Suzuki Carry & Every English Version Factory Service Manual Translation F6A Series 660cc Engine & Parts Manual Second Edition James L. Danko DE51V 51V DC51T DD51T DC51B DA52T DB52T DA52VSuzuki Carry & Every English Version Factory Service Manual Translation F6A Engine Manual Carry Truck 660cc 2WD &4WD Every Van 660cc AT-MT Models Suzuki Kei Vehicles Series Written By, James Danko Second Edition 2008Copyright © 2008 by James Danko All rights reserved. All text and graphi publication if the author, unless otherwise noted or credited. It is unlawful to reproduce-or copy in anyway-resell, or redistribute this information without the express written permission of the publisher. ‘This book is an independent publication, and the author and/or publisher thereof are not in anyway associated with, and are not authorized to act on behalf of any of the manufactures listed in this book. All registered trademarks are the property of their owners. The publisher reserves the right to revise this publication or change its content from time to time without obligation to notify any persons of such revision or changes. Edited By: James L. Danko Artwork: James L. Danko® Layout By: James L. Danko Printed in U.S.A Yokohama Motots Japan is a solely owned division of Nippon Security Inc. Yokohama Motors is a licensed new & used import/export automotive dealer based in Yokohama Japan. For more information please visit www-yokohamamotors.com All translations from original Japanese test to English completed by James Danko. Disclaimer: All translations from one language to another can involve technical errors. The author has found mistakes in the original Japanese text. The best suitable English vocabulary has been chosen by the author. Credits: I would like to thank the Suzuki Motors Corporation (Japan) for their part in supplying required information. ‘Suzuki™ Carry and Every and all copyrights of said trademarks are property of Suzuki Corp, Japan.Introduction ‘Due to the high request for English version manuals on Japanese mini trucks & Vans, ‘publishing wide variety information to provide the mini truck community with the to maintain their vehicles. Japanese mini tucks & vans are produced only for the Japanese market. Therefore, all ginal manuals are only available in Japanese. Service manuals are not sold to the public in Japan, as in many countries. You must be ‘car dealer to receive them. We have a few hundred in stock. We do not sell manuals from ‘own library. We will start publishing them in English (Translated) and our own original ‘This book or manual is for the professional mechanic. Simple items as how to change a plug, or an ait-filter are not in this book. It is full of diagrams and schematics that are ‘understood by a professional mechanic. How to do an engine overhaul using the correct ‘parts sizes, measurements, torque, etc. You will have the same information as the Suzuki techs have. We have manuals for all Japanese manufactures. It’s a time consuming process, please check back frequently as we post more information. For more information please visit our home page at www.yokohamamotors.com,Contents Vehicle Types Jacking Positions VIN Decoding Engine and Transmission Identification Service Data and Specifications ‘Tools (OEM) Engine Mounts and Frame Diagrams Engine Removal Intake Manifold Carry (Carbureted) 410. Intake Manifold Every Van (Carbureted) ‘AL. Intake Manifold (Throttle Body) ‘12. Timing Belt Parts and Part Numbers ‘13. Timing Belt Tensioner Truck & Van 14. Timing Belt Replacement Truck & Van 15, Valve Lash 2 Cylinder 16. Valve Lash 4 Cylinder 17. Oil 18. Oil System Pressure Testing 19. Oil Pump Removal-Replacement 20. Cylinder Head 2 Valve Overhaul 21. Pistons Connecting Rods Cylinder Block 22. Main Bearings, Crankshaft, Cylinder Block 23. Crankshaft Inspection, Oil Seal, Flywheel 24, Parts Section . Conversion ChartsSuzuki Carry Truck 2WD & 4WD pesit positSuzuki Every Van apa3 3B q 5 ee y a 3Floor Jack Locations‘Motors (English) ‘Other Locations of ID Plates 1. Sliding Door 2.1D Plate (Body Panel) 1. Seat Belt S&S 23D Plate (Body) Featess Vehicle Identification Suzuki Carry & Every ‘Example: DESIV=Vehicle Series 300001=Produetion number In Sequence® Every Van DES1V-500001 DF51V-500001 Carey Truck DesIT-100001~ DD51T-100001~ DC51B-100001~ Example: Car Manufactured in 2000 but not sold ‘until 2008=2008, Therefore, vehicles go by codes and manufactures date means nothing in Japan. “*Note: For manufactured year check the seat belt tag of any paperwork you have from your dealer. ID Plate Decoder 1. Vehicle Series 2 Vehicle VIN Number 3. Engine Series 4. Engine Teue Size(ec) 5. Body Color Code 6. Interior Color Code of Package Code 7. Makers Code (Por Sales Dept. Information) £8 Suzuki Corporation (Japanese)‘The Suzuki Carry has been a work horse in Japan for decades. Officially itis classified as a ILL! (Kei-vehicle or Light Vehicle) which is symbolized by the unique yellow license plates they use for registration. All Kei-vehicles must be manufactured under law with a maximum 660cc engine displacement. Due to the obvious safety issues for their size and weight they are designed for a maximum highway speed of 80 kilometers per hous, or roughly S0MPH. Although recently with the addition of five peed transmissions and 3-4 speed ‘automatics it is possible to travel at greater speeds. Since the average length of a Kei-Truck is roughly 10.2 feet it is not a good idea to push them to the limit as safety of drivability issues will arise. Average use in Japan for agricultural purposes and off road durability, these vehicles generally travel at 25MPH (40KPH) on local roads. As Japan is an island nation, roads are small and narrow. Kei-trucks are rarely seen going down the highway for long distance travel. ‘The other issues of engines overheating at prolonged highway speeds. Their high winding motors do not have adequate cooling systems for long distance travel. ‘The Suzuki Carry is built tough and properly maintained will last for many years. The platform is durable, and easy to repair. There are still thousands of them driving around Japan that are 20-30 years old. This in itself amazing as the average life cycle of a normal car in Japan is 5-10 years. ‘Common uses in Japan of Carry Truck and Every Van Agriculture Construction companies Dump trucks Delivery Vans (Every Van) Postal Rescue and fire trucks Police Patrol Moving companies eoeecccece Many, many more ‘The basic body style has not changed much from the 1980s to 1998. The engines from the late 1970s to the beginning of 1980s saw the change from the 550cc engine to the 660cc version. Some makers in the 1980s started producing engines with cither superchargers or turbochargers. Turbochargers and superchargers were not used that much on trucks but heavily on vans. Since vans we designed for on-road conditions and mostly delivery, they got the boost. Off road trucks could use the boost in power but due to dirty conditions and the chance of diet in a turbo would provide disaster for the engine. 2Vehicle Identification ‘One of the most highly requested questions we get at Yokohama Motors from overseas (emember, I’m in Japan) is what is my vehicle? What year is it? Is it a Suzuki or a Ate parts interchangeable? Can I get parts from a Suzuki dealer in Kansas? After 30 ‘ef questions I'm writing this book hoping to eliminate ot at least lessen the amount of Japanese vehicles have at least two ways to determine its identity. One is the standard VIN » Sometimes the VIN plate is attached by glue, screws, or rivets. If your plate is missing will also find a permanent stamped VIN code on the body (Near or Under Drivers Seat), VIN Stamp ‘This body stamp just happens to be next to the ID plate. This is not always the case. It can be located almost anywhere as there is no set rule for this marking. Most common is under the driver's seat in the engine compartment or around the kick-panel on the passenger side. You will also notice that neither picture indicates the production year. That’s because in Japan we don’t specifically have a year! Totally confused now? A model year is not used, per say inJapan. If I buy the same vehicle in December, 2007 it is a 2007. If I bought a car that was manufactured in 2006 and didn’t register it until 2008 it is a 2008 car. To make it even more confusing, if import a 1969 Camaro to Japan today and register it, it is a 2008 Camaro. Instead of model years as the western world is used to, Japanese makers identify vehicles by code, The code will tell the parts supplier of mechanic everything about the vehicle. There is no room for error; for example between a 1996 or a 1997. We don’t have a California or a New York version. A code tells all about the vehicle, period. If you really want to know the vehicles manufactured year and you do not have a copy of the Japanese registration, look at the seatbelt tag. But remember, when ordering parts the year will have nothing to do with it. Mistaken Identity Note: We have had people call for help and to their surprise found out their Suzuki was really a Mitsubishi! Not all vehicle name plates have English names on them! Use the chart below to correctly identify your truck! ‘Note* Japanese can spell names up to four different ways. Listed bellow is the most common. ‘Manufactures Names ora Suzuki Toertut) Isuzu 7 Toyota Too orl0 Honda Daihatsu 1 Mitsubishi oF Nissan uL Subaru Too Mazda T Yamaha “| ‘Common Japanese terms on paperwork ‘(Ghakenshou) Title or registration (kabushikikaisha) Corporation (Ghadaibangou) ‘VIN 3 (nenshikiy Year of manufacture- (Not model year) (katashiki) ‘Vehicle designation code(model) l U Go) Color 1"Engine & Transmision Identification Location FeA sa00001 Fe petadionsentes’ SD yeni Engine Series Automatic Transmision ID plate JATCO CORP MODEL HH200 wo aService Data- Carry Truck and Every Van Fuel Capacity (Liters) Carry Truck 36L Every Van 37L Conversion 1.0 Liter= 0.264 Gallon Engine Oil Requirements | Maximum 5000Km | Al!Models 10W.30 | Capecity 3125 Miles 2.9 Liters Oil Filter Change 10,000 Km (Harsh conditions 2500Km) 4 Speed Mr | 2Yearsor | Gear Oi1 #90 LLiter 20,000Km | Suzuki (GL-4) 2wp | — 5 Speed 12Liter ‘Transmission Oil L Part Time 4wp | 2.6 Liter Full Time 2.8 Liter AT — | 2Yearsor | Suzuki Normal | CP2-6L 40,000Km | AT oil S06 Turbo | Cp2sL Normal | 101 2wD Turbo | 13k Differential 2Years or | 75W-80 awd Front O7L 20,000Km | (C5) PartTime — | Rear ToL aD Front o7L Full Time [Rear iaGAP (Millimeters) Turbo |ND WIGEXR-U 0.7 0 0.8mm NGK BPRSE Plug & Gap Normal | ND XU2EPR-U 0.8 t0 0.9mm NGK DCPRIE Normal _| Part # 28BI9R (Right positive connection) Battery AC Equipped _| Part # 38B20B Also Refrigerated Trucks Ignition Timing Carburetor Vehicles Injection and Turbo Charged Tle 950+-50 ‘Non-Turbo Tale 900+-50 7 Degrees BDC ‘Turbo Charged 950+-50 5 Degrees BTDC Note: See Vehicle Tag Mounted in Engine Room for Specific Details aMy Car Notes: wSuzuki Factory Tool Part Numbers . 1, 00018~14510Compreor tare: 09816-44310 | 4Nake om 18—sr010 ores 7340 2 Nahe: o0gr6—anzt0 | 2 abe: 98164510 | 2Vabe ;a0e17-a8290 Moke £09816 14910 ake Gade Remuner | Vb Gai nt Set niet Reamer tate opaie-stmo | Po Ges 0816-58210 | > Vahe 0818 ~38220( m2 Vane GOGLS— SEDI.) no16—24541 | VARS o0n16— A457 | Va 016 — 9792000 Sen cwois—77s10 | 8-10 ‘08800-0410 ‘09804-17810 Spring Compemor | Yacume Hose Joint Hexagon Weeach yet HolderSuzuki Factory Tool Part Numbers 8028-18210 Oil Seal Guide “SO wen sec shaft Pulley Holder mons 7310 Oi Premureguge Set | opis—rmo | L-Gagewsis-esi0-ont| OM Presute Gage | Yacume Ga | cans=eiseo 9915-0500 anit e220 Carnshaft Holder Compression gage 4Valve | Compression gauge 2Vale| ‘htachment ‘AtachimentFrame Mount Diagram & Torque 1. Front Mounting Member 2. Front Mounting Bracket Left (SWD) 3. Frot Mounting Bracket Left (WD) 4. Front Mounting Right Bracket (Truck) 5. Front Mounting Right Bracket (Van) 6. Clutch Cable Bracket (MT) (i ox=Torgue Spec (kgm)Engine Removal ‘Truck 2WD & 4WD 1. Remove Front Seat . Remove Front Door (Easy Access) . Remove Battery Drain Coolant Drain Transmission Oil . Disconnect Exhaust Pipe . Remove Rear Driveshafe . Remove Front Driveshaft (4WD) 9. Disconnect Clutch Cable (MT) 10. Disconnect shifter Connections 11. Disconnect Speedometer Cable 12, Disconnect Electrical Connections 13, Remove Heater Hoses 14. Remove Air Cleaner 15, Remove Air Duct 16. Disconnect Accelerator Cable 17. Disconnect Fuel Hose & Plug Line 18. Un-Bolt Mounts 20. Remove Engine 1. Speedometer Cable 2. Exhaust PipeEngine Removal VAN 2 &4WD AT-MT Versions 1, Remove Battery Connetions 2, Remove Engine Service Cover 3. Remove Rear Bumper Drain Coolant System Remove right-left wheel 6. Drain Transmision Oil 7. Disconnect Electrical Harness from Engine 8. Disconect Speedometer Cable 9. Disonnect Accelerator Cable 10. Disconnect Transmision Cable U1, Disconnect Clutch Cable (MT Vehicle) 12. Remove Water Hose 13. Disconnect Vacume Hoses 14. Disconnect Fuel Hose 15. Remove (L-R) Brake Drum 16, Remove (L-R) Driveshaft hub 17. Disconnect Diveshaft connections 18. Disconnect Exhaust Center Pipe Bracket 19. Remove Front Drive Shaft (4WD Version) 20. Engine & Tranny Stiffiner 21, Remove Muffler 22, Remove Exhuast Center Pipe 23. Turbo-Charger Air Cleaner (If Equiped) 24. Remove Oil Filler Pipe (If Equiped) 25, Disconnect Tranny Mount 26. Remove Rear Engine Mounting Bracket 27. Unbolt Engine Front Mount 28. Unbolt Right Engine Mount 29. Remove EngineIntake Manifold 1. Carburetor Base 2. Carburetor Insulator 3. Intake Manifold 4. Gasket Remove or Disconnect the Following |. Remove Front Seats . Remove Center Member and Side-Brake 1 2. i, 4. Drain Engine Coolant 5. Disconnect Carburetor Water Hose 6. Disconnect Carburetor Fuel Line 7. Disconnect Accelerator Cable 8. Disconnect Vacuum Hoses 9. Disconnect Electrical Connections 10. Disconnect and Remove Carburetor Assembly II, Remove Manifold Attachment Boks . Remove Intake Manifold No : Use Only New Replacement Gaskets Torque: Intake Manifold Bolts to (kg.em) 180~280Valve Lash (2 Valve) ‘Valve Lash adjustment 2Vahe Engine 1, Remove Cylinder head valve cover 2. Rotate crankshaft to TDC position. Remove distributor cap and verify rotor buttom is facing #1 eylinder. 