09103-06092 Suzuki BOLT (6X15)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 173-5529 Piston Ring Compressor 1
B 4C-5593 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The joint between the connecting rod and the connecting rod cap is produced by fracturing. The connecting rod assembly must be handled with care in order to avoid damage to the mating surfaces. The connecting rod assembly must be replaced if any damage occurs to the mating surfaces. New connecting rod assemblies come with the connecting rod caps bolted on the connecting rod.Use only a soft jawed vise to hold the connecting rod assembly when removing the connecting rod cap bolts. Use only a soft faced hammer to tap the connecting rod cap when separating the connecting rod cap from the connecting rod.Failure to use a soft jawed vise and a soft faced hammer may result in damage to the connecting rod assembly.
Always use new connecting rod bolts during the installation of connecting rod assemblies that have fractured joints. Never reuse connecting rod bolts during the reassembly of fractured joint connecting rods.Reusing connecting rods bolts during reassembly of fractured joint connecting rods may result in engine damage.
Ensure that the fractured joints of the connecting rod are clean prior to installation. Use compressed air or a wire brush to clean the joints.
Apply clean engine oil to the pistons, the piston rings, and the cylinder bore.
Illustration 1 g00634923
Position the piston rings so that the end gaps are located 120 degrees from each other. Install Tooling (A) in order to compress the piston rings.
With the number one crankshaft throw at the bottom center, install the piston and connecting rod in the engine. Ensure that the proper piston and connecting rod are in the corresponding cylinder with the bearing retainer notch toward the right side of the engine. The etched number on the connecting rod must be positioned on the right side of the engine.
Line up the piston and the connecting rod with the crankshaft. Use a soft faced hammer and tap the piston into the cylinder bore until Tooling (A) comes off of the piston.
Illustration 2 g01062853
Before connecting rod (1) comes in contact with the crankshaft, install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting rod (1).
Apply clean engine oil to the surface of the upper half of connecting rod bearing (4). Use a soft faced hammer in order to tap the piston into the cylinder bore while you guide connecting rod (1) onto the crankshaft.
Place the lower half of connecting rod bearing (5) in corresponding connecting rod cap (3). Ensure that the bearing tab engages with the groove in connecting rod cap (3).
Apply clean engine oil to the surface of the lower half of connecting rod bearing (5). Install connecting rod cap (3) on connecting rod (1). Ensure that the number on connecting rod cap (3) matches the number on connecting rod (1). Ensure that the numbers are on the same side.
Apply Tooling (B) to the new connecting rod bolts.
Install new connecting rod bolts (2). Tighten connecting rod bolts (2) to a torque of 70 5 N m (52 4 lb ft).
Place an index mark on each connecting rod bolt. Tighten each connecting rod bolt (2) for an additional 120 5 degrees (1/3 turn). End By:
Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".