09320-09039 Suzuki CUSHION

Start By: a. remove spacer platesb. remove piston cooling jets The front end of the engine is opposite the flywheel end. The No. 1 cylinder is the front right cylinder, and the No. 2 cylinder is the front left cylinder. Put identification marks on each piston by cylinder number. Also, mark each piston as to its respective position to the front of the cylinder block. This is done if the piston assembly is to be removed from the rod assembly.1. Remove the cover from the front right side of the flywheel housing, and use tool (A) to turn the flywheel until all four bolts in the bearing caps can be removed.2. Put identification marks on each rod assembly as to its cylinder number. The rods are to be marked at location (X) and the rod cap at location (Y). These marks are on the same sides as the bearing tab slots. 3. Remove bolts (1) and bearing cap (2) from the connecting rod. 4. Push the piston up until the piston rings are clear of the cylinder liner. Remove pistons (3) and the connecting rods. 5. Use tool (B), and remove the rings that hold piston pin (4) in position. Remove pin (4), and remove piston (3) from connecting rod (5).6. Remove the bearings from the bearing cap and connecting rod (5). 7. Use tool (C) to remove piston rings (6) from piston (3).8. Clean the piston ring grooves on the piston with an acceptable ring groove tool. See Guideline For Reusable Parts - Procedure To Clean And Inspect 3500 Series Engine Pistons, Form No. SEBF8059-01 for complete details concerning cleaning pistons.9. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295-02 for more information about removal and installation of piston pin bearings.10. Heat the connecting rod in an oven to a temperature of 175° C to 260° C (350° F to 500° F). Never use a direct flame to heat the connecting rod. 11. Put 6V3043 Spacer (14) in the base plate. Put the connecting rod on the base plate of tooling (D).12. Put the connecting rod piston pin bearing end in the center of the port assembly of tooling (D). Install pin (9) in the center of the bore for the connecting rod bearing.13. Install 5P8649 Adapter (12). Put the hole in the adapter in alignment with the hole in the base plate of tooling (D).14. Install clamp bar (13) and clamp pin (10). The old bearing is pushed out by tooling (D) as the new bearing is installed.15. Put 6V3042 Pusher Adapter (11) in position as shown with the taper side down. The piston pin bearing joint must be in alignment with the hole in adapter (12) and the base plate of tooling (D).16. Put pusher (7) on adapter (11).17. Use tooling (D) to push the new piston pin bearing (8) into the connecting rod until adapter (11) of tooling (D) makes full contact with the connecting rod surface.18. Remove the connecting rod and the old piston pin bearing from tooling (D).19. Check the piston pin bearing bore diameter after the bearing is installed. The correct dimension is 70.000 0.008 mm (2.7559 .0003 in.).Install Pistons And Connecting Rod Assemblies
1. Use tool (A) to install the oil ring on piston (1). The oil ring spring ends are 180° from the ring end gap. The white colored section of the oil ring spring must be visible at the ring end gap.2. Use tool (A) to install the two compression rings on piston (1). Install the rings with the side marked "UP" toward the top of the piston.3. The middle piston ring (lower compression) must be installed with the green color strip to the right of the ring end gap.4. The top piston ring (upper compression) must be installed with the yellow color strip to the right of the end gap.5. The three piston ring end gaps must be approximately 120° apart after installation. 6. Put clean engine oil on pin (3), the pin bearing in rod (2) and the pin bore in piston (1). Put rod (2) in position in piston (1), and install pin (3). Use tool (B) to install rings (4) on each side of pin (3).7. Install the upper half of the connecting rod bearing in the connecting rod, and put clean engine oil on it. Make sure the tab on the back of the bearing fits in the groove of the rod. 8. Put clean engine oil on the piston rings and cylinder liner bore. Use tool (D) to put the piston rings under compression, and install the pistons and connecting rods in the cylinder liners.
Make sure the piston assembly is installed with the chamfer side (X) of the connecting rod bore next to the crankshaft thrust surface. The square shouldered side (Y) of the connecting rod bore must be next to the other connecting rod on the same crankshaft journal.
9. Install the lower half of the connecting rod bearing in cap (5), and put clean engine oil on it. Make sure the tab on the back of the bearing fits in the groove of the cap.10. See the topic, Install Connecting Rod Bearings, for the procedure to install the connecting rod caps and to check the bearing clearance.11. Check the side clearance between two connecting rods on the same crankshaft journal. The side clearance must be 0.850 0.232 mm (.0335 .0091 in.).End By: a. install piston cooling jetsb. install spacer plates