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03 Engine

Servis manual LJ80 Engine

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Jimny Kuning
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24 views43 pages

03 Engine

Servis manual LJ80 Engine

Uploaded by

Jimny Kuning
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
3. ENGINE Engine Services Not Requiring Engine Removal... 0. ..0e00.0s0005 4s 3-3. Dismounting the Engine ............. AERALRNERAUREYE 96 3-4, Engine Disassembly. coeees eee wettest ee nes gy 3-5. Engine Maintenance Service ............ OORT By 3-6. Engine Reassembly [Link]... 02.0200. we trae aan met a 3-7. Engine Inspection and Adjustments. . . SOAR eH 3-8. Engine Lubrication... 0.200.020 ee. a 3h; Deseraationsexsstnecie rermmnerens APRA TOT HZ 3 | 1) The engine is @ water-cooled, intine 4 cylinders, stroke cycle gasoline unit with its $.0.H.C. [single overhead camshatt) valve mechanism arrangad tor “V"-type valve configuration. The single overhead camshatt (6.0.H.C.} is mounted aver the cylinder head; it is driven from crank: shaft thraugh timing belt. Unlike conventional overhead valve (0.H.¥.) engines, this engine has na pushrods. Thus, drive for valves is more direct and enables the valves to follow the crankshaft without any delay. Fig. 3-7 a2 2} The distinctive features of this engine may be summarized as follows; 1, Because of inlet and exhaust ports arranged for croseflow patiern, with valves locatad in “V""-1ye configuratian, bath volumetie and scavenging efficiencies are very high 2. The combustion chamber forimad between piston crown and eylinder head is af a multi-spherical type shaped to provide squish, This feature is calculated to make available greater horsepower from a lesser amount of fuel, 3. The supports far cainshatt and rocker shalls are integral with the cylinder head, so that the valve mechanism noise is markedly reduced by the structural rigidity and, moreover, that the number of valve mechanism parts is reduced, let alone a mere compart size of the engine. 4, Tho timing bolt for driving the eamshaft runs quiet and is light in weight 5, & high-grade cast iran is used for the man deen skirts and retain greater rigiclity af the eylinder block. The blork is shaped ta present 6, The crankshaft is a one-piece forging, and is supported by five bearings for vibration freu running, 7, Heating by het water is employed for the inlet manifwld in order to foeilitate fuel carburetion and ensure the uniform distribution of the mixtura. The higher combustion efficiency of this engine is largely explained by this inlet manifold feature. =43 3) Blowby gas recycling system Blowby gas passaue is provided in the cylinder block to pass the blowiy gases from crankcase to cylinder head. In the head cover, an oil separator removes oil particles from the gases before the gases are drawn into the sir cleaner Alrclewner Fig. 32 3-2, Engine Services Not Requiring Eng’ The following parts or components da net 1 tion oF adjustment): Part or Component 1. Spark plug 2. Distributor 3. Exhaust manifald 4. Oil filter 5, Oil pressure unit 6. Cylinder head cover 7. Rocker shatt 8, Racker-arm 9. Rackerarm spring 1 10, Cam shaft 11. Cylinder heael 12, Radiator 19, Cooling fan 14, Camshaft timing belt pulley sine Removal equire engine removal to receive services (replacement, inspec: Nature of Service Replacement or inspection Replacement, inspection at adjustment Replacement or insaection Replacement Replacement Replacenient Replacement or inspection Replacement or inspection Replacement or inspection [ Resiacémant or inspection Replacement or inspection Replacement or inspection Replacement Replacement or inspection 15. Crankshatt timing belt pulley 16. Timing belt 17, Fuel pump, 18, Carburetor 9. Intake manifold Replacement or inspection Replacement or inspection Roplacemant Replaceient, \spection or adjustment Replacement 20. Altermator 21. Starter motor 22, Fan belt 23, Water pup 24, Pulleys (crank, generator, fant 26, Timing bell cower Replacement or inspection Replacement ar inspection Replaceinent, inspection or tension adjustment Replacement Replacement Replacement 26. Water hose Replacement ar inspection 3-3. Dismounting the Engine 1. Loosen two drain plugs, one an the battom af radistor and one on the cylinder block, to drain the cooling water, 2. Disconnect negative {—) and positive 4) cords from the battery terminals. 