Engine Mechanical: Overhaul Suzuki Aerio I

Valves and Cylinder Head Disassembly and Assembly

Reference: VALVES AND CYLINDER HEAD REMOVAL AND INSTALLATION

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1. When servicing cylinder head, remove intake manifold, injectors, exhaust manifold and water outlet cap from cylinder head.
2. Using special tools, compress valve springs and then remove valve cotters (1) also by using special tool. Special Tool 09916-14510 09916-16510 09919-28610 09916-84511
3. Release special tool, and remove spring retainers and valve springs.
4. Remove valve from combustion chamber side.
5. Remove valve stem seal (1) from valve guide, and then valve spring seat (2). NOTE: Do not reuse seal once disassembled. Be sure to use new seal when assembling.
6. Using special tool (Valve guide remover), drive valve guide out from combustion chamber side to valve spring side. Special Tool (A): 09916-46020 NOTE: Do not reuse valve guide once disassembled. Be sure to use new valve guide (oversize) when assembling.
7. Place disassembled parts except valve stem seal and valve guide in order so that they can be installed in their original positions.

Assembly

Reference: VALVES AND CYLINDER HEAD INSPECTION

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1. Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round. Special Tool 09916-34542 09916-38210
2. Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100 °C (176 to 212 °F) so that head will not be distorted, and drive new valve guide into hole with special tools. Drive in new valve guide until special tool (Valve guide installer) contacts cylinder head. After installing, make sure that valve guide protrudes by 13.5 mm (0.53 in.) from cylinder head. Special Tool 09916-57350 09916-57340 NOTE: Do not reuse valve guide once disassembled. Install new valve guide (Oversize). Intake and exhaust valve guides are identical. Valve guide oversize 0.03 mm (0.0012 in.) Valve guide protrusion "a" (In and Ex) 13.0 mm (0.51 in.)
3. Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore. Special Tool 09916-34542 09916-37810
4. Install valve spring seat to cylinder head.
5. Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide. Special Tool 09917-98221 09916-57350 NOTE: Do not reuse seal once disassembled. Be sure to install new seal. When installing, never tap or hit special tool with a hammer or else. Install seal to guide only by pushing special tool by hand. Tapping or hitting special tool may cause damage to seal.
6. Install valve to valve guide. Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem.
7. Install valve spring and spring retainer.
8. Using special tool (Valve lifter), compress valve spring and fit two valve cotters (1) into groove in valve stem. Special Tool 09916-14510 09916-16510 09919-28610 09916-84511
9. Install intake manifold, injectors, exhaust manifold and water outlet cap to cylinder head.

Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND INSTALLATION

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1. Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston.
2. Remove piston pin from connecting rod. Ease out piston pin circlips (1), as shown. Force piston pin out.

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS INSPECTION AND CLEANING

Note. Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows.

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1. Each piston (1) has stamped number 1 or 2 as shown. It represents outer diameter of piston.
2. There are also painted color (3) of red and blue on cylinder block (2) as shown.
3. Stamped number on piston and stamped mark on cylinder block should correspond. That is, install number 2 stamped piston to cylinder which is identified with mark blue and a number 1 piston to cylinder with mark red. Also, a letter A or B is stamped on piston head but ordinarily it is not necessary to discriminate each piston by this letter. Piston and cylinder specifications PISTON AND CYLINDER SPECIFICATIONS CHART Piston Cylinder Piston-to-cylinder clearance Number at the top (mark) Outer diameter Mark Bore diameter 1 89.98 - 89.99 mm (3.5426 - 3.5429 in.) Red 90.01 - 90.02 mm (3.5438 - 3.5440 in.) 0.02 - 0.04 mm (0.0008 - 0.0015 in.) 2 89.97 - 89.98 mm (3.5422 - 3.5425 in.) Blue 90.00 - 90.01 mm (3.5434 - 3.5437 in.) 0.02 - 0.04 mm (0.0008 - 0.0015 in.)
4. Install piston pin to piston (1) and connecting rod (3): After applying engine oil to piston pin and piston pin holes in piston and connecting rod, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install piston pin circlips. NOTE: Oil hole (4) come on intake side. NOTE: Circlip (4) should be installed so that circlip end gap comes within such range as indicated by arrow.
5. Install piston rings to piston: As indicated in figure at the left, 1st and 2nd rings have "RN" or "R" mark respectively. When installing these piston rings to piston, direct marked side of each ring toward top of piston. 1st ring (1) differs from 2nd ring (2) in thickness, shape and color of surface contacting cylinder wall. Distinguish 1st ring from 2nd ring by referring to figure. When installing oil ring (3), install spacer first and then two rails.
6. After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.