Suzuki: Engine K6A-YH6. Service manual - part 14

 

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Suzuki: Engine K6A-YH6. Service manual - part 14

 

 

7-10

REPAIR

7

7.4 Cooling System

Water Pump

Removal and Installation

See Figures 7-25 and 7-26.

Figure 7-25

1.

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

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.

Thermostat

Removal and Installation

See Figures 7-27 and 7-28.

Figure 7-27

1.

Remove cap screws (1).

2.

Remove filler neck (2).

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.

TN0726

1

2

TN0432

TN0701

2

1

TN0705

3

REPAIR

7-11

7

Water Temperature Sensor

Removal and Installation

See Figure 7-29.

Figure 7-29

1.

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

2.

Inspect water temperature sensor. Replace as 
needed.

Installation Notes

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

Install water temperature sensor by reversing the order of 
removal.

Thermostat Housing

Removal and Installation

See Figures 7-30 and 7-31.

Figure 7-30

1.

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

2.

Remove cap screw (1) and bracket (3).

3.

Remove nuts (4) and thermostat housing (2).

Figure 7-31

4.

Remove thermostat 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.)

TN0701

1

2

TN0707

1

2

3

4

TN0708

5

7-12

REPAIR

7

7.5 Front Cover, Timing Chain, 
and Tensioner

Cam Angle Sensor

Removal and Installation

See Figure 7-32.

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.

Installation Note

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

Install cam angle sensor by reversing the order of 
removal.

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 “Oil Pump Pickup” on 
page 7-31.)

Figure 7-33

9.

Remove idler pulley/alternator bracket (4).

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).

TN0709

1

2

3

TN0745

2

1

2

3

2

4

2

2

REPAIR

7-13

7

Installation

See Figures 7-34 and 7-35.

1.

Clean cylinder head, cylinder block, 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.

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.)

Required Materials

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

TN0386

TN0745

2

1

2

3

2

4

2

2

 

 

 

 

 

 

 

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