SUZUKI English Service Manual K6A Engine Overhaul Manual Cappuccino Wagon R Alto Jimny CarrySuzuki K6A Factory Engine Manual Engine Overhaul & Specifications Vehicle Series Jimny Alto Wagon R Carry Others James L. DankoCopyright © 2008 by James Danko All rights reserved. All text and graphics in this publication if the author, unless otherwise noted or credited. It is unlawful to reproduce-or copy in anyway-resell, or redistribute this information without the express written permission of the publisher. This book is an independent publication, and the author and/or publisher thereof are not in anyway associated with, and are not authorized to act on behalf of any of the manufactures listed in this book. All registered trademarks are the property of their owners. The publisher reserves the right to revise this publication or change its content from time to time without obligation to notify any persons of such revision or changes. Edited By: James L. Danko Artwork: James L. Danko® 2008 Layout By: James L. Danko Computer Assistance: Yoshiro (www.yoshiro.com) Printed in U.S.A Publisher LuLu.com ISBN: Reserved Irst Edition 2008 All translations from original Japanese test to English completed by James Danko. English: Automotive Terms used in this book are based on US/Canadian Vocabulary. Disclaimer: All translations from one language to another can involve technical errors. Credits: I would like to thank the Suzuki Motors Corporation (Japan) for their part in supplying required information, Credits: I would like to thank Yoshiro for all his computer technology to make these books happen. His computer graphics and technology is simply the best. www.yoshiro.com Suzuki™ Carry© and Every© and all copyrights of said trademarks are property of Suzuki Corp, Japan.Introduction Due to the high request for English version manuals on Japanese mini trucks & Vans, we are publishing wide variety information to provide the mini truck community with the ability to maintain their vehicles. Japanese mini tucks & vans are produced only for the Japanese market. Therefore, all original manuals are only available in Japanese. Service manuals are not sold to the public in Japan, as in many countries. You must be anew car dealer to receive them. We have a few hundred in stock. We do not sell manuals from our own library. We will start publishing them in English (Translated) and our own original versions. This book or manual is for the professional mechanic. It is written in Factory Service Manual style. It is full of diagrams and schematics that are easily understood by a professional mechanic. We have manuals for all Japanese manufactures. It’s a time consuming process, please check our web page frequently as we post more information. www.yokohamamotors.com K6A Important Information The K6A Engine has been used in numerous applications since its debut from Suzuki. There will be differences in external parts such as oil pans and Intake & Exhaust manifolds. This overhaul manual supports the main components such as cylinder head, camshafts, pistons and block units. For specific vehicle external parts configuration please check vehicle specific parts manuals. Tune-up specifications for vehicle specific information please check the information sticker located in or around