Using Plastic Gaging - Suzuki XL7 2007 Service Manual

1D-258 Engine Mechanical:
6. Using both hands, slowly guide the piston and
connecting rod assembly into the cylinder from the
top and bottom of the cylinder. DO NOT allow the
connecting rod to contact the cylinder wall.
7. When the J 8037 contacts the deck surface, gently
tap the piston into the cylinder using the handle end
of a dead-blow hammer. Guide the connecting rod
onto the crankshaft bearing journal using the EN
46121 while gently tapping the piston into the
cylinder with a soft-blow hammer.
8. Remove the EN 46121 from the connecting rod bolt
holes.
Connecting Rod Bearing Clearance
Measurement Procedure - Using Plastic Gaging
NOTE
Connecting rod bearings that have been run
in an engine should NEVER be reused.
Before final assembly it is important to check
the clearance of the new connecting rod
bearings.
1. Place a length of fresh, room temperature plastic
gaging material all the way across the connecting
rod bearing journal.
2. Install the connecting rod bearing into the connecting
rod cap.
NOTE
The connecting rod is non-directional
therefore the connecting rod bearing lock
tangs can face inboard or outboard.
3. Install the connecting rod end cap on its original
connecting rod and ensure the bearing lock tangs
are aligned on the same side of the rod.
CAUTION
!
Refer to "Fastener Notice: ".
CAUTION
!
Do not lubricate the NEW connecting rod
bolts. The NEW bolts have a pre-applied
graphite lubricant. Applying lubricant to the
connecting rod bolts will effect the clamp
load when the connecting rod bolts are
torqued. Improper clamp load can lead to
component failure and extensive engine
damage.
NOTE
Reuse the old connecting rod bolts ONLY for
measuring the connecting rod bearing
clearance.
4. Install the connecting rod bolts into the connecting
rod cap.
Tightening torque
Tighten the connecting rod bolts to 30 N⋅m (22 lb
ft).
5. Loosen the connecting rod bolts until the torque
reading is zero.
6. Re-tighten the connecting rod bolts.
a. First Pass
Tightening torque
Tighten the connecting rod bolts to 25 N⋅m
(18 lb ft).
b. Final Pass
Tightening torque
Tighten the connecting rod bolts an
additional 110 degrees using the J 45059.