09181-50006 Suzuki SHIM

4. Remove rod caps (1) from the connecting rods of these two pistons. Put tape or a piece of rubber hose over the connecting rod bolt threads to prevent damage to the crankshaft when the connecting rod and piston are removed. Push the piston up until the piston rings are above the cylinder liner. 5. Remove two pistons (2) and connecting rods.6. Do Steps 2 through 5 again to remove the other two pistons.Install Pistons
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings. 3. Put tool (A) in position on the cylinder liner as shown. Put the connecting rod and piston in position in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block.4. Push the piston into position while the connecting rod is put into position over the crankshaft. 5. Put clean engine oil on bearings, bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
6. Follow Steps 1 through 5 for the installation of the other two pistons.end by:a) install oil pumpb) install oil pan platec) install cylinder headDisassemble Pistons
start by:a) remove pistons1. Remove the rings from the piston with tool (A).2. Remove snap ring (3), piston pin (1) and connecting rod (2) from the piston.3. Remove the rod pin bearing from the connecting rod with a press and a drive plate and handle from tool group (B) that will fit the outside diameter of the bearing.4. Clean the piston ring grooves on old piston with tool (C) before new rings are installed. See SPECIAL INSTRUCTIONS Form No. GMG02394 and GMG02395 for information about the inspection and reconditioning of connecting rods. Also see the GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001.Assemble Pistons
1. Install a new rod pin bearing in the connecting rod with a press and a drive plate and handle from tool group (B) that will fit the outside diameter of the bearing. Use a pin boring machine to make the bearing the correct size. The bore in the bearing (new) must be 1.5017 .0003 in. (38.143 0.008 mm). The maximum permissible clearance between the bearing and piston pin (worn) must not be more than .003 in. (0.08 mm). 2. Install the connecting rod with the bearing tab groove (2) and number identification on the same side as the "V" mark (1) on top of the piston.3. Install the top piston ring that has the mark "UP-1" in the top groove of the piston with tool (A). Make sure the mark is toward the top of the piston.4. Install the intermediate piston ring that has the mark "UP-2" in the middle groove of the piston with tool (A). Make sure the mark is toward the top of the piston.
Install the oil ring with the gap in the spring 180° away from the gap in the ring.
5. Install the oil ring in the piston with tool (A).6. Check the clearance between the piston ring grooves and the rings. The maximum permissible clearance between all of the rings and piston grooves must not be more than .006 in. (0.15 mm). The clearance between the top ring (new) and groove must be .0028 to .0046 in. (0.071 to 0.117 mm). The clearance between the center ring (new) and groove must be .0023 to .0041 in. (0.058 to 0.104 mm). The clearance between the oil ring (new) and groove must be .0015 to .0035 in. (0.038 to 0.089 mm). Make sure all of the ring gaps are 90° apart before the pistons are installed.end by:a) install pistons