Suzuki K6A-YH6 Technical/Repair Manual
  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Engine
  5. K6A-YH6
  6. Technical/repair manual
Suzuki K6A-YH6 Technical/Repair Manual

Suzuki K6A-YH6 Technical/Repair Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

When Performance Matters.
™
Suzuki K6A-YH6 Engine
Technical/Repair Manual
!
WARNING: If incorrectly used this machine can cause 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 service the machine.
©2007 Jacobsen, A Textron Company. All rights reserved.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the K6A-YH6 and is the answer not in the manual?

Questions and answers

Related Manuals for Suzuki K6A-YH6

Summary of Contents for Suzuki K6A-YH6

  • Page 1 When Performance Matters. ™ Suzuki K6A-YH6 Engine Technical/Repair Manual WARNING: If incorrectly used this machine can cause 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 service the machine.
  • Page 2 RIGHT TO CHANGE ANY OF THIS INFORMATION Jacobsen® is a registered trademark of Textron Inc. WITHOUT NOTICE. Suzuki® is a registered trademark of the American Suzuki Motors Corporation ThreeBond™ is a trademark of the ThreeBond Co., Ltd. Plastigage® is a registered trademark of AE Clevite Inc.
  • Page 3 FOREWORD How to Use This Manual Warnings and Cautions Warning and Caution indicators are located throughout This manual is designed to provide multiple ways to the manual at specific points of interest. These notices locate and access repair information. are given to prevent personal injury, death and/or Read each section in entirety before beginning a equipment damage.

  • Page 4: Table Of Contents

    Table of Contents Safety Specifications and General Information Maintenance Theory of Operation Test and Adjustments Diagnostic Troubleshooting Repair Tools and Materials...

  • Page 5: Safety

    Chapter 1 Safety Introduction ..............1-3 Prepare for the Job .
  • Page 6 SAFETY Page Intentionally Blank...

  • Page 7: Introduction

    SAFETY Introduction Safety Notices Safety is the most important element of any repair Throughout this manual, the following key safety words procedure. Knowledge of the procedure to be performed will be used to alert the reader of potential hazards. and safe work habits are essential to preventing death, Become familiar with these words and their meaning.

  • Page 8: Keep Work Area Well Ventilated

    SAFETY Keep Work Area Well Ventilated • When using a lifting device, always connect the load so it is balanced. • Always use a lifting device on a hard, level surface. WARNING • Lower the lifting device to the lowest point before moving.

  • Page 9: Handle Fuel Safely

    SAFETY Handle Fuel Safely Handle Chemical Products Safely Handle fuel with care—it is highly flammable. WARNING WARNING • Never remove the fuel cap from the fuel tank, Exposure to chemical products could result in or add fuel, when the engine is running or serious injury.

  • Page 10: Dispose Of Waste Materials Safely

    SAFETY Dispose of Waste Materials Safely Routine service can produce waste products such as used oil, grease, and used batteries. If not handled properly, these materials can pose a threat to the environment. Collect fluids in well-marked, approved storage containers. Some waste fluids can react with certain types of plastics.

  • Page 11: Specifications And General Information

    Chapter 2 Specifications and General Information General Specifications ........... . 2-2 Engine Identification .

  • Page 12: General Specifications

    Procedures within this manual refer to the front and rear of the engine. Use the following guidelines when the front The Suzuki K6A is a 3-cylinder, fuel injected, dual and rear of the engine are referenced: overhead cam, liquid cooled, gas powered engine.

  • Page 13: Engine Component Locations

    SPECIFICATIONS AND GENERAL INFORMATION Engine Component Locations See Figures 2-2 through 2-5. TN0692 Throttle Body Crankshaft Pulley TN0690 Cylinder Head Water Pump Intake Manifold Oil Fill Thermostat Housing Figure 2-4 Fuel Injectors Ignition Coils Figure 2-2 TN0691 TN0693 Cam Cover Exhaust Manifold Cylinder Block/Lower Crankcase...
  • Page 14 SPECIFICATIONS AND GENERAL INFORMATION Engine Information Item Unit Specification Type K6A Normally Aspirated Number of Cylinders and In-line 3-Cylinder Transversely Mounted Arrangement Combustion Chamber Shape Pent-Roof Type Valve Mechanism Twin Cam, 4-Valve, Chain Driven Engine Displacement 40 (658) cu in. (cc) Bore x Stroke 2.68 x 2.38 (68.0 x 60.4) in.

