Suzuki K6A-YH6 Engine Technical Repair Manual Suzuki K6A-YH6 Engine Technical Repair Manual

Suzuki K6A-YH6 Engine

Technical/Repair Manual

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 t he entire manua l bef ore at tempti ng to
set up, operate, adjust or service the machine.

©2008 Jacobsen, A Textron Company. All rights reserved.

Foreword

General

This manual provides detailed information and
procedures to safely repair and maintain the following:

Suzuki K6A-YH6 gasoline engine

This manual is intended to introduce and guide the user
through the latest factory-approved troubleshooting and
repair techniques and practices.

Before you attempt to troubleshoot or make repairs, you
must be familiar with the operation of this engine . Refer to
the operator’s manual and parts manual for specific
information on these topics.

THE INFORMATION CONTAINED 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

!

Certain vehicle components contain or emit
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.

Trademark Acknowledgement

Jacobsen acknowledges the following trademarks for
company names or products mentioned within this
publication:

Jacobsen® is a registered trademark of Textron Inc.
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.

4171985 First Edition i

FOREWORD

How to Use This Manual

This manual is designed to provide multiple ways to
locate and access repair information.

Read each section in entirety before beginning a
procedure. Proper understanding of machine operation
and components is the ke y to successful diagnosti cs and
repair.

Make use of special information features with in this
manual in order to be b etter prepared to perform repairs.
Always follow manual procedures and safety guidelines.
Never ta ke shortcuts.

Table of Contents

Major machine components or topics of interest are
separated into specific chapters . Each man ual lists these
chapters in a main Table of Contents.

Chapter Table of Contents

Each chapter begins with a detailed Table of Contents
related to the specific machine component or system.

Use the Chapter Table of Contents to find specific
component or procedural information.

Warnings and Cautions

Warning and Caution indicators are located throughout
the manual at specific points of interest. These notices
are given to prevent personal injury, death and/or
equipment damage. Always heed these notices, and
practice common sense when performing any
maintenance or repair procedure.

Notes

Special notes are given in order to draw attention to
detailed instructions. These notes are intended to give
further important information regarding the machine
and/or a step in a procedure.

Troubleshooting

Troubleshooting charts are provided in chapter 6 to aid in
the diagnostic process. Use these suggest ions to aid in
identifying a potential mechanical or machine adjustment
problem.

Index

An alphabetical Index is located at the back of the
manual.

Use the Index to find specific components and related
procedures.

Required Tools and Materials

Some procedures will require the use of specific 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.

Quick Reference Specifications

A list of all machine specifications can be found in
Chapter 2 Specifications and General Inf ormation. This is
a list of all specifications from each chapter, combined
and listed in one place for easy reference.

Copyright 2008 Textron Inc.
“All rights reserved, including the right to reproduce this material or portions thereof in any form.”

ii 4171985 First Edition

Table of Contents

Safety

Specifications and
General Information

Maintenance

Theory of Operation

Tests and Adjustments

Diagnostic Troubleshooting

1
2
3
4
5
6

Repair

Tools and Materials

7
8

4171985 First Edition iii

Chapter 1

Safety

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Prepare for the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Keep Work Area Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Keep Work Area Well Ventilated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Use Proper Eye and Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Use Lifting Equipment Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Use Compressed Air and Air Tools Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Handle Fuel Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Store Volatile and Hazardous Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Handle Chemical Products Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Service Electrical Components Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Dispose of Waste Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1

4171985 First Edition 1-1

SAFETY

Introduction

Safety is the most important element of any repair
procedure. Knowledge of t he procedure to be performed
and safe work habits are essential to preventing death,
personal injury, or property damage. Use the following
statements as a common-sense guide to proper work
and tool-use habits.

1

Prepare for the Job

Preparation is essential to complete a procedure in a
safe and efficient man ner.

• Wear proper clothing. Loose or baggy clothing could
become tangled in moving parts.

• Use eye/face protection. Always use proper eye/face
protection to protect your eyes from flying debris or
chemical splatters.

• Wear protective footwear. Wear safety shoes
(steel-toe) to protect your feet from falling objects.

• Use gloves when handling parts. Parts may have
sharp edges or may be hot.

• Remove jew e lry prior to servicing electrical systems.

• Prepare proper tools and equipme nt. Alw ays use the
correct tool for the job. Improper or homemade tools
can cause injury or machine damage.

• Prepare needed parts and materials. Gather the
needed parts and materials before beginning the
procedure.

• Allow machine to cool. Man y components can get hot
during operation. Be sure to allow enough time for

components to cool before beginning service.

• Prepare proper work-space lighting. A well-lit work
area can make the job easier.

• Follow procedures and safety warnings. Service
procedures are written to be as safe and efficient as
possible. Neve r take shortcuts.

• Be prepared for emer gencies. Accidents can happen,
even under the best conditions. Fire extinguishers
and first aid kits should be well maintained and easily
accessible.

Safety Notices

Throughout this manual, the following key safety words
will be used to alert the reader of potential hazards.
Become familiar with these words and their meaning.
Take all precautions to avoid the hazards described.

This safety alert symbol is used to

!

Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or
serious injury.

Indicates a potentially hazardous situa tion which,
if not avoided, COULD result in death or serious
injury.

Indicates a potentially hazardous situa tion which,
if not avoided, MAY result in minor or moderate
injury and property damage. It may also be used
to alert against unsafe practices.

alert you to potential hazards.

DANGER

!

WARNING

!

CAUTION

!

NOTICE

Indicates a potentially hazardous situa tion which,
if not avoided, MAY result in property damage. It
may also be used to alert against unsafe
practices.

Keep Work Area Clean

A clean, organized, well lit work area is important to
promote safe w orking conditions.

• Keep floor clean of debris and clear of parts and
tools.

• Clean up any spilled fuel, oil, and/or chemicals
immediately.

• Store all air hoses and electrical cords properly when
not in use.

1-2 4171985 First Edition

SAFETY

Keep Work Area Well Ventilated

WARNING

!

Never operate the engine without proper
ventilation; exhaust fumes can be fatal if inhaled.

Certain test and adjustment procedures require the
engine to be running. Be sure work area is well
ventilated; never run the engine in an enclosed area.

Use Proper Eye and Face Protection

WARNING

!

Always use approved personal protection
equipment. Avoid workplace hazards by wearing
properly maintained, approved eye and face
protection. Failure to use app ropriate protection
equipment may result in death or serious injury.

• When using a lifting device, always connect the load
so it is balanced.

• Always use a lifting device on a hard, level surface.

• Lower the lifting 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

!

Always wear approved eye and ear protection
while using compressed air. Misuse of
compressed air could result in death or serious
injury.

• When using air nozzles, air pressure should
not exceed 30 psi (206.8 kPa).

• Never direct air nozzles or tools at a person.

• Never point air nozzles directly at skin.

1

Always wear eye protection while in a shop environment.

• Safety Glasses: Safety glasses offer a minimum le v el
of protection from flying debris.

• Face Shields: Face shields are often used along with
safety glasses to offer a higher level of protection
when sparks and flying debris are present.

• Vented Goggles: Goggles offer side protection not

offered by safety glasses alone.

• Unvented Goggles: Unvented goggles offer
protection from chemical splashes and vapors.

Use Lifting Equipment Safely

WARNING

!

Always chec k the lifting capaci ty and condition of
hoists, slings, cables, or chains before use.
Using underrated or worn lif ting components can
result in death or serious injury.

• Always use a lifting device with a lifting capacity
greater than the weight of the item being lifted.

• Secure the load to the lifting device using cables,
chains, or slings rated to handle the load be ing lifted.
Fasteners being used to connect lifting devices must
be strong enough to handle the load. Also be sure
the mounting point of load is strong enough to hand le
the load.

• Compressed air is a useful tool when used in a safe
manner.

• Always use eye and ear protection while using
compressed air and air tools.

• When using air tools, do not exceed the air pressure
rating for the tool.

• When using an impact wrench, always use approved
impact sockets. Never use standard sockets on an
impact wrench.

• Disconnect the air supply before changing air tool
attachments.

• Never point air nozzles or air tools at another person.

• Always maintain air tools properly.

4171985 First Edition 1-3

SAFETY

Handle Fuel Safely

Handle fuel with care—it is highly flammable.

WARNING

!

• Never remove the fuel cap from the fuel tank,
or add fuel, when the engine is running or
while the engine is hot.

1

• Do not smoke when handling fuel. Never fill
or drain the fuel tank indoors.

• Do not spill fuel. Clean spilled fuel
immediately.

• Never handle or store fuel container s nea r an
open flame or any device that may create
sparks and ignite the fuel or fuel vapors.

• Be sure to reinstall and tighten fuel cap
securely.

• Use an approved container; the spout must fit
inside the fuel filler neck. Avoid using cans
and funnels to transfer fuel.

Store fuel according to local, state, or federal ordinances
and recommendations from your fuel supplier.

Never overfill or allow the tank to become empty.
Use clean, fresh fuel.
Do not fill above the fuel filler neck.

Handle Chemical Products Safely

WARNING

!

Exposure to chemical products could result in
serious injury. Handle chemical products with
care. Refer to the chemical manufacturer’s
Material Safety Data Sheet (MSDS) for information
regarding health hazards, safe handling, and
emergency response procedures.

Routine service often requires the use of various
chemical products, including lubricants and cleaning
solutions. Many of these chemicals are flammable and
can pose health risks if not handled properly.

• Never mix chemicals. Mixing chemicals can produce
toxic or explosive results.

• Follow the manufacture’s recommendations for safe
usage and handling of the product.

• Various materials may pose a health hazard if used
incorrectly. A Material Safety Data Sheet (MSDS)
contains important information regarding proper
handling and health hazards, as well as emergency
response procedures. Contact the chemical
manufacturer to obtain an MSDS for the chemical
product.

Store Volatile and Hazardous Materials Safely

Store volatile materials (gasoline, diesel fuel, oil, etc.) in
approved contai ners that are clearly marked. Containers
should be stored in an approved safety cabinet away
from possible sources of ignition. Storage areas and
cabinets should be well ventilat ed to prevent the possible
build-up of fumes.

Service Electrical Components Safely

WARNING

!

Always disconnect the negati ve terminal first and
positive terminal last. Connect positive terminal
first and negative terminal last. Use care when
testing live circuits to prevent arcing. Arcing
could result in death or serious injury.

• Disconnect the battery negative (–) cable before
removing or installing electrical components. Always
connect the battery negative (–) cable last.

• Certain test and adjustment procedures must be
performed with the battery connected. Use care to
prevent arcing when working on live circuits or
components. Arcing can cause component damage
and could ignite flammable materials.

1-4 4171985 First Edition

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. Make sure the fluid to be stored is
compatible with the storage container. Never use food or
beverage containers to store waste fluids.

IMPORTANT

Never dispose of waste fluids by pouring on the
ground, down sewer drains, or into any body of
water.

• Dispose of waste fluids properly at approved local
recycling centers. If recycling facilities are not
available, contact your local community for the
correct disposal procedure for waste fluids.

• Dispose of old batteries properly. Battery electrolyte
contains sulfuric acid and other hazardous materials.
Never place an old battery in the trash. Batteries
must be disposed of in a manner consistent with EPA
and/or local regulations.

SAFETY

1

4171985 First Edition 1-5

1

SAFETY

Page Intentionally Blank

1-6 4171985 First Edition

Chapter 2

Specifications and General Information

2.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cylinder Numbering and Engine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Optional Engine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Engine Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Standard Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.2 Air Intake 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 Specifications . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.7 Cylinder Head, Cams, and Valve Train Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Tappet Shim Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.8 Lubrication System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2

2.9 Cylinder Block, Lower Crankcase, and Crankshaft Specifications . . . . . . . . . . . . . . . 2-10

Oversize Main Bearing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

4171985 First Edition 2-1

SPECIFICATIONS AND GENERAL INFORMATION

2.1 General Specifications

Engine Identification

Model and Serial Number

See Figure 2-1.

K6A

The Suzuki K6A is a 3-cylinder, fuel injected, dual
overhead cam, liquid cooled, gas powered engine.

2

1

2

Cylinder Numbering and Engine Orientation

Procedures within this manual refer to specific cylinder
numbers. The cylinders are numb ered 1 through 3,
starting closest to the timing chain and moving toward the
flywheel.

Procedures within this manual refer to the front and rear
of the engine. Use the fo llowing guidelines when th e front
and rear of the engine are referenced:

The timing chain side of the engine is considered the
front of the engine.

The flywheel side of the engine is considered the rear of
the engine.

Optional Engine Accessories

This manual is structured to cover all basic engine
components and repair. The addition of certain
accessories can affect troubleshooting, ad justment, and
repair procedures.

Refer to machine parts and maintenance manual for
specific information pertaining to accessory
troubleshooting, removal, repair, and installation
procedures.

TN0694

Figure 2-1

An identification number, like the one shown, is stamped
into the cylinder block, and is also written on the fuel rail.
The engine model number (1) is displayed first, followed

by the engine serial number (2).
Always provide the engine model and serial numbers

when ordering replacement parts or requesting service
information.