5. Using the chart below; use a fecler gage to slip herween crew and valve stem, Set to the specifications 2 Adjunment stew Vat Sem Note: Adjustment Serew Torque: (kg.em) 150~200 GhinderNomber] 1] 2 | 8 lcatinder 1 | iN | [roc Te [ ex extinct Rotate the crank 1 tuen, (OGirete mas ime to adjust Valve clearence measurements 1 | or cold (my EX aT IN | Hot (=) | EX 4 Install a new valve cover gasket and install valve cover, ‘do not over tighten valve cover bolts 5. Set timing to specifications (see timing settings at the begining of this bool). 6. Test drive vehicleCarburetor Intake Manifold VAN Caution: Never Drain Fluids While Hot. Always Drain C je Temperature Drain Radiator Remove Engine Service Cover Remove Air Cleaner Assembly Disconnect Electrical Connections Remove Vacuum Hoses Disconnect Accelerator Cable Disconnect Fuel Lines and Plug Remove Carburetor Cover Disconnect Water Hose Remove Carberator Attachment Bolts and Remove Carburetor . Remove Intake Manifold Attachment Bots and Remove Mainifold Sea ae hen Intake Manifold Torq ke: m) 180-280 Note: Never Reuse CoolantExhaust Manifold Truck 1, Exhaust Manifold Upper Cover 2 2.Gasket 3. Eshaut Manifold x 4. Eshaust manifold Lower Cover Remove Seat Remove Air Cleaner Assembly Remove Muffler Remove Eshaust manifold Upper Cover Remove Exhasut Manifold Lower Cover Remove Exhasut Manifold Attachment Bolts Remove Exhaust Manifold ‘Torque: Manifold Bolts (kg.cm) 180-200Exhaust Manifold Exhaust Manifold Upper Cover 2. Gasket 3. Exhaust May 4. Lower Cover 5. Case 6. Bracket 2 ne Service Cover S t Manifold Upper Cover B Manifold Lower Cover 5. Remove Center Exhaust Pipe - Disconnect Sensor C 8. Remove Manifold Attachment Bolts 9. Remove Manifold ‘Torque: Manifold Bolts (kg.cm) 100-200 Bracket Bolts (kg.cm) 180-280Timing Belt & Tensioner Part Numbers Timing Bat 0) 1. 0.79400 » 2 BSM-TTG0L 4 omso-oc Timing Bat Cover-Outside “Timing Bet Cover Timing Bae AN) “Timing Belt (Tur) Seal Seu Tiing Conernide sea 1 Ring: Timing Caner r ussoazsss ‘s-eea6a5001 “imsng et (Tabs)Timing Belt Tensioner Van & Truck 1. Timing Belt Inside Cover 2. Camshaft Pulley 5. Timing Belt Outside Seat 4. Timing Belt Outside Cover 5. Tensioner 6. Timing Bele 7 nside Cover: Oil Splash 8. Crankshaft Pulley “Note: Timing Belt Must be Changed Every 100,000 Kilometers (64,000 Miles) ‘Tensioner Replacement 1. Raise the Front of Vehicle. Place Jack Stands as recommended in this book 2. Remove Engine Service Cover 3. Remove Aktinator Bele Outside Con 4. ‘Tum Crankshaft Pulley Over to TDC Posistion (Top Dead Center) Note: Verify Distributor Rotor is Pointed to #1 Cylinder & Transmission Service Mark is Lined Up Through the Veiw Hole. 5. Remove Atlinator Belt 6. Remove Crankshaft Pulley 7. Remove Altinator Bak Inside Cover 8. Remove Timing Belt Outsice Cover 9. Remoner Tensioner and Inspect. If Over 50,000 Kilometers Replace. It is Not Recommended to Rete Tensioner. If Tensioner Shows Damage Replace Timing Belt te Is Always Best Policy to Replace Tensioner & Timing, Belt asa Set sasioner or Helt Replacement Always Adjust Valve LashTiming Belt Replacement L. Timing Belt Inside Cover Camshaft Timing Pulley Timing Belt Outside Seal iming Belt Outside Cover Tensioner Timing Belt 2 x a ‘6 *Belt change every 100,000 Kilometers *If tensioner fails, always replace belt a1. Tensioner 2. Tensioner bolt Timing Belt Replacement Procedure 4. Turn crank pulley until pointed to TDC 2. Remove etank riley 3. Remove outside cover 4. Loosen tensionet 5. Remove old belt 6.Clean area, 7.Inapect pasts for damage or cracks (replace if damaged) Service Point Check tensioner for free spin. Any resistance replace* Reverse Procedure ne 5~10 at Variable Speeds ‘ming Settings UL. Check Valve LashValve Lash (2 Valve) Valve Lash adjustment 2 Valve Engine 1, Remove Cylinder head valve cover 2 Rotate crankshaft to TDC position. Remove distributor cap nd verify rotor buttom is facing #1 eylinder. 3. Using the chart below; use a feeler gage to slip between the adjustment serew and valve stem. Set tothe specifications listed below. Note: Adjustment Screw Torque: (kg.em) 150-200 L thine Gage Gieneonel TTS ICrtindee 1 [IN |O|O fro ex [o lcvtindeet IN ° [Rotate the ceanke 1 twen [ex SG (0 Gite mark =Time to adjust Valve clearence measurements IN 015 ait 025 EX om 4. Lostalla new valve cover gasket and install valve cover. ‘do not over tighten valve cover bolts 5. Set timing to specifications (see timin begining of this bool) 6. Test drive vehicle settings a the4 dnment ta Roster te Valve Lash (4 Valve) Valve lash adjustment 4 Vale 1. Remove Cylinder head valve cover 2. Rotate cranshaft 0 TDC posistion. Remove diswibutor ear and verify rotor buton is facing #1 cylinder 3. Using the chart below, use a feler gage (oalip between the adjustment screw and valve stem. Set to