  • Page 15: Standard Torque Values

    SPECIFICATIONS AND GENERAL INFORMATION Standard Torque Values NOTE NOTICE Jacobsen uses Grade 5 plated bolts as standard, unless All torque values included in these charts are otherwise noted. When tightening plated bolts, use the approximate and are for reference only. Use of value given for lubricated.

  • Page 16: Air Intake And Exhaust System Specifications

    SPECIFICATIONS AND GENERAL INFORMATION 2.2 Air Intake and Exhaust System Specifications Item Unit Specification Intake Manifold Torque 97 (11) lb-in. (N•m) Exhaust Manifold Torque 204 (23) lb-in. (N•m) Intake Manifold Distortion Limit 0.003 (0.07) in. (mm) Exhaust Manifold Distortion Limit 0.003 (0.07) in.

  • Page 17: Front Cover, Timing Chain, And Tensioner Specifications

    SPECIFICATIONS AND GENERAL INFORMATION 2.6 Front Cover, Timing Chain, and Tensioner Specifications Item Unit Specification Front Cover Torque 97 (11) lb-in. (N•m) 2.7 Cylinder Head, Cams, and Valve Train Specifications Item Unit Specification Valve Clearance, Cold, Intake 0.007—0.009 (0.18—0.23) in. (mm) Valve Clearance, Cold, Exhaust 0.012—0.014 (0.30—0.35) in.

  • Page 18: Tappet Shim Selection Chart

    SPECIFICATIONS AND GENERAL INFORMATION Tappet Shim Selection Chart Part Number Stamped Number Thickness (mm) 4148102 2.18 4148103 2.20 4148104 2.22 4148105 2.24 4148106 2.26 4148107 2.28 4148108 2.30 4148109 2.32 4148110 2.34 4148111 2.36 4148112 2.38 4148113 2.40 4148114 2.42 4148115 2.44 4148116...

  • Page 19: Lubrication System Specifications

    SPECIFICATIONS AND GENERAL INFORMATION 2.8 Lubrication System Specifications Item Unit Specification Oil Pump Housing Torque 60 (6.78) lb-in. (N•m) Oil Pump Outer Rotor Side 0.003—0.005 (0.076—0.127) in. (mm) Clearance Limit Oil Pump Radial Clearance Limit 0.0004—0.006 (0.10—0.15) in. (mm) Inner Rotor and Pump Case 0.001—0.003 (0.025—0.076) in.

  • Page 20: Cylinder Block, Lower Crankcase, And Crankshaft Specifications

    SPECIFICATIONS AND GENERAL INFORMATION 2.9 Cylinder Block, Lower Crankcase, and Crankshaft Specifications Item Unit Specification Lower Crankcase (M10) Cap Screw 42 (57) b-ft (N•m) Torque Lower Crankcase (M8) Cap Screw 212 (24) lb-in. (N•m) Torque Cylinder Bore Inside Diameter 2.6771—2.6779 (68.000—68.020) in.

  • Page 21: Oversize Main Bearing Identification

    SPECIFICATIONS AND GENERAL INFORMATION Oversize Main Bearing Identification 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 0.0788—0.0789 in. (2.002—2.006 mm) Yellow 4140911 0.0790—0.0792 in.
  • Page 22 SPECIFICATIONS AND GENERAL INFORMATION 2-12...

  • Page 23: Maintenance

    Chapter 3 Maintenance Engine Oil Level ............. . . 3-2 Change Engine Oil .
  • Page 24 Replacement 5. Install dipstick (3). See Figures 3-3 and 3-4. Change Engine Oil Required Tools See Figure 3-2. Oil Filter Wrench (Suzuki PN 09915-47340) TN0534 Figure 3-2 1. Park the vehicle on a level surface. TN0694 Figure 3-3 2. Operate the engine until normal operating temperature is reached.
  • Page 25 MAINTENANCE 2. Using oil filter wrench, remove the oil filter (1). 2. Remove ignition coils (2). TN0352 Figure 3-4 TN0697 Figure 3-6 3. Coat new oil filter O-ring (2) with clean engine oil. 3. Remove spark plugs (3). NOTE Prevent contamination; clean oil filter housing before installing new oil filter.
  • Page 26 MAINTENANCE...

  • Page 27: Theory Of Operation

    Chapter 4 Theory of Operation General Engine Operation ..........4-2 Air Intake, Fuel, and Exhaust .

  • Page 28: General Engine Operation

    THEORY OF OPERATION 4.1 General Engine Operation See Figure 4-1. TN0746 Figure 4-1 The K6A engine is an in-line, 3-cylinder, twin overhead The cylinder head gasket is of 2-layer laminated stainless cam, 4-valve per cylinder, naturally aspirated, liquid steel which is excellent in durability and reliability. Use of cooled, gasoline engine.
  • Page 29 THEORY OF OPERATION Pistons attached to connecting rods are made of an aluminum alloy and use a full-floating piston pin. Piston pin holes are equipped with a “Ricardo Groove” to aid in lubrication. Pistons incorporate a slipper skirt with three rings: two compression and one oil type.