2-2 4171985 First Edition

Engine Component Locations

See Figures 2-2 through 2-5.

SPECIFICATIONS AND GENERAL INFORMATION

2

1

4

1 Oil Fill 3 Thermostat Housing
2 Fuel Injectors 4 Ignition Coils

Figure 2-2

6

5

3

TN0690

9

8

8 Throttle Body 11 Crankshaft Pulley
9 Cylinder Head 12 Water Pump
10 Intake Man if o ld

Figure 2-4

15

16

14

10

11

2

12

TN0692

17

7

5 Cam Cover 7 Exhaust Manifold
6 Cylinder Block/Lower

Crankcase

Figure 2-3

TN0691

13

18

13 Oil Pan 16 Front Co v er
14 Idler Pulley 17 Fuel Rail
15 Dipstick 18 Oil Filter

Figure 2-5

TN0693

4171985 First Edition 2-3

SPECIFICATIONS AND GENERAL INFORMATION

Engine Information

Item Unit Specification

Type K6A Normally Aspirated
Number of Cylinders and

Arrangement
Combustion Chamber Shape Pent-Roof Type
Valve Mechanism Twin Cam, 4-Valve, Chain Driven

2

Engine Displacement
Bore x Stroke
Compression Ratio 10.5
Cylinder Identification 1-2-3 from Timing Chain toward Flywheel
Firing Order 1-3-2
Maximum Output @ Engine Speed
Maximum Torque @ Engine Speed

cu in. (cc) 40 (658)

in. (mm) 2.68 x 2.38 (68.0 x 60.4)

hp/rpm 44 at 5000 (net)

lb-ft/rpm 45.7 at 4000 (net)

In-line 3-Cylinder Transversely Mounted

2-4 4171985 First Edition

Standard Torque Values

SPECIFICATIONS AND GENERAL INFORMATION

NOTICE

All torque values included in these charts are
approxi ma te and are for reference only. Use of
these torque value s is at yo ur sole risk. Jacobsen
is not responsible for any loss, claim, or damage
arising from the use of these charts.

Extreme caution should always be used when
using any torque value.

Inch Fastener Torque Values

SIZE UNITS GRADE 5 GRADE 8 SIZE UNITS GRADE 5 GRADE 8

Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry

#6-32 in-lb (Nm) – 20 (2.3) – – 7/16-14 ft-lb (Nm) 37 (50.1) 50 (67.8) 53 (71.8) 70 (94.9)

#8-32 in-lb (Nm) – 24 (2.7) – 30 (3.4) 7/16-20 ft-lb (Nm) 42 (56.9) 55 (74.6) 59 (80.0) 78 (105)
#10-24 in-lb (Nm) – 35 (4.0) – 45 (5.1) 1/2-13 ft-lb (Nm) 57 (77.2) 75 (101) 80 (108) 107 (145)
#10-32 in-lb (Nm) – 40 (4.5) – 50 (5.7) 1/2-20 ft-lb (Nm) 64 (86.7) 85 (115) 90 (122) 120 (162)
#12-24 in-lb (Nm) – 50 (5.7) – 65 (7.3) 9/16-12 ft-lb (Nm) 82 (111) 109 (148) 115 (156) 154 (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)

5/16-18 in-lb (Nm) 157 (17.7) 210 (23.7) 220 (24.8) 305 (34.4) 5/8-18 ft-lb (Nm) 128 (173) 170 (230) 180 (244) 240 (325)

5/16-24 in-lb (Nm) 173 (19.5) 230 (26.0) 245 (27.6) 325 (36.7) 3/4-10 ft-lb (Nm) 200 (271) 266 (360) 282 (382) 376 (509)

3/8-16 ft-lb (Nm) 23 (31.1) 31 (42.0) 32 (43.3) 44 (59.6) 3/4-16 ft-lb (Nm) 223 (302) 298 404 315 (427) 420 (569)

3/8-24 ft-lb (Nm) 26 (35.2) 35 (47.4) 37 (50.1) 50 (67.8) 7/8-14 ft-lb (Nm) 355 (481) 473 (641) 500 (678) 668 (905)

NOTE

Jacobsen uses Grade 5 plated bolts as standard, unless
otherwise noted. When tightening plated bolts, use the
value given for lubricated.

2

AMERICAN NATIONAL STANDARD FASTENERS

Metric Fastener Torque Values

METRIC F ASTENERS

Non-Critical

4.6 8.8 10.9 12.9

SIZE UNITS

Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry

M4 Nm (in-lb) – – – – – – 3.83 (34) 5.11 (45) 2.0 (18)
M5 Nm (in-lb) 1.80 (16) 2.40 (21) 4.63 (41) 6.18 (54) 6.63 (59) 8.84 (78) 7.75 (68) 10.3 (910 4.0 (35)
M6 Nm (in-lb) 3.05 (27) 4.07 (36) 7.87 (69) 10.5 (93) 11.3 (102) 15.0 (133) 13.2 (117) 17.6 (156) 6.8 (60)

M8 Nm (in-lb) 7.41 (65) 9.98 (88) 19.1 (69) 25.5 (226) 27.3 (241) 36.5 (323) 32.0 (283) 42.6 (377) 17.0 (150)
M10 Nm (ft-lb) 14.7 (11) 19.6 (14) 37.8 (29) 50.5 (37) 54.1 (40) 7 2.2 (53) 63.3 (46) 84.4 (62) 33.9 (25)
M12 Nm (ft-lb) 25.6 (19) 34.1 (25) 66.0 (48) 88.0 (65) 94.5 (70) 125 (92) 110 (81) 147 (108) 61.0 (45)
M14 Nm (ft-lb) 40.8 (30) 54.3 (40) 105 (77) 140 (103) 150 (110) 200 (147) 175 (129) 234 (172) 94.9 (70)

4171985 First Edition 2-5

Fasteners

into

Aluminum

SPECIFICATIONS AND GENERAL INFORMATION

2.2 Air Intake and Exhaust System Specifications

Item

Intake Manifold Torque
Exhaust Manifold Torque
Intake Manifold Distortion Limit
Exhaust Manifold Distortion Limit
Intake Manifold Vacuum at Idle

2

2.3 Electrical Specifications

Item

Spark Plug (NGK) Jacobsen PN 4119606
Spark Plug (Denso) Jacobsen PN 2701832
Spark Plug Gap
Spark Plug Torque
Firing order 1-3-2
Ignition Timing
ISC Duty Ratio
O

Sensor Feedback Duty Ratio % 5—95

2

Belt Deflection at Mid-Point with
17 ft-lb (23 N•m) of Force Applied

Alternator Belt Deflection—New
Alternator Belt Deflection

Readjustment

Unit Specification

lb-in. (N•m) 97 (11)
lb-in. (N•m) 204 (23)

in. (mm) 0.003 (0.07)
in. (mm) 0.003 (0.07)

psi (kpa) 7.7 (53)

Unit Specification

in. (mm) 0.031—0.035 (0.8—0.9)

lb-in. (N•m) 177 (20)

deg. / rpm 5 ± 1 / 800

% 5—30

in. (mm) 0.315—0.354 (8—9)
in. (mm) 0.472—0.59 (12—15)

2.4 Fuel System Specifications

Item

Fuel Pressure

Unit Specification

psi (kPa) 43 (294)

2.5 Cooling System Specifications

Item

Thermostat Start-to-Open
Thermostat Full Open

Unit Specification

°F (°C) 190 (88)
°F (°C) 205 (96)

2-6 4171985 First Edition

2.6 Front Cover, Timing Chain, and Tensioner Specifications

SPECIFICATIONS AND GENERAL INFORMATION

Item

Front Cover Torque

2.7 Cylinder Head, Cams, and Valve Train Specifications

Item

Valve Clearance, Cold, Intake
Valve Clearance , Cold, Exhaust
Intake and Exhaust Manifold Mating

Face Distortion Limit
Camshaft Housing Cap Screw

Torque
Camshaft Journal Outside Diameter
Camshaft Journal Inside Diameter
Camshaft Lobe Height, Intake
Camshaft Lobe Height, Exhaust
Cylinder Head/Block Mating Face

Distortion Limit
Camshaft Oil Clearance Standard
Camshaft Oil Clearance Limit
Valve Spring Tension Standard at

1.17 in. (29.9 mm)

Valve Spring Tension Limit at

1.17 in. (29.9 mm)
Valve Guide to Valve Stem

Clearance, Intake
Valve Guide to Valve Stem

Clearance Limit, Intake
Valve Guide to Valve Stem

Clearance, Exhaust
Valve Guide to Valve Stem

Clearance Limit, Exhaust
Tappet and Bore Clearance
Tappet and Bore Clearance Limit
Valve Spring Free Length
Valve Spring Right Angle Range
Cam Cover Cap Screw Torque
Cylinder Head Cap Screw Torque

Unit Specification

lb-in. (N•m) 97 (11)

Unit Specification

in. (mm) 0.007—0.009 (0.18—0.23 )
in. (mm) 0.012—0.014 (0.30—0.35 )
in. (mm) 0.000—0.002 (0.00—0.05 )

lb-in. (N•m) 97 (11)

in. (mm) 0.903—0.904 (22.934—22.955)
in. (mm) 0.905—0.906 (23.000—23.021)
in. (mm) 1.477—1.483 (37.520—37.680)
in. (mm) 1.470—1.476 (37.343—37.503)
in. (mm) 0.001 (0.03)

in. (mm) 0.002—0.003 (0.045—0.087)
in. (mm) 0.004 (0.10)

lb-ft (N•m) 22—26 (100—116)

lb-ft (N•m) 20 (88)

in. (mm) 0.0007—0.0018 (0.020—0.047)

in. (mm) 0.002 (0.07)

in. (mm) 0.0017—0.0028 (0.045—0.072)

in. (mm) 0.003 (0.09)

in. (mm) 0.0009—0.0024 (0.025—0.062)
in. (mm) 0.003 (0.10)
in. (mm) 1.35 (34.3)
in. (mm) 0.000—0.059 (0.00—1.5)

lb-in. (N•m) 96 (11)

lb-ft (N•m) 43.5 (59)

2

4171985 First Edition 2-7

SPECIFICATIONS AND GENERAL INFORMATION

Tappet Shim Selection Chart

Part Number

4148102 218 2.18
4148103 220 2.20
4148104 222 2.22
4148105 224 2.24
4148106 226 2.26
4148107 228 2.28
4148108 230 2.30

2

4148109 232 2.32
4148110 234 2.34
4148111 236 2.36
4148112 238 2.38
4148113 240 2.40
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 264 2.64

4148126 266 2.66
4148127 268 2.68
4148128 270 2.70
4148129 272 2.72
4148130 274 2.74
4148131 276 2.76
4148132 278 2.78
4148133 280 2.80
4148134 282 2.82
4148135 284 2.84
4148136 286 2.86
4148137 288 2.88
4148138 290 2.90
4148139 292 2.92
4148140 294 2.94
4148141 296 2.96
4148142 298 2.98
4148143 300 3.00

Stamped Number Thickness (mm)

2-8 4171985 First Edition

2.8 Lubrication System Specifications

SPECIFICATIONS AND GENERAL INFORMATION

Item

Oil Pump Housing Torque
Oil Pump Outer Rotor Side

Clearance Limit
Oil Pump Radial Clearance Limit
Inner Rotor and Pump Case

Clearance
Oil Pump Relief Valve Spring Free

Length
Oil Pump Relief Valve Spring

Tension at 1.516 in (38.5: mm)
of Length

Oil Pressure Sending Unit Torque
Oil Pressure-Minimum at 4000 rpm
Oil Pan Torque
Drain Plug Torque
Oil Filter Torque
Recommended Oil

Oil Capacity when Replacing
Without Filter

Oil Capacity when Also Replacing
Filter

Oil Change Interval—Normal
Conditions

Oil Filter Replacement

Unit Specification

lb-in. (N•m) 60 (6.78)

in. (mm) 0.003—0.005 (0.076—0.127)

in. (mm) 0.0004—0.006 (0.10—0.15)
in. (mm) 0.001—0.003 (0.025—0.076)

in. (mm) 2.063 (52.40)

lb-ft (N•m) 17.3 (4.44)

lb-in. (N•m) 115 (13)

psi (kPa) 40 (276)

lb-in. (N•m) 97 (11)

lb-ft (N•m) 36 (49)

lb-in. (N•m) 120 (13.5)

Normal /

Cold Region

qts (liters) 2.75 (2.6)

qts (liters) 2.96 (2.8)

hours After First 35 Hours—Then Every 100 Hours or 3 Months

hours After First 35 Hours—Then Every 100 Hours or 3 Months

10W-30 (SH) / 5W-30 (SG)

2

4171985 First Edition 2-9

SPECIFICATIONS AND GENERAL INFORMATION

2.9 Cylinder Block, Lower Crankcase, and Crankshaft Specifications

Item

Lower Crankcase (M10) Cap Screw
Torque

Lower Crankcase (M8) Cap Screw
Torque

Cylinder Bore Inside Diameter

2

Cylinder Bore Inside Diameter Limit
Piston Outside Diameter
Oil Control Ring End Gap
Oil Control Ring End Gap Limit
Second Compression Ring End

