Suzuki: Engine K6A-YH6. Manual - part 16

7-18

REPAIR

7

Installation

See Figures 7-44 and 7-45.

Figure 7-44

1.

Clean cam cover and cylinder head gasket surfaces.

2.

Install new gasket (1) to cam cover (2).

Figure 7-45

3.

Apply Three Bond™ 1215 to locations (3, 4, 5, and 6) 
as shown.

4.

Install cam cover and cap screws. (See “Cam Cover 
Torque Sequence” on page 7-18.)

Cam Cover Torque Sequence

See Figure 7-46.

Figure 7-46

1.

Tighten cap screws (1 through 6) in sequential order 
as shown. Torque cam cover cap screws at 
increments of 32 lb-in. (3.6 N•m), until specification is 
reached.

Cam Cover Cap Screws Torque: 96 lb-in. (11 N•m)

2.

Install PCV valve. (See “PCV Valve” on page 7-4.)

3.

Install spark plugs. (See “Spark Plugs” on page 7-8.)

4.

Install ignition coils. (See “Ignition Coils” on 
page 7-8.)

Required Materials

Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or 
equivalent

TN0725

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TN0366

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TN0554

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REPAIR

7-19

7

Camshafts

NOTICE

Removal

See Figures 7-47 and 7-48.

1.

Remove ignition coils. (See “Ignition Coils” on 
page 7-8.)

2.

Remove spark plugs. (See “Spark Plugs” on 
page 7-8.)

3.

Remove PCV valve. (See “PCV Valve” on page 7-4.)

4.

Remove cam cover. (See “Cam Cover” on 
page 7-17.)

5.

Remove crankshaft pulley. (See “Crankshaft Pulley” 
on page 7-37.)

6.

Remove idler pulley. (See “Idler Pulley” on 
page 7-38.)

7.

Remove oil pan. (See “Oil Pan” on page 7-30.)

8.

Remove front cover. (See “Front Cover” on 
page 7-12.)

9.

Remove timing chain. (See “Timing Chain” on 
page 7-14.)

Figure 7-47

Figure 7-48

IMPORTANT

Mark the camshaft timing gear faces to easily 
distinguish between intake and exhaust.

Take note of camshaft housings, location and 
orientation to aid in assembly.

10. Loosen the camshaft housing bolts in sequence as 

shown in figure 7-47.

11. Remove camshaft housings (14). Note the locations 

and orientation using the stamped markings.

• The “I” or “E” markings (12) refer to intake or exhaust 

side camshaft.

• The numerical markings (13) refer to the cylinder the 

housing corresponds with. The cylinders are 
numbered 1—3, starting from the timing chain 
moving toward the rear of engine.

• The arrow marking (15) points toward the timing 

chain (front of engine).

12. Remove the intake and exhaust camshafts. Inspect 

camshafts for signs of wear or damage. Replace as 
needed.

Remove camshaft housing cap screws using 
illustrated sequence. Incorrect removal can result 
in damaged camshafts.

When removing camshaft housings, camshafts, 
shims, and tappets, be sure to note location and 
orientation of all parts to aid in assembly.

Failure to install parts properly can result in 
engine damage and failure.

TN0409

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TN0416

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7-20

REPAIR

7

Inspection

See Figures 7-49 through 7-52.

IMPORTANT

Tappets and shims must be removed before 
measuring camshaft bearing clearance.

Be sure to note location and shim thickness of each 
tappet.

Figure 7-49

1.

Remove twelve tappets with shims. Be sure to note 
location and shim thickness of each tappet.

2.

Clean the camshaft journals and housings free of all 
oil.

3.

Tear off a piece of Plastigage as long as the full 
bearing width. (Tear through both the envelope and 
plastic thread at the same time.) Lay the piece of 
Plastigage across the full width of the lower bearing 
shell about 1/4 in. (6.3 mm) off center.

Figure 7-50

IMPORTANT

Do not turn camshaft during oil clearance 
measurement process.

Be sure dowel pins are properly aligned before 
installing camshaft housings.

4.

Install the camshaft housings. Apply engine oil to cap 
screws and tighten using sequence (1 through 11) at 
increments of 32 lb-in. (3.6 N•m) until specification is 
reached. Do not turn camshaft during measurement 
process.

Cam Housing Cap Screw Torque: 97 lb-in. (11 N•m)

Figure 7-51

5.

Remove cap screws and camshaft housings in 
opposite sequence of installation. The flattened 
Plastigage (12) will adhere to either the bearing shell 
or the camshaft.

6.

Using the supplied scale (13), take the measurement 
at the widest point of gauging plastic.

Camshaft Oil Clearance Standard: 0.002—0.003 in. 
(0.045—0.087 mm)

Camshaft Oil Clearance Limit: 0.004 in. (0.10 mm)

Required Tools and Materials

Plastigage™ Clearance Indicator

Micrometer

Inside Bore Gauge

TN0414

TN0409

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TN0410

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REPAIR

7-21

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Figure 7-52

7.

If the oil clearance exceeds the limit, remove the 
camshaft and retighten the camshaft housing to 
specification.

Cam Housing Cap Screw Torque: 97 lb-in. (11 N•m)

8.

Using a micrometer and bore gauge, measure the 
camshaft journal outside diameter (14) and the 
journal bore diameter (15).

If the measurement is beyond the standard range, 
either the camshaft or cylinder head must be 
replaced.

Camshaft Journal Outside Diameter: 0.903—0.904 
in. (22.934—22.955 mm)

Camshaft Journal Inside Diameter: 0.905—0.906 in.
(23.000—23.021 mm)

Cam Timing Sprocket

See Figure 7-53.

Figure 7-53

Inspect the camshaft timing sprockets (1) for wear and 
damage. If any abnormal condition is noted, replace the 
sprocket.

Camshaft Housing Bearing Face

See Figure 7-54.

Figure 7-54

Inspect the camshaft housing bearing face for pitting, 
melting, and seizure. If any abnormal condition is found, 
replace the cylinder head.

TN0411

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TN0505

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TN0408

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