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Suzuki K6A-YH6 Technical/Repair Manual Download Page 55

7

7-1

Chapter 7

Repair

7.1

Air Intake and Exhaust Systems  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Throttle Position Sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Pressure Sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
ISC (Idle Speed Control) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
PCV Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Intake Manifold  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Oxygen Sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Heat Shield  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.2

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Ignition Coils  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.3

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.4

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Water Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Thermostat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Water Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Thermostat Housing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.5

Front Cover, Timing Chain, and Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Cam Angle Sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Tension Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 7-14
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7.6

Cylinder Head, Cams, and Valve Train  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Cam Cover  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Cylinder Head  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Valves  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

7.7

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Dipstick Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Oil Pump Pickup  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 7-31
Crankshaft Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Oil Pressure Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Oil Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Summary of Contents for K6A-YH6

Page 1: ...use severe injury Those who use and maintain this machine should be trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or serv...

Page 2: ...ED IN THIS MANUAL IS BASED ON ENGINES MANUFACTURED UP TO THE TIME OF PUBLICATION JACOBSEN RESERVES THE RIGHT TO CHANGE ANY OF THIS INFORMATION WITHOUT NOTICE CALIFORNIA Proposition 65 Warning WARNING...

Page 3: ...fic tools and or materials These tools and or materials will be listed for reference prior to beginning a procedure Specifications Specifications are listed at the point of use with in the procedure Q...

Page 4: ...2 3 4 5 6 7 8 Table of Contents 5 1 Safety Specifications and General Information Maintenance Theory of Operation Test and Adjustments Diagnostic Troubleshooting Repair Tools and Materials...

Page 5: ...Well Ventilated 1 4 Use Proper Eye and Face Protection 1 4 Use Lifting Equipment Safely 1 4 Use Compressed Air and Air Tools Safely 1 4 Handle Fuel Safely 1 5 Store Volatile and Hazardous Materials Sa...

Page 6: ...1 2 SAFETY 1 Page Intentionally Blank...

Page 7: ...area can make the job easier Follow procedures and safety warnings Service procedures are written to be as safe and efficient as possible Never take shortcuts Be prepared for emergencies Accidents can...

Page 8: ...device to the lowest point before moving Move the load slowly Always support the load as soon as possible never leave a load suspended in mid air Use Compressed Air and Air Tools Safely WARNING Compr...

Page 9: ...turer to obtain an MSDS for the chemical product Service Electrical Components Safely WARNING Disconnect the battery negative cable before removing or installing electrical components Always connect t...

Page 10: ...er Never use food or beverage containers to store waste fluids IMPORTANT Dispose of waste fluids properly at approved local recycling centers If recycling facilities are not available contact your loc...

Page 11: ...ntake and Exhaust System Specifications 2 6 2 3 Electrical Specifications 2 6 2 4 Fuel System Specifications 2 6 2 5 Cooling System Specifications 2 6 2 6 Front Cover Timing Chain and Tensioner Specif...

Page 12: ...hin this manual refer to specific cylinder numbers The cylinders are numbered 1 through 3 starting closest to the timing chain and moving toward the flywheel Procedures within this manual refer to the...

Page 13: ...Thermostat Housing 2 Fuel Injectors 4 Ignition Coils 5 Cam Cover 7 Exhaust Manifold 6 Cylinder Block Lower Crankcase TN0690 1 2 3 4 TN0691 5 6 7 8 Throttle Body 11 Crankshaft Pulley 9 Cylinder Head 12...

Page 14: ...Mounted Combustion Chamber Shape Pent Roof Type Valve Mechanism Twin Cam 4 Valve Chain Driven Engine Displacement cu in cc 40 658 Bore x Stroke in mm 2 68 x 2 38 68 0 x 60 4 Compression Ratio 10 5 Cyl...

Page 15: ...209 1 4 20 in lb Nm 75 8 4 100 11 3 107 12 1 143 16 1 9 16 18 ft lb Nm 92 124 122 165 129 174 172 233 1 4 28 in lb Nm 85 9 6 115 13 0 120 13 5 163 18 4 5 8 11 ft lb Nm 113 153 151 204 159 215 211 286...

Page 16: ...e psi kpa 7 7 53 Item Unit Specification Spark Plug NGK Jacobsen PN 4119606 Spark Plug Denso Jacobsen PN 2701832 Spark Plug Gap in mm 0 031 0 035 0 8 0 9 Spark Plug Torque lb in N m 177 20 Firing orde...