Gap
Second Compression Ring End

Gap Limit
Top Compression Ring End Gap
Top Compression Ring End Gap

Limit
Cylinder Block Main Bearing

Journal Inside Diameter
Crankshaft Main Bearing Journal

Outside Diameter
Crankshaft/Cylinder Block Main

Bearing Journal Oil Clearance
Crankshaft/Cylinder Block Main

Bearing Journal Oil Clearance Limit
Piston Pin Outside Diameter
Piston Pin Bore Inside Diameter
Connecting Rod Small End Inside

Diameter
Connecting Rod Large End Inside

Diameter
Crankshaft Connecting Rod

Bearing Journal Outside Diameter
Crankshaft/Connecting Rod Oil

Clearance
Crankshaft/Connecting Rod Oil

Clearance Limit
Connecting Rod Torque
Crankshaft Pulley Cap Screw
Flywheel Cap Screw
Knock Sensor Torque

Unit Specification

lb-ft (N•m) 42 (57)

lb-in. (N•m) 212 (24)

in. (mm) 2.6771—2.6779 (68.000—68.020)
in. (mm) 2.6791 (68.050)
in. (mm) 2.675—2.676 (67.970—67.990)
in. (mm) 0.0039—0.0157 (0.10—0.40)
in. (mm) 0.047 (1.2)
in. (mm) 0.0137—0.0196 (0.35—0.50)

in. (mm) 0.039 (1.0)

in. (mm) 0.0047—0.0106 (0.12—0.27)
in. (mm) 0.027 (0.7)

in. (mm) 1.9291—1.9298 (49.000—49.018)

in. (mm) 1.770—1.771 (44.982—45.000)

in. (mm) 0.0007—0.0015 (0.020—0.040)

in. (mm) 0.002 (0.065)

in. (mm) 0.7084—0.7086 (17.995—18.000)
in. (mm) 0.7088—0.7092 (18.006—18.014)
in. (mm) 0.7087—0.7090 (18.003—18.011)

in. (mm) 1.6141—1.6148 (41.000—41.018)

in. (mm) 1.495—1.496 (37.982—38.000)

in. (mm) 0.0007—0.0015 (0.020—0.040)

in. (mm) 0.002 (0.065)

lb-ft (N•m) 24 (33)
lb-ft (N•m) 72 (98)
lb-ft (N•m) 50 (69)

lb-in. (N•m) 203 (23)

2-10 4171985 First Edition

Oversize Main Bearing Identification

SPECIFICATIONS AND GENERAL INFORMATION

Bearing Color

Brown 4140912 0.0785—0.0787 in.

Green 4140908 0.0787—0.0788 in.

Black 4140909 0.0788—0.0789 in.

No Color 4140910 0.0788—0.0789 in.

Yellow 4140911 0.0790—0.0792 in.

Part N umber Size Range

(1.996—2.000 mm)

(1.999—2.003 mm)

(2.002—2.006 mm)

(2.002—2.006 mm)

(2.008—2.012 mm)

2

4171985 First Edition 2-11

SPECIFICATIONS AND GENERAL INFORMATION

2

Page Intentionally Blank

2-12 4171985 First Edition

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

3

4171985 First Edition 3-1

MAINTENANCE

Engine Oil Level

See Figure 3-1.

1

2

3

3

Figure 3-1

1. Park the vehicle o n a level surface.

2. Operate the engine until normal operating
temperature is reached.

3. Stop the engine. Remov e dipstic k (3) and wipe clea n.
Install and remove dipstick again.

4. Check engine oil level.
If oil level is at or below lo w mark (1), add oil until the

level reaches the full mark (2).

5. Install dipstick (3).

TN0533

3. Stop the engine and place a suitable pan under the
engine.

WARNING

!

The engine oil will be hot. Av oid skin c ontact with
used engine oil.

4. Remove drain plug (1) with seal (2) and drain eng ine
oil.

NOTE

Always use new O-rings, gaskets, and seals.

5. Install drain plug (1) using new seal (2). Tighten to
specification.

Drain Plug Torque: 36 lb-ft (49 N•m)

6. Add new engine oil through cylinder head cover until
oil level reaches full mark on dipstick.

Engine Oil Capacity: 2.9 qt (2.7 L) without oil filter

7. Start engine and check for leaks.

8. Stop engine and check engine oil level. Top off as
needed.

Oil Filter

Replacement

See Figures 3-3 and 3-4.

Change Engine Oil

See Figure 3-2.

1

2

Figure 3-2

1. Park the vehicle o n a level surface.

2. Operate the engine until normal operating
temperature is reached.

Required Tools

Oil Filter Wrench (Suzuki PN 09915-47340)

1

TN0534

TN0694

Figure 3-3

1. Drain engine oil.

3-2 4171985 First Edition

MAINTENANCE

2. Using oil filter wrench, remove the oil filter (1).

2

TN0352

Figure 3-4

3. Coat new oil filter O-ring (2) with clean engine oil.

NOTE

Prevent contamination; clean oil filter housing before
installing new oil filter.

4. Install new oil filter and tighten to specification.

Oil Filter Tightening Torque: 120 lb-in. (13.5 N•m)

5. Fill engine oil.

Oil Capacity with Filter: 3.1 qt (2.9 L)

2. Remove ignition coils (2).

3

3

TN0697

Figure 3-6

3. Remove spark plugs (3).

5

4

Spark Plugs

Replacement

See Figures 3-5 through 3-7.

1

2

Figure 3-5

1. Remove cap screws (1).

TN0698

Figure 3-7

4. Set gap (5) on each new spark plug (4) to
specification.

Spark Plug Gap: 0.032—0.035 in. (0.8—0.9 mm)

5. Install new spark plugs, tighten to specification.
Spark Plug Tightening Torque: 177 lb-in. (20 N•m)

6. Install ignition coils.

TN0695

4171985 First Edition 3-3

MAINTENANCE

3

Page Intentionally Blank

3-4 4171985 First Edition

Chapter 4

Theory of Operation

4.1 General Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Air Intake, Fuel, and Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4

4.7 Cylinder Block and Lower Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Piston, Piston Rings, and Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4171985 First Edition 4-1

THEORY OF OPERATION

4.1 General Engine Operation

See Figure 4-1.

4

The K6A engine is an in-line, 3-cylinder, twin overhead
cam, 4-valve per cylinder, naturally aspirated, liquid
cooled, gasoline engine.

The compact K6A engine is constructed primarily of
durable, lightweight, heat-dissipating materials.

The cylinder head is a twin cam 4-valv e type and mad e of
aluminum alloy that is light in weight and e xcellent in heat
dissipation. Valves are direct driven from camshafts by
way of shim-adjustable tappets placed on top of valves.

The combustion chamber is a pent-roof type with the
spark plug arranged in the center for improved
combustion. Spark plugs are fired by direct mounted
individual coils for each plug.

The camshafts are made of lightweight hollow cast iron.
Camshaft drive is done with a chain drive that is
automatically adjusted by a chain tensioner. The chain
tensioner uses lubrication system pressure and spring
pressure to automatically compensate for chain wear.

TN0746

Figure 4-1

The cylinder head gasket is of 2-la yer lam inated stainless
steel which is excellent in durability and reliability. Use of
advanced coatings further enhance the fluid sealing
capabilities of the gasket.

The cylinder block is of a lightw eight alumin um tw o-piece
design, consisting of upper and lowe r castings. The lo wer
casting is a ladder design that incorporates the main
journal caps for added rigidity. Semi-wet pressed-in
cylinder sleeves are contained in the upper block casting.

The crankshaft is constructed of cast iron and utilizes
four main journals and three rod journals. Counter­balancing is achieved by weights on two of the journals.
Rod and main journal bearings are of a two-piece design
with the third main journal incor porating a thrust bearing.

Connecting rods are of a two-piece design made of
carbon steel. The rod cap is retained, using special
reamer type rod bolts and nuts.

4-2 4171985 First Edition

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.

The engine lubrication system incorporates a lightweight
aluminum oil pan with internal crankshaft baffle. Engine
oil is removed from t he pan through a str ainer pic kup b y a
crankshaft driven 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 water pump remo ves coolant fr om a full-flow
radiator and circulates the coolant through the entire
engine. The coolant temperature is controlled by the
cylinder-head-mounted thermostat housing containing
the thermostat.

The electronically controlled fuel injection system
efficiently supplies fuel to the engine, while maintaining
optimum performance and throttle respon s e. Port
injectors with a common fuel rail in conjunction with a
throttle body are used for fuel distribution.

THEORY OF OPERATION

4

4171985 First Edition 4-3

THEORY OF OPERATION

4.2 Air Intake, Fuel, and Exhaust

See Figure 4-2.

4

4

2

3

1

7

6

1 Injector (3 used) 5 Exhaust Manifold
2 Fuel Rail 6 Oxygen Sensor
3 Intake Manifold 7 Heat Shield
4 Throttle Body Assembly

Fuel is supplied from the fuel rail (2) to each cylinder via
electronically controlled fuel injectors (1 ), mo unt ed to t he
intake manifold (3) runners.

Air flow into the intake manifold is metered with a throttle
body assembly (4), which is fastened and sealed to the
intake manifold. The throttle body is controlled and
monitored by the ECM to adjust fuel/air mixtures.

5

TN0690

Figure 4-2

Exhaust gases are expelled through the exhaust side of
the cylinder head into the exhaust manifold (5), which is
fastened and sealed to the cylinder head. Exh aust gases
are monitored with the oxygen sensor (6), which provides
the ECM with data to adjust fuel/air mixtures. The entire
exhaust manif old is surroun ded by a heat shield (7) to aid
in prevention of accidental burns.

4-4 4171985 First Edition

4.3 Cooling System

See Figure 4-3.

1

THEORY OF OPERATION

8

7

1 Jiggle Pin 5 Water Pump
2 Cylinder Head 6 Cylinder Block
3Overflow Bottle 7Thermostat
4 Radiator 8 Thermostat Housing

The cooling system includes the radiator (4), w ater pump
(5), thermostat (7), and engine coolant passages.

Coolant is circulated from the water pump (5) into the
engine coolant passages and circulates around the
cylinders. From the cylinders, coolant flows up through
the block deck passages and into the cylinder head (2).
In the cylinder head (2), the coolant flows throu gh
passages around the intake and exhaust ports, valve
seats, and combustion cha mbers. Coolant flows toward
the rear of the cylinder head (2) and exits through the
thermostat housing (8).

During the warm-up period, the thermostat (7) is closed
and coolant flows only through the jiggle pin (1) opening
to provide a fast warm-up period. The jiggle pin (1) also
helps ensure that no air is trapped in the engine when
filling the cooling system.

Once the engine has reached operating temperat ure , the
thermostat (7) opens and allows coolant to flow through
the upper radiator hose to the ra diator (4) top tank.

6

Figure 4-3

Coolant circulates through the radiator (4), dissipates
heat, and then flows out of the radiator (4) through the
lower hose and into the su ction side of the water pump
(5).

If coolant temperature begins to become excessive, the
radiator pressure cap will open and allow excess coolant
to flow into the overflow bottle (3). When coolant
temperature lowers enough, the radiator cap will close.
As the coolant continues to cool, a vacuum will be
created in the radiator (4). This will open a valve in the
radiator cap that will syphon the excess coolant from the
overflow bottle (3) back into the radiator (4).

Coolant continues flowing through the engine and
radiator circuit until the coolant temperature drops below
the thermostat (7) opening temperature. The thermostat
(7) will remain open until coolant temperature falls below
the thermostat closing temperature. At that time the
thermostat (7) will close and begin a new cycle of
warming the coolant.

This repeated cycle of temperature control keeps the
engine at the optimal temperature for clean and efficient
performance.

2

3

4

4

5

4171985 First Edition 4-5

THEORY OF OPERATION

Thermostat

See Figure 4-4.

1

4

Figure 4-4

The cooling system thermostat (1) is contained in the
thermostat housing located on the rear of the cylinder
head. The thermostat controls the flow of coolant through
the engine. The thermostat is in the closed position when
the engine is cold. When coolant temperature reaches
190° F (88° C) the thermostat begins to open, allowing
coolant to circulate. The thermostat opens fully when
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 temperature r an ge. A
jiggle pin is provided in the thermostat to aid in the
bleeding of the system when filling.

TN0573

Water Pump

See Figure 4-5.

1

TN0747

Figure 4-5

The engine is equipped with a belt-driv en w ater pump ( 1)
driven from the crankshaft pulley. The water pump
circulates coolant throughout the entire coolin g system.
The water pump is equipped with a “weep hole” for
indication of seal wear. The pump is serviceable as a unit
only.

4-6 4171985 First Edition

4.4 Front Cover, Timing Chain, and Tensioner

See Figure 4-6.

