Engine Mechanical: Overhaul Suzuki Reno I

Cylinder Head and Valve Train Components Disassembly and Assembly

Tools Required

KM-571-B Gauge

KM-340-0 Cutter Set

KM-340-7 Guide Drift

KM-340-13 Cutters

KM-340-26 Cutters

KM-348 Valve Spring Compressor

KM-653 Adapter

KM-805 Valve Guide Reamer

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Scheme 55

1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to «CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION»(ref-236070-S17855192712006063000000) .
2. Remove the exhaust manifold heat shield bolts.
3. Remove the exhaust manifold heat shield.
4. Remove the exhaust manifold retaining nuts in the sequence shown.
5. Remove the exhaust manifold.
6. Remove the exhaust manifold gasket.
7. Remove the exhaust manifold studs.
8. Remove the thermostat housing mounting bolts.
9. Remove the thermostat housing assembly.
10. Remove the fuel rail assembly. Refer to «FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION»(ref-257068-S02080634982007062900000) .
11. Remove the coolant bypass housing mounting bolts and the housing.
12. Remove the intake manifold retaining nuts and retaining bolt in the sequence shown.
13. Remove the intake manifold.
14. Remove the intake manifold gasket.
15. Remove the Direct Ignition System (DIS) coil and the Exhaust Gas Recirculation (EGR) mounting bracket bolts.
16. Remove the DIS ignition coil and the EGR mounting bracket and ignition wires.
17. Remove the intake manifold studs.
18. Remove the spark plugs.
19. Remove the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.
20. Remove the intake camshaft caps. Maintain the correct positions for installation.
21. Remove the intake camshaft.
22. Remove the intake valve tappet adjusters.
23. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
24. Remove the exhaust camshaft.
25. Remove the exhaust valve tappet adjusters.
26. Compress the valve springs with the valve spring compressor KM-348 and the adapter KM-653.
27. Remove the valve retainers.
28. Remove the valve spring compressor KM-348 and the adapter KM-653.
29. Remove the valve spring caps.
30. Remove the valve springs. Maintain the original position of the valve springs for installation.
31. Remove the valves. Maintain the original position of the valves for installation.
32. Remove the valve stem seals.

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Scheme 57

1. Coat the valve stems with engine oil.
2. Insert the valves in the cylinder head in their original positions.
3. Insert the valve spring seats.
4. Push the accompanying assembly sleeve onto the valve stem.
5. Insert the new valve stem seat.
6. Carefully drive the valve stem seal onto the stop with light taps.
7. Install the valve springs in their original positions.
8. Install the valve spring caps.
9. Compress the valve springs with the valve spring compressor KM-348 and adapter KM-653.
10. Install the valve keys.
11. Remove the valve spring compressor KM-348 and adapter KM-653.
12. Lubricate the valve tappet adjusters with engine oil.
13. Install the valve tappet adjusters.
14. Install the intake camshaft.
15. Install the intake camshaft bearing caps in their original positions.
16. Install the exhaust camshaft.
17. Install the exhaust camshaft bearing caps in their original positions.
18. Install the camshaft bearing cap bolts.
19. Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap. Tighten: Tighten the camshaft bearing cap bolts to 8 N.m (71 lb-in).
20. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb-ft).
21. Install the DIS coil and EGR mounting bracket.
22. Install the DIS coil and EGR mounting bracket bolts. Tighten: Tighten the direct ignition system coil and exhaust gas recirculation mounting bracket bolts to 25 N.m (18 lb-ft).
23. Install the intake manifold studs.
24. Install the intake manifold gasket.
25. Install the intake manifold.
26. Install the intake manifold retaining nuts and retaining bolt in the sequence shown. Tighten: Tighten the intake manifold retaining nuts and retaining bolt to 22 N.m (16 lb-ft).
27. Install the fuel rail assembly. Refer to «FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION»(ref-257068-S02080634982007062900000) .
28. Install the thermostat housing assembly.
29. Install the thermostat housing mounting bolts. Tighten: Tighten the thermostat housing mounting bolts to 15 N.m (11 lb-ft).
30. Install the coolant bypass housing and mounting bolts. Tighten: Tighten the coolant bypass housing bolts to 15 N.m (11 lb-ft).
31. Install the exhaust manifold studs.
32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the sequence shown. Tighten: Tighten the exhaust manifold retaining nuts to 22 N.m (16 lb-ft).
35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 8 N.m (71 lb-in).
37. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to «CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION»(ref-236070-S17855192712006063000000) .

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Scheme 59

1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat within 0.025 mm (0.001 in.) maximum.
6. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 133.975 - 134.025 mm (5.274 - 5.276 in.). If the cylinder head height is less than 133.9 mm (5.271 in.), replace the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned spots.

Scheme 60

1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the oil seal grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be straight.
6. Inspect the valve face for grooving. If the groove is so deep that refacing the valve would result in a sharp edge, replace the valve.
7. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.
8. Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required.

Scheme 61

1. Clean the cylinder head.
2. Clean the valve guides.
3. Clean all of the threaded holes.
4. Clean the valves of carbon, oil, and varnish.

