Engine Mechanical: Overhaul Suzuki SX4 I рестайлинг

Disassembly

Reference: VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION

Note. If following parts are removed, keep them in order. They must go back in the position from which they were removed. 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. Using special tools (A) and (B), compress valve spring and then remove valve cotters (1) also by using special tool (C). CAUTION: When compressing the valve spring, be careful not to damage in inside surface of 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 from combustion chamber side.
6. Remove valve stem seal (1) and valve spring seat (2).
7. Using special tool, drive out valve guide from combustion chamber side to valve spring side. NOTE: Heat cylinder head to remove valve guide, if necessary. Special Tool (A): 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 (10.5 mm reamer) so as to remove burrs and make it truly round. CAUTION: Clean away shavings from reamed hole. Special Tool 09916-37320 09916-34542
2. Using special tools, 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. Heat cylinder head uniformly 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. Drive in new valve guide until special tool contacts cylinder head. After installation, make sure that valve guide protrudes by specified dimension "a" from cylinder head. CAUTION: For installing intake valve guide and exhaust valve guide, the same special tool (B) is used, but its application direction is different. Use it in proper direction. 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: Clean away shavings from 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: When installing, never tap or hit special tool with a hammer or else. Install seal to guide only pushing special tool by hand. Tapping or hitting special tool may cause damage to seal. Special Tool 09917-98221 09916-58210
6. Apply engine oil to valve stem seal, valve guide bore and valve stem.
7. Install valve to valve guide.
8. Install valve spring and valve spring retainer. NOTE: Valve spring does not have specific direction for installation.
9. Using special tools, compress valve spring and fit two valve cotters (1) into groove in valve stem. CAUTION: When compressing the valve spring, be careful not to damage inside surface of tappet installing hole. Special Tool 09916-14510 09916-14522 09916-84511
10. 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

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

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1. Using piston ring expander, 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. Take out 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 according the following procedure Check stamped number (2) on piston (1) as shown in figure. Check stamped number (4) on lower crank case (3) as shown in figure. Stamped number on piston and stamped number on lower crank case correspond with each other. Select proper piston referring the following table. Piston selection table PISTON SELECTION TABLE Stamped number on lower crank case 1 2 Stamped number on piston 1 2
2. Remove carbon deposit from piston head and ring grooves using a suitable tool.
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 so that circlip end gap comes within the range indicated by arrow (6).
4. Install piston rings to piston noting the following. As indicated in figure, 1st and 2nd rings have direct 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. Distinguish 1st ring from 2nd ring referring to the figure. 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.