5

2

1

3

4

9

10

THEORY OF OPERATION

6

7

8

4

1 Crankshaft Pulley 6 Tension Adjuster
2 Front Cover 7 Chain Guide
3 Tensioner Link 8 Crankshaft Sprocket
4Tensioner 9Oil Pump

Attached to the front of the engine is the one-piece cast
aluminum front cover. 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.

5 Timing Chain 10 Pickup Strainer

TN0748

Figure 4-6

4171985 First Edition 4-7

THEORY OF OPERATION

Front Cover

See Figure 4-7.

1

4

4

Figure 4-7

For the camshaft drive, a highly durable chain drive
system is used.

Through the timing chain (1), the crankshaft rota tio n 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.

The timing chain has aligning links (3, 4, and 8) that are
used for aligning with the timing marks on the respective
camshaft sprockets and crankshaft sprocket.

A chain guide (6) and chain tensioner (9) system are
used to ensure quiet and accurate operat ion.

Tension Adjuster

23

TN0749

See Figure 4-9.

2

1

3

The front cover (1 ) houses the crankshaf t-driven oil pump
(2) and front seal (3). Attached to the bottom of the cover
is the pickup strainer (4) for the oil pump.

Timing Chain

See Figure 4-8.

3 4

2

1

6

9

7

4

6

Figure 4-9

The tension adjuster (6) has a plunger (4) inside, which
pushes against the tensioner link to give proper tension.
This plunger is operated by engine oil pressure (1) as
well as spring tension (3). The plunger is designed to

5

trav el in only one way. Once the plunger has moved
outward, it will not come back due to the function of the
ratcheting mechanism (5).

There is a check ball (2) inside the plunger (4), which
keeps hydraulic pressure from dropping. With this
provision, the plunger can resist and absorb a kickback
force. During oper ation under low oil pressure , the ratchet
keeps the plunger from being pushed back, allowing
tension of the chain to be maintained. The result is quiet
operation without chain flapping.

5

TN0503

8

TN0502

Figure 4-8

4-8 4171985 First Edition

4.5 Cylinder Head and Valve Train

See Figure 4-10.

THEORY OF OPERATION

1

2

3
4
5

6

13

12

11

1 Camshaft Lobe 6 Valve Spring 11 Intake P ort
2 Shim 7 Valve Seal 12 Spark Plug Port
3 Tappet 8 Valve Spring Seat 13 Exhaust Port
4 Retainer Lock 9 Intake Valve
5 Valv e Spring Re tainer 10 Exhaust Valv e

The twin cam, 4-valve per cylinder head is constructed
with an aluminum alloy that is both lightweight and
efficient in heat dissipation. Valve angle is set narrow to
also make for a compact head design.

The spark plug port (12) is located in the center of the
combustion chamber, with the combustion chamber
being a pent-roof design for improved combustion
efficiency.

Figure 4-10

The intake (11) and exhaust ports (13) are arranged in a
cross-flow style with each cylinder 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), valve spring (6), valve seal
(7), and valve spring seat (8) are all installed over the
valve stem and held in place with the retainer locks (4).

The valves (9 and 10) are pushed down directly with the
camshaft lobe (1) via shim (2) and tappet (3). Valve lash
is adjusted by varying the thickness of the shim (2).

7

4

8

9

10

TN0750, 0523, 0493

4171985 First Edition 4-9

THEORY OF OPERATION

Head Gasket

See Figure 4-11.

Figure 4-11

The cylinder head gasket is made of a 2-layer laminated
stainless steel. The surface of the cylinder head gasket is

4

treated with a rubberized coating.

TN0494

Camshaft

See Figure 4-12.

2

1

3

TN0505

Figure 4-12

The intake (1) and exhaust (2) camshafts are made of
lightweight hollow cast iron. The camshaft timing
sprockets ( 3) are pr es s fi t o nt o t he fr on t o f th e c ams h afts
and are serviceable only with the camshaft. Engine oil
flows through the hollow center of the cams, direct
lubricating the camshaft journals. Camshaft lobes,
tappets, and valves are indirect splash lubricated from
the camshaft journals.

4-10 4171985 First Edition

4.6 Lubrication System

See Figure 4-13.

THEORY OF OPERATION

OIL PRESSURE

SWITCH

REGULATOR

VALVE

LUBE OIL PUMP

OIL SUCTION PIPE

(STRAINER)

BYPASS VALVE

LUBE OIL FILTER

CYLINDER BLOCK MAIN GALLERY

TENSION

ADJUSTER

TIMING

CHAIN

.

FRONT CAM

JOURNAL

CAMSHAFT

CAM JOURNALS

CRANK

JOURNALS

CRANK PIN

ROD PIN

ROD

JOURNALS

CONNECTING

ROD

4

The K6A engine uses a wet sump lubrication system,
which force f eeds oil thro ugh th e full-flo w oil filter and the
entire lubrication system.

The inner rotor of the oil pump is driven by the
crankshaft. The outer rotor is driven with the inner rotor.
The pump creates suction, and draws oil through the oil
pickup strainer from t he oil pan. The oil is pumped
through the main passage of the front cover into the
engine block and the oil filter.

An oil pressure switch is located in this passage to
monitor and warn of low oil pressure.

CAM FACE

PISTON PIN

TAPPETS,

VALVES

OIL PAN

TN0751

Figure 4-13

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 engine in the e v ent the filter become s plugged
or damaged and will not allow oil flow to the engine. F rom
the filter, the oil flows into the main gallery. The main
gallery sends oil to both the cylinder block and the
cylinder head.

4171985 First Edition 4-11

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 fl ows th rough to
the rod pins, lubricating the rod journals, and then passes
into a drilled passage in the connecting rod. Oil also
seeps out the sides of the crank and rod journals to
lubricate the sides of the journals. Any excess oil from
lubricating the crank and rod journals passes out from
the journals and returns to the oil pan.

The passage in the connecting rod leads to an oil jet at
the top of the large end of the rod.This jet sprays oil
upward to lubricate the cylinder walls, piston, and piston
pin. Excess oil drains back to the oil pan.

Oil from the main gallery is also sent up to the 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 engine.

When the oil reaches the cylinder head, the passage
splits. Oil is sent to the timing chain tension adjuster to
maintain proper chain tension. An orifice in the tension
adjuster also provides a spray to lubricate the timing

4

chain.
The oil is also sent up to the front of the cylinder head,

where it lubricates both of the front camshaft journals. Oil
enters both camshafts from the front journals and flows
through the camshafts, where it exits lube holes for each
of the other camshaft journals. Excess oil exits the
journals and splash lubricates the camshaft faces and
tappets. Oil seeps through oil holes in the ta ppet
adjusting shims and tappets to lubricate the valves.

Excess oil then flows through return passages from the

cylinder head and returns to the oil pan.

4-12 4171985 First Edition

THEORY OF OPERATION

4.7 Cylinder Block and Lower Crankcase

See Figure 4-14.

1

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 mad e of lightweight aluminum
alloy. The journal bearing caps are integrated into the
casting, which makes it possible to reduce weight,
improve rigidity, and suppre ss vibrating noise.

Crankshaft

See Figure 4-15.

2

2

1

3

TN0496

4

5

4

TN0497, 0498

Figure 4-15

The crankshaft (1) is constructed of cast iron. The
crankshaft has four main bearing journals and three rod
bearing journals, and is counterbalanced on rod thro ws 1
and 3 to reduce vibration. Each main journal contains a
two-piece main bearing (4 and 5), which is lubricated via
an oil hole (3). The third main journal contains a thrust
bearing (2). The front-mounted timing sprocket drives
both the timing chain and oil pump inner rotor. The
crankshaft pulley is equipped with a damper to reduce
vibration.

4171985 First Edition 4-13

THEORY OF OPERATION

Connecting Rod

See Figure 4-16.

1

2

4

Figure 4-16

The connecting rod is made of carbon steel with an
H-shaped cross section. The rod consists of two pieces,

4

the main beam (1) and the rod cap (3), which is fastened
with special reamer type rod bolts and nuts. The small
end of the rod is machined f or a full-floating pist on pin. An
oil jet (2) lubricates the cylinder wall, piston, and piston
pin. The rod bearings (4) are made of an aluminum alloy.

Piston, Piston Rings, and Piston Pin

See Figures 4-17 and 4-18.

4

5

3

6

TN0529

Figure 4-18

TN0499

The three-ring, skirt-type, full-floating pistons (1) are
made of an aluminum allo y. The pistons are equipped
with intake valve reliefs (2) machined into the face. The
piston pin bores are equipped with “Ricardo Groo v es” ( 3)
to aid in lubrication. The piston is assembled in the
engine with the floating-fit piston pin for lower friction.

All piston rings are located above the piston pin. The two
top rings are compression rings and the 3rd (6) is an oil
ring.

The 1st ring (4) is of barrel face type designed for
improved initial breaking in. The 2nd ring (5) is of taper
undercut type designed for better o il scraping
performance. A hard chrome is plated on the
circumference of the 1st ring for extended durability.

1

2

3

Figure 4-17

TN0527

4-14 4171985 First Edition

Chapter 5

Tests and Adjustments

5.1 Air Intake and Exhaust System s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.4 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5

4171985 First Edition 5-1

TESTS AND ADJUSTMENTS

5.1 Air Intake and Exhaust
Systems

Intake Manifold Vacuum Test

See Figure 5-1.

Required Tools

Vacuum Gauge: Suzuki PN 09915-67311 or
Equivalent

1. Warm up the engine.

1

2

PCV Va lve/Hose Test

See Figures 5-2 and 5-3.

1

TN0598

Figure 5-2

1. Remove the PCV valve (1) from the cylinder head
cover.

2. Start engine and bring to idle. Block the end opening
of PCV valve. Suction (vacuum) should be detected.

3. If any abnormal condition is found, replace the PCV
valve and hose.

5

2. Stop the engine.

3. Remove hose (2) from PCV valve and install vacuum
gauge (1) to PCV hose (2).

NOTES

Cap or plug PCV valve.
Place transmission in neutral position.

4. Start the engine. Measure the intake manifold
vacuum at idle.

Intake Manifold Vacuum at Idle: At least 7.7 psi (53
kPa)

5. Stop the engine. Remove the vacuum gauge and
install the PCV hose.

Figure 5-1

TN0538

TN0599

Figure 5-3

4. Remove the PCV valve and verify the internal check
ball can be heard when shaking the valve.

5. If any abnormal condition or restriction is found,
replace the PCV valve and hose.

5-2 4171985 First Edition

TESTS AND ADJUSTMENTS

5.2 Cooling System

Thermostat Test

See Figures 5-4 and 5-5.

2

1

TN0429

Figure 5-4

1. Check that the air bleed valv e (1) of thermostat is not
blocked.

2. Inspect valve seat (2) for any substance that could
interfere with sealing.

5.3 Cylinder Head, Cams, and
Valve Train

Valve Clearance Check and Adjustment

See Figures 5-6 through 5-13.

Valve

Clearance

Cold 0.007—0.009 in.

Check

1

Intake Exhaust

(0.18—0.23 mm)

0.012—0.014 in.
(0.30—0.35 mm)

3

Figure 5-5

3. Immerse the thermostat (4) in water and heat it
gradually with an appropriate heater (5).

4. Observe thermometer (3) 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

TN0539

4

1. Remove the cam cover (1). (See “Cam Cover” on
page 7-17.)

5

TN0430

2. Turn the crankshaft clockwise as viewed from front.

Figure 5-6

TN0540

Figure 5-7

4171985 First Edition 5-3

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 a way 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 c learance an d adjustment may be done in pair s
(Example: #1 Intake valves, then #2 Intake valves,
and so on.)

The valve clearance measurement must be
performed with the timing chain installed in place.

2

180

°

3

1

2

Figure 5-9

1. If the valve clearance is out of specification, adjust it
by replacing the shim (1).

2. Ensure that the valve is closed for the shim being
adjusted and turn the tappet to bring its cutaway (2)
inward.

3. Turn the crankshaft to open the valve needing
adjustment.

TN0361

5

Figure 5-8

3. When the cam lobe (2) to be checked points 180°
away from the shim face, measure the clearance
between the camshaft and shim using a f eeler g auge
(3).

4. Check measurement against valve clearance
specification.

5. Perform adjustment procedure if valve clearance is
out of specification.

Adjustment

Required Tools

Tappet Holder: Jacobsen PN 4139726

TN0360

3

Figure 5-10

4. Remove the camshaft housing cap screws (3).

4

TN0362

NOTE

The special tool stamped with “IN” must be used for
intake camshaft and tool with “EX” for exhaust camshaft.

Check that the special tool is not pushing on the shim.

5. Attach the special tool (4) with the camshaft housing
cap screws. Torque to specification.

Tightening Torque: 97 lb-in. (11 N•m)

5-4 4171985 First Edition

TESTS AND ADJUSTMENTS

5

TN0363

Figure 5-11

6. Turn the camshaft clockwise until the cam lobe is
180° away from the tappet and remove the shim (5)
from the tappet by lifting at the cutaway.

IMPORTANT

If the value “A” equals an odd number, use a shim

0.01 smaller than “A” value.