the engine compartment. Your vehicle specific setting information will be included on the sticker of your vehicle.SNARE NS Contents |. Engine Identification . Specialty Tools . Timing chain & Tensioner Section Oil Pump system & Overhaul . Cylinder Head & Valve Train Overhaul Section . Piston, Connecting Rod, Crankshaft, Cylinder Block Section . Detailed Service Specifications . Conversion ChartsEngine Series Decoding K6A~100001 Production Series Engine Series Engine Block Stamp CodeSpecialty Tools 1 1. Valve Compressor 2. Adapter Reamer Handle Reamer(5.5mm) Reamer (10.5mm) 09916-14910 09916-34542 09916-34550 09916-37320 Valve Guide Remover | Guide Installer Handle | Installer Attachement | Ring Compressor 09916-44910 09916-58210 09917-87010 09916-77310 | Flywheel Holder Oil Seal Guide Oil Seal Installer ‘Valve Stem Installer 09924-17810 09911-97020 09911-97030 09917-98221gS = Z Timing Ch 3 gg: chain Guard ig | ® No.2 § 2 [cam Timing 5 Sprocket Witensioner BH Turbo Oil Cooler Pipe wees By @Q 5 e 2 Belt EARN ete Pop Cove 'No. L EZ Oil Pump Assembly Be its araveoer dugg a1e=N9Y ON @ Bistrainer ism Tome] souorsuay. 29 ures Zurwy,Timing Chain & Tensioner 1. Timing Sprocket Mark 2. Slit Alignment Mark 4. Crank Key 1, Rotate Crankshaft to TDC (Top Dead Center) Note: Verify Rotor Pinted to #1 Cylinder Note: Engine No. KA6~1028584 Remove Timing Chain From Intake Side Camshaft ‘Timing Sprocket Engine No. KA6-1028585~ Remove Timing Chain From Cranshaft Timing Sprocket Caution: When Timing Chain is Removed, DO NOT ‘Turn Crankshaft. If Camshaft Must be Moved, The Crank Key Should Turn Max 30 Degrees. To Adjust Camshaft Hold With Wrench as in Diagram Inspection Timing Chain: If Damaged, Replace. iming Chain Must be Replaced on Engines ‘ith 80,000 Kilometers ‘Tensioner: Push Latch and Check for Free Travel. If Unit Does Not Move Freely Replace. Installation is Reverse or Removal Engine Series ~K6A-1028584 1, Put Cam Timing Sprocket point "g" or "UP" Posistion 2. Make Sure Crankshaft 3. Install Timing Sprocket fey" is Facing Upwards Engine Series K6A-1028585~ 1. Put Cam Timing Sprocket in "g" Posistion 2. Put Intake & Exhaust Cam Spocket in Alignment With "Slit" & Mark on Cylinder Head 3. Make Sure Crankshaft "Key" Is Facing Upwards Note: Use Diagram on Left 10‘Timing Chain, Tensioner 4. Apply Oil to Guide #1. Tighten Timing Chain Bolt To Specified Torque ‘Torque: 100 kg.cm 5. Pull Back Tension Adjuster and Retain With a Piece of Wire. Torque to Specification. Toque: 100 kg.cm. Engine Series: ~K6A-1028584 6. Install Spacer onto Chain Tensioner 7. Tighten Chain Tensioner Mounting Bolt Torque: 220 kg.cm 1. Blue Link Engine Series: ~K6A-1028584 3 | 8, Align "Blue" Link onto Exhaust Side Cam Timing | SprocketArrow. Nest, Align "Blue" Link to Match The Slit On The Bottom of The Crankshaft Sprocket a‘Timing Chain, Tensioner Engine Series: ~K6A1028584 9. Line Up All Blue Links With Appropriate Sockets. Tighten Cam Sprocket Bolts to Specified Torque Torque: 100 kg.cm Engine Series: K6A-1028585~ 9, Line Up All Blue Links as Shown, Torque to Specification ‘Torque: 220 kg.cm 10. Install Chain Guide No.2 ‘Torque: 100 kg.cm AL. After Setting Torque Confirm All Blue Links Are in Appropriate Locations. P Crank Sprocket 4. SlitSc Adhmter Pioneer —____! ‘Timing Chain, Tensioner 