  • Page 30: Air Intake, Fuel, And Exhaust

    THEORY OF OPERATION 4.2 Air Intake, Fuel, and Exhaust See Figure 4-2. TN0690 Injector (3 used) Exhaust Manifold Fuel Rail Oxygen Sensor Intake Manifold Heat Shield Throttle Body Assembly Figure 4-2 Fuel is supplied from the fuel rail (2) to each cylinder via Exhaust gases are expelled through the exhaust side of electronically controlled fuel injectors (1), mounted to the the cylinder head into the exhaust manifold (5), which is...

  • Page 31: Cooling System

    THEORY OF OPERATION 4.3 Cooling System See Figure 4-3. Jiggle Pin Water Pump Cylinder Head Cylinder Block Overflow Bottle Thermostat Radiator Thermostat Housing Figure 4-3 Coolant circulates through the radiator (4), dissipates The cooling system includes the radiator (4), water pump heat, and then flows out of the radiator (4) through the (5), thermostat (7), and engine coolant passages.

  • Page 32: Thermostat

    THEORY OF OPERATION Thermostat Water Pump See Figure 4-4. See Figure 4-5. TN0747 Figure 4-5 The engine is equipped with a belt-driven water pump (1) TN0573 driven from the crankshaft pulley. The water pump circulates coolant throughout the entire cooling system. Figure 4-4 The water pump is equipped with a “weep hole”...

  • Page 33: Front Cover, Timing Chain, And Tensioner

    THEORY OF OPERATION 4.4 Front Cover, Timing Chain, and Tensioner See Figure 4-6. TN0748 Crankshaft Pulley Tension Adjuster Front Cover Chain Guide Tensioner Link Crankshaft Sprocket Tensioner Oil Pump Timing Chain Pickup Strainer Figure 4-6 Attached to the front of the engine is the one-piece cast aluminum front cover.

  • Page 34: Front Cover

    THEORY OF OPERATION Front Cover For the camshaft drive, a highly durable chain drive system is used. See Figure 4-7. Through the timing chain (1), the crankshaft rotation is transmitted from the crankshaft timing sprocket (7) to the camshaft timing sprockets (2 and 5) installed on the end of the intake and exhaust camshafts.

  • Page 35: Cylinder Head And Valve Train

    THEORY OF OPERATION 4.5 Cylinder Head and Valve Train See Figure 4-10. TN0750, 0523, 0493 Camshaft Lobe Valve Spring Intake Port Shim Valve Seal Spark Plug Port Tappet Valve Spring Seat Exhaust Port Retainer Lock Intake Valve Valve Spring Retainer Exhaust Valve Figure 4-10 The twin cam, 4-valve per cylinder head is constructed...

  • Page 36: Head Gasket

    THEORY OF OPERATION Head Gasket See Figure 4-11. TN0494 Figure 4-11 The cylinder head gasket is made of a 2-layer laminated stainless steel. The surface of the cylinder head gasket is treated with a rubberized coating. Camshaft See Figure 4-12. TN0505 Figure 4-12 The intake (1) and exhaust (2) camshafts are made of...

  • Page 37: Lubrication System

    THEORY OF OPERATION 4.6 Lubrication System See Figure 4-13. OIL PRESSURE BYPASS VALVE SWITCH LUBE OIL FILTER CYLINDER BLOCK MAIN GALLERY CRANK JOURNALS REGULATOR CRANK PIN VALVE LUBE OIL PUMP TENSION FRONT CAM ROD PIN ADJUSTER JOURNAL OIL SUCTION PIPE TIMING (STRAINER) CAMSHAFT...
  • Page 38 THEORY OF OPERATION From the main gallery, oil distributes to the crankshaft journals and crank pins. The crankshaft is drilled between the crank pins and rod pins. Oil flows through to the rod pins, lubricating the rod journals, and then passes into a drilled passage in the connecting rod.

  • Page 39: Cylinder Block And Lower Crankcase

    THEORY OF OPERATION 4.7 Cylinder Block and Lower Crankshaft Crankcase See Figure 4-15. See Figure 4-14. TN0496 Figure 4-14 The cylinder block (1) is made of a lightweight aluminum alloy. The cylinders contain press-fit, semi-wet style liners for improved cooling and reliability. The lower crankcase (2) is made of lightweight aluminum alloy.