Shim Selection Chart

Stamped

Part Number

4148102 218 2.18
4148103 220 2.20
4148104 222 2.22
4148105 224 2.24
4148106 226 2.26
4148107 228 2.28
4148108 230 2.30
4148109 232 2.32
4148110 234 2.34
4148111 236 2.36
4148112 238 2.38

Number

Thickness

(mm)

Figure 5-12

7. Measure the thickness of the removed shim, and

determine the required thickness of the new shim
using the following equation:

A = B + (C – 0.20 mm)

A

Where

B
C

: Required thickness of new shim (mm)
: Thickness of removed shim (mm)
: Valve clearance measured (mm)

TN0364

4148113 240 2.40
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 264 2.64
4148126 266 2.66
4148127 268 2.68
4148128 270 2.70
4148129 272 2.72
4148130 274 2.74
4148131 276 2.76
4148132 278 2.78

5

4148133 280 2.80
4148134 282 2.82

4171985 First Edition 5-5

TESTS AND ADJUSTMENTS

Stamped

Part Number

4148135 284 2.84
4148136 286 2.86
4148137 288 2.88
4148138 290 2.90
4148139 292 2.92
4148140 294 2.94
4148141 296 2.96
4148142 298 2.98
4148143 300 3.00

Number

NOTE

Install the shim with its size marking facing tappet.

8. Install the selected shim with its stamped number
facing tappet side.

6

5

Thickness

(mm)

NOTICE

After completing the valve clearance adjustment,
check the c learance again to make sure it is
within the specification.

Installation Note

For installation procedure, reverse the sequence of
removal.

Cylinder Compression Test

See Figure 5-14.

Required Tools

Compression Gauge Set: Suzuki PN 09916-67011 or
Equivalent
Compression Gauge Hose: Suzuki PN 09915-64530
or Equivalent
Compression Gauge Hose Attachment B: Suzuki PN
09915-64550 or Equivalent

1. Warm up the engine.

2. Stop the engine, remove all the spark plugs and
disconnect the cam angle sensor coupler.

Figure 5-13

TN0365

IMPORTANT

If the crankshaft is turned in the normal direction
(turning the cam lobe clockwise), the v alve may
possibly hit the piston head.

9. Tur n ca ms ha ft coun te rclockwise until cam lobe has
fully opened the valve.

10. Remove special tappet tool and reinstall cam
housing cap screws.

11. Tighten the camshaft housing cap screws to
specification

Camshaft Housing Cap Screws Torque: 97 lb-in.
(11 N•m)

1

2

3

TN0537

1 Compression

Gauge Set

2 Compression

Gauge Hose

3. Install the special tools (1, 2, and 3) to the spark plug
hole being checked.

4. With the throttle fully open, operate the starter motor
and check the maximum reading on the compression
gauge.

3 Compression Gauge Hose

Attachment

Figure 5-14

5-6 4171985 First Edition

Compression Pressure at 400 rpm

Standard: psi

kPa
(kgf/cm²)

Service limit psi

kPa
(kgf/cm²)

Difference
Between
Cylinders

Maximum

psi
kPa
(kgf/cm²)

178.4
1,230

(12.5)

134.9
930

(9.5)

14.2
98

(1.0)

NOTICE

If the specified speed (400 rpm) is not attainable
due to lowered battery voltage, recharge the
battery and carry out the inspection again.

5. Carry out steps 3 and 4 above on all the cylinder s.

6. If the compression pressure is lower than the limit,
check that the special tool is properly installed. If the
installed condition is correct, the possible ca use may
be compression leak from piston ring or valv e.

7. After completing the inspection, install the spark
plugs and connect cam angle sensor.

TESTS AND ADJUSTMENTS

2

1

TN0536

Figure 5-15

2. Remove the oil pressure sending unit from the
cylinder block. (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.

5

3

5.4 Lubrication System

Oil Pressure Test

See Figures 5-15 through 5-17.

Required Tools

Oil Pressure Gauge: Suzuki PN 09915-77311 or
Equivalent

Oil Pressure Gauge Attachment: Suzuki PN
09915-78211 or Equivalent

1. Check that the following items are satisfactory.

• Oil Level Refill

• Oil Contamination Replace

• Oil Leakag e Repair

TN0353

Figure 5-16

5. Raise engine speed to 4000 rpm and measure the oil
pressure on the gauge (3).

Oil Pressure—Minimum at 4,000 rpm: 40 psi
(276 kPa)

6. If the oil pressure measurement is out of
specification, check the oil pump and oil filter.

4171985 First Edition 5-7

TESTS AND ADJUSTMENTS

5

4

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. Start the engine and check oil pressure switch for
leaks.

5

5-8 4171985 First Edition

Chapter 6

Diagnostic Troubleshooting

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Engine Starts Hard (But Cranks Properly). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Excessive Engine Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

White Exhaust Smoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Excessive Engine Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6

4171985 First Edition 6-1

DIAGNOSTIC TROUBLESHOOTING

Troubleshooting

Condition Probable Cause Remedy

Engine starts hard (but cranks properly). Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on

Poor idling. Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on

6

Insufficient engine power. Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on

page 7-8.)

Faulty igniti on coil. Check ignition coils. (See “Igni tion Coils”

on page 7-8.)

Faulty fuel injector. Check fuel injectors. (See “Injectors” on

page 7-9.)

Throttle body gasket leaking air. Check throttle body and gasket. (See

“Throttle Body” on page 7-4.)

Faulty ISC (idle speed control) valve. Check ISC (idle speed control) va lv e. (See

“ISC (Idle Speed Control) Valve” on
page 7-3.)

Faulty throttle posi tion sensor. Check t hrottle position sensor. (See

“Throttle Position Sensor” on pag e 7-3.)

Faulty manifold pressure sensor. Check pressure sensor.(See “Pressure

Sensor” on page 7-3.)

Intake manifold leaking air. Check intake manifold and gasket. (See

“Intake Manifold” on page 7-4.)

Exhaust restriction. Check exhaust manifold. (See “Exhaust

Manifold” on page 7-7.)

page 7-8.)

Faulty igniti on coil. Check ignition coils. (See “Igni tion Coils”

on page 7-8.)

Faulty oxygen sensor. Check oxygen sensor. (See “Oxygen

Sensor” on page 7-6.)

Faulty ISC (idle speed control) valve. Check ISC (idle speed control) va lv e. (See

“ISC (Idle Speed Control) Valve” on
page 7-3.)

Valve clearance adjustment. Check valve clearance. (See “Valve

Clearance Check and Adjustment” on
page 5-3.)

Faulty valve spring. Check valve springs. (See “Valves” on

page 7-27.)

page 7-8.)

Faulty igniti on coil. Check ignition coils. (See “Igni tion Coils”

on page 7-8.)

Faulty 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 vacuum. (See

“Intake Manifold Vacuum Test” on
page 5-2.)

Cylinder compression leakage. Check cylinder compression. (See

“Cylinder Compression Test” on
page 5-6.)

Faulty piston ring(s). Check piston rings. (See “Connecting

Rods and Pistons” on page 7-38.)

Faulty head gasket. Check head gasket. (See “Cylinder Head”

on page 7-24.)

Incorrect fuel. Use proper fuel.

6-2 4171985 First Edition

Condition Probable Cause Remedy

Engine surges or misses. Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on

Poor throttle response. Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on

Engine overheats. Coolant level low. Check coolant level.

DIAGNOSTIC TROUBLESHOOTING

page 7-8.)

Faulty igniti on coil. Check ignition coils. (See “Igni tion Coils”

on page 7-8.)

Faulty 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 vacuum. (See

“Intake Manifold Vacuum Test” on
page 5-2.)

page 7-8.)

Faulty igniti on coil. Check ignition coils. (See “Igni tion Coils”

on page 7-8.)

Faulty 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 vacuum. (See

“Intake Manifold Vacuum Test” on
page 5-2.)

Throttle body gasket leaking air. Check throttle body and gasket. (See

“Throttle Body” on page 7-4.)

Faulty throttle posi tion sensor. Check t hrottle position sensor. (See

“Throttle Position Sensor” on pag e 7-3.)

Incorrect fuel. Use proper fuel.

Water pump belt loose. Check belt tension.
Faulty thermostat. Check thermostat. (See “Thermostat Test”

on page 5-3.)

Faulty water pump. Check water pump. (See “Water Pump” o n

page 7-10.)

Faulty head gasket. Check cylinder head and gasket. (See

“Cylinder Head” on page 7-24.)

6

4171985 First Edition 6-3

DIAGNOSTIC TROUBLESHOOTING

Condition Probable Cause Remedy

Excessive fuel consumption. Fouled spark plug(s). Check spark plugs. (See “Spark Plugs” on

Excessive oil consumption. External oil leak. Check drain plug.

6

Low oil pressure. Incorrect engine oil. Change engine oil. (See “Change Engine

page 7-8.)

Faulty igniti on coil. Check ignition coils. (See “Igni tion Coils”

on page 7-8.)

Faulty 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 vacuum. (See

“Intake Manifold Vacuum Test” on
page 5-2.)

Throttle body gasket leaking air. Check throttle body and gasket. (See

“Throttle Body” on page 7-4.)

Faulty throttle posi tion sensor. Check t hrottle position sensor. (See

“Throttle Position Sensor” on pag e 7-3.)
Incorrect fuel. Use proper fuel.
Faulty oxygen sensor. Check oxygen sensor. (See “Oxygen

Sensor” on page 7-6.)
Restricted air cleaner element. Check air cleaner element.

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 pressure sending unit for leaks.
Check oil filter for leaks.
Check cam cover for leaks.

Internal oil leak. Check valves and seals. (See “Valves” on

page 7-27.)

Check PCV valve. (See “PCV Valve” on

page 7-4.)

Check piston rings/cylinder compression.

(See “Cylinder Compression Test” on

page 5-6.)

Check cylinder head and gasket. (See

“Cylinder Head” on page 7-24.)

Oil” on page 3-2.)
Low oil level. Check oil level. (See “Engine Oil Level” on

page 3-2.)
Restricted oil filter. Change oil filter. (See “Oil Filter” on

page 3-2.)
Faulty oil pump reli ef valve. Check oil pump relief valve. (See “Oil

Pump” on page 7-33.)
Faulty oil pump. Replace oil pump. (See “Oil Pump” on

page 7-33.)
Restriction in lubrication system. Check/clean lubrication system. (See

“Lubrication System” on page 4-11.)

6-4 4171985 First Edition

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. (See
“Connecting Rods and Pistons” on
page 7-38.)

Faulty 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 into cylinder. Check cylinder head. (See “Cylinder

Head” on page 7-24.)

Check head gasket. (See “Cylinder Head”

on page 7-24.)

Check cylinder liners. (See “Lower

Crankcase, Cylinder Block, and
Crankshaft” on page 7-42.)

Excessive engine vibration. Loose or faulty crankshaft pulley. Check crankshaft pulley. (See “Crankshaft

Pulley” on page 7-37.)

Loose or faulty flywheel/flex plate. Check flywheel/flex plate.

6

4171985 First Edition 6-5

DIAGNOSTIC TROUBLESHOOTING

6

Page Intentionally Blank

6-6 4171985 First Edition

7.1 Air Intake and Exhaust System s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 -3 2

Oil Pressure Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Chapter 7

Repair

7

4171985 First Edition 7-1

REPAIR

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

7

7-2 4171985 First Edition

REPAIR

7.1 Air Intake and Exhaust Systems

Throttle Position Sensor

Removal and Installation

See Figure 7-1.

1

2

TN0713

Figure 7-1

1. Remove screws (1) and throttle position sensor (2).

2. Inspect throttle position sensor. Replace as needed.

Installation Notes

Always use new O-rings, gaskets, and seals.
Install pressure sensor by reversing the order of removal.

ISC (Idle Speed Control) Valve

Removal and Installation

See Figure 7-3.

2

1

3

TN0691

Figure 7-3

1. Remove screws (2), ISC valve (3), and O-ring (1).

2. Inspect ISC valve. Replace as needed.

Pressure Sensor

Removal and Installation

See Figure 7-2.

1

1. Remove screws (2), pressure sensor (1), and O-ring
(3).

2. Inspect pressure sensor. Replace as needed.

2

3

Figure 7-2

Installation Notes

Always use new O-rings, gaskets, and seals.
Install ISC valve by reversing the order of removal.

7

TN0713

4171985 First Edition 7-3

REPAIR

PCV Valve

Removal and Installation

See Figure 7-4.

2

1

4

Figure 7-4

1. Remove clamp (1) and hose (2).

2. Remove PCV valve (4) from grommet (3 ).

3. Inspect and test PCV valve. Replace as needed.
(See “PCV Valve/Hose Test” on page 5-2.)

Installation Note

Install PCV valve by reversing the order of rem oval.

Throttle Body

Removal and Installation

See Figures 7-5 and 7-6.

7

1

2

3

TN0740

Figure 7-6

2. Remove throttle body gasket (3).

3

TN0711

Installation Notes

Always use new O-rings, gaskets, and seals.
Install new gasket and throttle body by reversing the

order of removal.