the specifications listed below. Cylinder Number] 1] 2 | 3 (Cylinder #1 ol ee in |o}o ex|o} jo 0.08 Cote (x) 7 7 0.10 on Hot ( a oe Adjustment screw lock nut torque (kg.cm) 100 to 130NS Opersing Temp Range) -‘~ uw gop 2 -) ew poe of ® Sean eee i Engine Oil Engine Oil Level Remove dip stick and check level. Level should be between the dots 2. If clean, add oil to proper level. Oil Change 1. Remove drain plug from oil pan. 2. Inspect oil for contaminents, if clean replace plug. 3.Filloil to proper capacity with recomended oil from the temperature chart. Verify level with dip stick. Oil Cpacity 2.3 Liter Check vehicle specifications chartBites imag cover Par or page Be Adapter a Szuki Equipement Engine Oil Pressure Test Oil Presure VAN (Caution: Make sure t cheek oil level is corrcet + Check oil evel add if necessary + Make sure ol is clean Change before test if dirty. -Hfcomtamiacnts sich as mctal shavings are ound, damage will occute to test equipment [At this point recomended to disassemble engine for inspection. 1 Remove plug ftom cylinder block ax shown, 2. Amtach gage and adapter as shown, 5 Star engine and run to operating temperature 4-Operating temp 9'C~100°C Rum engine 10 4000RPM. Presue range below. Oil Pressure Turbo 3.3~4.3 Non-Turbo 2.7~3.1 (ae) 5, Remove gage and adaptee. Use new silicon tape on plug and torque to specification bellow: 5. Start engine and inspect for leaks. hug torque (kg ex): 120~150 Pressure out of range: Replace pump and repeat procedure.Oil Pump Parts 1 Pamp (AD) 1. 1440076820 OW Pump Set 2 tabso7oH0L Rowe Ser 5. mimanaies Sore 4 UalS0G0X00 Rei Vnte Set 5. 1MW-74GIO Gasket Oi Pump Case in 8 i 7 onss06308 Bole S. o1ssoiesss Bale Pump (Al)1 Ower Rovor 2. Inner Rotor ing belt tensioner, timing belt. *more information sce "Timing belt removal”, Remove 2. Timing belt pulley 3. Engine front mounts ‘pan 5. Oil strainer 6, Remove the oil pump bolt (10) 7. Carefully remove assembly Pump Clearence Check Outer rotor 10 case elearanee must be below 0.13 (am). ‘Replace if clearence is out of range*o 1. Ceankahalt 2.0i1Seal Guide Oil Pump Side Clearence Measure side clearence. Side clearence must be below 0.15(mm) *Out of range replace* Auach oil pump *Do not over torque ‘Torque bole to (kggemm) 90-120 Oi Pump Gasket “Make sure all of the old gasket has been removed ans surface is clean hefore installing new gasker® ble timing cover assembley rays fill engine with new oil® Run engine a check oil pressure (begining of chapter)Oil Pan & Steainer ‘When ever removing of replacing the oll sainer always replace the O Ring, Before installing the O Ring, coat ‘with clean engine cl it Stesincr torque (kgm) 90-20 ‘Type! Oil Pan Gasket. Apply High Temp Gasket Sealer "Note: Make suce all suefaces are ol fee before applying sealane* Suzuki Sealant Part#1207C, 99000-31150 i Pan Torque (kgm) 90-120 ‘Type2 Oi Pan Gasket. Apply High Temp Gasket Sealet Note: Make sure all surfaces ate ol fee before applying sealane™ Suzuki Sealant Part#1207C. 99000-31150, Oi Pan Torque (gem) 90-120, aCylinder Head, Camshaft, Valve, Rocker Arm 2-Valve Head Camshaft 1. Cylinder Head 2. Valve Guide 4. Rocker Arm Shaft 5. Rocker Arm 6. Valve Spring 7. Intake Valve 8. Exhaust Valve Yokohama Motors Disassemble-Disconnect-Remove The Following 1. Remove front seat 2. Disconnect negative (-) battery cable 3. Remove Engine service cover 4. Deain coolant system 5. Remove air cleaner ease 6. Remove water pump 1 8 . Disconnect fuel hose Disconect vacume hoses 9. Disconnect accelerator cable 10. Disconnect wiring 11, Remove timming belt (see previous) 12. Remove cam shaft pulley 1B, Disconnect exhaust pipe and 14. #1F equipped Turbo attachments 15. Remove disteibutor 16, Remove valve cover 17, Remove cylinder head bolts (8) / 18, Remove cylinder head 4.am Shafi Har Tat 051-8207) foldCylinder Head (2-Valve) Yokohama Motors) 4. Remove Rocker Arm Shafts Screws 2, Remove intake and exhaust rocker atm shat, then remove rocker arm shaft springs 3. Carefully slide out cam shaft 4. Using a valve spring compressor remove springs “Snote-lable springs from original location ‘*Caution-never hit sticky springs with a steet hammer use only soft brass head hammer 1. Valve spring compressor 2. AdapterCylinder Head (2-Valve) Caution- Springs under extream pressute, use saftey glasses when removing springs 7. Remove valve lifter, spring retainer, valve spring 8. Remove valve 9. Remove valve strem oll seal, next remove valve spring seat Caution-Never re-use ol seas! [Note-if valve guides must he removed use Suzuld to! number (09916-44910) Inspection Using a micrometer cheek the cam hight. If its out ‘of spec replace camshaft Cam Hight ‘2° [Acceptable] Limit Titake eam Gem) w.14 30.6 Exhaustcam @ | 2.75 28Cylinder Head (2-Valve) Camshaf Journal “To determine the amount of out measure each ‘each end of the journal Within limits 0.050-0.091 Journal Kn Replace 0.15 Camshaft Outside (ea) | Diameter (me) Diameter 8.425~43, 50 | 5, 500~43,516 wos ams 43, 700~43, a | | “o 725, ars~n.00 | .o0~8. 