1, Alignment Mark 2. Crankshaft Key 12. Confirm Pad is Attached to Timing Chain Tensioner 43, When Attaching Timing Chain Tensioner Link to Chain Tensioner, Align ‘Tensioner Adjuster Plunger With Pad. ‘Torque: 100 kg.cm 14. Remove Adjuster Stopper & Lubricate Chain 15. Confirm Settings: Turn Over Crank Twice, Verifying Mark Alignment 16. Clean Matching Surface of Timing Chain Cover, Apply Sealant and Install 17. Tighten Timing Chain Cover to Specifications ‘Torque: 100 kg.cm4 ‘Timing Chain, Tensioner 18. Use Tool A: 09924-17810 Flywheel Adapter to Hold Crankshaft from Turning Install Crankshaft Pulley and Torque to Specifications Torque: 1000 kg-cm 19. Install Oil Pan Note: Use Sealant (Suzuki) Part #99000-31080-07F “Torque: 100 kg.cm 20. Attach Valve Cover Torque: 100 kg.cm 24. Install Water Pump Torque: 110 kg.cm Sealant: (Suzuki) Part # 99000-31080-07F 22. Install Remaining Components Per Vehicle RequirmentsOil Pump Assembly Old & New Version Oil Pump Assembly (Old Version Engine Series K6A-1060036~ Oil Pump Case [fj Inner-Rotor [Paovter Rotor Hl Rotor Pate Oil Pump Assembly Ot Pump Case BXlnner Rotor lf Rotor Plate | H)Ower-Rotor Pe Resi Vale) Newer Version EB\abe Sprin, Engine Series KA6-1060037~ is Reiner —3 ES @ ccip— x Oil Seal @Not Reusable I Repairable FA) Torque 2 Olt PointOuter Valve sree Retainer —— 3, C-Clip Thickness Straight Edge Bar Gage Oil Pump Removal & Replacement 1. Remove Timing Chain Cover and Assembly as in Listed in this Book Remove Oil Pump Assembly Verify Part Numbers Clean Unit for Inspection aeN Oil Pump Inspection Lateral Clearance 1. Use a Thickness Gage and First Check Outer Rotor to Case Clearance. If The Thickness is Out of Range Replace Case Lateral Clearance Limit: 0.31mm Side Clearance 1. Using a Thickness Gage and a Straight Edge Bar, Measure Side Clearance. Measure Both Outer & Inner Rotor Units. If Either are Out of Limits Replace Both Inner & Outer as a Set. Side Clearance Limit: 0.15mm Installation Install in Reverse Order Note: Never Reuse Gaskets 16Cylinder Head, Valve Train Bike ain ; r atin BXspring P= HS] @Bsrem ft a EXatee Spring Seat Bivatce Cylinder Head ad ; fae Ti big ea Head Gasket torque Moi Poin Bseatant Not Reusable Ml RepairableCylinder Head, Valve Train Removal 1. Remove Valve Cover & Timing Chain Front Assembly. 2. Use a Wrench and Hold Camshaft at the 6 Point Camshaft Retainer Part of Shaft. 3. Remove Sprockets From Camshafts 4. Remove Camshaft Caps & Remove Camshafts Note: Put Caps Back in Original Location 5. Use 10mm 12 Point Socket and Remove Head Bolts in Order Listed in Left Diagram. 6. Remove Cylinder Head and Discard Old Head Gasket. 7. Clean Head & Prepare for Disassembly Disassembly & Inspection 1, Remove Old Intake & Exhaust Manifold Gaskets and Discard 2, Remove Shim & Tappet and Position Valve Spring Compressor with Atachment Tool # A: 09916-14510 B: 09916-14910 (See Tool Page) 3. Remove Valves Retainers and Valves. Lable Position 4, Remove Spring Seat & Oil Seal 5. Use Valve Guide Remover and Remove Valve Guides. ‘Tool # A: 09916-44910Cylinder Head, Valve Train Camshaft Inspection 1. Place Camshaft in V-Block. Use a Dail Gage and Check Shaft Round-Out. Limit: 0.0mm 2. Cam "a" Height or "Max Lobe Lift" Use the Chart Below for Limitations. 