Intake Manifold

Removal

See Figure 7-7.

1

2

4

2

3

2

3

Figure 7-7

1. Remove throttle body. (See “Throttle Body” on
page 7-4.)

2. Remove fuel rail and injectors. (See “Injectors” on
page 7-9.)

3. Remove knock sensor. (See “Knock Sensor” on
page 7-37.)

TN0737

Figure 7-5

1. Remove cap screws (2) and throttle body (1).

7-4 4171985 First Edition

4. Remove PCV hose. (See “PCV Valve” on page 7-4.)

5. Remove cap screw (4).

6. Remove nine cap screws (2) and three nuts (3).

7. Remove intake manifold (1).

TN0736

REPAIR

Inspection

See Figure 7-8.

1. Inspect intake manifold for cracks, damage, and
distortion.

Figure 7-8

2. Using a straightedge and a feeler gauge, inspect the
mating face for distortion. Place the straightedge
across bolt hole centers at the locations indicated.
Measure any gaps with the feeler gauge. If the
measurement exceeds the limit, replace intake
manifold.

Intake Manifold Distortion Limit: 0.003 in. (0.07 mm)

Installation

See Figures 7-9 and 7-10.

TN0735

1. Install new intake manifold gasket (1).

2

4

3

3

5

3

4

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.

Intake Manifold Torque: 97 lb-in. (11 N•m)

4. Install PCV hose. (See “PCV Valve” on page 7-4.)

5. Install knock sensor. (See “Knock Sensor” on
page 7-37.)

6. Install fuel rail and injectors. (See “Injectors” on
page 7-9.)

7. Install throttle body. (See “Throttle Body” on
page 7-4.)

1

TN0735

Figure 7-9

NOTES

Clean intake manifold and cylinder head gasket surfaces
before installation.

Always use new O-rings, gaskets , and seals.

4171985 First Edition 7-5

7

REPAIR

Oxygen Sensor

Removal and Installation

See Figure 7-11.

Required Materials

Anti-Seize Compound

1

Figure 7-11

TN0699

Heat Shield

Removal and Installation

See Figures 7-12 and 7-13.

1

2

Figure 7-12

1. Remove cap screws (1) and lower half of heat shield
(2).

1

TN0729

1. Remove oxygen sensor (1).

2. Inspect oxygen sensor. Replace as needed.

Installation Notes

Apply Anti-Seize Compound to the threads of oxygen
sensor before installation.

Install oxygen sensor by reversing the order of removal.

7

3

4

Figure 7-13

2. Remove cap screws (3) and upper half of heat shield
(4).

Installation Note

Install heat shield by reversing order of removal.

3

TN0730

7-6 4171985 First Edition

REPAIR

Exhaust Manifold

Removal

See Figure 7-14.

2

1

4

Figure 7-14

1. Remove cap screws (4) and nuts (2).

2. Remove exhaust manifold (1) and gasket (3).

Inspection

See Figure 7-15.

2

3

TN0731

Installation

See Figures 7-16 and 7-17.

1

Figure 7-16

NOTES

Clean exhaust manifold and cylinder head gasket
surfaces before installation.

Always use new O-rings, gaskets, and seals.

1. Install new exhaust manifold gasket (1).

3

3

TN0732

Figure 7-15

1. Check exhaust manifold for cracks, damage, and
distortion.

2. Using a straightedge and a feeler gauge, inspect the
mating face for distortion. Place the straightedge
across bolt hole centers at the locations indicated.
Measure any gaps 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)

TN0734

2

7

4

5

TN0731

Figure 7-17

2. Install exhaust manifold (2) using cap scre ws (5) and
nuts (3). Tighten to specification.

Exhaust Manifold Torque: 204 lb-in. (23 N•m)

Installation Note

Start engine and check for e xhaust leaks.

4171985 First Edition 7-7

REPAIR

7.2 Electrical System

Ignition Coils

Removal and Installation

See Figure 7-18.

1

2

Figure 7-18

1. Remove cap screws (1).

2. Remove ignition coils (2).

3. Inspect ignition coils. Replace as needed.

Installation Note

Install ignition coils by reversing the order of removal.

TN0695

Spark Plugs

Removal and Installation

See Figures 7-19 and 7-20.

1

TN0697

Figure 7-19

1. Remove ignition coils. (See “Ignition Coils” on
page 7-8.)

2. Remove spark plugs (1).

3

2

7

Figure 7-20

3. Inspect spark plug (2) for signs of wear or damage.
Replace as needed.

4. Set spark plug electrode gap (3) to specification.
Spark Plug Gap: 0.031—0.035 in. (0.8—0.9 mm)

Installation Note

Install spark plugs by reversing the order of removal.

7-8 4171985 First Edition

TN0698

REPAIR

7.3 Fuel System

Injectors

Removal

See Figures 7-21 and 7-22.

WARNING

!

Fuel system may be under pressure. Relieve fuel
pressure before servicing system.

1

2

Installation

See Figures 7-23 and 7-24.

1

3

2

5

Figure 7-23

2

3

4

TN0739

3

Figure 7-21

1. Remove cap screws (3).

2. Remove fuel rail (1) and injectors (2) as an assembly.

4

5

Figure 7-22

TN0738

5

TN0739

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).

6

2. Install fuel rail (6) and injectors (7) as an assembly.

Secure with cap screws (8).

7

8

Figure 7-24

TN0738

7

3. Remove injectors (5) from fuel rail (4).

4. Replace as needed.

4171985 First Edition 7-9

REPAIR

7.4 Cooling System

Water Pump

Removal and Installation

See Figures 7-25 and 7-26.

1

Figure 7-25

Thermostat

Removal and Installation

See Figures 7-27 and 7-28.

2

1

2

TN0726

Figure 7-27

TN0701

1. Remove cap screws (2) and water pump (1).

7

Figure 7-26

2. Rotate the water pump pulley and check for noisy
operation, excessive resistance, or play in the pulley
shaft. If any abnormal condition is found, replace the
water pump.

Installation Notes

Always use new O-rings, gaskets , and seals.
Install the water pump with new O-ring, by reversing the

order of removal.

1. Remove cap screws (1).

2. Remove filler neck (2).

3

TN0432

TN0705

Figure 7-28

3. Remove thermostat (3).

4. Inspect and test thermostat. Replace as needed.
(See “Thermostat Test” on page 5-3.)

Installation Notes

Clean thermostat housing and filler neck mounting
surfaces of debris before installation.

Install thermostat by reversing order of removal.

7-10 4171985 First Edition

REPAIR

Water Temperature Sensor

Removal and Installation

See Figure 7-29.

1

2

Figure 7-29

1. Remove water temperature sensor (1) and
O-ring (2).

2. Inspect water temperature sensor. Replace as
needed.

TN0701

Thermostat Housing

Removal and Installation

See Figures 7-30 and 7-31.

1

4

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).

2

3

TN0707

Installation Notes

Always use new O-rings, gaskets , and seals.
Install water temperature sensor by reversing the order of

removal.

5

7

TN0708

Figure 7-31

4. Remove thermostat housing gasket (5).

5. Inspect thermostat housing for damage. Replace as
needed.

Installation Notes

Clean cylinder head and thermostat housing mating
surfaces before installation.

Always use new O-rings, gaskets, and seals.
Install thermostat housing by reversing the order of

removal.
Install thermostat. (See “Thermostat” on page 7-10.)

4171985 First Edition 7-11

REPAIR

7.5 Front Cover, Timing Chain, and Tensioner

Cam Angle Sensor

Removal and Installation

See Figure 7-32.

2

1

3

TN0709

Figure 7-32

1. Remove cap screw (1).

2. Remove cam angle sensor (2) and O-ring (3).

3. Inspect cam angle sensor. Replace as needed.

Front Cover

Removal

See Figure 7-33.

1. Remove ignition coils. (See “Ignition 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 “Crankshaft Pulley”
on page 7-37.)

6. Remove idler pulley. (See “Idler Pulley” on
page 7-38.)

7. Remove oil pan. (See “Oil Pan” on page 7-30.)

8. Remove oil pump pickup . ( See “O il Pump Pickup” on
page 7-31.)

2

1

2

3

Installation Note

Always use new O-rings, gaskets , and seals.
Install cam angle sensor by reversing the order of

removal.

7

2

2

2

9. Remove idler pulley/alternator bracket (4).

4

Figure 7-33

TN0745

NOTE

Front cover is located on cylinder block with dowel pins.
Cover must be removed straight away from engine.

10. Remove cap screws (2 and 3) and front cover (1).

7-12 4171985 First Edition

Installation

See Figures 7-34 and 7-35.

REPAIR

2

2

Required Materials

Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or
equivalent

1. Clean cylinder head, cylinder bloc k, and front cover
mating surfaces.

Figure 7-34

2. Apply Three Bond™ 1215 sealant to the front cover
at shaded areas shown.

IMPORTANT

Be sure oil pump inner rotor flats properly engage
with those of the crankshaft timing sprocket.

TN0386

3

1

2

2

2

Figure 7-35

3. Align dowel pins, oil pump rotor flats, and crankshaft
timing gear. Then install front cover (1).

4. Install cap screws (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/alternator bracket (4).

8. Install idler pulley. (See “Idler Pulley” on page 7-38.)

9. Install crankshaft pulley. (See “Crankshaft Pulley” on
page 7-37.)

10. Install cam cover. (See “Cam Cover” on page 7-17.)

11. Install PCV valve. (See “PCV Valve” on page 7-4.)

12. Install spark plugs. (See “Spark Plugs” on page 7-8.)

13. Install ignition coils. (See “Ignition Coils” on
page 7-8.)

4

TN0745

7

4171985 First Edition 7-13

REPAIR

Tension Adjuster

Removal and Installation

See Figure 7-36.

2

1

1. Remove front cover. (See “Front Cover” on
page 7-12.)

2. Remove cap screws (1) and tensioner link (2).

3. Remove cap screws (3) and tension adjuster (5).

4. Inspect tension adjuster and tensioner pad (4).
Replace as needed.

3

5

Figure 7-36

TN0549

Timing Chain

Removal

See Figures 7-37 and 7-38.

1. Remove front cover. (See “Front Cover” on
page 7-12.)

2

4

1

3

8

1

3

4

Installation Note

Install tension adjuster by reversing the order of removal.

7

5

7

6

Figure 7-37

TN0502

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. Turn the crankshaft and satisfy the following
conditions to bring number one cylinder to top dead
center.

• Blue timing chain links (2) align with slot/arrow (1) on
cam timing gears.

• Cam timing gear dots (3) align with index marks (8)
on cylinder head.

• Crankshaft timing sprocket keyway (4) faces up and
aligns with index mark (7) on cylinder block.

• Yellow timing chain link (6) aligns with crankshaft
timing gear slot (5).

7-14 4171985 First Edition

REPAIR

Inspection

10

11

9

See Figure 7-39.

1

2

18

17

16

15

Figure 7-38

3. Remove cap screws (9) and tensioner link (10).

4. Remove cap screw (16), spacer (17), and
tensioner (18).

5. Remove cap screws (11 and 13) and
chain guide (12).

6. Slide crankshaft timing sprocket (15) and timing
chain (14) off of crankshaft. Remove timing chain

from cam gear teeth.

14

12

13

TN0550

4

3

Figure 7-39

Inspect timing chain (1), chain guide (2), crankshaft
timing sprocket (3), and tensioner (4) for wear or
damage. Replace as needed.

TN0375

IMPORTANT

Do not turn camshafts or crankshaft with timing
chain removed.

4171985 First Edition 7-15

7

REPAIR

Installation

See Figures 7-40 through 7-42.

IMPORTANT

Make sure cylinder number 1 is at top dead center .

NOTICE

Be sure to re-check timing mark(s) alignment.
Improper installation may result in engine
damage.

2

3

1

4

8

5

9

11

Figure 7-41

5. Release tension adjuster (9) manual loc k using a rod
(11) approximately 0.8 in. (2 mm) in diameter.
Depress the lock with the rod and reset the piston
(10) as shown.

10

TN0380

7

1. Align blue timing chain links (2) with slot/arrow (1) on
cam timing gears.

2. Align cam timing gear dots (3) with index marks (4)
on cylinder head.

3. Be sure crankshaft timing 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.

7

Figure 7-40

6

TN0378

7-16 4171985 First Edition

REPAIR

7.6 Cylinder Head, Cams, and

12

19

18

17

13

14

15

16

TN0550

Figure 7-42

Valve Train

Cam Cover

Removal

See Figure 7-43.

1

2

1

NOTE

Apply engine oil to timing chain, tensioner, and guide
faces.

6. Apply oil to the timing chain guide (15) and secure

using cap screws (14 and 16).

7. Install tensioner (19) with spacer (18) and cap screw

(17).

8. Install tensioner link (13) using cap screws (12).

9. Install front cover. (See “Front Cover” on page 7-12.)

TN0724

Figure 7-43

1. Remove ignition coils. (See “Ignition 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 six cap screws (1) and cam cove r (2 ).