  • Page 40: Connecting Rod

    THEORY OF OPERATION Connecting Rod See Figure 4-16. TN0529 Figure 4-18 The three-ring, skirt-type, full-floating pistons (1) are TN0499 made of an aluminum alloy. The pistons are equipped Figure 4-16 with intake valve reliefs (2) machined into the face. The The connecting rod is made of carbon steel with an piston pin bores are equipped with “Ricardo Grooves”...
  • Page 41 Chapter 5 Tests and Adjustments Air Intake and Exhaust Systems ..........5-2 Intake Manifold Vacuum Test .

  • Page 42: Air Intake And Exhaust Systems

    Systems See Figures 5-2 and 5-3. Intake Manifold Vacuum Test See Figure 5-1. Required Tools Vacuum Gauge: Suzuki PN 09915-67311 or Equivalent 1. Warm up the engine. TN0598 Figure 5-2 1. Remove the PCV valve (1) from the cylinder head cover.

  • Page 43: Cooling System

    TESTS AND ADJUSTMENTS 5.2 Cooling System 5.3 Cylinder Head, Cams, and Valve Train Thermostat Test Valve Clearance Check and See Figures 5-4 and 5-5. Adjustment See Figures 5-6 through 5-13. Valve Clearance Intake Exhaust Cold 0.007—0.009 in. 0.012—0.014 in. (0.18—0.23 mm) (0.30—0.35 mm) Check TN0429...
  • Page 44 TESTS AND ADJUSTMENTS IMPORTANT The check and adjustment must be performed when engine is cold. Continue turning the crankshaft so that each different cam lobe will point away from the shim face successively. Measure each valve clearance at this position. (All the valve clearances can be measured during two complete turns of crankshaft.) Valve clearance and adjustment may be done in pairs TN0361...
  • Page 45 TESTS AND ADJUSTMENTS IMPORTANT If the value “A” equals an odd number, use a shim 0.01 smaller than “A” value. Shim Selection Chart Stamped Thickness Part Number Number (mm) 4148102 2.18 4148103 2.20 TN0363 Figure 5-11 4148104 2.22 6. Turn the camshaft clockwise until the cam lobe is 4148105 2.24 180°...

  • Page 46: Cylinder Compression Test

    See Figure 5-14. 4148143 3.00 Required Tools NOTE Compression Gauge Set: Suzuki PN 09916-67011 or Equivalent Install the shim with its size marking facing tappet. Compression Gauge Hose: Suzuki PN 09915-64530 1. Install the selected shim with its stamped number or Equivalent facing tappet side.

  • Page 47: Lubrication System

    5.4 Lubrication System Oil Pressure Test See Figures 5-15 through 5-17. Required Tools TN0353 Oil Pressure Gauge: Suzuki PN 09915-77311 or Figure 5-16 Equivalent 5. Raise engine speed to 4000 rpm and measure the oil Oil Pressure Gauge Attachment: Suzuki PN pressure on the gauge (3).
  • Page 48 TESTS AND ADJUSTMENTS TN0355 Figure 5-17 7. After completing 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.

  • Page 49: Diagnostic Troubleshooting

    Chapter 6 Diagnostic Troubleshooting Troubleshooting ............. . . 6-2 Engine Starts Hard (But Cranks Properly).

  • Page 50: Troubleshooting

    DIAGNOSTIC TROUBLESHOOTING Troubleshooting Condition Probable Cause Remedy Engine starts hard (but cranks properly). Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on page 7-8.) Faulty ignition coil. Check ignition coils. (See “Ignition Coils” on page 7-8.) Faulty fuel injector. Check fuel injectors.

  • Page 51: Engine Surges Or Misses

    DIAGNOSTIC TROUBLESHOOTING Condition Probable Cause Remedy Engine surges or misses. Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on page 7-8.) Faulty ignition coil. Check ignition coils. (See “Ignition Coils” on page 7-8.) Faulty fuel injector. Check fuel injectors. (See “Injectors” on page 7-9.) Valve clearance adjustment.

  • Page 52: Excessive Fuel Consumption

    DIAGNOSTIC TROUBLESHOOTING Condition Probable Cause Remedy Excessive fuel consumption. Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on page 7-8.) Faulty ignition coil. Check ignition coils. (See “Ignition Coils” on page 7-8.) Faulty fuel injector. Check fuel injectors. (See “Injectors” on page 7-9.) Valve clearance adjustment.

