09181-16008 Suzuki WASHER (16X24X2.0)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-6684 Piston Ring Compressor 1
B 8T-3052 Degree Wheel 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.
Thoroughly clean all of the components.
Lubricate the piston and the cylinder liner with clean engine oil.
Rotate the crankshaft until the connecting rod journal is at the bottom center. Lubricate the connecting rod journal with clean engine oil.
Align the tab on the connecting rod bearing with the tab groove on the connecting rod. Install the upper connecting rod bearing in the connecting rod.
Lubricate the bearing for the upper connecting rod journal with clean engine oil.
Align the piston rings on the piston so that the distance between the gaps is 120 degrees.
Illustration 1 g00550602
Install Tooling (A) on the piston. Note: Ensure that Tooling (A) is installed correctly and that the piston can easily slide out of the tool.Note: The arrow or the "FRONT" mark that is on the top of the piston must be toward the front of the engine.
Carefully push the piston and the connecting rod assembly into the cylinder liner and onto the connecting rod journal.
Align the tab on the connecting rod bearing with the tab groove on the connecting rod cap. Install the connecting rod bearing in the connecting rod cap.
Lubricate the lower connecting rod bearing with clean engine oil.
Illustration 2 g00778087
Put connecting rod cap (5) in position and install new bolts (4) that fasten the connecting rod cap to the connecting rod. Tighten the connecting rod cap bolts to a torque of 48 N m (35 lb ft). Note: Do Not reuse the old bolts in order to secure the connecting rod cap.
Use Tooling (B) to achieve the correct final torque. Note: If Tooling (B) is not used, place an index mark on each bolt.
Turn the bolts for an additional 90 degrees.
Rotate the crankshaft in order to ensure that there is no binding.
Repeat Step 2 through Step 14 for the remaining piston and connecting rod assemblies.
Illustration 3 g00699985
Position oil suction tube (2) on the cylinder block.
Install bolt (3) in the main bearing cap. Install bolt (1) in the cylinder block. End By:
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
Install the lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".
Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".