5. Inspect and replace as needed.

7

4171985 First Edition 7-17

REPAIR

Installation

See Figures 7-44 and 7-45.

Required Materials

Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or
equivalent

1

2

TN0725

Figure 7-44

1. Clean cam cover and cylinder head gasket surfaces.

2. Install new gasket (1) to cam cover (2).

Cam Cover Torque Sequence

See Figure 7-46.

2

5

1

6

3

4

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. (3.6 N•m), until specification is
reached.

Cam Cover Cap Screws Torque: 96 lb-in. (11 N•m)

2. Install PCV valve. (See “PCV Valve” on page 7-4.)

3. Install spark plugs. (See “Spark Plugs” on page 7-8.)

4. Install ignition coils. (See “Ignition Coils” on
page 7-8.)

3

7

4

5

6

Figure 7-45

3. Apply Three Bond™ 1215 to locations (3, 4, 5, an d 6)
as shown.

4. Install cam cover and cap screws. (See “Cam Cover
Torque Sequence” on page 7-18.)

TN0366

7-18 4171985 First Edition

Camshafts

NOTICE

Remove camshaft housing cap screws using
illustrated sequence. Incorrect remov al 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 res ult in
engine damage and failure.

12

15

REPAIR

13

14

TN0416

Figure 7-48

Removal

See Figures 7-47 and 7-48.

1. Remove ignition coils. (See “Ignition 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 “Crankshaft Pulley”

on page 7-37.)

6. Remove idler pulley. (See “Idler Pulley” on

page 7-38.)

7. Remove oil pan. (See “Oil Pan” on page 7-30.)

8. Remove front cover. (See “Front Cover” on

page 7-12.)

9. Remove timing chain. (See “Timing Chain” on

page 7-14.)

2

9

11

IMPORTANT

Mark the camshaft timing gear faces to easily
distinguish between intake and exhaust.

Take note of camshaft housings, location and
orientation to aid in assembly.

10. Loosen the camshaft 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 intak e or e xhaust
side camshaft.

• The numerical markings (13) ref er to the cylin der the
housing corresponds with. The cylinders are
numbered 1—3, star t i ng fro m th e tim i ng cha in
moving toward the rear of engine.

• The arrow marking (15) points toward the timing
chain (front of engine).

12. Remove the intake and exhaust camshafts. Inspect
camshafts for signs of wear or damage. Replace as
needed.

7

7

5

3

4

1

4171985 First Edition 7-19

8

Figure 7-47

10

6

TN0409

REPAIR

Inspection

See Figures 7-49 through 7-52.

Required Tools and Materials

Plastigage™ Clearance Indicator
Micrometer
Inside Bore Gauge

10

7

9

3

1

5

IMPORTANT

Tappets and shims must be removed before
measuring camshaft bearing clearance.

Be sure to note location and shim thickness of each
tappet.

1. Remove twelve tappets with shims. Be sure to note

7

location and shim thickness of each tappet .

2. Clean the camshaft journals and housings free of all
oil.

3. Tear off a piece of Plastigage as long as the full
bearing width. (Tear through both the envelope and
plastic thread at the same time.) Lay the piece of
Plastigage across the full width of the lower bearing
shell about 1/4 in. (6.3 mm) off center.

Figure 7-49

TN0414

8

11

4

Figure 7-50

2

6

TN0409

IMPORTANT

Do not turn camshaft during oil clearance
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 thro ugh 1 1) at
increments of 32 lb-in. (3.6 N•m) until specification is
reached. Do not turn camshaft during measurement
process.

Cam Housing Cap Screw Torque: 97 lb-in. (11 N•m)

12

Figure 7-51

13

TN0410

5. Remove cap screws and camshaft housings in
opposite sequence of installation. The flattened
Plastigage (12) will adhere to either the bearing shell
or the camshaft.

6. Using the supplied scale (13), take the measurement
at the widest point of gauging plastic.

Camshaft Oil Clearance Standard: 0.002—0.0 03 in.
(0.045—0.087 mm)

Camshaft Oil Clearance Limit: 0.004 in. (0.10 mm)

7-20 4171985 First Edition

14

15

Figure 7-52

7. If the oil clearance exceeds the limit, remove the
camshaft and retighten the camshaft housing to
specification.

Cam Housing Cap Screw Torque: 97 lb-in. (11 N•m)

8. Using a micrometer and bore gauge, measure the
camshaft journal outside diameter (14) and the
journal bore diameter (15).

If the measurement is beyond the standard range,
either the 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)

TN0411

REPAIR

Cam Timing Sprocket

See Figure 7-53.

1

TN0505

Figure 7-53

Inspect the camshaft timing sprockets (1) for wear and
damage. If any abnormal condition is noted, replace the
sprocket.

Camshaft Housing Bearing Face

See Figure 7-54.

1

TN0408

Figure 7-54

7

Inspect the camshaft housing bearing face for pitting,
melting, and seizure. If any abnormal condition is found,
replace the cylinder head.

4171985 First Edition 7-21

REPAIR

Tappets and Shims

See Figure 7-55.

1

Figure 7-55

1. Inspect shim (1) and tappet (2) for any signs of wear.
If any abnormal condition is found, repl ace as
needed.

2. Measure tappet outside diameter and tappet bore
inside diameter. Calculate clearance and compare to
specification. Replace as needed.

Tappet and Bore Clearance: 0.0009—0.0024 in.
(0.025—0.062 mm)

Tappet and Bore Clearance Limit: 0.003 in.
(0.10 mm)

2

TN0412

Installation

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.

TN0414

Figure 7-56

IMPORTANT

Be sure tappets and shims are installed in correct
location.

1. Apply engine oil to all surfaces of tappets and shims,
and install in proper locations.

7

1

2

Figure 7-57

2. Apply engine oil to camshaft journals, lobes, and
timing sprockets. Align timing gear dots (1) with the
index marks (2) on the cylinder head.

TN0415

7-22 4171985 First Edition

3

6

Figure 7-58

4

5

TN0416

IMPORTANT

Be sure camshaft housings are properly located.
Be sure dowel pins are properly aligned before

installing camshaft housings.

3. Check that the camshaft housing markings (3, 4, and

6) are located properly.

• The “I” or “E” markings (3) refer to intake or exhaust
side camshaft.

• The numerical markings (4) refer to the cylinder the
housing corresponds with. The cylinders are
numbered 1—3, starting from the timing chain
moving toward the rear of engine.

• The arrow marking (6) points towar d the timing cha in
(front of engine).

4. Apply engine oil to cap screws and hand tight en the
camshaft housings (5) to the cylinder head.

REPAIR

6. Check valve clearance. (See “V alve Clearan ce 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. Install idler pulley. (See “Idler Pulley” on page 7-38.)

11. Install crankshaft pulley. (See “Crankshaft Pulley” on
page 7-37.)

12. Install cam cover. (See “Cam Cover” on page 7-17.)

13. Install PCV valve. (See “PCV Valve” on page 7-4.)

14. Install spark plugs. (See “Spark Plugs” on page 7-8.)

15. Install ignition coils. (See “Ignition Coils” on
page 7-8.)

10

3

7

9

8

11

5. Tighten camshaft housings, using seque nc e
(1 through 11) at increments of 32 lb-in. (3. 6 N•m)
until specification is reached.

Camshaft Housing Torque: 97 lb-in. (11 N•m)

4

Figure 7-59

1

2

5

7

6

TN0409

4171985 First Edition 7-23

REPAIR

Cylinder Head

Removal

See Figure 7-60.

1. Remove throttle body. (See “Throttle Body” on
page 7-4.)

2. Remove fuel rail and injectors. (See “Injectors” on
page 7-9.)

3. Remove intake manifold. (See “Intake Manifold” on
page 7-4.)

4. Remove exhaust manifold. (See “Exhaust Manifold”
on page 7-7.)

5. Remove ignition coils. (See “Ignition Coils” on
page 7-8.)

6. Remove spark plugs. (See “Spark Plugs” on
page 7-8.)

7. Remove PCV valve. (See “PCV Valve” on page 7-4.)

8. Remove cam cover. (See “Cam Cover” on
page 7-17.)

9. Remove crankshaft pulley. (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 chain. (See “Timing Chain” on
page 7-14.)

14. Remove camshafts and tappets. (See “Camshafts”
on page 7-19.)

Inspection

See Figure 7-61.

NOTICE

Do not scratch cylinder head surface when
removing carbon deposits.

1

TN0404

Figure 7-61

Remove carbon deposits from the combustion chamber
(1). Check the intake port, exhaust port, combustion
chamber and entire cylinder head mating surface for
cracks.

7

4

2

15. Loosen cap screws (1 through 8) sequentially as
shown, and remove cylinder head and gasket.

7-24 4171985 First Edition

6

7

Figure 7-60

8

5

1

3

TN0403

REPAIR

Cylinder Block Mating Face Distortion

See Figures 7-62 and 7-63.

IMPORTANT

A distorted cylinder head may cause combustion gas to
leak through the head gasket, resulting in overheating
and reduced power.

1

Figure 7-62

2

TN0405

Intake and Exhaust Manifold Mating Face Distortion

See Figure 7-64.

2

1

TN0407

Figure 7-64

Using a straightedge (2) and a feeler gauge (1), inspect
the manifold mating faces for distortion. Place the
straightedge across the mating face, and measure any
gaps with the feeler gauge. If the measurement exceeds
the limit, repair or replace the cylinder head.

Intake and Exhaust Manifold Mating Face Distortion
Limit: 0.000—0.002 in. (0.00—0.05 mm)

Figure 7-63

Using a straightedge (2) and a feeler gauge (1), inspect
the mating face for distor tion. Place the straightedge
across bolt hole centers at the locations indicated.
Measure any gaps 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)

TN0406

7

4171985 First Edition 7-25

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.

4

6

8

1

Figure 7-65

1. Clean cylinder head and cylinder block mating
surfaces. Place head gasket on cylinder block with
forked end toward the front of the engine (arrow).

2. Install cylinder head using care to align dowel pins.

3. Apply oil to cylinder head cap screw threads and
seating faces and install. Do not tighten 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.

7

TN0413

2

4. Torque the cap screws in sequence to 22 lb-ft (30
N•m).

• Set torque wrench to 35 lb-ft (47 N•m) and repeat
torque sequence.

• Reverse the torque sequence and loosen all cap
screws.

• Re-torque cap screws in sequence to 35 lb-ft
(47 N•m).

• Torque cap screws (1 through 8) in sequence to final
specification.

Cylinder Head Cap Screw Torque: 43.5 lb-ft (59 N•m)

4

7

Figure 7-66

6

5

8

3

TN0403

1

2

5. Tighten cap screws (1 through 8) in sequence, to
specification.

Cylinder Head Cap Screw Torque: 43.5 lb-ft (59 N•m)

7-26 4171985 First Edition

7

Figure 7-67

5

3

TN0403

Valves

Disassembly

See Figure 7-68.

Required Tools

Valve Spring Compressor

REPAIR

1

2

8

3

7

6

5

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. Remove valve spring retainer (7), valve spring (3),
valve seal (4), and valve spring seat (6).

5. Inspect all parts for wear or damage. (See
“Inspection” on page 7-28.)

4

7

TN0492

Figure 7-68

4171985 First Edition 7-27

REPAIR

Inspection

Valves

See Figure 7-69.

1

3

2

5

Figure 7-69

4

1

Valve Springs

See Figures 7-70 and 7-71.

Required Tools

Veneer Caliper
Spring Compression Gauge
Square

2

1

3

2

TN0506

1. Clean and inspect intake (5) and exhaust (4) valves,
valve stems (3) , valve stem tips (1), and retainer lock
grooves (2).

2. Using a micrometer , measure the valve stem (3) OD.

3. Using an inside micrometer, measure the ID of valve
guide.

Compare valve stem OD measurement to valve

guide ID measurement. Calculate clearance and
replace as needed.

7

Valve Guide to Valve 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)
V alve Gu ide to Valve Stem Clearance Limit, Exhaust:

0.003 in. (0.09 mm)

TN0558, 0559

Figure 7-70

3

4

TN0760

Figure 7-71

1. Measure the free length of valve springs using a
veneer caliper (1). Compare measurement to
specification. Replace as needed.

Valve Spring Free Length: 1.35 in. (34.3 mm)

7-28 4171985 First Edition

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. 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.
(0.00—1.5 mm)

Installation Notes

Always use new O-rings, gaskets , and seals.
Apply clean engine oil to tappet and valve stem contact

surfaces.
Install valve assembli es with new valv e seals by re versing

the order of removal.
Check valve clearance. (See “Valve Clearance Check

and Adjustment” on page 5-3.)

REPAIR

7

4171985 First Edition 7-29

REPAIR

7.7 Lubrication System

Dipstick Tube

Removal and Installation

See Figure 7-72.

2

1

Figure 7-72

1. Remove nut (1).

2. Remove dipstick tube (2) and O-ring (3).

3. Inspect dipstick tube and O-ring. Replace as needed.

3

TN0713

Oil Pan

Removal

See Figure 7-73.