Page 17: ...1 470 1 476 37 343 37 503 Cylinder Head Block Mating Face Distortion Limit in mm 0 001 0 03 Camshaft Oil Clearance Standard in mm 0 002 0 003 0 045 0 087 Camshaft Oil Clearance Limit in mm 0 004 0 10...

Page 18: ...40 4148114 242 2 42 4148115 244 2 44 4148116 246 2 46 4148117 248 2 48 4148118 250 2 50 4148119 252 2 52 4148120 254 2 54 4148121 256 2 56 4148122 258 2 58 4148123 260 2 60 4148124 262 2 62 4148125 2...

Page 19: ...lve Spring Tension at 1 516 in 38 5 mm of Length b ft N m 17 3 4 44 Oil Pressure Sending Unit Torque lb in N m 115 13 Oil Pressure Minimum at 4000 rpm psi kPa 40 276 Oil Pan Torque lb in N m 97 11 Dra...

Page 20: ...Journal Inside Diameter in mm 1 9291 1 9298 49 000 49 018 Crankshaft Main Bearing Journal Outside Diameter in mm 1 770 1 771 44 982 45 000 Crankshaft Cylinder Block Main Bearing Journal Oil Clearance...

Page 21: ...ation Bearing Color Part Number Size Range Brown 4140912 0 0785 0 0787 in 1 996 2 000 mm Green 4140908 0 0787 0 0788 in 1 999 2 003 mm Black 4140909 0 0788 0 0789 in 2 002 2 006 mm No Color 4140910 0...

Page 22: ...2 12 SPECIFICATIONS AND GENERAL INFORMATION 2...

Page 23: ...3 3 1 Chapter 3 Maintenance Engine Oil Level 3 2 Change Engine Oil 3 2 Oil Filter 3 2 Replacement 3 2 Spark Plugs 3 3 Replacement 3 3...

Page 24: ...op the engine and place a suitable pan under the engine WARNING 4 Remove drain plug 1 with seal 2 and drain engine oil NOTE Always use new O rings gaskets and seals 5 Install drain plug 1 using new se...

Page 25: ...orque 120 lb in 13 5 N m 5 Fill engine oil Oil Capacity with Filter 3 1 qt 2 9 L Spark Plugs Replacement See Figures 3 5 through 3 7 Figure 3 5 1 Remove cap screws 1 2 Remove ignition coils 2 Figure 3...

Page 26: ...3 4 MAINTENANCE 3...

Page 27: ...4 6 Water Pump 4 6 4 4 Front Cover Timing Chain and Tensioner 4 7 Front Cover 4 8 Timing Chain 4 8 Tension Adjuster 4 8 4 5 Cylinder Head and Valve Train 4 9 Head Gasket 4 10 Camshaft 4 10 4 6 Lubric...

Page 28: ...justed by a chain tensioner The chain tensioner uses lubrication system pressure and spring pressure to automatically compensate for chain wear The cylinder head gasket is of 2 layer laminated stainle...

Page 29: ...oil pump with integral oil pressure regulator Engine oil is routed through a full flow oil filter that houses an internal filter bypass valve and then distributed throughout the engine A belt driven...

Page 30: ...s controlled and monitored by the ECM to adjust fuel air mixtures Exhaust gases are expelled through the exhaust side of the cylinder head into the exhaust manifold 5 which is fastened and sealed to t...

Page 31: ...r 4 top tank Coolant circulates through the radiator 4 dissipates heat and then flows out of the radiator 4 through the lower hose and into the suction side of the water pump 5 If coolant temperature...

Page 32: ...en coolant temperature reaches 205 F 96 C allowing full coolant system circulation As engine load is varied the thermostat will vary its open or closed percentage to maintain the engine in an optimum...

Page 33: ...The front cover attaches the oil pump pickup strainer and houses the oil pump and front seal Contained under the front cover is the timing chain chain guide and chain tensioner setup 1 Crankshaft Pull...

Page 34: ...n guide 6 and chain tensioner 9 system are used to ensure quiet and accurate operation Tension Adjuster See Figure 4 9 Figure 4 9 The tension adjuster 6 has a plunger 4 inside which pushes against the...

Page 35: ...having two intake and two exhaust valves for improved intake and exhaust efficiency Intake valves are faced with a dual angle while exhaust valves have a single angle face The valve spring retainer 5...

Page 36: ...igure 4 12 Figure 4 12 The intake 1 and exhaust 2 camshafts are made of lightweight hollow cast iron The camshaft timing sprockets 3 are press fit onto the front of the camshafts and are serviceable o...

