Suzuki K6A-YH6 User manual

Suzuki K6A-YH6 Engine
Technical/Repair Manual
WARNING: If incorrectly used this machine can cause severe injury. Those
who use and maintain this machine should be trained in its proper use,
warned of its dangers and should read the entire manual before attempting to
set up, operate, adjust or service the machine.
!
©2007 Jacobsen, A Textron Company. All rights reserved.
When Performance Matters.
™

3
Foreword
General
This manual provides detailed information and
procedures to safely repair and maintain the following:
Suzuki K6A-YH6 gasoline engine
This manual is intended to introduce and guide the user
through the latest factory-approved troubleshooting and
repair techniques and practices.
Before you attempt to troubleshoot or make repairs, you
must be familiar with the operation of this engine. Refer to
the operator’s manual and parts manual for specific
information on these topics.
THE INFORMATION CONTAINED IN THIS MANUAL IS
BASED ON ENGINES MANUFACTURED UP TO THE
TIME OF PUBLICATION. JACOBSEN RESERVES THE
RIGHT TO CHANGE ANY OF THIS INFORMATION
WITHOUT NOTICE.
CALIFORNIA
Proposition 65 Warning
!
WARNING
Trademark Acknowledgement
Jacobsen acknowledges the following trademarks for
company names or products mentioned within this
publication:
Jacobsen® is a registered trademark of Textron Inc.
Suzuki® is a registered trademark of the
American Suzuki Motors Corporation
ThreeBond™ is a trademark of the ThreeBond Co., Ltd.
Plastigage® is a registered trademark of AE Clevite Inc.
Certain vehicle components contain or emit
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.

4
FOREWORD
How to Use This Manual
This manual is designed to provide multiple ways to
locate and access repair information.
Read each section in entirety before beginning a
procedure. Proper understanding of machine operation
and components is the key to successful diagnostics and
repair.
Make use of special information features with in this
manual in order to be better prepared to perform repairs.
Always follow manual procedures and safety guidelines.
Never take shortcuts.
Table of Contents
Major machine components or topics of interest are
separated into specific chapters. Each manual lists these
chapters in a main Table of Contents.
Chapter Table of Contents
Each chapter begins with a detailed Table of Contents
related to the specific machine component or system.
Use the Chapter Table of Contents to find specific
component or procedural information.
Index
An alphabetical Index is located at the back of the
manual.
Use the Index to find specific components and related
procedures.
Required Tools and Materials
Some procedures will require the use of specific tools
and/or materials. These tools and/or materials will be
listed for reference, prior to beginning a procedure.
Specifications
Specifications are listed at the point of use with in the
procedure.
Quick Reference Specifications
A list of all machine specifications can be found in
Chapter 2 Specifications and General Information. This is
a list of all specifications from each chapter, combined
and listed in one place for easy reference.
Warnings and Cautions
Warning and Caution indicators are located throughout
the manual at specific points of interest. These notices
are given to prevent personal injury, death and/or
equipment damage. Always heed these notices, and
practice common sense when performing any
maintenance or repair procedure.
Notes
Special notes are given in order to draw attention to
detailed instructions. These notes are intended to give
further important information regarding the machine
and/or a step in a procedure.
Troubleshooting
Troubleshooting charts are provided in chapter 6 to aid in
the diagnostic process. Use these suggestions to aid in
identifying a potential mechanical or machine adjustment
problem.
Copyright 2007 Textron Inc.
“All rights reserved, including the right to reproduce this material or portions thereof in any form.”

2
3
4
5
6
7
8
Table of Contents
5
1
Safety
Specifications and
General Information
Maintenance
Theory of Operation
Test and Adjustments
Diagnostic Troubleshooting
Repair
Tools and Materials

1-1
Chapter 1
1
Safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Prepare for the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Keep Work Area Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Keep Work Area Well Ventilated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Use Proper Eye and Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Use Lifting Equipment Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Use Compressed Air and Air Tools Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Handle Fuel Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Store Volatile and Hazardous Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Handle Chemical Products Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Service Electrical Components Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Dispose of Waste Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-2
SAFETY
1
Page Intentionally Blank

