Suzuki Carry & Every English Version Factory Service Manual Translation F6A Series 660cc DE51V Engine ie ORS Parts Manual DC51T Second Edition DD51T DC51B DA52T DB52T James L. Danko 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 graphics in this publication if the author, unless otherwise noted of 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 ate not in anyway associated with, and are not authorized to act on behalf of any of the manufactures listed in this book. All registeted 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 Motors 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 ‘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, ot an air-filtet are not in this book. Itis full of diagrams and schematics that are understood by a professional mechanic. How to do an engine overhaul using the correct sizes, measurements, torque, etc, You will have the same information as the Suzuki F 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) |. Intake Manifold Every Van (Carbureted) I, Intake Manifold (Throttle Body) ‘2. Timing Belt Parts and Part Numbers 43. Timing Belt Tensioner Truck & Van 14. Timing Belt Replacement Truck & Van 15. Valve Lash 2 Cylinder 16. Valve Lash 4 Cylinder 17. Oi 18. Oil System Pressure Testing Oil Pump Removal-Replacement . Cylinder Head 2 Valve Overhaul Pistons Connecting Rods Cylinder Block . Main Bearings, Crankshaft, Cylinder Block . Crankshaft Inspection, Oil Seal, Flywheel . Parts Section . Conversion Charts 8s RERRSuzuki Carry Truck 2WD & 4WD pest positJacking LocationsFloor Jack Locations 4wDUnder Seat ‘Other Locations of ID Plates 2D Plate axtastat Side Inner Fender | Sliding Door (Body Panel) Motors (English) Vehicle Identification Eyer Suzuki Carry & Every Example: DESIV=Vehicle Series 500001=Production number “In Sequence* Every Van DESIY-500001 DF51V-s00001 Carry Truck pesiT-100001~ DDS1T-100001~ pesiB-100001~ * Note: Model Years do not exist in Japan, only Series. 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 ehcek the seat belt tag oF ny paperwork you have from your dealer, 1D Plate Decoder L Vehicle Series 2 Vehicle VIN Number 3. Engine Series 4. Engine Tewe Size(ec) 5. Body Color Code 6. Imerior Color Code or Package Code 17. Makers Code (For Sales Dep. Information) 8 Suzuki Corporation(apanese)‘The Suzuki Carry has been a work horse in Japan for decades. Officially it is classified as a0100 (Kei-vehicte of 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 hour, 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 ate 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 eeooeoecee 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 either superchargers or turbochargers. Turbochargers and superchargers were not used that much on trucks but heavily on vans. Since vans we designed for on-toad 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 dirt in a turbo would provide disaster for the engine.Vehicle Identification ‘One of the most highly requested questions we get at Yokohama Motors from overseas (remember, P’m in Japan) is what is my vehicle? What year is it? Is it a Suzuki or a Ace parts interchangeable? Can I get parts from a Suzuki dealer in Kansas? After 30 ‘ef questions I’m writing this book hoping to eliminate of at least lessen the amount of ts. 