Suzuki Aerio, Verona 2002-06

Camshaft, Bearings & Lifters

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Bearing Replacement



Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary.

Inspection



  1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
  2.  
  3. Check the cam lobes for damage. If the lobe is damaged or excessively worn, replace the camshaft.
  4.  
  5. Measure the cam lift height. The specifications for cam lobe height:
    1. 5-Cylinder Engines-Intake 0.331 inch (8.40mm), Exhaust 0.356 inch (9.05mm)
    2.  
    3. 6-Cylinder Engines-Intake 0.331 inch (8.40mm), Exhaust 0.356 inch (9.05mm)
    4.  

  6.  
  7. Check the cam surface for abnormal wear or damage, and replace if necessary.
  8.  
  9. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary.
  10.  

Removal & Installation



2.0L And 2.3L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove or disconnect the following:

    Engine assembly
     
    Oil pan
     
    Timing chains
     
    Camshaft position (CMP) sensor
     

  8.  
  9. To secure work in the following steps, reinstall mounting member, engine front torque bush, rear mounting and rear mounting No.2 bracket.
  10.  
  11. Set key on crankshaft in position by turning crankshaft. This is to prevent interference between valves and piston.
  12.  
  13. Loosen camshaft housing bolts in such order as indicated in figure and remove them.
    NOTE
    Never disassemble hydraulic valve lash adjuster. Don-t apply force (1) to body of adjuster, oil in high pressure chamber in adjuster will leak.



    Click image to see an enlarged view

    Fig. Loosen the camshaft bearing caps in the sequence shown-2.0L and 2.3L engine



    Camshaft housings
     
    Camshafts
     
    Valve lash adjusters
     

  14.  
  15. Immerse removed adjuster in clean engine oil and keep it there until reinstalling it so as to prevent oil leakage. If it is left in air, place it with its bucket body facing down. Don-t place on its side or with bucket body facing up.
  16.  

To install:

  1. Before installing valve lash adjuster to cylinder head, fill oil passage of cylinder head with engine oil according to following procedure:


    1. Pour engine oil through oil holes and check that oil comes out from oil holes in sliding part of valve lash adjuster.
    2.  
    3. Perform this check on both intake and exhaust sides.
    4.  

  2.  
  3. Install valve lash adjusters to cylinder head. Apply engine oil around valve lash adjuster and then install it to cylinder head.
  4.  
  5. Match matchmark on crank timing sprocket and mating surface of cylinder block and lower crankcase.
  6.  
  7. Lubricate the lobes and journals of the camshaft with clean engine oil.
  8.  
  9. Install or connect the following:



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2.0L and 2.3L engines

    Camshafts
     

  10.  
  11. Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match marks on cylinder head and camshafts.
    NOTE
    Install camshaft in such direction that its end with groove for CMP sensor installation comes to exhaust side.



    Camshaft housing pins
     

  12.  
  13. Check position of camshaft housings.
  14.  
  15. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housings as indicated by these marks.
  16.  
  17. Apply sealant to exhaust camshaft end housing sealing surface area.
  18.  
  19. After applying oil to housing bolts, tighten them temporarily first. Then tighten them by following numerical order in figure.
  20.  
  21. Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to 8 ft. lbs. (11 Nm).

    CMP sensor
     
    Timing chains
     
    Oil pan
     
    Engine assembly
     
    Negative battery cable
     

  22.  
  23. Start the engine and check for any water or oil leaks when finished.
  24.  
  25. Check ignition timing as necessary.
    NOTE
    Don-t turn camshafts or start engine (i.e., valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and camshafts. As it takes time for valves to settle in place, operating engine within half an hour after their installation may cause interference to occur between valves themselves or valves and piston.

  26.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Make sure the engraved position numbers on the camshaft caps are not mixed up. Camshaft caps should follow the numeric order when installing, intake camshaft caps 1-3-5-7-9-11-13 and exhaust camshaft caps 2-4-6-8-10-12-14.



    Cylinder head
     
    Intake cam sprocket and exhaust cam sprocket
     
    Camshaft cap bolts gradually and in sequence
     



    Intake camshaft and exhaust camshaft

    Click image to see an enlarged view

    Fig. Loosen the camshaft bearing caps in the sequence shown-2.5L engine

     

  8.  

To install:

  1. Installation should follow the removal procedure in the reverse order.
  2.  
  3. Lubricate the lobes and journals of the camshafts with clean engine oil.
  4.  
  5. Install or connect the following:
    NOTE
    The intake camshaft can be identified by the groove near the cam sprocket flange. The exhaust camshaft has no groove.


    NOTE
    Make sure the engraved position numbers on the camshaft caps are not mixed up. Camshaft caps should follow the numeric order when installing, intake camshaft caps 1-3-5-7-9-11-13 and exhaust camshaft caps 2-4-6-8-10-12-14.



    Intake and exhaust camshafts
     



    Click image to see an enlarged view

    Fig. Camshaft cap installation sequence-2.5L engine



    Camshaft caps in sequence
     



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2.5L engine

  6.  
  7. Tighten the camshaft cap bolts in sequence to 89-124 inch lbs. (10-14 Nm).
    NOTE
    Intake and exhaust cam sprockets are identified by the engraved marks, -IN- for intake and -EX- for exhaust respectively.



    Cam sprockets. Tighten the cam sprocket bolts to 13-16 ft. lbs. (18-22 Nm).
     



    Cylinder head
     
    Negative battery cable
     

  8.  
  9. Start the engine and check for any water or oil leaks when finished.
  10.  
  11. Check ignition timing as necessary.
  12.  