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Scheme 63

1. Lubricate the valve seat using a fine-grained paste.
2. Lift the valve rhythmically from the seat with a commercially available valve grinding tool in order to distribute the paste.
3. Check the contact pattern on the valve head and in the cylinder head.
4. Clean the valves the valve guides and the cylinder head.

Scheme 64

1. Ensure that there are no crater line burns on the valve cone.
2. The valve may be reground only two times. Do not grind the valve stem end.
3. Ensure that the angle at the valve face is 45°.
4. Inspect the assembly height of the intake valves and the exhaust valves.

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Scheme 66

1. Measure the diameter of the valve guide using gauge KM-571-B and a commercially available inside micrometer.
2. An oversize service code is on the valve guide and the valve stem end. The following table gives the correct size, reamer, and production code for each service. VALVE GUIDE AND VALVE STEM END REFERENCE CHART Size Reamer Production Code Service Code Normal - - K 0.075 KM-805 1 K1 0.150 - 2 K2
3. Ream the valve guide from the upper side of the cylinder head to the next oversize.
4. After reaming, cross out the code and emboss the valve guide with the new code.

Scheme 67

1. Place the cylinder head on wooden blocks.
2. Cut the intake and the exhaust valve seats using the guide drift KM-340-7 as follows: Valve seat - A 45° surface using the cutter KM-340-13. Upper correction angle - A 30° surface using the cutter KM-340-13. Lower correction angle - A 60° surface using the cutter KM-340-26.
3. Clean the chippings from the cylinder head.
4. Inspect the dimension for the valve seat width. Intake: 1.2 - 1.4 mm (0.047 - 0.055 in.) Exhaust: 1.4 - 1.8 mm (0.055 - 0.070 in.)
5. Inspect the assembly height of the intake valves and the exhaust valves. If the dimension is exceeded, install new valves. Inspect the assembly height of the intake valves and the exhaust valves again. If the valve assembly height is still too large despite replacing the valves, replace the cylinder head.

Crankshaft Disassembly and Assembly

Tools Required

KM-412 Engine Overhaul Stand

KM-470-B Angular Torque Gauge

J-36792 or KM-635 Crankshaft Rear Oil Seal Installer

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1. Remove the engine. Refer to «Engine Removal and Installation»(ref-257073-S26912113182007062900000) .
2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.
4. Remove the crankshaft rear oil seal.
5. Mount the engine assembly on the engine overhaul stand KM-412.
6. Remove the front timing belt cover bolts.
7. Remove the front timing belt cover.
8. Remove the crankshaft pulley bolts.
9. Remove the crankshaft pulley.
10. Loosen the timing belt automatic tensioner bolt.
11. Rotate the timing belt automatic tensioner hex-key clockwise to release the tension.
12. Remove the timing belt idler pulley bolt and nut.
13. Remove the timing belt idler pulleys.
14. Remove the timing belt.
15. Remove the engine mount retaining bolts.
16. Remove the engine mount.
17. Disconnect the breather tubes from the camshaft cover.
18. Remove the spark plug cover bolts.
19. Remove the spark plug cover.
20. Disconnect the ignition wires from the spark plugs.
21. Remove the camshaft cover bolts.
22. Remove the camshaft cover washers.
23. Remove the camshaft cover and the camshaft cover gasket.
24. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
25. Remove the intake camshaft gear.
26. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt.
27. Remove the exhaust camshaft gear.
28. Remove the crankshaft timing belt gear.
29. Remove the rear timing belt cover bolts and cover.
30. Rotate the engine on the engine overhaul stand KM-412.
31. Remove the oil pan retaining bolts.
32. Remove the oil pan.
33. Remove the oil suction pipe and support bracket bolts.
34. Remove the oil suction pipe.
35. Remove the crankshaft bearing bridge and oil pan scraper bolts.
36. Remove the oil pan scraper.
37. Remove the crankshaft bearing bridge bolts.
38. Remove the crankshaft bearing bridge.
39. Remove the oil pump retaining bolts.
40. Remove the oil pump.
41. Mark the order of the connecting rod bearing caps.
42. Remove the connecting rod bearing cap bolts for all of the pistons.
43. Remove the connecting rod bearing caps and the lower connecting rod bearings.
44. Mark the order of the crankshaft bearing caps.
45. Remove the crankshaft bearing cap bolts.
46. Remove the crankshaft bearing caps and the lower crankshaft bearings.
47. Remove the crankshaft.
48. Clean the parts, as needed.