916 ans aos | 4.205~44.050 | 44. 100~44, 15 48.915 44.125Cylinder Head (2-Valve) Rocker Arm Shaft Inspection Use a dial gage to check diameter for warp age Maximum allowance 0.12 (mm) Roker Arm and Roker Arm Shaft Clearance Rocker Arm and Shaft clearence Allowance 0.005-0.040 Replace 0.06 Valve Stem & Guide Measurments Allowance | Li UN) 5:465~5. 400 Valve Stem outer Diameter” | EX] 3s50=a.465 | — Valve Guide iN] Ssm~5512 | 550 Taide ae Diameter Ex | ssm~s5i2 | a5 Tem & Galle Saba fn 5G cena. | aor oo am Lae] ex | acs~o06 | 0.00Cylinder Head (2-Valve) Tha bore gage is not fo use a dail gage. Us right as an example lable, it posible dhe diagram to the Ifthe play between the stem and the guide the range below. Replace valve Place a Valve in a V block, and using a Bage rotate valve. Maximum allowance: 0.08 (mm) Valve Seat Angle] EX 13-L5(n ‘Valve to Valve Seat face IN 13-45¢mm) ) ‘Valve Seat Cutter 45 Deg. Use extream caution when cutting valve seats, It is recommended to start with a small cutter and work up t0 a larger cutter. Finally with 45 degree cutter It is recommended to take the head to a machine shop for this operation. Over- ccunting can cause serious damage to the head. ®Cylinder Head (2-Valve) Valve Lap Degree Diagram Cylinder Head Plane Use a straight edge bar and a feeler gage Allowange 0.05(mm) ‘Over range, have head machined to spect Manifold Face (Cylinder Head) Use a straight edge bar and a feeler gage. Allowance 0.10(mm) *Out of range, have face milled at a machine shop*8] Cylinder Head (2-Valve) Assembly 1. Before installation of new valve guides use a Hmm reamer. 2. Pre-heatcylindet head to 80-100 Degrces Celcius Use the proper tools as displayed in left. Install guides. Oversize Guides (mm) 0.038 3. After installation, use a 5.5(aim) eeamer to verify "*Note-lubicate new seals with lean engine oilCylinder Head (2-Valve) Assembly 6. Lubricate valve with engine oil and slide into ‘guide, Make sure guide slides without 7. See chart om left for proper spring seating 8. Using a valve comptessor, install valve keepers 9. Heavily lubricate camshaft with engine oil ‘and install 10, Install rocker arm shaft. Make sure tang isin the correct direction as noted in the diagram on the left. F “Crank Polley directionCylinder Head (2-Valve) Intake Manifold Side Pees) c ie C2 Exhaust manifold side Assembly Install new head, fom the left for 1. Follow the diagram Do not use sealant Make sure all surfaces are clean Install head assembly Torque to (kg.em) 550-600 Follow torque sequence on the chatt tothe left Assemble remaining parts asin previous section of this chapter, 2Cylinder Head (4-Valve) ‘Yokohama Morors 1. Camshaft 2. Valve rocker intake No. 1 Arm 3. Valve rocker intake No.2 Arm 4. Rocker Aem No.1 Shaft 5. Rocker Arm No.2 Shaft 6. Valve Spring Set 7. Intake Valve 8. Exhaust Valve 9, Exhaust Valve Roker Arm 10. Cylinder Head / 1. Camshaft holder (09917-68220) Revomal 1. Drain coolant system 2. Remove service cover 3. Reome air cleaner case 7. Disconnect accelerator cable 8 Remove timing bel (see previous steps) 9, Disconaeet Elcetrical connectors 10, Remove camshaft timing pulley 1H. Remove timing belt inside cover 12, Remove exhaust center pipe 15, Remove exhaust manifold 1. Remove eylinder headCylinder Head (4-Valve) Disassembly Rocker Arm Shaft Remove TImtake Rocker An ‘Camshaft Caps Camsha Remove Cylinder head Bolts (8) Remove Cylinder Head 1 Vale Compressor] Using sping compres smn vas Ps 2 Adapter ‘*Spring under extreme pressure, always apepetaey glee ‘Yokohama MotorsCylinder Head (4-Valve) Inspection Vale guide remover Using an appropriate tool, eemove valve guides *Note-Never re-use valve guides* Camshaft Warp Age Using a dail gage, check the camshaft Allowance: Below 0.10 (mm) Check the camshaft housing caps for setatches,ete. "IE visable damage existe-eplace*Cylinder Head (4-Valve) Inspection Re-insert camshaft into head and torque caps Torque (kg-em) 90-100 *Make sure camshaft is well oiled* Using Plastigage, check clearance Allowance 0.045-0.087(anmm) Limit 0.12¢mm) Rocks Atm Fo0t i emtne Screw Rocker Arm Shaft Clearance = Allowance 0,000,040 - Limit 0.006(aum)Cylinder Head (4-Valve) Valve Inspection oom) | (mumy Allowance | Limit Valve Stem | IN | 4.065~4on0} - Bx | 4oso~to0s | - Valve Guide | IN | 5.0m~s012| 5.04 Taner Dia | ex |S.0m~3. 