SAFETY
1-3
1
Introduction
Safety is the most important element of any repair
procedure. Knowledge of the procedure to be performed
and safe work habits are essential to preventing death,
personal injury, or property damage. Use the following
statements as a common-sense guide to proper work
and tool-use habits.
Prepare for the Job
Preparation is essential to complete a procedure in a
safe and efficient manner.
• Wear proper clothing. Loose or baggy clothing could
become tangled in moving parts.
• Use eye/face protection. Always use proper eye/face
protection to protect your eyes from flying debris or
chemical splatters.
• Wear protective footwear. Wear safety shoes
(steel-toe) to protect your feet from falling objects.
• Use gloves when handling parts. Parts may have
sharp edges or may be hot.
• Remove jewelry prior to servicing electrical systems.
• Prepare proper tools and equipment. Always use the
correct tool for the job. Improper or homemade tools
can cause injury or machine damage.
• Prepare needed parts and materials. Gather the
needed parts and materials before beginning the
procedure.
• Allow machine to cool. Many components can get hot
during operation. Be sure to allow enough time for
components to cool before beginning service.
• Prepare proper work-space lighting. A well-lit work
area can make the job easier.
• Follow procedures and safety warnings. Service
procedures are written to be as safe and efficient as
possible. Never take shortcuts.
• Be prepared for emergencies. Accidents can happen,
even under the best conditions. Fire extinguishers
and first aid kits should be well maintained and easily
accessible.
Safety Notices
Throughout this manual, the following key safety words
will be used to alert the reader of potential hazards.
Become familiar with these words and their meaning.
Take all precautions to avoid the hazards described.
!
DANGER
!
WARNING
!
CAUTION
NOTICE
Keep Work Area Clean
A clean, organized, well lit work area is important to
promote safe working conditions.
• Keep floor clean of debris and clear of parts and
tools.
• Clean up any spilled fuel, oil, and/or chemicals
immediately.
• Store all air hoses and electrical cords properly when
not in use.
This safety alert symbol is used to
alert you to potential hazards.
Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or
serious injury.
Indicates a potentially hazardous situation which,
if not avoided, COULD result in death or serious
injury.
Indicates a potentially hazardous situation which,
if not avoided, MAY result in minor or moderate
injury and property damage. It may also be used
to alert against unsafe practices.
Indicates a potentially hazardous situation which,
if not avoided, MAY result in property damage. It
may also be used to alert against unsafe
practices.
!

1-4
SAFETY
1
Keep Work Area Well Ventilated
!
WARNING
Certain test and adjustment procedures require the
engine to be running. Be sure work area is well
ventilated; never run the engine in an enclosed area.
Use Proper Eye and Face
Protection
!
WARNING
Always wear eye protection while in a shop environment.
• Safety Glasses: Safety glasses offer a minimum level
of protection from flying debris.
• Face Shields: Face shields are often used along with
safety glasses to offer a higher level of protection
when sparks and flying debris are present.
• Vented Goggles: Goggles offer side protection not
offered by safety glasses alone.
• Unvented Goggles: Unvented goggles offer
protection from chemical splashes and vapors.
Use Lifting Equipment Safely
!
WARNING
• Always use a lifting device with a lifting capacity
greater than the weight of the item being lifted.
• Secure the load to the lifting device using cables,
chains, or slings rated to handle the load being lifted.
Fasteners being used to connect lifting devices must
be strong enough to handle the load. Also be sure
the mounting point of load is strong enough to handle
the load.
• When using a lifting device, always connect the load
so it is balanced.
• Always use a lifting device on a hard, level surface.
• Lower the lifting device to the lowest point before
moving. Move the load slowly.
• Always support the load as soon as possible; never
leave a load suspended in mid-air.
Use Compressed Air and Air
Tools Safely
!
WARNING
• Compressed air is a useful tool when used in a safe
manner.
• Always use eye and ear protection while using
compressed air and air tools.
• When using air tools, do not exceed the air pressure
rating for the tool.
• When using an impact wrench, always use approved
impact sockets. Never use standard sockets on an
impact wrench.
• Disconnect the air supply before changing air tool
attachments.
• Never point air nozzles or air tools at another person.
• Always maintain air tools properly.
Never operate the engine without proper
ventilation; exhaust fumes can be fatal if inhaled.
Always use approved personal protection
equipment. Avoid workplace hazards by wearing
properly maintained, approved eye and face
protection. Failure to use appropriate protection
equipment may result in death or serious injury.
Always check the lifting capacity and condition of
hoists, slings, cables, or chains before use.
Using underrated or worn lifting components can
result in death or serious injury.
Always wear approved eye and ear protection
while using compressed air. Misuse of
compressed air could result in death or serious
injury.
• When using air nozzles, air pressure should
not exceed 30 psi (206.8 kPa).
• Never direct air nozzles or tools at a person.
• Never point air nozzles directly at skin.