Page 37: ...s located in this passage to monitor and warn of low oil pressure The oil is routed through a full flow oil filter equipped with a bypass valve The bypass valve will open and allow oil flow to the eng...

Page 38: ...cylinder head On its way up to the cylinder head the oil passes through a restrictor orifice This limits the amount of oil to the head and ensures the proper amount of oil in the lower end of the eng...

Page 39: ...rove rigidity and suppress vibrating noise Crankshaft See Figure 4 15 Figure 4 15 The crankshaft 1 is constructed of cast iron The crankshaft has four main bearing journals and three rod bearing journ...

Page 40: ...The three ring skirt type full floating pistons 1 are made of an aluminum alloy The pistons are equipped with intake valve reliefs 2 machined into the face The piston pin bores are equipped with Rica...

Page 41: ...ems 5 2 Intake Manifold Vacuum Test 5 2 PCV Valve Hose Test 5 2 5 2 Cooling System 5 3 Thermostat Test 5 3 5 3 Cylinder Head Cams and Valve Train 5 3 Valve Clearance Check and Adjustment 5 3 Cylinder...

Page 42: ...the engine Remove the vacuum gauge and install the PCV hose PCV Valve Hose Test See Figures 5 2 and 5 3 Figure 5 2 1 Remove the PCV valve 1 from the cylinder head cover 2 Start engine and bring to idl...

Page 43: ...to verify that the thermostat opens at the specified temperature Replace thermostat if not to specifications Thermostat Start to Open Temperature 190 F 88 C Full Open Temperature 205 F 96 C 5 3 Cylind...

Page 44: ...shim using a feeler gauge 3 4 Check measurement against valve clearance specification 5 Perform adjustment procedure if valve clearance is out of specification Adjustment Figure 5 9 1 If the valve cl...

Page 45: ...s of new shim mm B Thickness of removed shim mm C Valve clearance measured mm Part Number Stamped Number Thickness mm 4148102 218 2 18 4148103 220 2 20 4148104 222 2 22 4148105 224 2 24 4148106 226 2...

Page 46: ...op the engine remove all the spark plugs and disconnect the cam angle sensor coupler Figure 5 14 3 Install the special tools 1 2 and 3 to the spark plug hole being checked 4 With the throttle fully op...

Page 47: ...See Oil Pressure Sending Unit on page 7 32 3 Install the special tools 1 and 2 into the oil pressure sending unit hole 4 Warm up the engine Figure 5 16 5 Raise engine speed to 4000 rpm and measure th...

Page 48: ...g the inspection remove the special tools Wrap teflon tape 4 on the oil pressure sending unit 5 threads and tighten it to specification Oil Pressure Sending Unit Torque 115 lb in 13 N m 8 Start the en...

Page 49: ...perly 6 2 Poor Idling 6 2 Insufficient Engine Power 6 2 Engine Surges or Misses 6 3 Poor Throttle Response 6 3 Engine Overheats 6 3 Excessive Fuel Consumption 6 4 Excessive Oil Consumption 6 4 Low Oil...

Page 50: ...park Plugs on page 7 8 Faulty ignition coil Check ignition coils See Ignition Coils on page 7 8 Faulty oxygen sensor Check oxygen sensor See Oxygen Sensor on page 7 6 Faulty ISC idle speed control val...

Page 51: ...y fuel injector Check fuel injectors See Injectors on page 7 9 Valve clearance adjustment Check valve clearance See Valve Clearance Check and Adjustment on page 5 3 Vacuum leak Check intake manifold v...

Page 52: ...consumption External oil leak Check drain plug Check oil pan for leaks Check rear main crankshaft seal for leaks Check front cover crankshaft seal for leaks Check front cover for leaks Check oil press...

Page 53: ...timing chain or tension adjuster Check timing chain and tensioner See Timing Chain on page 7 14 Exhaust leak Check exhaust manifold See Exhaust Manifold on page 7 7 White exhaust smoke Coolant leaking...

Page 54: ...6 6 DIAGNOSTIC TROUBLESHOOTING 6...

Page 55: ...el System 7 9 Injectors 7 9 7 4 Cooling System 7 10 Water Pump 7 10 Thermostat 7 10 Water Temperature Sensor 7 11 Thermostat Housing 7 11 7 5 Front Cover Timing Chain and Tensioner 7 12 Cam Angle Sens...