  • Page 53: Excessive Engine Noise

    DIAGNOSTIC TROUBLESHOOTING Condition Probable Cause Remedy Excessive engine noise. Valve train noise. Check valve clearance. (See “Valve Clearance Check and Adjustment” on page 5-3.) Crankshaft/connecting rod noise. Check crankshaft, connecting rods, and bearings. (See “Lower Crankcase, Cylinder Block, and Crankshaft” on page 7-42.) Check pistons, piston rings, piston pins, and small end of connecting rod.
  • Page 54 DIAGNOSTIC TROUBLESHOOTING...

  • Page 55: Repair

    Chapter 7 Repair Air Intake and Exhaust Systems ..........7-3 Throttle Position Sensor .
  • Page 56 REPAIR Cylinder Block and Lower Crankcase ........7-37 Knock Sensor .

  • Page 57: Air Intake And Exhaust Systems

    REPAIR 7.1 Air Intake and Exhaust Installation Notes Always use new O-rings, gaskets, and seals. Systems Install pressure sensor by reversing the order of removal. Throttle Position Sensor ISC (Idle Speed Control) Valve Removal and Installation Removal and Installation See Figure 7-1. See Figure 7-3.

  • Page 58: Pcv Valve

    REPAIR PCV Valve Removal and Installation See Figure 7-4. TN0740 Figure 7-6 2. Remove throttle body gasket (3). Installation Notes Always use new O-rings, gaskets, and seals. TN0711 Install new gasket and throttle body by reversing the Figure 7-4 order of removal. 1.
  • Page 59 REPAIR Inspection 1. Inspect intake manifold for cracks, damage, and distortion. TN0736 Figure 7-10 2. Install intake manifold (2) and cap screw (5). 3. Install nine cap screws (3) and three nuts (4). Tighten to specification. TN0735 Figure 7-8 Intake Manifold Torque: 97 lb-in. (11 N•m) 4.

  • Page 60: Oxygen Sensor

    REPAIR Oxygen Sensor Heat Shield Removal and Installation Removal and Installation See Figure 7-11. See Figures 7-12 and 7-13. Required Materials Anti-Seize Compound TN0729 Figure 7-12 1. Remove cap screws (1) and lower half of heat shield (2). TN0699 Figure 7-11 1.

  • Page 61: Exhaust Manifold

    REPAIR Exhaust Manifold Installation See Figures 7-16 and 7-17. Removal See Figure 7-14. TN0732 Figure 7-16 NOTES TN0731 Figure 7-14 Clean exhaust manifold and cylinder head gasket surfaces before installation. 1. Remove cap screws (4) and nuts (2). Always use new O-rings, gaskets, and seals. 2.

  • Page 62: Electrical System

    REPAIR 7.2 Electrical System Spark Plugs Removal and Installation Ignition Coils See Figures 7-19 and 7-20. Removal and Installation See Figure 7-18. TN0697 Figure 7-19 TN0695 1. Remove ignition coils. (See “Ignition Coils” on Figure 7-18 page 7-8.) 1. Remove cap screws (1). 2.

  • Page 63: Fuel System

    REPAIR 7.3 Fuel System Installation See Figures 7-23 and 7-24. Injectors Removal See Figures 7-21 and 7-22. WARNING Fuel system may be under pressure. Relieve fuel pressure before servicing system. TN0739 Figure 7-23 NOTE Always use new O-rings, gaskets, and seals. TN0738 1.

  • Page 64: Cooling System

    REPAIR 7.4 Cooling System Thermostat Removal and Installation Water Pump See Figures 7-27 and 7-28. Removal and Installation See Figures 7-25 and 7-26. TN0701 TN0726 Figure 7-27 Figure 7-25 1. Remove cap screws (2) and water pump (1). 1. Remove cap screws (1). 2.

  • Page 65: Water Temperature Sensor

    REPAIR Water Temperature Sensor Thermostat Housing Removal and Installation Removal and Installation See Figure 7-29. See Figures 7-30 and 7-31. TN0707 Figure 7-30 1. Remove thermostat. (See “Thermostat” on TN0701 page 7-10.) Figure 7-29 2. Remove cap screw (1) and bracket (3). 1.

  • Page 66: Front Cover, Timing Chain, And Tensioner

    REPAIR 7.5 Front Cover, Timing Chain, Front Cover and Tensioner Removal See Figure 7-33. Cam Angle Sensor 1. Remove ignition coils. (See “Ignition Coils” on page 7-8.) Removal and Installation 2. Remove spark plugs. (See “Spark Plugs” on See Figure 7-32. page 7-8.) 3.
  • Page 67 REPAIR Installation See Figures 7-34 and 7-35. Required Materials Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or equivalent 1. Clean cylinder head, cylinder block, and front cover mating surfaces. TN0745 Figure 7-35 3. Align dowel pins, oil pump rotor flats, and crankshaft timing gear.