SAFETY
1-5
1
Handle Fuel Safely
Handle fuel with care—it is highly flammable.
!
WARNING
Store fuel according to local, state, or federal ordinances
and recommendations from your fuel supplier.
Never overfill or allow the tank to become empty.
Use clean, fresh fuel.
Do not fill above the fuel filler neck.
Store Volatile and Hazardous
Materials Safely
Store volatile materials (gasoline, diesel fuel, oil, etc.) in
approved containers that are clearly marked. Containers
should be stored in an approved safety cabinet away
from possible sources of ignition. Storage areas and
cabinets should be well ventilated to prevent the possible
build-up of fumes.
Handle Chemical Products
Safely
!
WARNING
Routine service often requires the use of various
chemical products, including lubricants and cleaning
solutions. Many of these chemicals are flammable and
can pose health risks if not handled properly.
• Never mix chemicals. Mixing chemicals can produce
toxic or explosive results.
• Follow the manufacture’s recommendations for safe
usage and handling of the product.
• Various materials may pose a health hazard if used
incorrectly. A Material Safety Data Sheet (MSDS)
contains important information regarding proper
handling and health hazards, as well as emergency
response procedures. Contact the chemical
manufacturer to obtain an MSDS for the chemical
product.
Service Electrical Components
Safely
!
WARNING
• Disconnect the battery negative (–) cable before
removing or installing electrical components. Always
connect the battery negative (–) cable last.
• Certain test and adjustment procedures must be
performed with the battery connected. Use care to
prevent arcing when working on live circuits or
components. Arcing can cause component damage
and could ignite flammable materials.
• Never remove the fuel cap from the fuel tank,
or add fuel, when the engine is running or
while the engine is hot.
• Do not smoke when handling fuel. Never fill
or drain the fuel tank indoors.
• Do not spill fuel. Clean spilled fuel
immediately.
• Never handle or store fuel containers near an
open flame or any device that may create
sparks and ignite the fuel or fuel vapors.
• Be sure to reinstall and tighten fuel cap
securely.
• Use an approved container; the spout must fit
inside the fuel filler neck. Avoid using cans
and funnels to transfer fuel.
Exposure to chemical products could result in
serious injury. Handle chemical products with
care. Refer to the chemical manufacturer’s
Material Safety Data Sheet (MSDS) for information
regarding health hazards, safe handling, and
emergency response procedures.
Always disconnect the negative terminal first and
positive terminal last. Connect positive terminal
first and negative terminal last. Use care when
testing live circuits to prevent arcing. Arcing
could result in death or serious injury.

1-6
SAFETY
1
Dispose of Waste Materials
Safely
Routine service can produce waste products such as
used oil, grease, and used batteries.
If not handled properly, these materials can pose a threat
to the environment.
Collect fluids in well-marked, approved storage
containers. Some waste fluids can react with certain
types of plastics. Make sure the fluid to be stored is
compatible with the storage container. Never use food or
beverage containers to store waste fluids.
IMPORTANT
• Dispose of waste fluids properly at approved local
recycling centers. If recycling facilities are not
available, contact your local community for the
correct disposal procedure for waste fluids.
• Dispose of old batteries properly. Battery electrolyte
contains sulfuric acid and other hazardous materials.
Never place an old battery in the trash. Batteries
must be disposed of in a manner consistent with EPA
and/or local regulations.
Never dispose of waste fluids by pouring on the
ground, down sewer drains, or into any body of
water.