1. Plastigage 2. Scale Type Cam Height "a" Limit Normal IN 37.54~37.70 EX 37.05<37.21 iN 37.65~37.82 Turbo [x 32.75~37.91 on __38.24~ 38.40 Wagon "R" [rx 38.21~38.40 Note: If Camshaft is out of Limits Replace Unit Camshaft Housing Track & Caps 1. Use a Straight Edge & Check Camshaft Track for Straightness. If Head is Warped Replace Head. Inspect Retainer Caps for Damage or Scratches. Replace if Damaged or Scratches are Detected 2, Inspect Head Oil & Water Passages 3. Place Camshafts in Cradle and Torque Caps to Specifications. Oil shaft well before Setting Torque Value. Check for Free Spin. Torque: 10N*M (100kg.cm) 4. Use Platigage and Check Limitations Use Diagram on Left Oil Orifice: Limit 0.045~0.087mm. 9Cylinder Head, Valve Train Note: Measurments Shall be Taken at an Ambient ‘Temperature of 20C (Celsius) Tappet & Shim Inspection Inspect Shim for Damage. Replace With Exact Shim Size for Initial Replacement Testing. j Note: Never Mix Shims With Other Tappets ‘Tappet Inspection i —~C)- ————— TT “Tappet Outside Diameter 26,959~26.575mm Cylinder Head Bore 27.000~27.021 Use a Micrometer to Inspect Outside Diameter of Tappet Use Dial Gage to Inspect Cylinder Head Tappet Bore Valve Stem & Valve Guide Inspection 1 | Valve Stem IN| 5.405~S.480 Thickness 5.A40~5.455 = Valve Guide N ~ A] Diameter EX, cee 5.54 Valve Stemto | IN | 020~0017 | 097 ‘Valve Guide = — Clearance ex | o0s~oore | 009 Use a Micrometer and Dial Gage to Inpect Valve Stem and Valve Guide Clearances ‘Any Part Outside of Specifications Must Be Replaced With New PartsCylinder Head, Valve ‘Train Note: Make Sure Valves Are Marked and Not Mixed From Original Position Valve Stem Tip 1. Valve Stem 2. Taper be |____™4. Valve Head Thickness 1, Width Limie Valve Inspection 1, Remove Any & All Carbon Deposits 2. Replace Bent or Scratched Valves 3. Replace Valve if Tip Surface is Worn More Than Specifications Limit: 0.5mm. Valve Head Thickness a T_Normal Replace Valve Head a OF [Thickness (mm) [EX | _115__| 05. Place Valve in V-Block. Use a Dial Gage and Check For Round-Out. Replace if Out of Specification Round-Out Limit: 0.08mm_ Valve Seat Angle Width Measurment Limit IN: 1.1~1.5mm EX:1.2~1.6mm aCylinder Head, Valve Train Valve Seat Use the Diagram on the Left for Proper Valve Seat Angie Cuts. Note: Valve Seats are Not Replaceable Cylinder Head Inspection Remove All Corbon Deposits and Inpspect for Cracks, if Cracks are Detected Head Must be Replaced Use the Two Diagrams on the Left to Check Straightness Use a Straight Edge and Thickness Gage to Measure Head Check Straightness (4) Ways as Shown in Diagram Surface Limitation: 0.005mm Resurfacing Limitations: 0.0immOr Cylinder Head, Valve Train Cylinder Head Intake & Exhaust Manifold Surface Use a Thickness Gage & Straight Edge to Inspect, Cylinder Head Intake & Exhaust Manifold Surface Straightness. Limit: 0.10mm_ Resurface Limit 0.9mm~1.0mm Valve Spring Inspection Check Valve Spring Free Length Use the Chart Below for Specifications Note: Free Length Must be 36.30. Any Veriation Can Cause ‘Valve Train Damage. Any Engine With Over 80,000 Kilometers Spring Must be Replaced. Spring Straightness Place Spring on Flat Surface and Place Straight Edge Next to Measure Straightness Measure from Top of Spring With Thickness Gage Limit: 0.0~1.3mm Springs over 80,000 