Suzuki Aerio, Verona 2002-06

Balance Shaft

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Removal & Installation



8-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect or remove the following:

    Engine fan, refer to Engine Fan removal and installation
     
    Engine coolant
     
    Coolant hoses
     
    Intake manifold
     
    Water pump
     
    Exhaust manifold on Bank 1 with catalytic converter
     
    Timing chain. Refer to Timing Chain and Sprockets removal and installation
     
    Variable valve timing (VVT) units on intake and exhaust camshafts, Bank 1. Refer to Camshaft and Valve Lifters removal and installation

    Click image to see an enlarged view

    Fig. Exhaust manifold and catalytic converter removal-8-Cylinder Engine

     

  4.  
  5. Remove camshafts.
  6.  
  7. Lift out the valve lifters using a magnet or suction cup.
    NOTE
    Make a note of the positions of each part.



    Click image to see an enlarged view

    Fig. Valve lifters location-8-Cylinder Engine

  8.  
  9. Remove the balance shaft.
    NOTE
    Check that the engine block has a drainage hole by the rear balance shaft bearing. If there is no drainage hole, one will need to be drilled.



    Click image to see an enlarged view

    Fig. Location of drainage hole for rear balance shaft bearing-8-Cylinder Engine



    Click image to see an enlarged view

    Fig. Drilling drainage hole for balance shaft bearing-8-Cylinder Engine

  10.  
  11. To drill the drainage hole for rear balance shaft bearing:

    Drill down to the drainage duct using the correct drill bit 0.315 inch (8mm)
     
    Carefully blow the area clean after drilling
     

  12.  

To install:

  1. Install balance shaft into position.
  2.  
  3. Install cylinder head and tighten bolts in sequence from center outwards in two steps:
    1. Step 1-30 ft. lbs. (40 Nm).
    2.  
    3. Step 2-angle-tighten 90°.

      Click image to see an enlarged view

      Fig. Cylinder head torque sequence-8-Cylinder Engine

    4.  

  4.  
  5. Install the valve lifters.
    NOTE
    If the cylinder head has been replaced, the valve clearance must be adjusted. Refer to Valve Lash adjustment.

  6.  
  7. Lubricate and install valve lifters.
  8.  
  9. Install:

    Exhaust manifold and tighten the eight M8 nuts to 18 ft. lbs. (24 Nm)
     
    Two M8 bolts for the exhaust manifold bracket and tighten to 18 ft. lbs. (24 Nm)
     
    The M8 bolt and two M8 nuts attaching coolant pipes and tighten to 18 ft. lbs. (24 Nm)
     
    Two M8 upper bolts holding the water pump and tighten to 18 ft. lbs. (24 Nm)
     
    Coolant hoses and clamps
     
    Camshafts
     
    Timing chain and sprockets
     
    Camshaft cover
     
    Ignition coils
     
    Air induction pipe.
     
    Intake manifold, refer to Intake Manifold removal and installation.
     
    Engine fan, refer to Engine Fan removal and installation
     

  10.  
  11. Refill the cooling system using the proper grade and type of engine coolant.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Run engine and allow it to reach full operating temperature. Recheck fluid levels. Fill as required.
  16.  

 
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