012) 5.04 tw |aceoma, on] aor | ex |aonma om] 008 Ira bore gage is not available, use a dailgage as in the example to the left Limice IN 0.14(@m) EX 0.18(mm) Using « V-Block and a dail gage check valve face Limi .03(eam)Cylinder Head (4-Valve) Surfaces Using a straight edge and a feeler gage, check surface clearance Allowance 0.05(mm) Using a straight edge check clearance Manifold Face: Allowance 0.10(mm) Valve Sping Chart — Allowance | Limit Innce | 2.9 3.8 Valve Spring(mm) |— [ Valve Spring Pressure (4/41. 5m) |eem2e| meCylinder Head (4-Valve) T 1. 10.5mm Reamer (09916-37320) 4. Valve guide installer attachment 2 Valve quide installer handle 3. Vue ide guide 1.Vahe Guide 2.5mm Reamer Assembly Using 105(me) reame, ream out guide holes Warm head to herwcen 80-10 degrees Celsius Use proper valve guide installation tool sNote-Never ress vale guides? Maximum oversize guide use: 0.031) [After guide installation, use aSmm reamero clean ‘guide holes “Make sure no shavingy ae left in the holesVale Spring inder Head (4-Valve) Assembly 1. Large Pitch Side 2. Small Pitch Side 3. Valve Spring Retainer Side 44 Valve Spring Seat SideCylinder Head (4-Valve) ‘Assembly Install head gasket using the diagram on the left. "Make sute the gasket is ol fee and clean* Do not use sealant on the head gasker® Hest Cylinder Head Torque 600-650(kg-cm) L Arm 2. Pivot 1. Timing Pulley Key 2. Oil Seal Camshaft Torque Spee (gem) 90-120Cylinder Head (4-Valve) Assembly | Assemble Rocker Arms Camshaft Holder ssa 7 1. Timing Bete Inside Cover ‘Timing Belt Inside Cover (kgsem) 90-120 Do not over worque® Set Camshaft pulley torque (kgsem) 500-600 Assemble accessories and attachments Set Valve Lash To Spec (sce previous)Piston & Rings-Connecting Rod-Cylinder Piston Diagram 660c¢ 2 Valve and 4 Valve to fing Pet tae ge Tae y aera ret ‘poe et 300 pares "*Note-When remoring pistons place vacume hose ot fel hose over the bolt ends to prevent cylinder ‘wall scratches during temoval*™ Cylinder Diagean ‘Top After piston removal check for lip to determine ‘excessive wearing. Excessive wearing will require ‘lindex boring, Oversize pistons and rings ate available in 0.25(mm) oe maximum 0.50(mem) sizes. Use the chart on the left to determine diameter limits. The following charts and diagrams provide sam | the correct sizes per horing requirments Bottom EsmePiston & Rings-Connecting Rod-Cylinder Cylinder Bore Measurements 1.150 Piston Rings 1. Piston Ring 2. Thickness Gage Cylinder Bore Inside Diameter: 65.070(mm) Taper 0.10(mm) “Note: one at mote elindees are oot of round ot Ti all eyndrs moat be bore to dc ame Piston Size aon | Ace | _ 8 ox ws = Oversize 0.25 | 65, 215~65, 235 [7 overine 080 | 0.0508 a5 Ring Clearance Chast Ring ‘side comme? = Second a0Piston & Rings-Connecting Rod-Cylis Measure Ring End Gap Piston Pin Connecting Rod Side Clearence [Before installing mew piston rings, the ring end gap must be checked, 1. Cylinder Block 2. Fecler Gage 3. Piston Ring “Note: Check: from top to bottom of eylinder* = Allowance | Limit Top Ring | aso | a7 2nd Ring — | 0.15~0.90 | 07 1 Pin and Piston Boss Clearance Piston Pin Hole Outer 17.9951, 000 (15, 90518, 000) Piston Boss | 18,006~18,014 - Inner Dia | 4.00616. 0149 C necting Rod Clearance Allowance: 0.10.2(enm)Piston & Rings-Connecting Rod-Cylinder disassembly, this test should he preformed* Beend Rate Failure @ 0.05(mm) ‘Twist Rate Failure (@0.10(e%m) ‘ligament Machine Connecting Rod Bearings “*Note: Do Not Remove Old Bearings With Sharp Tools Damage Will Occure* Note: Always replace both upper and lower bearing as ase “*Note: If an etegulatty is indicated, measure the etank journal with a micrometer “*Note: Only standard (STD) replacement hearings ava ‘Warning: Do not rotate the crankshaft while Bearing Clearance Measurement Clearance Allowance 0.020-0.040(mm) Bearing Size Nosmak STD Crankshaft (mm) 35.982-36.00 1 Plastigage 2, Seale Bearing Cap Torque (kgzem) 310-350Piston & Rings-Connecting Rod-Cylinder Connecting Rod Alighment a [tf 4 rod knocking noise was detected before -mbl this test should he preformed ™ Bend Rate Failure @ 0,08(mm) ‘Twist Rate Failure (@0.10(mm) Alignment Machine “Note: Do Not Remove Old Beatings With Sharp Tools Damage Will Occure* "Note: Always replace both upper and lower bearing, as aset™ Note: If an regulary i journal witha mies indicated, measue the crank * “*Note: Only standard (STD) replacement bearings available ‘*Warning: Do not votate the crankshaft w aging material is berween the bearing and journal Bearing Clearance Measurement Clearance Allowance 0.020-0.040(mm) Beating Size Normal: STD (Crankshaft (mm) 35.982-36,00 1. Plastigage 2. Seale Bearing Cap Torque (kg.em) 310-350Piston & Rings-Connecting Rod-Cylinder Piston Assembly "Note: Always use new piston rings* Install the connecting tod to the piston, making sute the piston direction arrow on the piston facing the feont of the engine. Piston Make sure the piston pin is well lubricated, install retaining, * 2. Arrow to Fromt | clips and verify they ate well seated. 