Kilometers Must be Replaced Assembly Before Installing New Valve Gui to Clean Bores Before Install jes Use a Reamer (10.5mm) a Tools: A: 09916-37320 Reamer (10.5mm) B: 09916-34542 Handle (Reamer) 2BClyinder Head, Valve Train Valve Guide Installation Note: Warm Head to 80~100 Celsius Before Installation Note: If Guide Fails Installation and Removed it Must be Discarded & Replaced Note: Valve Guide Oversize Outside Diameter Limit Limit: 10.583~10.598mm IN: 1imm limm Use Diagram on Left "a! Use Tools A: 09916-58210 Valve Guide Installer Handle B: 09917-87010 Valve Guide Installer Attachment Install Guides: Use Tools Listed Above and Install All Valve Guides Valve Guide Reaming Use Tool 09916-34550 Reamer (5.5mm) 09916-34542 Handle Ream All Guides With Above Listed Tools Valve Stem Seals Install Valve Stem Oil Seals With Following Tools Tools A: 09917-98221 Valve Stem Instaler 19916-58210 Installer Handle Note: Coat Seals With 30W Engine Oil Before Installation Note: Valve Stem Seals Can Not be ReusedCylinder head, Valve Train 1. Large Pitch 2. Small Pitch 3. Retainer Side 4. Seat Side Valve Spring Installation Use the Diagram on Left for Valve Spring Intallation Guide Use the Following Tools for Valve Spring Installation Tools A: 09916-14510 Spring Compressor B: 09916-14910 Attachment Install Valves and Keepers Installation of Cylinder Head Note: Make Sure All Surfaces are Clean & Oil Free Note: Check New Gasket for Proper Location Mark Note: Do Not Coat Head Bolts With Oil Not Do Not Install Head With Spark Plugs Installed 1. Place Head Gasket on Cylinder block 2. Place Cylinder Head on Block Over New Gasket 3. Install All Head Bolts Finger Tight 4. Use 10mm Socket and Torque Wrench and Initially ‘Torque to 150 kg.cm. Wait 10 Minutes and Torque to 350 kg.cm. Wait 15 Minutes and Final Torque to 600 kg.cm Note: Use Torque Sequence from Left Diagram. Note: With Timing Chain Removed, Do Not Turn Crankshaft More Than 30 Degrees to the LeftCylinder Head, Valve Train Tappet & Shim Installation 1. Coat Tappet and Shim With New 30W Engine Oil 2. Install Tappet and Shim 3. Cover Camshafts in Engine Oil & Place in Housing 4, Install No.1 Housing First and Finger Tighten. 5. Install No.5 Housing 6. Install Reming Caps and Finger Tighten Bolts Use Torque Sequence Diagram on Left 7. Torque All Bolts to 10N*m (100kg.cm) Attach Timing Chain and Other Components Complete Intallation & Tune to Vehicle Specifications 1. Camshaft Intake No.5 Housing | eeePiston, Connecting Rod, Crankshaft, Cylinder Block BD |Top Ring SS Secondary Ring rome SE svi 5 Oa @soap Ring connecting Rod —flciutch Housing Baconnecting Plate Rod Bearing Bi. we Qe a a Crankshaft PA Horque HO’ Point EJ Sealant @ Not Reusable Replaceable 27Piston, Connecting Rod, Crankshaft, Cylinder Block Flywheel Bolt Engine Disassembly Remove Engine Remove Timing Chain Assembly Remove Cylinder Head Rotate Engine & Remove Pistons ayer Note: Use Vacuum Hose to Cover Connecting Rod Bolts Before Piston Removal Use Tool A: 09924-17810 Flywheel Holder to Retain Flywheel While Removing Bolts 5. Remove Flywheel 6. Clean Engine Block Note: Mark Pistons With Location Information 7. Remove Piston Pin C-Clips & Disassemble Pistons Note: C-Clips Can Not be Reused Block Inspection Use Dial Gage and Inspect Cylinder Bore