Engine Mechanical: Overhaul Suzuki Kizashi I

Disassembly

Reference: VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION

Note. Parts must go back in the position where they were. Keep them in the following order: Valve cotter Valve spring retainer Valve spring Valve spring seat Intake valve Exhaust valve Tappet

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1. Remove oil venturi plug (1).
2. Remove tappets from cylinder head.
3. Use special tools (A) and (B) to compress valve spring and use special tool (C) to remove valve cotters (1). CAUTION: When compressing the valve spring, be careful not to damage inner side of the tappet installing hole. Special Tool 09916-14510 09916-14522 09916-84511
4. Release special tools (A) and (B), and remove spring retainer and valve spring.
5. Remove valve.
6. Remove valve stem seal (1) and valve spring seat (2).
7. Use special tool to remove valve guide from combustion chamber side to valve spring side. NOTE: Heating cylinder head 80 to 100°C (176 to 212°F) may facilitate valve guide removal. Special Tool 09916-44910

Reassembly

Reference: VALVE AND VALVE GUIDE INSPECTION

Reference: CYLINDER HEAD INSPECTION

Reference: VALVE SPRING INSPECTION

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1. Before installing valve guide into cylinder head, ream guide hole with special tool (A) so as to remove burrs and make it truly round. CAUTION: The engine could be damaged if shavings remain inside the valve guide hole after reaming it. Be sure to thoroughly remove shavings from the reamed hole. Special Tool 09916-37320 09916-34542
2. Use special tools to install valve guide to cylinder head as follows. Special Tool 09916-58210 09916-56510 NOTE: Never reuse valve guide. Install new oversized valve guide. Intake and exhaust valve guides are identical. Uniformly heat cylinder head to a temperature of 80 to 100°C (176 to 212°F) so that it will not be distorted, and drive new valve guide into guide hole with special tools. Install new valve guide until special tool contacts cylinder head. After installation, make sure that valve guide protrudes from cylinder head by specified dimension "a". CAUTION: The same special tool (B) is used to install intake valve guide and exhaust valve guide but the direction in which it is applied differs. For intake valve guide The side (2) should be directed to valve guide. For exhaust valve guide The side (1) should be directed to valve guide. Valve guide protrusion "a" IN: 16.3 - 16.7 mm (0.642 - 0.657 in.) EX: 12.3 - 12.7 mm (0.485 - 0.500 in.)
3. Ream valve guide bore with special tool. CAUTION: The engine could be damaged if shavings remain inside the valve guide hole after reaming it. Be sure to thoroughly remove shavings from the reamed hole. Special Tool 09916-34550 09916-34542
4. Install valve spring seat to cylinder head.
5. Install new valve stem seal (1) to valve guide. After applying engine oil to valve stem seal and spindle of special tool (A), fit valve stem seal to spindle, and then install valve stem seal to valve guide pushing special tool by hand. After installation, check that valve stem seal is properly fixed to valve guide. CAUTION: If the valve stem seal is installed by striking the special tool with a hammer or other similar tool, the valve stem seal may be damaged, causing oil to get down past the seal. Be sure to push the special tool only by hand to force the valve stem seal into position. Special Tool 09917-98221 09916-58210
6. Apply engine oil to valve stem, then install valve to valve guide.
7. Install valve spring and valve spring retainer. NOTE: Valve spring does not have specific direction for installation.
8. Use special tools to compress valve spring and fit two valve cotters (1) into groove in valve stem. CAUTION: Damaging the wall surface of the tappet fitting hole could result in engine problems. Prevent the special tool from touching the tappet sliding surface in the cylinder head. Special Tool 09916-14510 09916-14522 09916-84511
9. Install venturi plug (1). Tightening torque Venturi plug (a): 3.5 N.m (0.36 kg-m, 2.5 lbf-ft)

Piston, Piston Ring and Connecting Rod Disassembly and Reassembly

Reference: PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION

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1. Use a piston ring expander to remove 1st and 2nd rings and oil ring from piston.
2. Remove piston pin from connecting rod as follows. Remove piston pin circlips (1), as shown in the illustration. Remove piston pin.

Reference: CYLINDER, PISTON AND PISTON RING INSPECTION

Reference: PISTON PINS AND CONNECTING RODS INSPECTION

Reference: CRANKSHAFT PIN AND CONNECTING ROD BEARINGS INSPECTION

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.

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1. To replace piston, select proper piston using the following procedures: Check stamped number (2) on piston (1) as shown in figure. Check stamped number (4) on lower crankcase (3) as shown in figure. Stamped number on piston and stamped number on lower crankcase correspond with each other. Select proper piston, refer the following table. Piston selection table PISTON SELECTION CHART Stamped number on lower crankcase 1 2 Stamped number on piston 1 2
2. Use a suitable tool to remove carbon deposit from piston head and ring grooves.
3. Assemble piston pin, piston (1) and connecting rod (2) as follows. Apply engine oil to piston pin, piston pin hole in piston and connecting rod. Fit connecting rod to piston. NOTE: Be sure to position front mark (4) on piston and oil hole (5) of connecting rod (2) at specified position as shown in figure. Insert piston pin to piston and connecting rod. Install new piston pin circlips (3). NOTE: Install circlip so that circlip end gap comes within the range indicated by arrow (6).
4. Install piston rings to piston noting the following points: As indicated in figure, 1st and 2nd rings have discrimination mark (1) respectively. When installing these piston rings to piston, direct discrimination mark side of each ring toward top of piston. 1st ring (2) differs from 2nd ring (3) in thickness, shape and color of surface contacting cylinder wall. Refer to the figure to distinguish 1st ring from 2nd ring. When installing oil ring (4), install spacer first, and then install two rails.
5. After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.