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, of 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 of around the kick-panel on the passenger side. } You will also notice that neither picture indicates the production year. That’s because in Japan | wwe don't specifically have a year! Totally confused now? A model year is not used, per say inJapan. If buy the same vehicle in December, 2007 it is a 2007. If | 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 L 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. Ifyou 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 yeat will hhave 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 ort TD ertidd Tew doo orl) Honda oor a Mitsubishi To ertouoo ooo Subaru 7 i Yamaha ‘Common Japanese terms on paperwork ‘(Ghakenshou) Title or registration (kabushikikaisha) Corporation. (ehadaibangou) ‘VIN U0 (nenshiki) ‘Year of manufacture- (Not model year) (katashiki) Vehicle designation code(model) (iro) Color wEngine & Transmision Identification Location Fes 5300001 fg or podidbaneiet SO) Sseondary Engine Series Automatic Transmision ID plate JATCO CORP MODEL HH200 aRService Data- Carry Truck and Every Van PasliGepectny Ulin | Garnp'toaete ar, | COMVERSE TR 808 Celio Every Van 37L, ] Engine Oil Requirements | Maximum 5000Km 3125 Miles All Models 10W-30 Capacity 2.9 Liters Oil Filter Change 10,000 Km (Harsh conditions 2500Km) Speed MT 2Years or | Gear O11 #90 LiLiter 20,000Km — | Suzuki (GL-4) 2wD 5 Speed 1.2Liter ‘Transmission Oil Part Time awD | 2.6 Liter Full Time 2,8 Liter AT — | 2Yearsor | Suzuki Normal | CP 2-6L 40,000Km — | AT oil SD06 Turbo Cp 2.8L Normal | LOL 2wD Turbo 1.3L Differential 2 Years or 75-80 4wD ‘Front 0.7L 20,000Km | (GL-5) Pan'Time | Rear ToL 4wD Front 0.7L FullTime | Rear Tab 6GAP (Millimeters) Turbo | ND WIGEXR-U 0.7 10 0.8mm NGK BPRSE ‘Plug &Gap Normal | ND XU2EPR-U 0.8 t0 0.9mm NGK DCPRTE Normal _| Part # 28BI9R (Right positive connection) Battery AC Equipped _ | Part # 38B20B Also Refrigerated ‘Trucks Ignition Timing Carburetor Vehicles Injection and Turbo Charged Tale 950+-50 ‘Non-Turbo Tdle 900+-50 7 Degrees BTDC ‘Turbo Charged 950+-50 5 Degrees BIDC Note: See Vehicle Tag Mounted in Engine Room for Specific Details 7My Car Notes:Suzuki Factory Tool Part Numbers oms—en0 Oa Fie Wien Skee 1, 0018 14510Compreor Nake: oan6—s00 2Nike :coart— 98200 cdve = o10—a8210 Nae: OF 14910 NINN vane nie-srmgo | RM Sees | Gen on8—88210 | > \ahe 918 ~ 32200 se) 2 Ve Oe | onaie~sisat [EVANS 00018 SHSTOG ae) | Vale O18-ITIOMUTSEN)—eamer Hane idee Gdetoeaie —_|* | ees | | vwois~r7310 Speng Compressor 900-0410 comet 17810 Hexagon Wench hye HerSuzuki Factory Tool Part Numbers \, | nes 77310 Se eee oe | _ peemincane a -e Compression gage 4Valve [Crankshaft Pulley Holder | _ Camshaft Hokler ‘Atachancat o2015-e7a10 Vacume Gage ons15— 1610 Compression gage 2Vahe| ‘Attachment Oi Peau T-Box 19mm Wrench | Attachment =Frame Mount Diagram & Torque 4. Feoat Mounting Member 2. Front Mounting Bracket Left ($WD) 3. Front Mounting Bracket Left (WD) 4. Froat Mounting Right Bracket (Truck) 5. Front Mounting Right Bracket (Van) 6. Chutch Cable Bracket (MT) (Box=Torque Spee dem)Engine Removal Truck 2WD & 4WD 1. Remove Front Seat 2. Remove Front Door (Easy Access) 3. Remove Battery 4. Drain Coolant 3. Drain Transmission Oil G. Disconnect Exhaust Pipe 7. Remove Rear Driveshaft 8, Remove Front Driveshaft (1WD) 9. Disconnect Clutch Cable (MT) 10. Disconneet shifter Connections 1. Disconnect Speedometer Cable 12, Disconneet Electrical Conncetions 13. Remove Heater Hoses 1 14. Remove Air Cleaner 15, Remove Air Duct My 1G. Disconneet Accelerator Cable eA. dmin Pug | 17. Disconnect Fuel Hose & Plug Line 18. Un-Bolt Mounts 20. Remove Engine 1. Coolant Drain Plug 4. Speedometer Cable 2. Exhaust Pipe1. Coolarit Drain Plug ‘Manat Trans Vehicle Engine Removal VAN 2 &4WD AT-MT