Page 56: ...7 2 REPAIR 7 7 8 Cylinder Block and Lower Crankcase 7 37 Knock Sensor 7 37 Crankshaft Pulley 7 37 Idler Pulley 7 38 Connecting Rods and Pistons 7 38 Lower Crankcase Cylinder Block and Crankshaft 7 42...

Page 57: ...s 2 pressure sensor 1 and O ring 3 2 Inspect pressure sensor Replace as needed Installation Notes Always use new O rings gaskets and seals Install pressure sensor by reversing the order of removal ISC...

Page 58: ...rottle body 1 Figure 7 6 2 Remove throttle body gasket 3 Installation Notes Always use new O rings gaskets and seals Install new gasket and throttle body by reversing the order of removal Intake Manif...

Page 59: ...See Figures 7 9 and 7 10 Figure 7 9 NOTES Clean intake manifold and cylinder head gasket surfaces before installation Always use new O rings gaskets and seals 1 Install new intake manifold gasket 1 F...

Page 60: ...ensor before installation Install oxygen sensor by reversing the order of removal Heat Shield Removal and Installation See Figures 7 12 and 7 13 Figure 7 12 1 Remove cap screws 1 and lower half of hea...

Page 61: ...s with the feeler gauge If the measurement exceeds the limit repair or replace exhaust manifold Exhaust Manifold Distortion Limit 0 003 in 0 07 mm Installation See Figures 7 16 and 7 17 Figure 7 16 NO...

Page 62: ...the order of removal Spark Plugs Removal and Installation See Figures 7 19 and 7 20 Figure 7 19 1 Remove ignition coils See Ignition Coils on page 7 8 2 Remove spark plugs 1 Figure 7 20 3 Inspect spar...

Page 63: ...lace as needed Installation See Figures 7 23 and 7 24 Figure 7 23 NOTE Always use new O rings gaskets and seals 1 Install injectors 5 into fuel rail 1 using new O rings 3 and isolators 2 and 4 Figure...

Page 64: ...s Always use new O rings gaskets and seals Install the water pump with new O ring by reversing the order of removal Thermostat Removal and Installation See Figures 7 27 and 7 28 Figure 7 27 1 Remove c...

Page 65: ...lation See Figures 7 30 and 7 31 Figure 7 30 1 Remove thermostat See Thermostat on page 7 10 2 Remove cap screw 1 and bracket 3 3 Remove nuts 4 and thermostat housing 2 Figure 7 31 4 Remove thermostat...

Page 66: ...on Coils on page 7 8 2 Remove spark plugs See Spark Plugs on page 7 8 3 Remove PCV valve See PCV Valve on page 7 4 4 Remove cam cover See Cam Cover on page 7 17 5 Remove crankshaft pulley See Cranksha...

Page 67: ...s 2 and 3 Tighten to specification Front Cover Torque 97 lb in 11 N m 5 Install oil pump pickup See Oil Pump Pickup on page 7 31 6 Install oil pan See Oil Pan on page 7 30 7 Install idler pulley alter...

Page 68: ...Cover on page 7 12 Figure 7 37 NOTES The crankshaft may need to be rotated several times before cylinder number one reaches top dead center All timing index marks must be aligned simultaneously 2 Tur...

Page 69: ...haft timing sprocket 15 and timing chain 14 off of crankshaft Remove timing chain from cam gear teeth IMPORTANT Do not turn camshafts or crankshaft with timing chain removed Inspection See Figure 7 39...

Page 70: ...ng sprocket keyway 8 faces up and aligns with index mark 5 on cylinder block 4 Align yellow timing chain link 7 with crankshaft timing gear slot 6 and slide timing gear onto crankshaft NOTICE Figure 7...

Page 71: ...sioner link 13 using cap screws 12 9 Install front cover See Front Cover on page 7 12 7 6 Cylinder Head Cams and Valve Train Cam Cover Removal See Figure 7 43 Figure 7 43 1 Remove ignition coils See I...

Page 72: ...Torque Sequence See Figure 7 46 Figure 7 46 1 Tighten cap screws 1 through 6 in sequential order as shown Torque cam cover cap screws at increments of 32 lb in 3 6 N m until specification is reached C...

Page 73: ...shaft housing bolts in sequence as shown in figure 7 47 11 Remove camshaft housings 14 Note the locations and orientation using the stamped markings The I or E markings 12 refer to intake or exhaust s...

Page 74: ...e measurement process Be sure dowel pins are properly aligned before installing camshaft housings 4 Install the camshaft housings Apply engine oil to cap screws and tighten using sequence 1 through 11...