2
2-1
Chapter 2
Specifications and General Information
2.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cylinder Numbering and Engine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Optional Engine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Engine Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Standard Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2 Air Intake and Exhaust System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Fuel System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5 Cooling System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6 Front Cover, Timing Chain, and Tensioner Specifications . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.7 Cylinder Head, Cams, and Valve Train Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Tappet Shim Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.8 Lubrication System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.9 Cylinder Block, Lower Crankcase, and Crankshaft Specifications . . . . . . . . . . . . . . . 2-10
Oversize Main Bearing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-2
SPECIFICATIONS AND GENERAL INFORMATION
2
2.1 General Specifications
Engine Identification
Model and Serial Number
See Figure 2-1.
K6A
The Suzuki K6A is a 3-cylinder, fuel injected, dual
overhead cam, liquid cooled, gas powered engine.
Figure 2-1
An identification number, like the one shown, is stamped
into the cylinder block, and is also written on the fuel rail.
The engine model number (1) is displayed first, followed
by the engine serial number (2).
Always provide the engine model and serial numbers
when ordering replacement parts or requesting service
information.
Cylinder Numbering and Engine
Orientation
Procedures within this manual refer to specific cylinder
numbers. The cylinders are numbered 1 through 3,
starting closest to the timing chain and moving toward the
flywheel.
Procedures within this manual refer to the front and rear
of the engine. Use the following guidelines when the front
and rear of the engine are referenced:
The timing chain side of the engine is considered the
front of the engine.
The flywheel side of the engine is considered the rear of
the engine.
Optional Engine Accessories
This manual is structured to cover all basic engine
components and repair. The addition of certain
accessories can affect troubleshooting, adjustment, and
repair procedures.
Refer to machine parts and maintenance manual for
specific information pertaining to accessory
troubleshooting, removal, repair, and installation
procedures.
TN0694
12

SPECIFICATIONS AND GENERAL INFORMATION
2-3
2
Engine Component Locations
See Figures 2-2 through 2-5.
Figure 2-2
Figure 2-3
Figure 2-4
Figure 2-5
1 Oil Fill 3 Thermostat Housing
2 Fuel Injectors 4 Ignition Coils
5 Cam Cover 7 Exhaust Manifold
6 Cylinder Block/Lower
Crankcase
TN0690
1
2
3
4
TN0691
56
7
8 Throttle Body 11 Crankshaft Pulley
9 Cylinder Head 12 Water Pump
10 Intake Manifold
13 Oil Pan 16 Front Cover
14 Idler Pulley 17 Fuel Rail
15 Dipstick 18 Oil Filter
TN0692
8
910
11
12
TN0693
13
14
15
17
16
18

2-4
SPECIFICATIONS AND GENERAL INFORMATION
2
Engine Information
Item Unit Specification
Type K6A Normally Aspirated
Number of Cylinders and
Arrangement In-line 3-Cylinder Transversely Mounted
Combustion Chamber Shape Pent-Roof Type
Valve Mechanism Twin Cam, 4-Valve, Chain Driven
Engine Displacement cu in. (cc) 40 (658)
Bore x Stroke in. (mm) 2.68 x 2.38 (68.0 x 60.4)
Compression Ratio 10.5
Cylinder Identification 1-2-3 from Timing Chain toward Flywheel
Firing Order 1-3-2
Maximum Output @ Engine Speed hp/rpm 44 at 5000 (net)
Maximum Torque @ Engine Speed b-ft/rpm 45.7 at 4000 (net)

