Suzuki: Engine K6A-YH6. Manual — part 10
5-4
TESTS AND ADJUSTMENTS
5
IMPORTANT
The check and adjustment must be performed when
engine is cold.
Continue turning the crankshaft so that each
different cam lobe will point away from the shim face
successively. Measure each valve clearance at this
position. (All the valve clearances can be measured
during two complete turns of crankshaft.)
Valve clearance and adjustment may be done in pairs
(Example: #1 Intake valves, then #2 Intake valves,
and so on.)
The valve clearance measurement must be
performed with the timing chain installed in place.
Figure 5-8
3.
When the cam lobe (2) to be checked points 180°
away from the shim face, measure the clearance
between the camshaft and shim using a feeler gauge
(3).
4.
Check measurement against valve clearance
specification.
5.
Perform adjustment procedure if valve clearance is
out of specification.
Adjustment
Figure 5-9
1.
If the valve clearance is out of specification, adjust it
by replacing the shim (1).
2.
Ensure that the valve is closed for the shim being
adjusted and turn the tappet to bring its cutaway (2)
inward.
3.
Turn the crankshaft to open the valve needing
adjustment.
Figure 5-10
4.
Remove the camshaft housing cap screws (3).
NOTE
The special tool stamped with “IN” must be used for
intake camshaft and tool with “EX” for exhaust camshaft.
Check that the special tool is not pushing on the shim.
5.
Attach the special tool (4) with the camshaft housing
cap screws. Torque to specification.
Tightening Torque: 97 lb-in. (11 N•m)
Required Tools
Tappet Holder: Jacobsen PN 4139726
TN0360
180
°
2
3
TN0361
2
1
TN0362
3
4
TESTS AND ADJUSTMENTS
5-5
5
Figure 5-11
6.
Turn the camshaft clockwise until the cam lobe is
180° away from the tappet and remove the shim (5)
from the tappet by lifting at the cutaway.
Figure 5-12
7.
Measure the thickness of the removed shim, and
determine the required thickness of the new shim
using the following equation:
IMPORTANT
If the value “A” equals an odd number, use a shim
0.01 smaller than “A” value.
Shim Selection Chart
TN0363
5
TN0364
A = B + (C – 0.20 mm)
Where
A
: Required thickness of new shim (mm)
B
: Thickness of removed shim (mm)
C
: Valve clearance measured (mm)
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
5-6
TESTS AND ADJUSTMENTS
5
NOTE
Install the shim with its size marking facing tappet.
8.
Install the selected shim with its stamped number
facing tappet side.
Figure 5-13
IMPORTANT
If the crankshaft is turned in the normal direction
(turning the cam lobe clockwise), the valve may
possibly hit the piston head.
9.
Turn camshaft counterclockwise until cam lobe has
fully opened the valve.
10. Remove special tappet tool and reinstall cam
housing cap screws.
11. Tighten the camshaft housing cap screws to
specification
Camshaft Housing Cap Screws Torque: 97 lb-in.
(11 N•m)
NOTICE
Installation Note
For installation procedure, reverse the sequence of
removal.
Cylinder Compression Test
1.
Warm up the engine.
2.
Stop the engine, remove all the spark plugs and
disconnect the cam angle sensor coupler.
Figure 5-14
3.
Install the special tools (1, 2, and 3) to the spark plug
hole being checked.
4.
With the throttle fully open, operate the starter motor
and check the maximum reading on the compression
gauge.
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
Part Number
Stamped
Number
Thickness
(mm)
TN0365
6
After completing the valve clearance adjustment,
check the clearance again to make sure it is
within the specification.
Required Tools
Compression Gauge Set: Suzuki PN 09916-67011 or
Equivalent
Compression Gauge Hose: Suzuki PN 09915-64530
or Equivalent
Compression Gauge Hose Attachment B: Suzuki PN
09915-64550 or Equivalent
1
Compression
Gauge Set
3
Compression Gauge Hose
Attachment
2
Compression
Gauge Hose
TN0537
3
1
2
TESTS AND ADJUSTMENTS
5-7
5
NOTICE
5.
Carry out steps 3 and 4 above on all the cylinders.
6.
If the compression pressure is lower than the limit,
check that the special tool is properly installed. If the
installed condition is correct, the possible cause may
be compression leak from piston ring or valve.
7.
After completing the inspection, install the spark
plugs and connect cam angle sensor.
5.4 Lubrication System
Oil Pressure Test
See Figures 5-15 through 5-17.
1.
Check that the following items are satisfactory.
•
Oil Level
Refill
•
Oil Contamination
Replace
•
Oil Leakage
Repair
Figure 5-15
2.
Remove the oil pressure sending unit from the
cylinder block. (See “Oil Pressure Sending Unit” on
page 7-32.)
3.
Install the special tools (1 and 2) into the oil pressure
sending unit hole.
4.
Warm up the engine.
Figure 5-16
5.
Raise engine speed to 4000 rpm and measure the oil
pressure on the gauge (3).
Oil Pressure—Minimum at 4,000 rpm: 40 psi
(276 kPa)
6.
If the oil pressure measurement is out of
specification, check the oil pump and oil filter.
Compression Pressure at 400 rpm
Standard:
psi
kPa
(kgf/cm²)
178.4
1,230
(12.5)
Service limit
psi
kPa
(kgf/cm²)
134.9
930
(9.5)
Difference
Between
Cylinders
Maximum
psi
kPa
(kgf/cm²)
14.2
98
(1.0)
If the specified speed (400 rpm) is not attainable
due to lowered battery voltage, recharge the
battery and carry out the inspection again.
Required Tools
Oil Pressure Gauge: Suzuki PN 09915-77311 or
Equivalent
Oil Pressure Gauge Attachment: Suzuki PN
09915-78211 or Equivalent
TN0536
1
2
TN0353
3
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