  • Page 68: Tension Adjuster

    REPAIR Tension Adjuster Timing Chain Removal and Installation Removal See Figure 7-36. See Figures 7-37 and 7-38. 1. Remove front cover. (See “Front Cover” on page 7-12.) TN0549 Figure 7-36 1. Remove front cover. (See “Front Cover” on page 7-12.) 2.
  • Page 69 REPAIR Inspection See Figure 7-39. TN0375 Figure 7-39 Inspect timing chain (1), chain guide (2), crankshaft timing sprocket (3), and tensioner (4) for wear or damage. Replace as needed. TN0550 Figure 7-38 3. Remove cap screws (9) and tensioner link (10). 4.
  • Page 70 REPAIR Installation NOTICE See Figures 7-40 through 7-42. Be sure to re-check timing mark(s) alignment. IMPORTANT Improper installation may result in engine Make sure cylinder number 1 is at top dead center. damage. TN0380 Figure 7-41 5. Release tension adjuster (9) manual lock using a rod (11) approximately 0.8 in.

  • Page 71: Cylinder Head, Cams, And Valve Train

    REPAIR 7.6 Cylinder Head, Cams, and Valve Train Cam Cover Removal See Figure 7-43. TN0550 Figure 7-42 TN0724 NOTE Figure 7-43 Apply engine oil to timing chain, tensioner, and guide faces. 1. Remove ignition coils. (See “Ignition Coils” on page 7-8.) 6.
  • Page 72 Installation Cam Cover Torque Sequence See Figure 7-46. See Figures 7-44 and 7-45. Required Materials Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or equivalent TN0554 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.

  • Page 73: Camshafts

    REPAIR Camshafts NOTICE Remove camshaft housing cap screws using illustrated sequence. Incorrect removal can result in damaged camshafts. When removing camshaft housings, camshafts, shims, and tappets, be sure to note location and orientation of all parts to aid in assembly. Failure to install parts properly can result in TN0416 engine damage and failure.
  • Page 74 REPAIR Inspection See Figures 7-49 through 7-52. Required Tools and Materials Plastigage™ Clearance Indicator Micrometer Inside Bore Gauge IMPORTANT Tappets and shims must be removed before measuring camshaft bearing clearance. Be sure to note location and shim thickness of each TN0409 tappet.
  • Page 75 REPAIR Cam Timing Sprocket See Figure 7-53. TN0505 Figure 7-53 Inspect the camshaft timing sprockets (1) for wear and damage. If any abnormal condition is noted, replace the sprocket. TN0411 Figure 7-52 Camshaft Housing Bearing Face 7. If the oil clearance exceeds the limit, remove the See Figure 7-54.
  • Page 76 REPAIR Tappets and Shims Installation See Figure 7-55. NOTICE Be sure to install tappets, shims, camshafts, and camshaft housings at proper locations. Failure to install parts properly can result in engine damage and failure. See Figures 7-56 through 7-59. TN0412 Figure 7-55 1.
  • Page 77 REPAIR 6. Check valve clearance. (See “Valve Clearance Check and Adjustment” on page 5-3.) 7. Install timing chain. (See “Timing Chain” on page 7-14.) 8. Install front cover. (See “Front Cover” on page 7-12.) 9. Install oil pan. (See “Oil Pan” on page 7-30.) 10.

  • Page 78: Cylinder Head

    REPAIR Cylinder Head Inspection See Figure 7-61. Removal NOTICE See Figure 7-60. 1. Remove throttle body. (See “Throttle Body” on Do not scratch cylinder head surface when page 7-4.) removing carbon deposits. 2. Remove fuel rail and injectors. (See “Injectors” on page 7-9.) 3.
  • Page 79 REPAIR Cylinder Block Mating Face Distortion Intake and Exhaust Manifold Mating Face Distortion See Figures 7-62 and 7-63. See Figure 7-64. IMPORTANT A distorted cylinder head may cause combustion gas to leak through the head gasket, resulting in overheating and reduced power. TN0407 Figure 7-64 Using a straightedge (2) and a feeler gauge (1), inspect...
  • Page 80 REPAIR Installation See Figures 7-65 through 7-67. IMPORTANT Make sure cylinder head and cylinder block are free of oil and debris. Make sure cylinder head bolt holes are free of oil, water, or debris. TN0403 Figure 7-66 4. Torque the cap screws in sequence to 22 lb-ft (30 N•m).