SPECIFICATIONS AND GENERAL INFORMATION
2-5
2
Standard Torque Values
Inch Fastener Torque Values
Metric Fastener Torque Values
NOTICE
NOTE
Jacobsen uses Grade 5 plated bolts as standard, unless
otherwise noted. When tightening plated bolts, use the
value given for lubricated.
All torque values included in these charts are
approximate and are for reference only. Use of
these torque values is at your sole risk. Jacobsen
is not responsible for any loss, claim, or damage
arising from the use of these charts.
Extreme caution should always be used when
using any torque value.
AMERICAN NATIONAL STANDARD FASTENERS
SIZE UNITS GRADE 5 GRADE 8 SIZE UNITS GRADE 5 GRADE 8
Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry
#6-32 in-lb (Nm) – 20 (2.3) – – 7/16-14 ft-lb (Nm) 37 (50.1) 50 (67.8) 53 (71.8) 70 (94.9)
#8-32 in-lb (Nm) – 24 (2.7) – 30 (3.4) 7/16-20 ft-lb (Nm) 42 (56.9) 55 (74.6) 59 (80.0) 78 (105)
#10-24 in-lb (Nm) – 35 (4.0) – 45 (5.1) 1/2-13 ft-lb (Nm) 57 (77.2) 75 (101) 80 (108) 107 (145)
#10-32 in-lb (Nm) – 40 (4.5) – 50 (5.7) 1/2-20 ft-lb (Nm) 64 (86.7) 85 (115) 90 (122) 120 (162)
#12-24 in-lb (Nm) – 50 (5.7) – 65 (7.3) 9/16-12 ft-lb (Nm) 82 (111) 109 (148) 115 (156) 154 (209)
1/4-20 in-lb (Nm) 75 (8.4) 100 (11.3) 107 (12.1) 143 (16.1) 9/16-18 ft-lb (Nm) 92 (124) 122 (165) 129 (174) 172 (233)
1/4-28 in-lb (Nm) 85 (9.6) 115 (13.0) 120 (13.5) 163 (18.4) 5/8-11 ft-lb (Nm) 113 (153) 151 (204) 159 (215) 211 (286)
5/16-18 in-lb (Nm) 157 (17.7) 210 (23.7) 220 (24.8) 305 (34.4) 5/8-18 ft-lb (Nm) 128 (173) 170 (230) 180 (244) 240 (325)
5/16-24 in-lb (Nm) 173 (19.5) 230 (26.0) 245 (27.6) 325 (36.7) 3/4-10 ft-lb (Nm) 200 (271) 266 (360) 282 (382) 376 (509)
3/8-16 ft-lb (Nm) 23 (31.1) 31 (42.0) 32 (43.3) 44 (59.6) 3/4-16 ft-lb (Nm) 223 (302) 298 404 315 (427) 420 (569)
3/8-24 ft-lb (Nm) 26 (35.2) 35 (47.4) 37 (50.1) 50 (67.8) 7/8-14 ft-lb (Nm) 355 (481) 473 (641) 500 (678) 668 (905)
METRIC FASTENERS
SIZE UNITS
Non-Critical
Fasteners
into
Aluminum
Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry
M4 Nm (in-lb) – – – – – – 3.83 (34) 5.11 (45) 2.0 (18)
M5 Nm (in-lb) 1.80 (16) 2.40 (21) 4.63 (41) 6.18 (54) 6.63 (59) 8.84 (78) 7.75 (68) 10.3 (910 4.0 (35)
M6 Nm (in-lb) 3.05 (27) 4.07 (36) 7.87 (69) 10.5 (93) 11.3 (102) 15.0 (133) 13.2 (117) 17.6 (156) 6.8 (60)
M8 Nm (in-lb) 7.41 (65) 9.98 (88) 19.1 (69) 25.5 (226) 27.3 (241) 36.5 (323) 32.0 (283) 42.6 (377) 17.0 (150)
M10 Nm (ft-lb) 14.7 (11) 19.6 (14) 37.8 (29) 50.5 (37) 54.1 (40) 72.2 (53) 63.3 (46) 84.4 (62) 33.9 (25)
M12 Nm (ft-lb) 25.6 (19) 34.1 (25) 66.0 (48) 88.0 (65) 94.5 (70) 125 (92) 110 (81) 147 (108) 61.0 (45)
M14 Nm (ft-lb) 40.8 (30) 54.3 (40) 105 (77) 140 (103) 150 (110) 200 (147) 175 (129) 234 (172) 94.9 (70)
4.6 8.8 10.9 12.9

2-6
SPECIFICATIONS AND GENERAL INFORMATION
2
2.2 Air Intake and Exhaust
System Specifications
2.3 Electrical Specifications
2.4 Fuel System Specifications
2.5 Cooling System
Specifications
Item Unit Specification
Intake Manifold Torque lb-in. (N•m) 97 (11)
Exhaust Manifold Torque lb-in. (N•m) 204 (23)
Intake Manifold Distortion Limit in. (mm) 0.003 (0.07)
Exhaust Manifold Distortion Limit in. (mm) 0.003 (0.07)
Intake Manifold Vacuum at Idle psi (kpa) 7.7 (53)
Item Unit Specification
Spark Plug (NGK) Jacobsen PN 4119606
Spark Plug (Denso) Jacobsen PN 2701832
Spark Plug Gap in. (mm) 0.031—0.035 (0.8—0.9)
Spark Plug Torque lb-in. (N•m) 177 (20)
Firing order 1-3-2
Ignition Timing deg. / rpm 5 ± 1 / 800
ISC Duty Ratio %5—30
O2Sensor Feedback Duty Ratio %5—95
Belt Deflection at Mid-Point with
17 ft-lb (23 N•m) of Force Applied
Alternator Belt Deflection—New in. (mm) 0.315—0.354 (8—9)
Alternator Belt Deflection
Readjustment in. (mm) 0.472—0.59 (12—15)
Item Unit Specification
Fuel Pressure psi (kPa) 43 (294)
Item Unit Specification
Thermostat Start-to-Open °F (°C) 190 (88)
Thermostat Full Open °F (°C) 205 (96)