Diameter Use Two Diagrams on Left for Reference Limitations Cylinder Bore: Limit 65.070mm ‘Taper Limit: 010mm. Note: See Parts Manual for Ovcersize Pistons & Rings 2BPiston, Connecting Rod, Crankshaft, Cylinder Block Note: Engines with Over 100,000 Kilometers Piston Must be Replaced Note: Engines with Over 65,000 Kilometers Piston Rings Must be Replaced Piston Measurment Piston Ring Side Clearance —_-z7 Piston Measurment Measure Piston Size Using the Diagram on Left Measurment Must be Taken 15mm Up From Bottom of Skirt ——————— Stock Size Over Si Dn ‘Over Size 0.50mm_ Piston Size (mm) 68.47~68.49 Piston Gap Clearance: 0.025~0.045mm Piston Ring Specifications Use Thickness Gage and Inspect Side Clearance | | | 1. Piston Ring 2. Thickness Gage 2. Thickness | Piston Ring _|_Limit Replace Ring Gap [Top 0.03~0.07 0.2 (mm) Secondary | 0.02~0.06 0.10 Oil 0.06~0.15 = Piston Ring Gap (Bore) Place Ring in Bore as in Diagram on Left Measure from Lowest Stroke Point on Up Gage [Limits | Replace] " op Ring Jop-027 [07 | 3.Pinton Ring] | PAt0ORIOE.[Scondang——s5-0.s0 [10 ing (0.10~0.40 | 15Piston, Connecting Rod, Crankshaft, Cylinder Block Pisto Pi n Pin ston Pin Piston Pin Inspection Note: C-Clips Can Not be Reused Use The Diagrams on Left & Charts Below to Inspect the Clearances Listed Below ‘Tools Required: Micrometer & Dial Gage ‘Connecting Rod (Small) Inside Dia Piston to Piston Pin Gap (mm) Piston Pin Gap Connecting Rod @mall End) to 0,003~0.016 ‘Thrust Gap. Connecting Rod Inspection With Crankshaft in Place, Connect Rod and Torque to Specification. Use Thickness Gage & Check Limie ‘Over Thrust Gap CAi~0.51 0.35, Note: Any Connecting Rod That Fails, Replace. Connecting Rod Alignment Specifications Use Diagram on Left for Reference Bend Rate: 0.05mm Twist Rate: 0.10mm 30Piston, Connecting Rod, Crankshaft, Cylinder Block Crankshaft Meaurment — Crankshaft Inspection Crankshaft Diameter Round Out Measurment Tools Required: Micrometer ‘Taper Limit: 0.0imm Calculation: -B ab Note: Crankshaft Found Out of Round Should be Replaced and New Set of Standard Bearings Installed Connecting Rod Bearing Inspection 1. Remove Bearing Cap 2. Inspect for Wear, Replace if Worn Note: Replace ll Bearing if Engine Over 60,000 Kilometers Crankshaft Cap Toqure: 32N*m (330kg.cm) Diagram 1. Rod Bearing Cap 2, Identification Stamp 3. Camshaft Pulley Direction Oil Oriface : Limit 0.020~0.040 atPiston, Connecting Rod, Crankshaft, Cylinder Block Assembly Note: If Pistons Have Been Replaced Make Sure Proper Markings are Stamped or Stamps Added. Factory Piston Replacements at 2 |cCylinder Codes | 1, Piston 2. Mark 3.Con Rod 4. Oil Hole (Intake Side) Piston [Cylinder | Piston & Cyl INo[OutDia [No] In Dia Gap (mm) 1 |67.9801~67.9900 R |6s.001~68.020 _| 0.021~0.0399 1 [679700679800 B [6¢.00~68.01 | 0.02~0.08 R=Red B=Blue Check Block Tag as in Left Diagram to See if Pistons are Factory Installed Replacements or Oversize. Use Diagram on Left for Proper Connecting Rod Configuration. Forward Mark to Front of Engine & Oil Hole Must be Pointed to Intake Direction Note: Make Sure All Moving Parts are Well Lubricated With 30W Engine Oil | Piston Pin C-Clips | Use Diagram on Left for Installation Location C-Clip Mut Face Either 12 O'Clock or 6 O'Clock | Position Piston Rings Install Rings With Marks