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Engine Mechanical: Overhaul Suzuki SX4 I

Mechanical 16 illustrations ~1013 words

Valves and Cylinder Head Disassembly and Reassembly

Reference: VALVES AND CYLINDER HEAD REMOVAL AND INSTALLATION

Scheme 98

Scheme 98: Disassembly
Scheme 98: Disassembly

Scheme 99

Scheme 99
Scheme 99

Scheme 100

Scheme 100
Scheme 100
  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.

Reassembly

Reference: VALVES AND VALVE GUIDES INSPECTION

Scheme 101

Scheme 101: Reassembly
Scheme 101: Reassembly

Scheme 102

Scheme 102
Scheme 102

Scheme 103

Scheme 103
Scheme 103

Scheme 104

Scheme 104
Scheme 104

Scheme 105

Scheme 105
Scheme 105

Scheme 106

Scheme 106
Scheme 106

Scheme 107

Scheme 107
Scheme 107
  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 specified value 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: 14.5 mm (0.57 in.) Ex: 13.5 mm (0.53 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. Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Be sure to position spring in place with its bottom end (small-pitch end) facing the bottom (valve spring seat side).
  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 by referring to «INSTALLATION»(ref-268922-S30980548672007102700000) .
  10. Install exhaust manifold by referring to «INSTALLATION»(ref-268927-S28658476662007102700000) .
  11. Install injectors by referring to «INSTALLATION»(ref-268903-S27899048902007102700000) .

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

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

Scheme 108

Scheme 108: Disassembly
Scheme 108: Disassembly

Scheme 109

Scheme 109
Scheme 109
  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). 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.

Scheme 110

Scheme 110: Reassembly
Scheme 110: Reassembly

Scheme 111

Scheme 111
Scheme 111

Scheme 112

Scheme 112
Scheme 112

Scheme 113

Scheme 113
Scheme 113
  1. Each piston (1) has stamped number (2) (Scheme 111) It represents outer diameter of piston.
  2. There are also painted color (3) of red or blue on cylinder block (2).
  3. Stamped number on piston and painted color (or stamped number) on cylinder block should correspond. That is, install number "2" stamped piston to cylinder which is identified with blue painted (or "2" stamped) and a number "1" piston to cylinder with red painted (or "1" stamped). 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 outer diameter and cylinder bore diameter specification PISTON OUTER DIAMETER AND CYLINDER BORE DIAMETER SPECIFICATION Piston Cylinder Number Outer diameter Paint (Number) Bore diameter 1 83.9800 - 83.9900 mm (3.3063 - 3.3066 in.) Red (1) 84.0101 - 84.0200 mm (3.3075 - 3.3078 in.) 2 83.9700 - 83.9799 mm (3.3059 - 3.3062 in.) Blue (2) 84.0000 - 84.0100 mm (3.3071 - 3.3074 in.)
  4. Install piston pin to piston (1) and connecting rod (3): After applying engine oil to piston pin, piston pin holes in piston and inner surface of connecting rod small end, fit connecting rod to piston (Scheme 112)and insert piston pin to piston and connecting rod, and install piston pin circlips. NOTE: Oil hole (4) comes on intake side. Circlip (5) 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 (Scheme 113), 1st and 2nd rings have "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 (Scheme 113). 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.

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