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1. Coat the crankshaft bearings with engine oil.
2. If replacing the crankshaft, transfer the pulse pickup sensor disc to the new crankshaft.
3. Install the crankshaft.
4. Install the lower crankshaft bearings in the bearing caps.
5. Inspect the crankshaft end play with the crankshaft bearings installed.
6. Check for permissible crankshaft end play. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
7. With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
9. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.
10. Install the crankshaft bearing caps and the bolts. Tighten: Tighten the crankshaft bearing cap bolts to 50 N.m (37 lb-ft) plus 45° and 15°.
11. Remove the crankshaft bearing cap bolts and the caps.
12. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
13. Inspect the bearing clearance for permissible tolerance ranges. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
14. Apply a bead of adhesive sealing compound to the grooves of the crankshaft bearing caps.
15. Install the crankshaft bearing caps to the engine block.
16. Tighten the crankshaft bearing caps using new bolts. Tighten: Tighten the crankshaft bearing cap bolts to 50 N.m (37 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the crankshaft bearings another 45° and 15°.
17. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
18. Cut the plastic gauging threads to the length of the connecting rod bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.
19. Install the connecting rod bearing caps. Tighten: Tighten the connecting rod bearing cap bolts to 35 N.m (26 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the connecting rod bearing cap bolts another 45° plus 15°.
20. Remove the connecting rod bearing caps.
21. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
22. Inspect the bearing clearance for permissible tolerance ranges. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
23. Install the connecting rod bearing caps to the connecting rods.
24. Tighten the connecting rod bearing caps using new bolts. Tighten: Tighten the connecting rod bearing cap bolts to 35 N.m (26 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the connecting rod cap bolts another 45° plus 15°.
25. Install the oil pump.
26. Install the oil pump retaining bolts. Tighten: Tighten the oil pump retaining bolts to 10 N.m (89 lb-in).
27. Install the crankshaft bearing bridge and bolts. Tighten: Tighten the crankshaft bearing bridge bolts to 20 N.m (15 lb-ft) plus 45° using the angular torque gauge KM-470-B.
28. Install the crankshaft bearing bridge and oil pan scraper bolts. Tighten: Tighten the crankshaft bearing bridge and oil scraper bolts to 20 N.m (15 lb-ft) plus 45° using the angular torque gauge KM-470-B.
29. Install the oil suction pipe.
30. Install the oil suction pipe and support bracket bolts. Tighten: Tighten the oil suction pipe bolts to 8 N.m (81 lb-in) and oil suction pipe support bracket bolt to 6 N.m (53 lb-in).
31. Coat the new oil pan gasket with sealant.
32. Install the oil pan gasket to the oil pan.
33. Install the oil pan.
34. Install the oil pan retaining bolts. Tighten: Tighten the oil pan retaining bolts to 10 N.m (89 lb-in).
35. Rotate the engine on the engine overhaul stand KM-412.
36. Install the rear timing belt cover.
37. Install the rear timing belt cover bolts. Tighten: Tighten the rear timing belt cover bolts to 7 N.m (62 lb-in).
38. Install the crankshaft gear and bolt. Tighten: Tighten the crankshaft gear bolt to 145 N.m (107 lb-ft) plus 30° plus 15° using the angular torque gauge KM-470-B.
39. Install the engine mount and retaining bolts. Tighten: Tighten the engine mount retaining bolts to 45 N.m (33 lb-ft).
40. Install the timing belt automatic tensioner.
41. Install the timing belt automatic tensioner bolts. Tighten: Tighten the timing belt automatic tensioner bolts to 25 N.m (18 lb-ft).
42. Install the timing belt idler pulley.
43. Install the timing belt idler pulley bolt and nut. Tighten: Tighten the timing belt idler pulley nut to 25 N.m (18 lb-ft).
44. Install the intake camshaft gear.
45. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place. Tighten: Tighten the intake camshaft gear bolt to 50 N.m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.
46. Install the exhaust camshaft gear.
47. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place. Tighten: Tighten the exhaust camshaft gear bolt to 50 N.m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.
48. Install the timing belt. Refer to «Timing Belt Removal and Installation»(ref-257073-S15577769162007062900000) .
49. Adjust the timing belt tension. Refer to «Timing Belt Check and Adjust»(ref-257073-S40201972272007062900000) .
50. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover to cylinder head seal.
51. Install the camshaft cover and the camshaft cover gasket.
52. Install the camshaft cover washers.
53. Install the camshaft cover bolts. Tighten: Tighten the camshaft cover bolts to 8 N.m (71 lb-in).
54. Connect the ignition wires to the spark plugs.
55. Install the spark plug cover.
56. Install the spark plug cover bolts. Tighten: Tighten the spark plug cover bolts to 8 N.m (71 lb-in).
57. Connect the breather tube to the camshaft cover.
58. Install the front timing belt cover.
59. Install the front timing belt cover bolts. Tighten: Tighten the front timing belt cover bolts to 8 N.m (71 lb-in).
60. Install the engine lifting device.
61. Remove the engine from the engine overhaul stand KM-412.
62. Install a new crankshaft rear oil seal using installer J-36792.
63. Install the flywheel or flexible plate.
64. Install the flywheel or the flexible plate bolts. Tighten: Tighten the flywheel bolts to 65 N.m (48 lb-ft). Use the angular torque gauge KM-470-B to tighten the flywheel bolts another 30° plus 15°. For the automatic transmission, tighten the flexible plate bolts to 45 N.m (33 lb-ft).
65. Install the engine. Refer to «Engine Removal and Installation»(ref-257073-S26912113182007062900000) .