Facing Upwards 2Piston, Connecting Rod, Crankshaft, Cylinder Block ‘Top Ring Secondary Ring Front Rear | Use Diagram on Left to Verify Ring Type and Facing Direction Ring Installation Guide Use the Diagram on Left for Installation Information Mark (To Front of Engine) Top Ring (Compression) Secondary Ring (Compresion) Oil Ring Oil Ring Spacer 45 Degrees av aeye Crankshaft Center Journal Measure Round Out Limit: 0.04mm_ Main Bearing ‘Use Diagram on Left for Proper Installation ‘Torque: 56N*m (580 kg.cm) ‘Thrust Bearing Limitations Front~Rear Limitation: 0.11~0.31mm_ ‘Thrust Bearing Thickness Limitation Limit: 2.500mm Oversise: 2.563mm_ 3BPiston, Connecting Rod, Crankshaft, Cylinder Block Journal Cap Identification Specifications —T 5 z 3 Crankshaft Journal | 44994 | 44988 | 44.982 Ouiside Diameter__| ~15,000 | ~s4904 | ~s4988 Bearing Cap Diameter |” Bearing Cap Marking Numbers 7 213 | Bearing Cap Inside | 49.000 | 49.006 | 49.012 Diameter ~s9.006 | ~s9o12 | ~s9.018 Bearing Color Codes "Color Code Bearing Size Thickness | Green 1.996~2.000 Black 1.992.003 No-Color 2.002~2.006 | Yellow 2.005~2.009 i Blue 2.008~2,012 1. Paint Mark | 4Piston, Connecting Rod, Crankshaft, Cylinder Block Crankshaft Specification Continued Flywheel Inspection Tool Required: Dial Gage Use Dial Gage to Inspect Flywheel Surface Round Out Limitation: 0.20mm Cylinder Block Deck ‘Tools Required: Thickness Gage Straight Edge Limitation: 0.05mm (See Previous Section for More Detail) nkshaft Journal Stamped 2 3 Bearing [1 | Green Biack | _No-Color Cap 2 | Black No-Golor| Yellow ID 3|_No-Color | Yellow Blue Oil Seal Must be Replaced Note: See Part Book for Proper Part Number 35Piston, Connecting Rod, Crankshaft, Cylinder Block 1. Cylinder Block 2. Bearing 3. Oil Seal oO 1, Thrust Bearing 7) 36 ‘Torque Sequence Assembly 1. Install Bearings Note: Coat With 30W Engine Oil 2. Cover New Oil Seal With 30W Engine Oil and Install. 3. Clean Lower Deck Surface and Apply Sealant. Place New Gasket and Allow to Dry. Note: Do Not Put Sealant on Top of Gasket 4. Coat All Bearing With Fresh Oil. Install Crankshaft. Torque Caps to Specification. Note: Torque in Stages Until Maximum Torque Level Achieved Torque: Bolts: 1~8: 580kg.cm Bolts: 9~16 400 kg.cm 5. Sping Crankshaft to Verify Free Movement. If Binding Occurs Remove Caps and Troubleshoot Problem.Piston, Connecting Rod, Crankshaft, Cylinder Block 1. Bearing Cap 2.Mark 3. Crank Pulley Direction 6. Place Used Rubber Vacuum Hose on Connecting Rod Bolts Before Installation 7. Coat With 30W Engine Oil & Intall Upper Connecting Rod Bearing 9. Verify Mark on Piston is Facing Forward to Front of Engine 10. Coat Piston, Rings, and All Componnents With 30W Engine Oil. 11, Use Tool A: 09916-77310 (Ring Compressor) and Install Piatons. Note: Only Use Wood or Plactic Handle to Install Pistons. 12. Install Lower Connecting Rod Bearing in Cap, Coat with 30W Engine Oil and Attach Caps. 13. Torque to Specifications Torque: 330 kg.cm Note: Turn Over Engine With Crankshaft Adapter And Check For Smoothness. Use Abundant Oil Coating. 