3. Remove the lower portions of shroud pane! from the radiator, 4, Take down the radiator, after disconnecting the water hoses from thermostat and water inict pipe. 5. Disconnect the accelerator wire from carbu retor body. G. Disconnect the choke wire fram carburetor body. 7. Disconnect the sir inlit how from carbu- retar body. #8, Disconnmct the water tose {leading to the car heater} from water inlet pi 9, Disconnect breather haxo from cylinder head. 10. Disconnect the lead wire fram water tem- perature gauge, This gauge is an the inlet manifold, 14, Disconnect the couplar and white lead wire from the alternator terminals. nect black/yellow lead wire battery cord, 13. Disconnect water pipe from the inlet mani told. 14. From the fuel pump, disconnect two pipes. leading to (wel tank, 15, Disconnect clutch cable from engine mount ing. 16. Sever exhaust manifold from mutiler by undeing the joint. 17. Disconnect the lead wire from oil prosure teri at. 18. Undo the joint betwwen transmission and engine, 19. Pull off high-tension cord trem the ignition oil. 20, Remove the nuts securing the engine mount ings to make the engine ready for removal RAY ing means. Throughout this MANUAL, the four cylinders of the ungine are identified by numbers: No. 1, No, 2, No. 3 and No. 4 [Link] from front end Fig. 33 3-4. Engine Disassembly i readily. identi Se = Carry out angine disassembly in the following sequence Loosen drain plug and drain out engine oil. Fig. 34 Remave clutch cover, Remove distributer assembly. Fig 36 Remove fuel pump # Fig. 27 Take dawn distributor case. Fig, 3.8 Remove cooling fan Ease out water pump pulley. amy Fu. 39 Fig, 3-12 Take down alternator Remove crank pulley simitarly, with special too! E (09916-97310) hitched to flywheel so that crankshaft will not turn, Fig. 310 Remove alternator mounting stay. ir = 4: Remove outside cover on timing belt, Fig. 3-15 Remove timing belt tensioner. CAUTION: ue Before removing the tensioner, be sure to - bring the srankshaft keyway (1, to the left side, af shown. This is necessary to avoid 2 piston crown hitting the valves up above. — Never rotate crankshaft until cylinder head | Or rocker army shafts are removed.) Fig. 8:18 Remove timing belt. Fig. £17 Remove the camshaft timing belt pulley, with special tool (08830-40113) attached, as shown, to lock the carnshalL Similarly remove the erankshalt timing belt Remave cylinder head front side ease. pulley. Fig. 3-22 Fig. 3191 Remove waler pump case. After removing the pulley key, take out timing belt guide Fig. 3-23 Remove exhaust manifold cover. ae. ae Fig. 320 Take down timing belt inside cover. 5D — Take off exhaust inanifald and its gaskes. Fig, 3.25 Using special ton! 4) 409915.473101, remove oil filter Fig. 3-26 Draw bypass hose off inlet manifold Fig. 3-27 Take down inlet manifold, Fig. 3.28 Sever and remave water inlut pipe. Fig. 3-29 Take off cylinder head cover. Loosen the 8 valve adjusting screws fully, Leave the screws in place Loosen rocker arm shaft securing screws: thers are 10 screws, Fig. 232 While drawing out rocker arm shatt, separate valve rocker arms and rocker arm springs. Remove camshaft thrust plate, and draw cam- shaft out toward (rent and, Fig. 3-34 Remove cylinder head i i it ii I Fig. 3 Use valve lifter © (09916-14510) to compress the valve spring in order to free valve cotter pieces for removal. In this way, remove valve spring and valves, Fig. 2.38 Remove flywheel, using special tool ® (09916 97310} as shown Fig. 237 Take down oil pan. T I Fig As the first step of crankshatt removal, remove the connucting rod caps for No, 2 and No. 3 cylinders, and take aut pistons, each complete with its connecting rod, trom cylinder head side. Fig, 3-40 Remove the connecting rod caps for Na. 1 and No. 4 cylinders and, as mentioned above, take ut the pistons and