5- & 6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belt
     
    Front cover
     
    Timing belt
     
    Ignition coil cover
     
    Camshaft Position (CMP) sensor or distributor, as equipped
     
    Switch holder and shield at left rear of the engine
     
    Ignition coils
     
    Camshaft sprockets
     
    Cylinder head cover
     
    Camshafts
     
    Hydraulic lash adjusters
     

  4.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters
     
    Camshafts
     
    Cylinder head cover and tighten the bolts to 13 ft. lbs. (17 Nm)
     
    Camshaft sprockets and tighten the bolts to 15 ft. lbs. (20 Nm)
     
    Ignition coils
     
    Switch holder and shield at left rear of the engine
     
    CMP sensor or distributor, as equipped
     
    Ignition coil cover
     
    Timing belt
     
    Front cover
     
    Accessory drive belt
     
    Negative battery cable
     

  2.  

8-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove intake manifold. Refer to Intake Manifold removal and installation.
  4.  
  5. Remove air induction pipe.
  6.  
  7. Remove ignition coils on the left and right banks, refer to Ignition Coil Pack removal and installation.
  8.  
  9. Remove camshaft covers, refer to Camshaft Covers removal and installation.
  10.  
  11. Remove timing chain, refer to Timing Chain and Sprockets removal and installation.
  12.  
  13. Turn the crankshaft back approximately 45° so that the position setting tool is straight up.
    NOTE
    The camshafts should rotate freely.



    Click image to see an enlarged view

    Fig. Position setting tool installed backed off 45°-8-Cylinder Engine

  14.  
  15. Remove load from the camshafts and valve lifters:
    1. For Bank 1, cylinders 1-3-5-7, turn the camshafts approximately 45° clockwise.

      Click image to see an enlarged view

      Fig. Removing load from Bank 1 camshafts-8-Cylinder Engine

    2.  
    3. For Bank 2, cylinders 2-4-6-8, turn the camshafts approximately 10° counter-clockwise.

      Click image to see an enlarged view

      Fig. Removing load from Bank 2 camshafts-8-Cylinder Engine

    4.  

  16.  
  17. Remove the variable valve timing (VVT) unit:

    Remove the 4 M6 bolts and the cap
     
    Remove the 2 M6 bolts for the chain tensioner
     
    Discard the 2 filters

    Click image to see an enlarged view

    Fig. Removing the variable valve timing (VVT) unit-8-Cylinder Engine

     

  18.  
  19. Remove the 8 M6 bolts holding the intake camshaft bearing caps.
    NOTE
    Ensure that the camshaft is relieved from load against the valve lifters to prevent damaging the components. Note location of components.

  20.  
  21. Remove the chain tensioner.
  22.  
  23. Remove the camshaft.
  24.  
  25. To remove exhaust camshaft, remove the 8 M6 bolts holding the exhaust camshaft bearing caps and remove exhaust camshaft.
  26.  
  27. Remove the valve lifters using a magnet or suction cup. Make note of the position of each lifter.

    Click image to see an enlarged view

    Fig. Removing camshaft and chain-8-Cylinder Engine

  28.  

To install:

  1. Install valve lifters, refer to Valve Lifters adjustment.
  2.  
  3. Install VVT unit on the camshaft with 1 M10 bolt, but do not tighten.
  4.  
  5. Install the camshaft, chain, and chain tensioner.
    NOTE
    Adjust the marking on the VVT unit to the color marking on the camshaft chain.



    Click image to see an enlarged view

    Fig. Aligning timing marks on VVT unit-8-Cylinder Engine

  6.  
  7. Install the camshaft bearing caps and tighten to 88 inch lbs. (10 Nm).
  8.  
  9. Install 2 new filters.
  10.  
  11. Install the 4 M6 bolts on the end cap of the camshafts and tighten to 18 inch lbs. (10 Nm).
  12.  
  13. Install the 2 M6 bolts for the chain tensioner and tighten to 18 inch lbs. (10 Nm).
  14.  
  15. Install tool 999 7236.

    Click image to see an enlarged view

    Fig. Installation of camshaft tool 999 7236-8-Cylinder Engine

  16.  
  17. Minimize the slack of the camshaft chain.
    1. Use tool 999 7232.
    2.  
    3. For cylinder head 1, 3, 5 and 7 (Bank 1), turn the VVT unit on the exhaust camshaft counter-clockwise, until the chain is tensioned underneath.
    4.  
    5. For cylinder head 2, 4, 6 and 8 (Bank 2), turn the VVT unit on the exhaust camshaft counter-clockwise, until the chain is tensioned on top.
    6.  
    7. Tighten the bolt in the center of the intake camshaft VVT unit. Tighten to 15 ft. lbs. (20 Nm).
    8.  

  18.  
  19. Install tool 999 7229 on the intake camshaft.
  20.  
  21. Tighten the center 1 M10 bolt on the camshaft to 37 ft. lbs. (50 Nm).
  22.  
  23. Remove the counterhold.

    Click image to see an enlarged view

    Fig. Adjusting camshaft chain tension-8-Cylinder Engine



    Click image to see an enlarged view

    Fig. Installation of camshaft tool 999 7229-8-Cylinder Engine

  24.  
  25. Install timing chain, refer to Timing Chain and Sprockets removal and installation.
  26.  
  27. Install camshaft covers, refer to Camshaft Covers removal and installation.
  28.  
  29. Install ignition coils on the left and right banks, refer to Ignition Coil Pack removal and installation.
  30.  
  31. Install air induction pipe.
  32.  
  33. Install intake manifold. Refer to Intake Manifold removal and installation.
  34.  

 
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