there is oil pressure immediately on start-up and will prevent
engine damage.

3. Fill the oil pump with petroleum jelly to prime the oil pump.

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4. Install the relief valve, the spring and retainer. See TORQUE SPECIFICATIONS.
5. Install the oil pump cover to the oil pump body. Secure the cover with 5 bolts. See TORQUE
SPECIFICATIONS.

Installation

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

1. Install the oil pump with the chain on the sprocket and secure with the 3 bolts verifying the long bolt (3)
is in the proper location.

Tighten

Tighten the bolts to 27 N.m (19.5 lb ft).

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Fig. 37: Bolts & Oil Pump

Courtesy of GENERAL MOTORS CORP.

2. Push the center of the oil pump chain guide with a force of 0.5-0.6 N (0.11-0.13 lb) and secure the guide
with the 2 bolts (1).

Tighten

Tighten the 2 bolts to 11 N.m (7.5 lb ft).

3. Install the front engine cover. Refer to TIMING CHAIN COVER & FRONT OIL SEAL.
4. Install the upper oil pan. Refer to REMOVAL (UPPER).

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5. Install the lower oil pan. Refer to REMOVAL (LOWER).

Fig. 38: Tightening Bolts Securing Oil Pump Chain Guide

Courtesy of GENERAL MOTORS CORP.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Air Conditioner (A/C) Compressor Bracket Mounting Bolts 40 (55)
Air Conditioner (A/C) Compressor Mounting Bolts 17 (23)
Camshaft Position Sensor Bolt 11 (15)
Camshaft Timing Sprocket Bolts 58 (80)
Connecting Rod Bearing Cap Nuts 33 (45)
Crankshaft Pulley Bolt 109 (150)
Cylinder Head Bolts (1)

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First Step 39 (53)

Second Step 61 (84)
Third Step Loosen to 0
Fourth Step 39 (53)
Fifth Step 61 (84)
Sixth Step (Final Torque) 76 (105)
Accessory Drive Belt Tensioner Bolts 19 (25)
Engine Cooling Fan Nuts 18 (25)
Engine Ground Wire Bolts 11 (15)
Engine Mount Nuts 37 (50)
Engine Oil Drain Plug 26 (35)
Exhaust Manifold-to-Bracket Bolts 37 (50)
Exhaust Manifold-to-Cylinder Head Nuts 22 (30)
Flywheel Retaining Bolts (Automatic Transmission) 51 (70)
Fuel Rail Banjo Fitting 22 (30)
Generator Mounting Bolts and Nuts 17 (23)
Heated Oxygen (HO2S1 and HO2S2) Sensor 33 (45)
Intake Manifold Bolts and Nuts 17 (23)
Lower Crankcase Bolts
First Step 14 (19)
Second Step (Final Torque) 20 (27)
Main Bearing Cap Bolts
First Step 31 (42)
Second Step (Final Torque) 42 (58)
Negative Battery Cable 11 (15)
Oil Pressure Switch 11 (14)
Oil Pump Bolts 20 (27)
Power Steering Pump Bolts 19 (25)
Spark Plugs 18 (25)
Strut Tower Brace 37 (50)
Timing Chain Tensioner Nuts (Left Camshaft) 33 (45)
Timing Chain Tensioner Shoe Nut (Primary) 20 (27)
Torque Converter Bolts 65 (47)
Transmission to Engine Mounting Bolts 58 (80)
Water Pump Bolts 20 (27)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolts (2)(3) 106 (12)
Crankshaft Position Sensor Bolt 53 (6)
Cylinder Head Cover Bolts 93 (10.5)
Cylinder Head M6 Bolt 97 (11)
Engine Oil Pan Nuts and Bolts 97 (11)

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Exhaust Manifold Heat Shield Bolts 89 (10)

Generator Terminal Nut 71 (8)
Ignition Coil Bolts 89 (10)
Oil Pump Case Bolts 106 (12)
Oil Pump Strainer Bolts 97 (11)
Starter Bolts 97 (11)
Throttle Body Bolts and Nuts 106 (12)
Timing Chain Cover Nuts and Bolts 97 (11)
Timing Chain Guide Bolts (Primary) 79 (9)
Timing Chain Tensioner Bolts (Left Camshaft) 106 (12)
Timing Chain Tensioner Bolts (Right Camshaft) 97 (11)
Timing Chain Tensioner Bolts (Primary) 97 (11)
(1) Tighten in sequence. See Fig. 39.

(2) Tighten in sequence. See Fig. 20.

(3) Tighten in sequence. See Fig. 19.

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Fig. 39: Cylinder Head Bolt Tightening Sequence

Courtesy of SUZUKI OF AMERICA CORP.

ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Application Specification

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Displacement 153 Cu. In. (2.5L)

Bore 3.31" (84 mm)
Stroke 2.95" (75.0 mm)
Compression Ratio 9.5:1
Fuel System SFI

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application In. (mm)
Crankshaft
End Play
Standard .0044-.0122 (.112-.310)
Limit .0149 (.378)
Runout (Center Journal) .0023 (.058)
Thrust Bearing
Standard .0984 (2.500)
Oversize .1009 (2.563)
Main Bearings
Journal Diameter
Size Mark "1" 2.5588-2.5590 (64.994-
65.999)
Size Mark "2" 2.5586-2.5588 (64.988-
64.994)
Size Mark "3" 2.5583-2.5586 (64.981-
64.988)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance
Standard .0008-.0016 (.020-.040)
Limit .0023 (.058)
Bearing Cap Bore Diameter
"A" 2.7559-2.7561 (69.999-70.005)
"B" 2.7561-2.7563 (70.005-70.010)
"C" 2.7563-2.7566 (70.010-70.018)
Connecting Rod Bearings
Journal Diameter
Standard 1.9678-1.9685 (49.982-
49.999)
Undersize 1.9580-1.9586 (49.733-
49.748)
Journal Out-Of-Round .0004 (.010)

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Journal Taper .0004 (.010)

Oil Clearance
Standard .0010-.0022 (.025-.056)
Limit .0031 (.079)

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS
Application In. (mm)
Bore Diameter
Pin Bore .8269-.8272 (21.003-21.011)
Maximum Bend .0020 (.050)
Maximum Twist .0039 (.099)
Side Play
Standard .0099-.0157 (.251-.399)
Limit .0177 (.450)

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

Application In. (mm)
Pistons
Clearance .0008-.0015 (.020-.038)
Diameter 3.3063-3.3067 (83.980-83.990)
Pins
Diameter .8266-.8268 (20.996-21.000)
Piston Fit Slip
Rod Fit Slip
Rings
No. 1
End Gap
Standard .0079-.0137 (.200-.348)
Limit .0276 (.701)
Side Clearance .0012-.0027 (.030-.069)
No. 2
End Gap
Standard .0138-.0196 (.351-.498)
Limit .0276 (.701)
Side Clearance .0008-.0023 (.020-.058)
No. 3 (Oil)
End Gap
Standard .0079-.0275 (.201-.699)

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Limit .0709 (1.801)

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK
Application In. (mm)
Cylinder Bore
Diameter (1)
Size Mark "1" 3.3075-3.3078 (84.010-84.018)
Size Mark "2" 3.3071-3.3074 (84.000-84.008)
Maximum Limit 3.3090 (84.049)
Maximum Taper .004 (.10)
Maximum Out-Of-Round .004 (.10)
Maximum Deck Warpage .0024 (.061)
(1) Cylinder bore diameter determined by number stamped on block head surface.

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

Application In. (mm)
Intake Valves
Face Angle 45 Degrees
Head Thickness
Standard .039 (.99)
Limit .023 (.58)
Face Width .0433-.0512 (1.099-1.300)
Stem Diameter .2348-.2354 (5.964-5.979)
Exhaust Valves
Face Angle 45 Degrees
Head Thickness
Standard .047 (1.19)
Limit .027 (.69)
Face Width .0433-.0512 (1.099-1.300)
Stem Diameter .2339-.2344 (5.941-5.954)
Valve Springs
Free Length
Inner Standard 1.4204 (36.078)
Inner Service Limit 1.3780 (35.001)
Outer Standard 1.5921 (40.439)
Outer Service Limit 1.5441 (39.220)
Out-Of-Square

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Inner (1)

Outer (1)

Side Clearance
Inner .063 (1.63)
Outer .070 (1.77)
Lbs. @ In. (kg @ mm)
Pressure
Inner Standard 15.2-17.4 @ 1.08 (6.9-7.9 @
27.43)
Inner Service Limit 13 @ 1.08 (5.9 @ 27.43)
Outer Standard 33.9-39.2 @ 1.25 (15.4-17.8
@ 31.75)
Outer Service Limit 30 @ 1.25 (13.3 @ 31.75)
(1) Information is not available from manufacturer.

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD
Application In. (mm)
Maximum Warpage
Head-To-Block .002 (.05)
Manifold-To-Block .004 (.10)
Valve Seats
Seat Angle 45 Degrees
Seat Width .0433-.0512 (1.099-1.300)
Valve Guides
Valve Guide I.D. .2362-.2367 (5.999-6.012)
Valve Guide Installed Height .53 (13.5)
Valve Stem-To-Guide Oil Clearance
Intake Valve
Standard .0008-.0018 (.020-.046)
Limit .0027 (.069)
Exhaust Valve
Standard .0018-.0028 (.046-.071)
Limit .0035 (.089)

CAMSHAFT SPECIFICATIONS

CAMSHAFT
Application In. (mm)
Bore Diameter 1.0236-1.0249 (25.999-26.032)

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Journal Diameter 1.0220-1.0228 (25.959-25.979)

Journal Runout .0039 (.099)
Lobe Height
Intake
Standard 1.5530-1.5593 (39.446-39.606)
Limit 1.5512 (39.400)
Exhaust
Standard 1.5523-1.5586 (39.428-39.588)
Limit 1.5512 (39.400)
Oil Clearance
Standard .0008-.0029 (.020-.074)
Limit .0047 (.119)

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