SPECIFICATIONS AND GENERAL INFORMATION
2-7
2
2.6 Front Cover, Timing Chain,
and Tensioner Specifications
2.7 Cylinder Head, Cams, and
Valve Train Specifications
Item Unit Specification
Front Cover Torque lb-in. (N•m) 97 (11)
Item Unit Specification
Valve Clearance, Cold, Intake in. (mm) 0.007—0.009 (0.18—0.23)
Valve Clearance, Cold, Exhaust in. (mm) 0.012—0.014 (0.30—0.35)
Intake and ExhaustManifold Mating
Face Distortion Limit in. (mm) 0.000—0.002 (0.00—0.05)
Camshaft Housing Cap Screw
Torque lb-in. (N•m) 97 (11)
Camshaft Journal Outside Diameter in. (mm) 0.903—0.904 (22.934—22.955)
Camshaft Journal Inside Diameter in. (mm) 0.905—0.906 (23.000—23.021)
Camshaft Lobe Height, Intake in. (mm) 1.477—1.483 (37.520—37.680)
Camshaft Lobe Height, Exhaust in. (mm) 1.470—1.476 (37.343—37.503)
Cylinder Head/Block Mating Face
Distortion Limit in. (mm) 0.001 (0.03)
Camshaft Oil Clearance Standard in. (mm) 0.002—0.003 (0.045—0.087)
Camshaft Oil Clearance Limit in. (mm) 0.004 (0.10)
Valve Spring Tension Standard at
1.17 in. (29.9 mm) b-ft (N•m) 22—26 (100—116)
Valve Spring Tension Limit at
1.17 in. (29.9 mm) b-ft (N•m) 20 (88)
Valve Guide to Valve Stem
Clearance, Intake in. (mm) 0.0007—0.0018 (0.020—0.047)
Valve Guide to Valve Stem
Clearance Limit, Intake in. (mm) 0.002 (0.07)
Valve Guide to Valve Stem
Clearance, Exhaust in. (mm) 0.0017—0.0028 (0.045—0.072)
Valve Guide to Valve Stem
Clearance Limit, Exhaust in. (mm) 0.003 (0.09)
Tappet and Bore Clearance in. (mm) 0.0009—0.0024 (0.025—0.062)
Tappet and Bore Clearance Limit in. (mm) 0.003 (0.10)
Valve Spring Free Length in. (mm) 1.35 (34.3)
Valve Spring Right Angle Range in. (mm) 0.000—0.059 (0.00—1.5)
Cam Cover Cap Screw Torque lb-in. (N•m) 96 (11)
Cylinder Head Cap Screw Torque b-ft (N•m) 43.5 (59)

2-8
SPECIFICATIONS AND GENERAL INFORMATION
2
Tappet Shim Selection Chart
Part Number Stamped Number Thickness (mm)
4148102 218 2.18
4148103 220 2.20
4148104 222 2.22
4148105 224 2.24
4148106 226 2.26
4148107 228 2.28
4148108 230 2.30
4148109 232 2.32
4148110 234 2.34
4148111 236 2.36
4148112 238 2.38
4148113 240 2.40
4148114 242 2.42
4148115 244 2.44
4148116 246 2.46
4148117 248 2.48
4148118 250 2.50
4148119 252 2.52
4148120 254 2.54
4148121 256 2.56
4148122 258 2.58
4148123 260 2.60
4148124 262 2.62
4148125 264 2.64
4148126 266 2.66
4148127 268 2.68
4148128 270 2.70
4148129 272 2.72
4148130 274 2.74
4148131 276 2.76
4148132 278 2.78
4148133 280 2.80
4148134 282 2.82
4148135 284 2.84
4148136 286 2.86
4148137 288 2.88
4148138 290 2.90
4148139 292 2.92
4148140 294 2.94
4148141 296 2.96
4148142 298 2.98
4148143 300 3.00