Page 75: ...camshaft or cylinder head must be replaced Camshaft Journal Outside Diameter 0 903 0 904 in 22 934 22 955 mm Camshaft Journal Inside Diameter 0 905 0 906 in 23 000 23 021 mm Cam Timing Sprocket See Fi...

Page 76: ...e Limit 0 003 in 0 10 mm Installation NOTICE See Figures 7 56 through 7 59 Figure 7 56 IMPORTANT Be sure tappets and shims are installed in correct location 1 Apply engine oil to all surfaces of tappe...

Page 77: ...housings 5 to the cylinder head Figure 7 59 5 Tighten camshaft housings using sequence 1 through 11 at increments of 32 lb in 3 6 N m until specification is reached Camshaft Housing Torque 97 lb in 1...

Page 78: ...See Crankshaft Pulley on page 7 37 10 Remove idler pulley See Idler Pulley on page 7 38 11 Remove oil pan See Oil Pan on page 7 30 12 Remove front cover See Front Cover on page 7 12 13 Remove timing...

Page 79: ...s with the feeler gauge If the measurement exceeds the limit repair or replace the cylinder head Cylinder Block Head Mating Face Distortion Limit 0 001 in 0 03 mm Intake and Exhaust Manifold Mating Fa...

Page 80: ...ten at this time IMPORTANT If the cylinder head cylinder block or the cylinder head cap screw have been replaced go to step 4 If installing previously removed parts go to step 5 Figure 7 66 4 Torque t...

Page 81: ...spring compressor remove retainer locks 8 3 Release valve spring compressor and remove valve 5 4 Remove valve spring retainer 7 valve spring 3 valve seal 4 and valve spring seat 6 5 Inspect all parts...

Page 82: ...Stem Clearance Intake 0 0007 0 0018 in 0 020 0 047 mm Valve Guide to Valve Stem Clearance Limit Intake 0 002 in 0 07 mm Valve Guide to Valve Stem Clearance Exhaust 0 0017 0 0028 in 0 045 0 072 mm Val...

Page 83: ...88 N m 3 Using a square 4 check valve spring right angle Use a feeler gauge to measure distance 3 Compare measurement to specification Replace as needed Valve Spring Right Angle Range 0 000 0 059 in 0...

Page 84: ...tube and O ring Replace as needed Installation Notes Always use new O rings gaskets and seals Install dipstick tube by reversing the order of removal Oil Pan Removal See Figure 7 73 Figure 7 73 1 Dra...

Page 85: ...l See Change Engine Oil on page 3 2 Oil Pump Pickup Removal and Installation See Figure 7 76 Figure 7 76 1 Remove oil pan See Oil Pan on page 7 30 2 Remove cap screws 1 oil pump pickup 2 and O ring 3...

Page 86: ...aft baffle by reversing the order of removal Install oil pump pickup See Oil Pump Pickup on page 7 31 Install oil pan See Oil Pan on page 7 30 Oil Pressure Sending Unit Removal and Installation See Fi...

Page 87: ...nd relief valve 9 6 Inspect parts and replace as needed See Inspection on page 7 33 Inspection NOTES Clean engine oil from oil pump rotor bore and inner and outer rotors before performing measurements...

Page 88: ...it replace the oil pump assembly Oil Pump Outer Rotor Side Clearance Limit 0 003 0 005 in 0 076 0 127 mm Inner Rotor and Pump Case Clearance See Figure 7 82 Figure 7 82 1 Using a micrometer measure th...

Page 89: ...he spring Oil Pump Relief Valve Spring Free Length 2 063 in 52 40 mm 2 Using a spring compression gauge 2 compress relief valve spring to specification and record the force reading If force reading is...

Page 90: ...ner and outer rotor as previously marked 2 Install relief valve 11 spring 10 retainer 9 and circlip 8 3 Install inner rotor 4 and outer rotor 5 4 Install oil pump housing 6 using screws 7 Tighten to s...

Page 91: ...nstallation Notes Install knock sensor by reversing the order of removal Tighten knock sensor to specification Knock Sensor Torque 203 lb in 23 N m Crankshaft Pulley Removal and Installation See Figur...

Page 92: ...e 7 90 IMPORTANT Note the placement and orientation of connecting rods and caps prior to removal 5 The connecting rods and caps are stamped 2N 3 on the intake manifold side of the engine Mark the oppo...