1

3

2

1

1. Drain engine oil. (See “Change Engine Oil” on
page 3-2.)

2. Remove twelve cap screws (2), thr ee nuts (1), and oil
pan (3).

3. Inspect oil pan. Replace as needed.

2

1

2

2

TN0741

Figure 7-73

Installation Notes

Always use new O-rings, gaskets , and seals.
Install dipstick tube by reversing the order of removal.

7

7-30 4171985 First Edition

REPAIR

Installation

See Figures 7-74 and 7-75.

Required Materials

Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or
equivalent

1. Clean cylinder block, front cover, and oil pan mating
surfaces.

Figure 7-74

2. Apply Three Bond™ 1215 Sealant to the oil pan
mating surface as shown.

1

3

2

1

TN0397

Oil Pump Pickup

Removal and Installation

See Figure 7-76.

1

3

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).

3. Inspect oil pump pickup and O-ring. Replace as
needed.

Installation Notes

Always use new O-rings, gaskets, and seals.
Install oil pump pickup with new O-ring by reversing the

order of removal.
Install oil pan. (See “Oil Pan” on page 7-30.)

2

TN0742

7

2

2

1

2

TN0741

Figure 7-75

3. Install oil pan (3) using three nuts (1) and twelve cap
screws (2). Tighten to specification.

Oil Pan Torque: 97 lb-in. (11 N•m)

4. Fill engine oil. (See “Change Engine Oil” on
page 3-2.)

4171985 First Edition 7-31

REPAIR

Crankshaft Baffle

Removal and Installation

See Figure 7-77.

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.)

1

Oil Pressure Sending Unit

Removal and Installation

See Figure 7-78.

1

TN0715

Figure 7-78

1. Remove oil pressure sending unit (1).

2. Inspect oil pressure sending unit. Replace as
needed.

3

2

Figure 7-77

NOTE

Cap screws (1) require the use of a 12-point 8 mm
socket.

7

3. Remove cap screws (1 and 2) and crankshaft
baffle (3).

Installation Notes

Install crankshaft 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.)

TN0743

Installation Notes

Apply thread sealant to the oil pressure sending unit
before installation.

Install oil pressure sending unit by reversing the order of
removal.

7-32 4171985 First Edition

REPAIR

Oil Pump

Removal

See Figure 7-79.

1

2

9

8
7

6

Figure 7-79

1. Remove front cover. (See “Front Cover” on

page 7-12.)

2. Remove seven screws (5) and oil pump housing (4).

NOTE

Mark inner and outer rotor before removal to aid during
installation.

3. Remove inner rotor (2) and outer rotor (3).

4. Remove oil seal (1).

5. Remove circlip (6), retainer (7), spring (8), and relief

valve (9).

6. Inspect parts and replace as needed. (See

“Inspection” on page 7-33.)

3

4

5

TN0557

Inspection

NOTES

Clean engine oil from oil pump rotor bore, and inner and
outer rotors, before performing measurements.

Outer Rotor Radial Clearance

See Figure 7-80.

2

1

TN0391

Figure 7-80

1. Using a feeler gauge, measure the clearance
between outer rotor (1) and the oil pump case rotor
bore (2). If the clearance is beyond the service limit,
replace the oil pump assembly.

Oil Pump Radial Clearance Limit:

0.0004—0.006 in. (0.10—0.15 mm)

7

4171985 First Edition 7-33

REPAIR

Outer Rotor Side Clearance

See Figure 7-81.

1

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. If measurement is beyond service
limit, 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.

1

2

2

7

TN0394

Figure 7-82

1. Using a micrometer, measure the outside diameter of
the inner rotor shoulder (1).

2. Measure the inside diameter of the oil pump bore
hole (2). If measurements are not within service limit,
replace oil pump assembly.

Inner Rotor and Pump Case Clearance:

0.001—0.003 in. (0.025—0.076 mm)

7-34 4171985 First Edition

Relief Valve Spring

See Figure 7-83.

Required Tools

Veneer Caliper
Spring Compression Gauge

REPAIR

1

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.
(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 less than
specification, replace the spring.

Oil Pump Relief Valve Spring Tension at 1.516 in.
(38.5 mm) of Length: 17.3 lb-ft (23.45 N•m)

2

TN0558, 0559

7

4171985 First Edition 7-35

REPAIR

Installation

See Figures 7-84 and 7-85.

Required Tools

Bushing, Bearing and Seal Driver (Suzuki PN
09913-75520) or equivalent

1

2

3

Figure 7-84

NOTE

Install inner 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 specification.

Oil Pump Housing Torque: 60 lb-in. (6.78 N•m)

TN0561

1. Using bushing, bearing, and seal driver (1), insta ll
new oil seal (2) into front cover (3).

7

11

10

9

4

5

6

7

8

Figure 7-85

7-36 4171985 First Edition

TN0557

REPAIR

7.8 Cylinder Block and Lower Crankcase

Knock Sensor

Removal and Installation

See Figure 7-86.

2

1

3

Crankshaft Pulley

Removal and Installation

See Figure 7-87.

1

2

TN0721

Figure 7-87

1. Remove cap screw (1) and crankshaft pulley (2).

2. Inspect and replace as needed.

4

Figure 7-86

1. Use a small screwdriver to depress internal tab (2)

and release electrical connector (3) from bracket (1).

2. Remove knock sensor (4) from cylinder block.

3. Inspect and replace as needed.

Installation Notes

Install knock sensor by reversing the order of removal.
Tighten knock sensor to specification.
Knock Sensor Torque: 203 lb-in. (23 N•m)

TN0718

Installation Notes

Install crankshaft pulley by reversing the order of
removal.

Tighten crankshaft pulley cap screw to specification.
Crankshaft Pulley Cap Screw: 72 lb-ft (98 N•m)

7

4171985 First Edition 7-37

REPAIR

Idler Pulley

Removal and Installation

See Figures 7-88 and 7-89.

1

Figure 7-88

1. Remove cap screws (1).

TN0721

Connecting Rods and Pistons

Removal

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 “O il Pump Pickup” on
page 7-31.)

4. Remove crankshaft baffle. (See “Crankshaft Baffle”
on page 7-32.)

1

2

2

7

Figure 7-89

2. Remove idler pulley (3) and spacer (2).

3. Inspect and replace as needed.

Installation Note

Install idler pulley by reversing the order of removal.

3

TN0722

3

TN0752

Figure 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
opposite (exhaust) side of connecti ng rods and caps
1 through 3, starting at the timing chain (front of
engine) moving toward the back.

6. Remove nuts (1) and cap (2).

NOTICE

Prevent cylinder bore damage. Place rubber hose
over connecting rod bolts before removing from
cylinder.

Do not drop piston and rod ass embly. When the
piston rings are free of the cylinder bore, the
assembly will move freely.

7. Place rubber hose over connecting rod bolts and
slide connecting rod and piston out the top of the
cylinder block.

7-38 4171985 First Edition

Disassembly

See Figures 7-91 and 7-92.

REPAIR

7

8

Required Tools

Piston Ring Expander

1

6

Figure 7-91

1. Label pistons to correspond with previously labeled
connecting rods.

2. Remove circlips (1), piston pi n (6), and connecting
rod (5).

IMPORTANT

Be sure to note location and orientation of piston
rings to aid in assembly.

NOTICE

Do not expand piston rings any further than
necessary to remove. Piston rings can be
damaged if expanded too far.

3. Using a piston ring expander, remove piston rings
(2, 3, and 4). Be sure to note location and orientation
of each ring.

9

2

3

4

Figure 7-92

4. Remove bearings (8) from connecting rod (7) and
cap (9).

5. Inspect all parts for wear or damage. Replace as

5

needed.

TN0499

Inspection

Connecting Rods

TN0753

1. Inspect connecting rods for cracks, w ear, or damage.
Replace as needed.

2. Measure connecting rod small end ID. Compare
measurement 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. Measure connecting rod large end ID. Compare
measurement to specification and crankshaft
connecting rod journal OD specification. Calculate or
measure oil clearance and compare to specification.
Repair or replace as needed.

Connecting Rod Large End ID: 1.6141—1.6148 in.
(41.000—41.018 mm)

Crankshaft Connecting Rod Journal OD:

1.495—1.496 in. (37.982—38.000 mm)
Crankshaft/Connecting Rod Oil Clearance:

0.0007—0.0015 in. (0.020—0.040 mm)
Crankshaft/Connecting Rod Oil Clearance Limit:

0.002 in. (0.065 mm)

7

4171985 First Edition 7-39

REPAIR

Piston, Piston Pin, and Piston Rings

1. Inspect piston, piston pin, and piston rings for cracks,
wear, or damage. Replace as needed.

2. Measure piston OD. Compare to specification and
cylinder bore ID. Replace as needed.

Piston OD: 2.675—2.676 in. (67.970—67.990 mm)
Cylinder Bore ID: 2.6771—2.6779 in.

(68.000—68.020 mm)

3. Measure piston pin OD. Compare measurement to
specification and connecting rod small end ID.
Replace as needed.

Piston Pin OD: 0.7084—0.7086 in.
(17.995—18.000 mm)

Connecting Rod Small End ID: 0.7087—0.7090 in.
(18.003—18.011 mm)

4. Measure piston rings end gap. Compare to
specifications. 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 Compression Ring End Gap Limit: 0.039 in.

(1.0 mm)
Oil Control Ring End Gap: 0.0039—0.0157 in.

(0.10—0.40 mm)
Oil Control Ring End Gap Limit: 0.047 in. (1.2 mm)

7

Assembly

NOTICE

Prevent engine failure. Always clean parts of dirt
and debris. Coat all bearings and contact
surfaces with clean oil.

See Figures 7-93 through 7-97.

Required Tools

Piston Ring Expander, Piston Ring Compressor

1

3

4

Figure 7-93

NOTE

Be sure to align bearing tangs (4) with recessed grooves
in the connecting rod and cap.

1. Align bearing tangs (4) with recessed grooves in
connecting rod (2) and cap (1) and install bearings
(3).

2

4

3

TN0754

7-40 4171985 First Edition

REPAIR

5

13

12

11

Figure 7-94

8

6

14

16

7

TN0529

15

TN0753

Figure 7-96

NOTE

Apply clean oil to piston pin, connecting rod, and piston

9

contact surfaces before assembly.

5. Install connecting rod (15), piston pin (14), and

circlips (13) to piston (16).

NOTICE

10

Prevent cylinder bore damage. Place rubber hose
over connecting r o d bolts before installing.

Figure 7-95

IMPORTANT

Install all piston rings with markings facing the top of
the piston. Be sure to position the piston ring gaps
as shown.

2. Using a piston ring expander, install the bottom oil
control ring (7). Align the expander ring gap (8) with
the intake side of piston. Align the control ring gaps
(9 and 12) as shown.

3. Using a piston ring expander, install the second
piston ring (6) with markings facing up, and the
undercut facing down. Position the ring gap (10) as
shown.

4. Using a piston ring expander, install the first ring (5)
with markings facing the top of the piston. Position
the ring gap (11) as shown.

6. Cover connecting rod bolts with rubber hose and
apply clean oil to connecting rod bearing.

7

NOTE

Confirm the proper position of ring gaps before installing
piston ring compressor.

7. Using a piston ring compressor, install the piston and
connecting rod as an assembly. Be sure the arrow on
face of piston faces the timing chain (front of engine).

Be sure the stamping “2N” on connecting rods and
caps face the intake side of the engine, along with
the valve reliefs in the face of the piston.

Be sure the piston and connecting rod are installed in
the correct cylinder, as previously numbered.

8. Coat the crankshaft rod journal with clean engine oil
and carefully engage the connecting rod.

4171985 First Edition 7-41

REPAIR

17

Figure 7-97

18

TN0752

NOTE

Apply clean oil to the connecting rod cap bearing and
crankshaft journal.

9. Install connecting rod cap (17) and nuts (18). Tighten
to specification.

Connecting Rod Torque: 24 lb-ft (33 N•m)

10. Install crankshaft baffle. (See “Crankshaft Baffle” on
page 7-32.)

11. Install oil pump pickup. (See “Oil Pump Pickup” on
page 7-31.)

12. Install oil pan. (See “Oil Pan” on page 7-30.)

13. Install cylinder head. (See “Cylinder Head” on
page 7-24.)

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.)

3. Remove oil pump pickup . ( See “O il Pump Pickup” on
page 7-31.)

4. Remove crankshaft baffle. (See “Crankshaft Baffle”
on page 7-32.)

1

2

2

1

2

7

3

2

5. Using a 12-point 8 mm socket, remove six screws
and washers (1).

6. Using a 12-point 10 mm socket, remove eight scre ws
and washers (2).

1

Figure 7-98

TN0755

NOTE

The lower crankcase is located u sing f our dow el pins and
is sealed to the cylinder block using Three Bond ™ 1215
sealant. The lower crankcase must be lifted off square.

7. Use a soft face mallet to loosen lower crankcase (3)
from cylinder block. Remove lower crankcase from
cylinder block. Be sure to lift lower crankcase off
square.

7-42 4171985 First Edition