Piston, Connecting Rod, And Bearing Removal - Suzuki XL7 2007 Service Manual

3. Remove and discard the crankshaft rear oil seal
housing.
Piston, Connecting Rod, and Bearing
Removal
Reference: "Crankshaft Rear Oil Seal and Housing
Removal: ".
Special tool
EN 46121 Connecting Rod Guide Pin Set
NOTE
• An arrow/dot showing proper piston
orientation is located on the top of the
piston.
• If the connecting rod bearings have been
used in a running engine, you must
replace them with NEW connecting rod
bearings for reassembly.
1. Before removing the connecting rods, check the
connecting rod side clearance using the following
procedure:
a. Tap the connecting rod to one end of the
crankshaft journal with a dead-blow or wooden
hammer.
b. Using feeler gages, measure the clearance
between the crankshaft counterweight and the
connecting rod.
c. The connecting rod side clearance should not
exceed specifications. Refer to "Engine
Mechanical Specifications".
d. If the end play exceeds the specified limits,
measure the width of the crankpin end of the
connecting rod. Refer to "Piston, Connecting
Rod, and Bearings Cleaning and Inspection".
e. If the connecting rod width is significantly smaller
than specified and severe wear is present on the
side of the connecting rod, replace the
connecting rod.
f. If the connecting rod width is within specification
and excessive scoring is present on the
crankshaft journals, replace the crankshaft.
2. Using a marker, number each piston face. Draw an
arrow along the centerline of the piston pointing
toward the front of the engine.
CAUTION
!
Do not use a stamp, punch or any other
method that may distort or stress the
connecting rod or connecting rod cap.
Extensive engine damage may result from a
connecting rod that is distorted or stressed.
3. Mark the cylinder number on the connecting rod and
the connecting rod cap with a scribe, paint stick or
permanent marker.
CAUTION
!
Powdered metal connecting rods have rod
bolts which yield when torqued. If the rod
bolts are loosened or removed the rod bolts
must be replaced. Rod bolts that are not
replaced will not torque to the correct clamp
load and can lead to serious engine damage.
4. Remove the connecting rod bolts.
NOTE
The connecting rod caps must remain with
the original connecting rod.
5. Remove the connecting rod cap.
Engine Mechanical: 1D-159