connecting rods Fig. 244 Remove oil pump case. Fig, 3-42 Remove oil seal housing. Fig. 343 Alemove crankshaft bearing eaps, and take out crankshaft, Fig, 3-08 From each piston, ease out pistan pin eirclips, as shown Fig, 3-45 Force piston pin out. Fig. 346 Fin. 3, peewee — | Cylinder head * De-carbon the cylinder head: Deposits of carbon will be found on its com- bustion chamber surfaces and exhaust ports. Remember, overheating tendency and lass of output are often due to excessive carbon accumulation, De-carbon the valves, toa, ie ee » Flatness of gasketed surface: Using a straightedge and thicknass gauge, cchack the flatness at a total of 7 locations, If the limit, stated below, is exceeded, correct the gasketed surface with a surface plate and sandpaper of about #400: place the sand- paper on and over the surface plate, and rub the gasketed surface against the sandpaper to grind off high spots. Should this fail to reduce the thickness gauge readings to within ‘the Fimit, replace the eylindar head Leakage of combustion gases from this gasketed joint is often due to a warped gasket ed surface; such leakage results in reduced power autput and hence a higher cost of fuel per kilometer. Limit on flatness | 0,05 mm (0,002 in.) Fig. $-50 * Flatness of manifold seating faces: Gheck the seating feces of cylinder head for manifolds, using a straightedge and thickness gauge, in order to determine whether these faces should be corrected or the cylinder head replaced. Limit on flatness | 0.10 mn (0.004 ind | Fig. $51 Checking exhourt mania seating face tar Fig. 352 Ghacking jnlet manitaut aanting tace tar Boies Rockerarm shaft and rocker arms * Wear ‘Check these parts for wear and, as necessary, lace them. The extent of wear is deter- mined on the basis of two readings, one on rocker arm 1D. and the other on shaft diame- rer. Ion ‘Beaneard | Lime, lei | aimee | 10560-4551 in. merch ow, M865 14.980 me mums vaoee®- e048 | taoo2 rt ames veenn | adie | shat = {H.0082 0.0016 in io.0027 n.t aurance | Exhuose Fig. 289 @ Rocker-arm shaft deflection: Using “V" blocks and a dial yauge as shown in Fig, 3-94, check the shaft for straightness in terms of deflection. I the limit is exceeded, correct it by cald working with @ wooden mallet or replace it, | Deflection limit | 0.05 mm (0.0023 ia.) =i56= * If the tip. af adjusting serew @ is badty worn, replace the screw. The arm must be replaced if its cam-riding face @ is badly worn. * Visually examine each racker-arm suring for evidence of breakage or weakening. Be sure to replace springs tound in bad candition. Us VW VW VA WA Vw WMO Fig. 3.58 Valve guides ® Using 2 micrometer and caliper, take diameter readings on valve stems and quides to deter- mina the stem clearance in the guide. Be sure to take a reading at mors than ene place along the length of each stem and guide, as shown in Fig, 3.57 st Mert taneare Limit niet | B:BE8- 8.980 rn ae 40.2782 - 0.2748 int am 5.88 - 6.80 mm diameter | ERMINE Tip 755.5 7744 ind 700. 7:015 mm Valve Welot/to.2788-0.2961 na | ule = 1, ah ye0a- 7.018 mm | Exhmure ig S76 -0,2761 in) 10,030 0.086mm 0.0% mm Sterner M8 | 9008 -9,0019 in.) 10.0027 int eaee 8.030 -0.040 mm 0.08 «rm FM |g 0912 m.0025 18,1 40.0035 in. Fig, B57 If the caliper like the ane shown in Fig. 3.87 is Not available, check the end deflection ef the valve stem in place with a dial gauge rigged as shown in Fig. 3-58. Move the stem end in the directions) ‘S) and determina whether replace: ment is necessary or not, by referring to these limiting vatues: c az alow seen ard e000 nl | dat eetion st |0.18 ee ta. 0085 i = Valve guide replacement Valve guidias are shrink-fiuied. The matheel af removal and installation is as follows: 1} Using the guide remawver (00016-4145 108, cirive the valve quicle out to remove it fram ue tap side af cylinder head, After driving the quide out, ream the guide hole with 212 min (0.472 in.) reamer {Special too! 09016-37310) to remove burrs, mak ing sure that the hole diameter efter ream. ing eames within this range: vole ME | ogo. 12.048 e (0.8736 -0.1749 in} Male es Exhaust Fig. 2.59 Zi Heat the cylinder head uniformly