  • Page 81: Valves

    REPAIR Valves Disassembly See Figure 7-68. Required Tools Valve Spring Compressor TN0492 Figure 7-68 1. Remove shims (1) and tappets (2). 2. Using a valve spring compressor, remove retainer locks (8). 3. Release valve spring compressor and remove valve (5). 4.
  • Page 82 REPAIR Inspection Valve Springs See Figures 7-70 and 7-71. Valves See Figure 7-69. Required Tools Veneer Caliper Spring Compression Gauge Square TN0506 Figure 7-69 1. Clean and inspect intake (5) and exhaust (4) valves, valve stems (3), valve stem tips (1), and retainer lock TN0558, 0559 grooves (2).
  • Page 83 REPAIR 2. Using a spring compression gauge (2), compress the valve spring to 1.17 in. (29.9 mm). Compare the tension reading to specification and replace as needed. Pound Force at 1.17 in. (29.9 mm) Height: Valve Spring Tension Standard: 22—26 lb-ft (100—116 N•m) Valve Spring Tension Limit: 20 lb-ft (88 N•m) 3.

  • Page 84: Lubrication System

    REPAIR 7.7 Lubrication System Oil Pan Removal Dipstick Tube See Figure 7-73. Removal and Installation See Figure 7-72. TN0741 Figure 7-73 TN0713 1. Drain engine oil. (See “Change Engine Oil” on Figure 7-72 page 3-2.) 1. Remove nut (1). 2. Remove twelve cap screws (2), three nuts (1), and oil pan (3).

  • Page 85: Oil Pump Pickup

    Oil Pump Pickup Installation See Figures 7-74 and 7-75. Removal and Installation Required Materials See Figure 7-76. Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or equivalent 1. Clean cylinder block, front cover, and oil pan mating surfaces. TN0742 Figure 7-76 1. Remove oil pan. (See “Oil Pan” on page 7-30.) 2.

  • Page 86: Crankshaft Baffle

    REPAIR Crankshaft Baffle Oil Pressure Sending Unit Removal and Installation Removal and Installation See Figure 7-77. See Figure 7-78. Required Tools 12-Point 8 mm Socket 1. Remove oil pan. (See “Oil Pan” on page 7-30.) 2. Remove oil pump pickup. (See “Oil Pump Pickup” on page 7-31.) TN0715 Figure 7-78...

  • Page 87: Oil Pump

    REPAIR Oil Pump Inspection NOTES Removal Clean engine oil from oil pump rotor bore, and inner and See Figure 7-79. outer rotors, before performing measurements. Outer Rotor Radial Clearance See Figure 7-80. TN0391 Figure 7-80 1. Using a feeler gauge, measure the clearance between outer rotor (1) and the oil pump case rotor TN0557 bore (2).
  • Page 88 REPAIR Outer Rotor Side Clearance Inner Rotor and Pump Case Clearance See Figure 7-81. See Figure 7-82. TN0392 Figure 7-81 1. Place a straightedge (1) across the oil pump rotor bore. Use a feeler gauge (2) to measure the clearance between the straightedge and the outer rotor side surface.
  • Page 89 REPAIR Relief Valve Spring See Figure 7-83. Required Tools Veneer Caliper Spring Compression Gauge TN0558, 0559 Figure 7-83 1. Use a veneer caliper to measure the free length of relief valve spring (1). If relief valve spring measures less than specification, replace the spring. Oil Pump Relief Valve Spring Free Length: 2.063 in.
  • Page 90 2. Install relief valve (11), spring (10), retainer (9), and Required Tools circlip (8). Bushing, Bearing and Seal Driver (Suzuki PN 3. Install inner rotor (4) and outer rotor (5). 09913-75520) or equivalent 4. Install oil pump housing (6) using screws (7). Tighten to specification.

  • Page 91: Cylinder Block And Lower Crankcase

    REPAIR 7.8 Cylinder Block and Lower Crankshaft Pulley Crankcase Removal and Installation See Figure 7-87. Knock Sensor Removal and Installation See Figure 7-86. TN0721 Figure 7-87 1. Remove cap screw (1) and crankshaft pulley (2). 2. Inspect and replace as needed. Installation Notes TN0718 Install crankshaft pulley by reversing the order of...