Page 93: ...urement to specification and piston pin OD specification Repair or replace as needed Connecting Rod Small End ID 0 7087 0 7090 in 18 003 18 011 mm Piston Pin OD 0 7084 0 7086 in 17 995 18 000 mm 3 Mea...

Page 94: ...ons Replace as needed Top Compression Ring End Gap 0 0047 0 0106 in 0 12 0 27 mm Top Compression Ring End Gap Limit 0 027 in 0 7 mm Second Compression Ring End Gap 0 0137 0 0196 in 0 35 0 50 mm Second...

Page 95: ...aces before assembly 5 Install connecting rod 15 piston pin 14 and circlips 13 to piston 16 NOTICE 6 Cover connecting rod bolts with rubber hose and apply clean oil to connecting rod bearing NOTE Conf...

Page 96: ...d See Cylinder Head on page 7 24 2 Remove oil pan See Oil Pan on page 7 30 3 Remove oil pump pickup See Oil Pump Pickup on page 7 31 4 Remove crankshaft baffle See Crankshaft Baffle on page 7 32 Figur...

Page 97: ...e rear main seal 4 and crankshaft 5 Figure 7 100 9 Remove crankshaft main bearings 6 and thrust bearings 7 Figure 7 101 10 Remove other half of crankshaft main bearings 9 from lower crankcase 8 TN0756...

Page 98: ...passages for debris or obstructions Clean as needed Crankshaft 1 Inspect crankshaft for cracks or damage Replace as needed Inspect main and rod journals for scratches wear or damage Repair or replace...

Page 99: ...and thrust bearing faces Figure 7 104 NOTE Thoroughly clean cylinder block lower crankcase mating surface Thoroughly clean crankshaft journals before installation 6 Apply a liberal amount of clean en...

Page 100: ...gh 19 to 30 lb ft 40 N m Loosen all cap screws in the reverse order Tighten eight screws and washers sequentially 12 through 19 to 30 lb ft 40 N m Torque cap screws sequentially 12 through 19 to final...

Page 101: ...urface 14 Using a bushing bearing and seal driver tool install new rear main seal 27 15 Rotate crankshaft and check for any abnormal resistance 16 Install crankshaft baffle See Crankshaft Baffle on pa...

Page 102: ...7 48 REPAIR 7...

Page 103: ...8 8 1 Chapter 8 Tools and Materials Special Tools 8 1 Required Materials 8 2...

Page 104: ...Pressure Gauge Figure 8 3 Oil Pressure Gauge Attachment Figure 8 4 Compression Gauge Set Figure 8 5 Compression Gauge Hose Description Suzuki Part Number Oil Filter Wrench 09915 47341 Oil Pressure Gau...

Page 105: ...r Figure 8 9 Bearing Installer Required Materials The following materials or suitable equivalents must be used to perform some procedures within this manual Always use the right supplies for the job D...

Page 106: ...8 4 TOOLS AND MATERIALS 8...

Page 107: ...nspection 7 35 Connecting Rods and Pistons Assembly 7 35 Disassembly 7 34 Inspection 7 35 Removal 7 34 Repair 7 34 Cooling System Repair 7 10 Specifications 2 5 Tests and Adjustments 5 3 Theory of Ope...

Page 108: ...pecifications 2 6 Theory of Operation 4 7 Fuel System Repair 7 9 Specifications 2 5 Fuel Safety 1 5 G General Engine Operation 4 2 H Hazardous Materials Storage 1 5 Head Gasket Theory of Operation 4 1...

Page 109: ...Removal 7 30 Repair 7 30 Oil Pump Pickup Removal and Installation 7 29 Repair 7 29 Oversize Main Bearing Identification Specifications 2 10 Oxygen Sensor Removal and Installation 7 5 Repair 7 5 P PCV...

Page 110: ...Air Intake and Exhaust Systems 5 2 Cooling System 5 3 Cylinder Head Cams and Valve Train 5 3 Lubrication System 5 7 Theory of Operation 4 2 Air Intake Fuel and Exhaust 4 4 Camshaft 4 10 Connecting Rod...

Page 111: ...essure 6 4 Poor Idling 6 2 Poor Throttle Response 6 3 White Exhaust Smoke 6 5 V Valve Springs Inspection 7 27 Valves Clearance Check and Adjustment 5 3 Disassembly 7 26 Inspection 7 27 Installation 7...

Page 112: ...IX 6 INDEX IX...

Page 113: ...p com Equipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations A worldwide dealer network and factory trained technic...

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