Versions 1. Remove Battery Connections Remove Engine Service Cover Remove Rear Bumper Drain Coolant System 5. Remove right-left whee! Drain Transmision Oil , Disconnect Electrical Harness from Engine Disconect Speedometer Cable 9. Disonnect Accelerator Cable 10. Disconnect Transmision Cable AL, 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. Unbokt Right Engine Mount 29, Remove EngineIntake Manifold 1. Carburetor Base 2. Carburetor Insulator 3. Intake Manifold 4. Gasket Remove of Disconnect the Following |. Remove Front Seats 2. Remove Center Member and Side-Brake 3. Remove Air Cleaner 4. Drain Engine Coolant 5. Disconnect Carburetor Water Hose 6, Disconnect Carburetor Fucl Line 7. Disconnect Accelerator Cable 8. Disconnect Vacuum Hoses 9% Disconnect Electrical Connections 10. Disconnect and Remove Carburetor Assembly: AL Remove Manifold Attachment Bolts . Remove Intake Manifold Note: Use Only New Replacement Gaskets ‘Torque: Intake Manifold Bolts to (kg.em) 180~280Valve Lash (2 Valve) ‘Vae Lash adjustment 2Vahe Engi 1 Remove Cylinder head valve cover 2. Rotate crankahaft to TDC position. Remove distributor cap and verify rotor buttom is facing #1 cylinder. betwee 3. Using the chart below, une a feeler gage t x the adjustment screw and valve stem, Set to the specifications listed below. kg-em) 150-200 Adie Sr tttew 2.Adjvumene sew 3 vate Som irNomboe] 7] 2] 3 T ° [Cylinder 1 1 [Fie froc f ex fol [o | estinaert IN lo feeeticemiinm Tex] fol (© Givete mark = Time to aduse Valve clearence measurements N 05 a EX oT IN 0.25 Hor (=)Carburetor Intake Manifold VAN Caution: Never Drain Fluids While Hot, Always Drain Coolant at Outside 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 10, Remove Carberator Attachment Bolts and Remove Carburetor I, Remove Intake Manifold Atachment Bots and Remove Mainifold Intake Manifold Torq (kgsem) 180~280 Note: Never Reuse CoolantExhaust Manifold Trick 1. Exhaust Manifold Upper Cover 2. Gasket 3. Exhaut Manifold Q 4, Exhaust manifold Lower Cover Remove Seat Remove Air Cleaner Assembly Remove Muffler Remove Exhaust manifold Upper Cover Remove Eshasut Manifold Lower Cover Remove Exhasut Manifold Atachment Bolts Remove Exhaust Manifold “Torque: Manifold Bolts (kxg.em) 180~200Exhaust Manifold Van Exhaust Manifold Upper Cover 2. Gasket 3. Exhaust Manifold 4. Lower Cover 3. Case 1. Jack Up Front of Vehicle 2. Remove Engine Service Cover 3. Remove Exhaust Manifold Upper Cover 4. Remove Exhaust Manifold Lower 5. Remove Center Exh 7. Disconnect Bracket Attachment 8. Remove Manifold Attachment Boks 9. Remove Manifold ‘Torque: Manifold Bolts (kg.cm) 100~200 Bracket Bolts (kg.cm) 180~280Timing Belt & Tensioner Part Numbers “Timing Bat V) ‘Corer Ting Be Tie Gover: Outside 4 gin-06406 Spacer GSN 7 Bolted Ge Sea: Timing Pel CnerOueide Juste ERing: Ting Bel Cer Sea i 1 1594-70800 Sea Seal Set Timing Covetnsie Cap OD36 Pulley: Camabat Timi ae I omzneasent Pin ming Bak AY) “Timing Bele (Tord) Batutnside Ibvetesot Cover Outee estes Gromit (omeccios Spacer aaMANI7 Somer tear en20 onsets at B ttae-tdate Seal SoTiming Covertosile 5. Msee7aB00 Sen Dake Taine ‘Tensor Dot Paley: Cann Timi halt Pin Timing Bat (Turd)Timing Belt Tensioner 1. Timing Belt Inside Cover 2. Camshatt Pulley 3, Timing Belt Outside Seat 4. Timing Bel Ouiside Cover 5. Tensioner 8. Crankshaft Paley ing Belt Must be Changed Every 100,000 Rilometers (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. Remore Altinator Belt Outside Con 4. Tum Crankshaft Pulley Over to TDC Posistion (Top Dead Center) Note: Verify Distributor Rotors P lind && Transmission Service Mark is Lined Up Through the Veiw Hole 5. Remote Atlinator Belt 6 Remove Crankshaft Pulley 7. Remove Altinator Bele Inside Cover 8. Remove Timing Belt Outsicle Cover 9. Remover Tensioner and Inspect. [f Over $0,000 Kilometers Replace, tis Not Recommended ‘to Reuse Tensioner. If Tensioner Shows Damage Replace Timing Belt. Note: Its Always Best Policy to Replace Tensioner & Timing Belt asa SetTiming Belt Replacement 1, Timing Bek Inside Cover 2 Camshaft Timing Pulley iming Belt Outside Seal imine Belt Outside Cover Tensioner ming Belt vw *Belt change every 100,000 Kilometers "IE tensioner fails, always replace belt 21 Tensioner 2. Tensionc® bolt Timing Belt Replacement Procedure 1. Turn crank polley until pointed to TDC 2. Remove crank pulley 3. Remove outside cover 4 Loosen tensione 5. Remove old belt 6. Clean area 7. Inspect parts for damage ot eracks (replace if damaged) Service Point * Check tensioner for free spin. Any resistance replace* at Variable Speeds Settings UL, Cheek Valve LashValve Lash (2 Valve) Valve Lash adjustment 2 Valve Engine 1. Remove Cylinder head valve cover 2 Rotate crankshaft co TDC position. Remove distributor cap sand verify rotor buttom is facing #1 eylindes 43. Using the chart below, use a fecler gage t stip between the adjustment serew’and valve stem. Set tothe specifications listed below Note: Adjustment Screw Torque: (kg.em) 150~200 Cylinder Nomber] 1] 2] 2 lestindee OBE Ipc ex |o oninaer 1N Tusa Gage Rocate the crunk urn ex | fo (O Cite mark =Time to adit Valve clearence measurments IN 0.15 EX an Cold (w=) A. lnstall a new “do not over tighten valve eo 5. Set timing to specifications (see timing settings a the begin i 6. Test drive vehicleValve Lash (4 Valve) ‘Valve lash adjustment 4 Valve 4, Remove Cylinder head valve cover 2. Rotate cranshaft to TDC posistion. Remove distributor car and verify rotor buton is facing #1 cylinder 43. Using the chart below, use a feeler gage to slip between ‘the adjustment screw and valve stem. Set to the specifications listed below. 2] ° ° {Cylinder #1 i ° Rotate the crank f uta EX ° (Circle matk=Time to adjust iw] ee cum |) ex) aw tw |e Hose {0 x) aR Adjustment serew lock nut torque (kg:cm) 100 to 130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. "Oa Dip seek Oil Change 1. Remove drain plug from oil pan. 2. Inspect oil for contaminents, if clean replace plug. 3.Fill oil to proper capacity with recomended oil from the temperature chart. Verify level with dip stick. Oil Cpacity 23 Liter Check vehicle specifications chart -» 7 -u t pe eee epee aeDio stick POW Level Pit cover 10 Pressure gage TAN Prone pipe state OS: Te Part or page Adapter Sui Equipement Engine Oil Pressure Test Oil Presure VAN (Caution: Make sure to check oil level is corrcet + Cheek oil evel add if necessary + Make sure oil is elean Change before tes if dirty. {Hf contaminents sich as metal shavings ate ‘ound, damage will occute wo fest equipment. [Atthis point recomended wo dsasasible engine for inspection. 1 Remove plug fom cylinder black ae shown, 2. Auach gage and adapter as shown, 5 Start engine and ewn to operating temperature. Operating temp 9°C~100'C Run engine to 4000RPM. Presue ange below. Oil Pressure (heen) :Tutho 8,9~4.3 Non-Tusbo 2.7~3.7 5. Remove gage and adapter. Use new silicon tape on plug and torque to specification bellow, 8. Start engine and inspect for leaks. Phug vorque (eg + ex): 120~150 Pressure out of range: Replace pump and repeat procedure,Oil Pump Parts cam) 1100-76829. O11 Pomp Ser Rocce Set Rebof Vine Set 9) Goskst Oi Pomp Case in oi Paamp AOil Pump Procedure 1 Remove the following Cranek pulley, outside cover, timing belt tensioner, timing belt. more information see "Timing belt removal Remove 2. Timing belt pulley 3. Engine front mounts 4,0 pan 5. Oilstriner 6, Remove the oil pump bolts (10). 