Suzuki: Engine K6A-YH6. Service manual - part 21

 

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Suzuki: Engine K6A-YH6. Service manual - part 21

 

 

7-38

REPAIR

7

Idler Pulley

Removal and Installation

See Figures 7-88 and 7-89.

Figure 7-88

1.

Remove cap screws (1).

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.

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 “Oil Pump Pickup” on 
page 7-31.)

4.

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

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 connecting 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

7.

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

TN0721

1

TN0722

3

2

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

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

TN0752

2

1

3

REPAIR

7-39

7

Disassembly

See Figures 7-91 and 7-92.

Figure 7-91

1.

Label pistons to correspond with previously labeled 
connecting rods.

2.

Remove circlips (1), piston pin (6), and connecting 
rod (5).

IMPORTANT

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

NOTICE

3.

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

Figure 7-92

4.

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

5.

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

Inspection

Connecting Rods

1.

Inspect connecting rods for cracks, wear, 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)

Required Tools

Piston Ring Expander

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

TN0753

1

6

5

2

3

4

TN0499

7

8

9

7-40

REPAIR

7

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)

Assembly

NOTICE

See Figures 7-93 through 7-97. 

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).

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

Required Tools

Piston Ring Expander, Piston Ring Compressor

TN0754

1

2

3

3

4

4

REPAIR

7-41

7

Figure 7-94

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.

Figure 7-96

NOTE

Apply clean oil to piston pin, connecting rod, and piston 
contact surfaces before assembly.

5.

Install connecting rod (15), piston pin (14), and 
circlips (13) to piston (16).

NOTICE

6.

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

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.

TN0529

6

5

7

9

8

12

10

11

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

TN0753

15

14

16

13

 

 

 

 

 

 

 

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