Suzuki Aerio, Verona 2002-06

Crankshaft Damper (Balancer)

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Removal & Installation



5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The cross stay between the suspension turrets
     
    The servo reservoir and the expansion tank. Lift up and place on top of the engine.
     
    The accessory drive belt, refer to Accessory Drive Belts removal and installation
     
    The upper timing belt cover
     
    Remove the right front wheel
     
    Remove the nut from the cover in the fender liner
     

  4.  
  5. Install counterhold 999 5433 on the crankshaft damper.
  6.  
  7. Remove crankshaft damper center nut.
  8.  
  9. Work the crankshaft damper loose and remove by hand.

    Click image to see an enlarged view

    Fig. Using Counterhold 999 5433 to remove crankshaft damper-5-Cylinder Engines

  10.  

To install:

  1. Install the crankshaft damper and tighten the center nut to 133 ft. lbs. (180 Nm).
  2.  
  3. Remove the counterhold 999 5433 and install new bolts. Tighten to 18 ft. lbs. (25 Nm) and angle-tighten 30°.
  4.  
  5. Turn the crankshaft 2 turns. Check that the markings on the crankshaft damper and camshaft pulley correspond.
  6.  
  7. Install or connect the following:
    NOTE
    Ensure that the hoses are correctly positioned.



    Front timing belt cover. Tighten to 106 inch lbs. (12 Nm)
     
    Upper timing belt cover
     
    Accessory belt
     
    Servo reservoir
     
    Expansion tank
     



    Engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm)
     
    Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm)
     
    Fender liner cover
     
    Front wheel and tighten lug nuts to 102 ft. lbs. (138 Nm)
     

  8.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove:

    The bolt holding the engine stabilizer brace to the bracket on the engine
     
    The bolts holding the engine stabilizer brace to the suspension turrets
     
    The engine stabilizer brace.
     

  4.  
  5. Remove the plastic pipes between the turbocharger and charge air cooler and between the air cleaner and turbocharger. Put them to one side.
  6.  
  7. Remove the clamp from the intake manifold for the turbocharger for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the firewall.
  8.  
  9. Relieve the load from the belt tensioner and remove the accessory belt.
  10.  
  11. Remove the upper timing belt cover.
  12.  
  13. Remove the front timing belt cover.
    1. The air duct, cover, surround and control module box
    2.  
    3. The hose between the thermostat housing and the expansion tank
    4.  
    5. The front timing belt cover.
    6.  

  14.  
  15. Lift up the servo reservoir and place it on top of the engine.
    NOTE
    Ensure that the oil does not leak from the ventilation hole in the filler cap.

  16.  
  17. Seal the hose between the expansion tank and the radiator. Disconnect the hose at the tank.
  18.  
  19. Lift up the expansion tank and place it on top of engine.
  20.  
  21. Raise the car.
  22.  
  23. Remove:

    The right front wheel
     
    The plastic nuts on the cover in the fender liner.
     

  24.  
  25. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.
  26.  
  27. Remove the 4 crankshaft damper bolts.
  28.  
  29. Install Counterhold 999 5433 onto the crankshaft damper.
  30.  
  31. Remove crankshaft damper center nut.
  32.  
  33. Work the crankshaft damper loose and remove by hand.

    Click image to see an enlarged view

    Fig. Using Counterhold to remove crankshaft damper-6-Cylinder Engines

  34.  

To install:

  1. Install the crankshaft damper and tighten the center nut to 133 ft. lbs. (180 Nm).
  2.  
  3. Remove the counterhold 999 5433 and install 4 new bolts. Tighten to 18 ft. lbs. (25 Nm) and angle-tighten 30°.
  4.  
  5. Turn the crankshaft 2 turns. Check that the markings on the crankshaft damper and camshaft pulley correspond.
  6.  
  7. Install or connect the following:

    Front timing belt cover. Tighten to 106 inch lbs. (12 Nm)
     
    Upper timing belt cover
     
    Accessory belt
     
    The plastic nuts for the cover in the right-hand fender liner
     
    Front wheel and tighten lug nuts to 102 ft. lbs. (138 Nm)
     

  8.  
  9. Lower the car.
  10.  
  11. Install the front cover:
    1. The front timing belt cover
    2.  
    3. The hose between the thermostat housing and the expansion tank
    4.  
    5. The surround, cover, and air ducts for the control module box
    6.  

  12.  
  13. Install:

    The expansion tank
     
    Hose between the expansion tank and the radiator
     
    Servo reservoir
     
    Upper timing belt cover
     

  14.  
  15. Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp.
  16.  
  17. Install the plastic hoses between the turbocharger and charge air cooler and between the air cleaner and turbocharger.
  18.  
  19. Tighten the hose clamps.
  20.  
  21. Install:

    The engine stabilizer brace and tighten to 37 ft. lbs. (50 Nm)
     
    The bolt holding the engine stabilizer brace to the bracket on the engine and tighten to 59 ft. lbs. (80 Nm)
     

  22.  
  23. Check:

    Coolant level
     
    The servo fluid level
     

  24.  

8-Cylinder Engines
  1. Remove the accessory belt, refer to Accessory Drive Belts removal and installation.
  2.  
  3. Remove the right front wheel.
  4.  
  5. Remove 1 plastic nut of the wheel arch liner. Bend aside the wheel arch liner.
  6.  
  7. Install counterhold 999 7196 and undo the center bolt.
  8.  
  9. Insert bolt from counterhold 999 7198 in the center hole of the crankshaft.
  10.  
  11. Install puller 999 5304.
  12.  
  13. Pull off the crankshaft damper.

    Click image to see an enlarged view

    Fig. Using Counterhold 999 7196 to remove crankshaft damper-8-Cylinder Engines



    Click image to see an enlarged view

    Fig. Using Puller 999 5304 to remove crankshaft damper-8-Cylinder Engines

  14.  

To install:

  1. Clean the surface for the sealing ring on the crankshaft damper with cloth 951 1024.
  2.  
  3. Install bolt 999 7198 in the center hole of the crankshaft.
  4.  
  5. Install counterhold 999 7196 and drift 999 7198.

    Click image to see an enlarged view

    Fig. Counterhold 999 7196 and drift 999 7198 used to install crankshaft damper

  6.  
  7. Press the crankshaft damper into the stop using the old center bolt and tighten to 74 ft. lbs. (100 Nm).
  8.  
  9. Remove the center bolt and discard it.
  10.  
  11. Insert a new bolt at the crankshaft damper and tighten:

    Step 1: 89 ft. lbs. (120 Nm)
     
    Step 2: back off at least 1 turn
     
    Step 3: 37 ft. lbs. (50 Nm)
     
    Step 4: plus 90°
     

  12.  
  13. Remove counterhold 999 7196.
  14.  
  15. Install the wheel arch liner; tighten the plastic nut.
  16.  
  17. Install the right front wheel and tighten lug nuts to 102 ft. lbs. (138 Nm).
  18.  
  19. Lower the vehicle.
  20.  
  21. Install the accessory drive belt.
  22.  
  23. Start the engine and check for leaks and proper function.
  24.  

 
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