to any. where between 80°C and 100°C (176?F- 2IZF) so that the head will not distort, and drive the oversize guide inte the hole with the valve quide installer set (09916 57310 and 09916-57320). See Fig. 3-60. Be sure to carry out this steo speodily sa that all guides will go into the cylinder head in steady temperature state. valve nud oweeien p08 mw (0.0082 ins Vawegulee pctavion [168mm 140 9 Stared Lie aaeure Wii m A) Check all valve guides in place far 1,0, and, if the |.0, reading compared with the stem diameter reading indicates too small a fadial clearance, ream the guide LD, with the reainer «) 409916-34520}, as shown in Fig. 3-61 Valves * Inspect each valve for wear, burn or distor tign at its face and stern and, as necessary, replace it © Measure the thickness @ of valve head. If the given to this thickness is exceed. ud, the waive must be replaced, Walve head thickness 2 Ee ean Esha) 0.7 mon {0.1275 04 “4 ® | Fig. 362 — sR * Check the end face ef each valve stem for wear, This face meets the rocker arm intermittently in operation, and might became concaved or otherwise irregular. ‘As necessary, smoothen the end face with an oil stone and, if Uhis grinding removes the end stock by as much as 0.5 mm {0.0196 in.} (as measured from the original face), replace the valve. 0.5 mm. (0.0196 in} Replacement values have their stems machin- ed te the following diameter rangus. Standard jalee 6.3685 6.980 mm vave | (0.2742 9.2748 stem 6.955 - 6.670 mm diameter 40.2738 - 0.2744 in. Exhaust © Check each valve for radial runout with a dial gauge and ""V"" block, as shown in Fig. 3. The abject of this check is to determine Whether the vale stem ig true and square relative to the head. Limiton valve head | ra ut 0.03 mm (0.0012 int If the limit is exceeded, do not atteinal to correct the stem, replane the valve, instead Fig. 268 ae gantact width: Produce a contact patlerm an each valve in the usual manner, namely, by giving a unitorm ¢oat of reu-lead paste to the valve seat and by rotatingly tapping the seat wiih the valve head. ‘The valve lapper (the toot used in valve ‘The pattern produced on the seating face of the valve must bo a continuous ring without any break, and the width GW) of the pattern Must be within the stated range, Stared wating warm | intake rewwaled by sonst Dettarn on val face 141.8 mm sevnsr2 - 0.0590 in. Fig. $04 Fig. 265 © Valve seat repair A valve seat not producing a unitorm contact with its valve or showing a width if of the seating contact that is off the specified range must be repaired by regrindiny or by cutting ‘and regrinding and finished by lapping. WEXHAUST VALVE SEAT: Use a valve seat cutter to make three cuts in the order illustrated in Fig. 367, Three cutters must be used: the first for making the 15° angle, the second for making the 75° angle and the last for making the 45° seat angle, The third cut @) must be made te produce the desired seat width Seat width@ifor1.3- 1.5mm exhaust valve seat | (0.0612 - 0.0590 i en = Fig. 67 Vater seo angtes for exhaust valve seat 2)INLET VALVE SEAT; The cutting sequence is the same as for exhaust valve seats but the secand angle differs, as will be noted in Fig. 3.68 Seat width itor 1.3-1.6 mm inlet valve seat, (0.0512 - 0.0590 in.) Fig, 3-68 Value sent angles dor inlet valve seat HIVALVE LAPPING: Lap the valve on the seat in twa steps, first with a coarsesize lapping compound applied to the face and the second with a fine-size compound, each lime using a valve lapper according 19 the usual lapping methad. Fig. 3-69 Apotying Ingping compound ta valve face =60- Fig, 3-70 Gontsce pattern @uniform in width Valve springs ¢ Referring to the criterion-data given below, check to be sure that each spring is in sound condition, free of any evidence of breakaga or weakening, — Remember, weakened vale springs can be the cause of chatter, not to mention the possibility of reducing the power output due to gas leakage caused by decreased sea ting pressure, tem Standiacd Linit Wale —F trie tea | ATI 465 rom | ae 41.8079 in) 41.8307 in. Valve 28 - 30 ky for 24 ka tar spring 40 mm 40mm proioad (57.3. 