44, Install Cylinder Head & Timing Chain 15. Attach Oil Pan 37Piston, Connecting Rod, Crankshaft, Cylinder Block Rear Oil Seal Engine Series: K6A-1060037~ Rear Oil Seal Installation ‘Tools: A: 09911-97020 Oil Seal Guide 09911-97030 Oil Seal Installer 16. Coat New Oil Seal and Install 17. Use Tool A: 09924-17810 Flywheel Holder & Install Flywheel. Torque: 700 kg.cm 38Service Data Benchmark Usage Limits | Memo IN Cold 0.18-0.23 : Valve Gap Hot 0:21-0.27 = | EX Cold 018-023 E a Hot 0.20-0.26 ~ i ‘Cylinder Matching Surface(mm) : 0.05 Manifold Ataching Surface(mm) : ~~ 0.10 iN Tis z Valve Seat | Matching width(mm) EX 1246 = ‘Angle ) Seat face B ~ _t Flat surface | INSOEXAS Valve Valve Head IN 10 07 — ‘Thickness(mm) EX 1.15 05 Valve Head (mm) = 008 Valve Guide Internal 5,500-5.512 5.54 ~~] Diameter(mm) 5.500-5.512 5.54 Valve Guide External AC5-5.480 : Diameter(mm) 440-5. 455 : | Gap Berween Valve Guide and 0.020-0.047 007 ‘Valve System(mm) 0.045-0.072 0.09 | Height of the Valve Guide 1 5 © | Valve Spring Free Length(mm) 36.30 = e Tensile @ Spring Height 28.5mm 132-152 1250128) J WNikgf}) g Straightaess Limit (mm) 7 a [_ (NA) Gap becween Valve Rocker Arm Shaft(mm) : NA (mm) : Cam Shaft Round Out (mm) : ‘Height ‘Normal T IN 37.54-37.70 ~ OFCAM EX 37053721 | Turbo N 37.66-37 82 : (Except Works R) EX 37.75-37. 91 - Works R IN 38.24-38.40 = EX 38.24-38.40 5 (Cylinder Head’s Cam Shaft I Bearings Internal Diameter (mm) 2 93.00-23,021 eal | 3 4 ‘Cam Shaft Bearings’ o _ External Diameter(mm) @ 22.934-22.955, 22.784 ® | @ Gap of Cam Shaft Oil Orifice (mm) 0,045-0.087 0.12Term ~ Benchmark Usage Limit | Memo Cylinder Marching Surface(ram) : 005 | 5 Internal Diameter(mm) ~68.00-68.020 | 68070 | ~*i| g Bore Limit in Internal Diameter(mm) : O10 a Taper of Internal Diameter(mm) | = 0.10 . Main Journal Internal Diameter(mm) 4900-49-18 E Taternal Expansion Limits(mm) i : 2 Piston External Diameter [_ 67970-67990 : Gap between Piston and Cylinder [0010-0050 a0 Piston Ring Gap of Assembly | __0.7 012-027 OT [ Mier(mm) 0.10 035-050 0.10 15 O04 13 | z Gap of Free 5 69 - 3 Miter(mm) - aT —— ____| Gap berween oz 0030-0070 I Ring and Ring [0.10 0.020-0.060 Chase(mm) : 0.06-0.15 : Piston Pin Boss Internal Diameter 18,006-18.014 | 2 Piston Pin External Diameter 17.995-18.000 = I 3 Bend(mm) = 005 | _ é “Twist(mam) : 0.10 & Large End Internal Diameter(mm) 41.000-41.018 : g Large End Thrust Gap(mm) O11-031 035 Connecting Rod Bearing Oil Gap(mm) 0.020-0.040 0.065 Straightness(mm) : 0.04 Journal, Pin Straightness(mm) : 07 g ‘Journal Pin Taper(mm) 0.01 r ‘Journal External Diameter(mm) “44,982-45.000 = E Pin External Diameter(mm) [_37.982-38.000 . Gap Crankshaft Bearing 0.020-0.040 011-031Conversion Charts CONVERSION OF TORQUE Convert Convert From To Multiply From To Multiply | Ib.in. oz. in. 16 oz.in. Ib.in. -0625 Ib.in. Ib. ft. -08333 Ib.ft. Ib.in. 12 Ib.in. kg.cm. 1.1519 kg.cm. Ib.in. 8681 Ib.in. kg.m. .011519 | Kavtre Ib.in. 86.81 Ib.in. Nm piso) Nm Ib.in. 8.85 Ib.in. dNm 1:13 dNm Ib.in. | 885 Ib.ft. kg.m. 1382 kg.m. Ib. ft. 7.236 Ib. ft. Nm 1.356 lium Ib. ft. 7376 Nm dNm 10 dNm Nm 10 Nm kg.cm. 10.2 kg.cm. Nm .09807 Nm kg.m. .102 kg.m. Nm 9.807 aThank you! For More Information on other fine publications check the following resources. www.lulu.com www.amazon.com Automotive Specialty www.yokohamamtors.com Automotive Service Manuals Suzuki Subaru Honda Mitsubishi Daihatsu Toyota Nissan OthersSUZUKI English Service Manual K6A Engine Overhaul Manual Cappuccino Wagon R Alto Jimny Carry 660cc K6A Engine