15644-93J00 Suzuki COVER, FUEL FILTER

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A (13)     9U-6198     Crankshaft Turning Tool     1    
A (2)     9U-7336     Housing     1    
5P-7305 Engine Turning Tool     1    
B     8T-3052     Degree Wheel     1    
C     383-1654     Spacer     1    
( 13 ) The Crankshaft Turning Tool is used on the front pulley.
( 2 ) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Discard all used connecting rod bolts.
Inspect the pins of the crankshaft for damage. If the crankshaft is damaged, replace the crankshaft or recondition the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove" and Disassembly and Assembly, "Crankshaft - Install". Ensure that the connecting rod bearings are clean and free from wear or damage. If necessary, replace the connecting rod bearings.
Illustration 1 g01260354
Illustration 2 g01001160
Aligning the bearing in the center of the connecting rod
Clean the connecting rod (2) . Position Tooling (C) onto connecting rod (5) .
Install the upper half of connecting rod bearing (4) to connecting rod (5) . Ensure that the bearing is centralized in the connecting rod. Refer to Illustration 2. Remove Tooling (C) .The ends of the bearing must be centered in the connecting rod. The ends of the bearing must be equally positioned in relation to the faces of the connecting rod.
Clean the connecting rod cap (2) . Position Tooling (C) onto connecting rod cap (2) .
Install lower connecting rod bearing (3) to connecting rod cap (2) . Ensure that the connecting rod bearing is centralized in the connecting rod cap. Refer to Illustration 2. Remove Tooling (C) .The ends of the lower connecting rod bearing must be centered in the connecting rod cap. The ends of the lower connecting rod bearing must be equally positioned in relation to the faces of the connecting rod cap.
Lubricate upper connecting rod bearing (4) with clean engine oil.
If necessary, use Tooling (A) in order to rotate the crankshaft until the crankshaft pin is at the bottom dead center position.
Carefully pull connecting rod (5) against the crankshaft pin.Note: Do not allow the connecting rod to contact the piston cooling jet.
Lubricate the pin of the crankshaft and lubricate lower connecting rod bearing (3) with clean engine oil.
Illustration 3 g01479452
Typical example
Install connecting rod cap (2) to connecting rod (5) .Note: Ensure that etched Number (X) on connecting rod cap (2) matches etched Number (X) on connecting rod (5) . Ensure the correct orientation of the connecting rod cap. The forged Marks (Y) on the connecting rod and the connecting rod cap should be on the same side. Refer to Illustration 1.
Install new bolts (1) . Tighten the bolts evenly to a torque of 18 N m (13 lb ft).Note: Do not reuse the old bolts in order to secure the connecting rod cap.
Tighten the bolts evenly to a torque of 40 N m (30 lb ft).
Use Tooling (B) to turn the bolts through an additional 120 degrees.
Ensure that the installed connecting rod assembly has tactile side play. Carefully rotate the crankshaft in order to ensure that there is no binding.
Repeat Step 2 through Step 14 for the remaining connecting rod bearings.Note: If all connecting rod bearings require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3. Ensure that both pairs of the connecting rod bearings are installed before changing from one pair of cylinders to another pair of cylinders.
If the glow plugs were removed, install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Install".End By: If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, "Balancer - Install". If the engine is not equipped with a balancer, install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove and Install".