88.1 1bf (52. iby Lr i : L in.) 157 in| Fig. 272 Checking the soring for preload © Spring squarenwss Use a square and surface plate to chock each spring for squareness in terms of the clearance (D, Fig. 3-73, between the end of valve spring and the square. Valve springs found to ex hibit a larger clearance than the limit must bo replaced Valve spring squere- 2.0mm ness 40.079 in.) Hai falazceses| 36, Engine Reassembly Lpeaw ee a in sand subbing euioee of A es ere ee “Use engine oil (Refer to. SO el Tightening torque data This is a listup of important tightening jobs identified by parts ta he secured: what tas kom To Granksnatt baring 4a-45 | ore ans Connweringeoit twang, 28 2 | aus 240 Crankset auliey be!) Bonn | aHs.aa0 Flywheel bolt [Link] | 700-225 Cytingr res welt Be Go | aon 440 Seath ls za-no | 4m 215 (Carmchatt pulley bo: 50-60 | anB 410 Votan acunting rut te-20 | 19-140 wat eo vation Ta Inte OW drain plug 20.25 145-1 Ohpmanurgtar ate aa. 8 otfitw Nod) pasi98 On am sean | ms ino prank vein | sass Tinga oom bok 0a a Oylainrieatcoerbas |oa-07 | 20. 50 Engine reassembly is the reverse of engine disassembly as far as sequence is concerned, but there are many reassembling steps that invelve measures necessary for restoring the engine as close to the factary-assembied condi- tion as possible. Only those staps will be dealt swith, ‘Crankshaft Be sure to oil crankshaft journal bearings as shown Fig. 3-89 ane 2 Thrust bearings for thw crankshaft are an item prone to escape the serviceman's attention be careful not to leave them out, These bear ings go inte place with their oil groove side facing the crank web. Be sure to oil erankshaft jaurnals as shown. Fig. 101 When fitting crankshaft bearing caps to jour nals after setting the crankshaft in place, be sure to paint the arrew mark fon each cap) to front side. Fit them sequentially in the os cending order, 1, 2. 3, 4 and 5, starting from front {pulley} side, 43-48 kgm Tightening torque for bearing cap bolts (31.5 - 34.5 lb-ft) Gradual and unifarm tightening is important for bearing cap bolts, Make sure that the five caps become tight equally and sively te the stated torque value, Gil seal hausing This housing demands a naw gasket: de not re: use the gasket removed in disassembly. After balting the housing to the block, the gasket exlgos might bulge aut; if sp, cut off the edges to make the joint seam flat and smooth: use a sharp knife. After cutting, apply SUZUKI BOND Na. 4, as shown, neeemnpaernes at Bere moomiog te no. i “ieemonctowonae ee EES seee Gil pump Piston and piston rings The gasket far oil pump ease must be new. As POSITION OF PISTON RELATIVE TO CON- in the case of oil seal housing, cut off the gasket NECTING ROD: The arrow ©) on the crown ta smoathen the joint seam, points to front (pulley) sive, and the ail hole i comes on inlet port side, See Fig, 3-107. ear ita From sine Fig. $405 After cutting the gasket edges, apnly SUZUKI Fig. 3-107 BOND No. 4. Before fitting rings to piston, check to be sure that first ring has RN mark and second ring R mark, After mounting the three rings, distribute their end gaps as illustrated in Fig. 9-108, Fiermamber, the marked side of cach ring (ist and 2nd} comes on top side. ep Fig. 3-108 -B- Use of the piston ring compressor ‘# (09916 77310}, Fig. 3109, is mandatory in insert Ristons into cylinder block, Using this com pressor ®, feed the piston and connecting rad combination into the bore fram the gasketed surface side of block, starting «with Ne. 1 and No, 4 cylinders, while the crankshaft in place is %@ turned as to hold No. 1 and Na. 4 crank- ping at bottom dead center, Install No. 2 and No. 3 combinations similarly Pay attention to these reminders: # Point the piston crown arrow to front side. * Be sure that the number (marked on the crown at the time af disassembly} tallies with the cylinder number © Liberally oil the bigund bearings before {iL ting them to crankpins. # Oil the bore just before feeding in thw piston. CAUTION: © s the journal eee nat ny hitel is felt, took the be ibe ae Fig. F110 Gonnecting rads Two stoppers

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