3. Connecting Rod 4 Oil Hole (acing Intake) Piston Ring Chart 1. Top Compression Ring 2 Secondary Compression Ring, SOW Ring Ring Gap Location Use the chat tothe lft for Ring Gap Direction 1. Areow (Pointing to front of engine) 2. Top Compression Ring 3. Sccond Compress fac 5. Intake direction 6. Exhanse 7.45 degrees 8.01 Ring 1. Guide Hose w protect jowenalMain Bearing-Crankshaft, Cylinder Block 1. Cylinder Block 5, Thrust Bearing 9. Input Shaft Bearing 2.Front Main Seal 6, rear Oil Seal 10. Flywheel 3. Main Bearing 7. Oil Seal Housing Gasket 4. Crankshaft 8. Oil Seal Housing Yokohama MotorsMain Bearing-Crankshaft, Clyinder Block Crankshaft Inspection “Note: Before removing crankshaft verily previows rorque setting were correct Follow the torque sequence guild to the left. ‘Torque should be (kgscm) 550-600 Remove Crankshaft Crankshaft Journal Taper/Out of round Limit Using a dial gage check the crankshaft The est should involve minimum 3 tuens per Journal Out of cound Limit: 0.05(en) Inspect thrust bearings for unusual ware, Remove thrust bearings and discard **Not: Do not re-use dheust bearings Replace with new bearings iS lL. Theust BearinleMain Bearing-Crankshaft, Cylinder Block Crankshaft Inspection Main Bearing torque (kig-em) 550-600 Cranckshaft End-Play Allowance: 0.13-0.28(mm) Using a micrometer, check journal taper Crankshaft Journal STD 43.982-44,000(mmm) Journal Taper Allowance: 0.01(mm) Re-Install Crankshaft and torque to Spee ‘Torque (kg.cm) 550-600 Use the diagram on the left for sequence Crankshaft Bearing Orifice (Oil Hole) Allowance: 0.020-0.040(mm)Main Bearing-Crankshaft, Cylinder Block 1, Rear Oil Seal Cylinder Block Deck Check Taseall new rear oil seal “*Note: Take cuation not co damage seal Lip Flywheel Roundness Check Limit (on) 022 Flywheel Torque: (kg.em) 400-450 ‘Using a staighr edge bar and a feeler gage check Ihead deck for levelness Allowance: 0.05(am) ‘Out of spec, have deck re-surfaced aEngine Related Diagrams & Part Numbers Engine Gasket Set av) Gast Set Engine Gasket: Cinder ead baate of 9. #737300 ML A2ENGO Gasket Throtle Body 12. 416539.76001 Gasket Oil iter Adapce Cae (AWD) Bipuserte — Gaket1 mst07KAW —O:1Pan 2 omur-o0ss a ont2 5. otataatas 101sTo06I6s Baleranks AV) Distato-o89 Disatoiae Ring Se Ps Ring Set: Piston OS: 05 Paton OS: 0.25 Piston: OS: 030 Pisun Pi Snap Ring Connecting Rod Assomby . (Com Rod Bearing US: 028 kaso ett D4. i00GINGOAD Crane Beasing Set SED. 92 snimtatst0425 — Ceanhahite Meng Sot US8.25 102, DsomseRe-on That Reorng: E286) I tomas Osea Betis 12 estate, Timing Bek Paley 1 Banettio0 Crankshaft Paley 1 ssa? key 1 ernennoo Ceambat (48) Bh teen 78X00 24, este 25. i7saL74noF Cranks (4¥) Cranks Paley Bote ranks (AY) Pat Sea, sons Honing Of Sea Pin Flywhee Bale tos Bearing: Bop Pint) Spring Pin 6x (AT) ele Aerator £758 (LEM) Sate 76Cente (Tube) BUBSHES0 Ring Set Piston STD A500 Pati STD (Track). {auLeapstono (an) IaMLc8480408.Piowns 08 025 (7) Iaultcapsiaas 128 (Van) RILEAs0-50 0 (Truck) ton OS 030 (Vim) Piston Pin CT) Sau Ring 1216076680 Conmecting Rod Assembly (1) Biewndst Connecting Rul Arce (¥) misea8033. Ne L RUSISAUL-ON0 Co Roa Besring (1) IKLSISI-0N0 Con Kod Beans (V) IsLstI-25 earng: Under: 0.25 (1) ist ewring: US0.25 (Van) 221s0EI0 Cranks (1) 2 EBEAOISO Crank (8) B300-1810440 Bearing St Crankshaft SED (E &V) ‘asoo-cstouws Rowing US-0.25 (TEN) 12300-12820 Thrust aring 128 123H042020.012 Thru Bearing T2863 (233208 Oise oat Cea (Tudo) 2 26544401 Timing Bet Paley 1. evattW9 — Cronksbat Pulley 14 ossasos9 Key 15. 161940000 Crane alley Bak 16 Onon-c00s Oita wand 1. UseLTaBOL ise 1 o1ssioaens Bot N2I200255 Screw 20. ORM Pin 2 banranen —Fywhect 2. wiesioos? Bole toaty 2. 2025-70800 Bewring: Input Shalt Det ab2t0609—Pin(StT) 242.0905-06008 Spring Pin 6x4 (AT) DS TRETAAOL “Nernst Bl 1-79¢mm (LEMESO) Crust (Turbo)CamshatVaes 4¥) OilSeal 350796 Sats Rocket Arm No. Shafts Rovhes Arm Ne Rocker Arma ntae No Rocker Arm: Intake No Rocker Art: Exhaust Austen Serv: Inte Adjustment Sere 1. bats Non ML bxtsasbe0 No 12 BeOLate | Washer Naver fntake Vie: Exh Springs Vane Revs eeper (Vis) Seat Cae Spring Camstuatvates (Tbs) ratiso moss ‘pouzans0 1a. 95-70000 HL oeatsontw 2098 Laeseanto © amar antes Oil Sel S2st796 Plates Carat Thews Shaft Vale Rocker Arm: Vale Rooker Spring Rocker Arm Make Totake Valet Exhant Spring Vale Nur Recpe (Vas) Revie Seat Vale Spring 7Timing Bae (aN) 1 WTS ey Timing Bee (AY) Timing Bed (Tanboyhte Body (4) ssi-tns0 135.039 eta Menifld Nok Bracket Intake Manifold Nod ale Bracket: Serge Tank Toga Manifol/ Theat Body (4) | Inake Maniford/Thett Bo (HN) Pact 2 26 ISWETIGOO Gaskets Thott Bey 2 as0-06508 Hat Nite Puscoba Ine Maniford/ ete Boy (48) Pat 2