  • Page 92: Idler Pulley

    REPAIR Idler Pulley Connecting Rods and Pistons Removal and Installation Removal See Figure 7-88. See Figure 7-90. 1. Remove cylinder head. (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.
  • Page 93 REPAIR Disassembly See Figures 7-91 and 7-92. Required Tools Piston Ring Expander TN0499 Figure 7-92 4. Remove bearings (8) from connecting rod (7) and cap (9). 5. Inspect all parts for wear or damage. Replace as needed. Inspection Connecting Rods TN0753 1.
  • Page 94 REPAIR Piston, Piston Pin, and Piston Rings Assembly 1. Inspect piston, piston pin, and piston rings for cracks, NOTICE wear, or damage. Replace as needed. 2. Measure piston OD. Compare to specification and Prevent engine failure. Always clean parts of dirt cylinder bore ID.
  • Page 95 REPAIR TN0529 Figure 7-94 TN0753 Figure 7-96 NOTE Apply clean oil to piston pin, connecting rod, and piston contact surfaces before assembly. 5. Install connecting rod (15), piston pin (14), and circlips (13) to piston (16). NOTICE Prevent cylinder bore damage. Place rubber hose over connecting rod bolts before installing.

  • Page 96: Lower Crankcase, Cylinder Block, And Crankshaft

    REPAIR Lower Crankcase, Cylinder Block, and Crankshaft Disassembly See Figures 7-98 through 7-101. Required Tools 8 and 10 mm 12-point sockets 1. Remove cylinder head. (See “Cylinder Head” on page 7-24.) 2. Remove oil pan. (See “Oil Pan” on page 7-30.) TN0752 3.
  • Page 97 REPAIR TN0756 Figure 7-99 TN0758 8. Remove rear main seal (4) and crankshaft (5). Figure 7-101 10. Remove other half of crankshaft main bearings (9) from lower crankcase (8). TN0757 Figure 7-100 9. Remove crankshaft main bearings (6) and thrust bearings (7).
  • Page 98 REPAIR Inspection Crankshaft 1. Inspect crankshaft for cracks or damage. Replace as Cylinder Block and Lower Crankcase needed. Inspect main and rod journals for scratches, 1. Carefully inspect cylinder block and lower crankcase wear, or damage. Repair or replace as needed. for cracks or damage.
  • Page 99 REPAIR Assembly See Figures 7-102 through 7-107. Required Tools and Materials 8 and 10 mm 12-point sockets Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or equivalent Bushing, Bearing, and Seal Driver Tool NOTICE Prevent premature engine failure: • Thoroughly clean all parts before assembly.
  • Page 100 REPAIR 9. Apply Three Bond™ 1215 to the lower crankcase mating surface. TN0755 Figure 7-106: Torque Sequence M8 Cap Screws TN0755 IMPORTANT Figure 7-105: Torque Sequence M10 Cap Screws The remaining two M8 main bearing cap screws are installed with the crankshaft baffle. (See “Crankshaft NOTE Baffle”...
  • Page 101 REPAIR TN0759 Figure 7-107 13. Apply Three Bond™ 1215 to cylinder block/lower crankcase joints (26). NOTE Apply clean engine oil to rear main seal inner diameter and crankshaft stub seal surface. 14. Using a bushing, bearing, and seal driver tool, install new rear main seal (27).
  • Page 102 REPAIR 7-48...

  • Page 103: Tools And Materials

    Chapter 8 Tools and Materials Special Tools ..............8-1 Required Materials .
  • Page 104 See Figures 8-1 through 8-9. The following tools or suitable equivalents must be used to perform some procedures within this manual. Always use the correct tool for the job. Description Suzuki Part Number Oil Filter Wrench 09915-47341 Oil Pressure Gauge 09915-77311...
  • Page 105 Always use the right supplies for the job. Description Part Number Plastigage Oil Clearance Kit — Three Bond™ 1215 Sealant Suzuki PN 99000-1080-15A Anti-Seize Compound — Figure 8-7: Vacuum Gauge Figure 8-8: Tappet Holder...
  • Page 106 TOOLS AND MATERIALS...
  • Page 107 INDEX Cooling System Repair ......7-10 Specifications ......Air Intake and Exhaust Systems Tests and Adjustments .
  • Page 108 INDEX Electrical Hazardous Materials Storage ....1-5 Specifications ......2-5 Head Gasket Electrical Components, Safety .
  • Page 109 INDEX Oxygen Sensor Removal and Installation ....Repair ......Lifting Equipment, Safety .
  • Page 110 INDEX Specifications Theory of Operation ..... 4-2 Air Intake and Exhaust Systems ..2-5 Air Intake, Fuel, and Exhaust .
  • Page 111 INDEX Troubleshooting Diagnostic ......6-2 Engine Overheats ..... 6-3 Engine Surges or Misses .
  • Page 112 INDEX IX-6...
  • Page 113 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 technicians backed by Textron Parts Xpress provide reliable, high-quality product support. Textron Golf, Turf &...

Table of Contents

Save PDF