SPECIFICATIONS AND GENERAL INFORMATION
2-9
2
2.8 Lubrication System
Specifications
Item Unit Specification
Oil Pump Housing Torque lb-in. (N•m) 60 (6.78)
Oil Pump Outer Rotor Side
Clearance Limit in. (mm) 0.003—0.005 (0.076—0.127)
Oil Pump Radial Clearance Limit in. (mm) 0.0004—0.006 (0.10—0.15)
Inner Rotor and Pump Case
Clearance in. (mm) 0.001—0.003 (0.025—0.076)
Oil Pump Relief Valve Spring Free
Length in. (mm) 2.063 (52.40)
Oil Pump Relief Valve Spring
Tension at 1.516 in (38.5: mm)
of Length
b-ft (N•m) 17.3 (4.44)
Oil Pressure Sending Unit Torque lb-in. (N•m) 115 (13)
Oil Pressure-Minimum at 4000 rpm psi (kPa) 40 (276)
Oil Pan Torque lb-in. (N•m) 97 (11)
Drain Plug Torque b-ft (N•m) 36 (49)
Oil Filter Torque lb-in. (N•m) 120 (13.5)
Recommended Oil Normal /
Cold Region 10W-30 (SH) / 5W-30 (SG)
Oil Capacity when Replacing
Without Filter qts (liters) 2.75 (2.6)
Oil Capacity when Also Replacing
Filter qts (liters) 2.96 (2.8)
Oil Change Interval—Normal
Conditions hours After First 35 Hours—Then Every 100 Hours or 3 Months
Oil Filter Replacement hours After First 35 Hours—Then Every 100 Hours or 3 Months

2-10
SPECIFICATIONS AND GENERAL INFORMATION
2
2.9 Cylinder Block, Lower
Crankcase, and Crankshaft
Specifications
Item Unit Specification
Lower Crankcase (M10) Cap Screw
Torque b-ft (N•m) 42 (57)
Lower Crankcase (M8) Cap Screw
Torque lb-in. (N•m) 212 (24)
Cylinder Bore Inside Diameter in. (mm) 2.6771—2.6779 (68.000—68.020)
Cylinder Bore Inside Diameter Limit in. (mm) 2.6791 (68.050)
Piston Outside Diameter in. (mm) 2.675—2.676 (67.970—67.990)
Oil Control Ring End Gap in. (mm) 0.0039—0.0157 (0.10—0.40)
Oil Control Ring End Gap Limit in. (mm) 0.047 (1.2)
Second Compression Ring End
Gap in. (mm) 0.0137—0.0196 (0.35—0.50)
Second Compression Ring End
Gap Limit in. (mm) 0.039 (1.0)
Top Compression Ring End Gap in. (mm) 0.0047—0.0106 (0.12—0.27)
Top Compression Ring End Gap
Limit in. (mm) 0.027 (0.7)
Cylinder Block Main Bearing
Journal Inside Diameter in. (mm) 1.9291—1.9298 (49.000—49.018)
Crankshaft Main Bearing Journal
Outside Diameter in. (mm) 1.770—1.771 (44.982—45.000)
Crankshaft/Cylinder Block Main
Bearing Journal Oil Clearance in. (mm) 0.0007—0.0015 (0.020—0.040)
Crankshaft/Cylinder Block Main
Bearing Journal Oil Clearance Limit in. (mm) 0.002 (0.065)
Piston Pin Outside Diameter in. (mm) 0.7084—0.7086 (17.995—18.000)
Piston Pin Bore Inside Diameter in. (mm) 0.7088—0.7092 (18.006—18.014)
Connecting Rod Small End Inside
Diameter in. (mm) 0.7087—0.7090 (18.003—18.011)
Connecting Rod Large End Inside
Diameter in. (mm) 1.6141—1.6148 (41.000—41.018)
Crankshaft Connecting Rod
Bearing Journal Outside Diameter in. (mm) 1.495—1.496 (37.982—38.000)
Crankshaft/Connecting Rod Oil
Clearance in. (mm) 0.0007—0.0015 (0.020—0.040)
Crankshaft/Connecting Rod Oil
Clearance Limit in. (mm) 0.002 (0.065)
Connecting Rod Torque b-ft (N•m) 24 (33)
Crankshaft Pulley Cap Screw b-ft (N•m) 72 (98)
Flywheel Cap Screw b-ft (N•m) 50 (69)
Knock Sensor Torque lb-in. (N•m) 203 (23)