7. Carefully remove assembly Pump Clearence Check Outer rotor to ease clearance must be below 0.13 (mm), "Replace if clearence is out of range*Oil Pump Side Clearence Measure side clearence. clearence must be below 0.15(mm) *Out of range replace* Attach ol pump *Do not over torque ‘Torque bolts to (kyeem) 906120 Oil Pump Gasket “Make allof the old gasker has been removed ice is clean before installing new gasket Re-assemble timing cover assembley “Always fill engine with new oil* Run engine a check oil peessure (begining of chapter)Oil Pan & Strainer ‘When ever comoving or replacing the oil seiner always replace the O Ring Before installing the O Ring, coat ‘sith lean engine ol it Seesiner torque (ken) 9020 ‘Type Oil Pan Gasket. Apply High Temp Gasket Scaler "Note: Make suce all suefaces ate ol fee before applying sealant Suzuki Sealant Pactf#1207C. 99000-51150 il Pan Torque (kgzem) 90-120 ‘type Oit Pan Gasket. Apply igh "Temp Gasket Seater Note: Make suce all surfaces ate ol fre before applying sealant Suauki Sealant Par#1207C 99000-31150 it Pan Torque (kg.cm) 90-120, aCylinder Head, Camshaft, Valve, Rocker Arm 2 Valve Head |. Cylinder Head 2. Valve Guide Camshaft - Rocker Arm Shaft Rocker Arm - Valve Spring Intake Valve Exhaust Valve Disassemble-Disconneet-Remove The Following. 1. Remove front seat 2. Disconnect negative (-) battery cable 3. Remove Engine serviee cover 4. Drain coolant system 5, Remove air cleaner case 6. Remove water pump 7. Diseonnect fuel hose 8. Disconect vacume hoses 9. Disconnect accelerator cable 10. Disconnect wiring 11, Remove timming bel (sce previous) 12. Remove cam shaft pulley 18. Disconnect exhaust pipe and Ma 14. #1F equipped Turbo attachments 415, Remove disteibutor 16, Remove valve cover 17, Remove cylinder head bolts (8) Z 418, Remove cylinder head aCylinder Head (2-Valve) T Driver Yokohama Motors 1. Remove Rocker Arsn Shafts Serews 2. Remove intake and exhaust rocker atm shall, then remove rocker arm shaft springs 3. Carefully side out cam shafe 4. Using a vale spring compressor remove springs *tnote-lable springs from original location ‘*Caution-never hit tice springs witha steel hammer use only soft brass head ammee* 1. Valve spring 2. AdapterCylinder Head (2-Valve) 1 Tweezers 2. Valve kespers Yokohama Motors CCaution- Springs under extrcam pressure, use saftey ‘glasses when removing springs 7. Remove valve lifter, spring retainer, valve spring 8. Remove valve 9. Remove valve sttem oil seal, next remove valve spring seat Caution-Never -use oi seat Note-if valve guides must be removed se Suzuld too! number (09916-44910) Inspection ‘Using a micrometer check the cam hight. If itis out ‘of spec replace camshaft Cam Hight “2” [Acceptable] Limit Trvake cam (oq) we | 08 Exhaust cam > | as 29.6Cylinder Head (2-Valve) Camshaft Straightness Measuement Use a dail indicator to measure for straightness rotate the camshaft and observe the ceadis \ Reading mut not exceed 0.8(m) fc oplace cama Camshaft Jouenal To determine the amount of outoFround, ‘measure each journal in two different directions and eompate to specifications ‘Also check for joural taper by measuring at ‘each end of the journal Journal lite: Within is Replace saes—, 450 | 43, 500~48.516 sn.905 9.925 sx025~4s, 650 | 4a, rooms, 716 ams 18.725 11825~18, 050 | 43.000~H8.016 13.155 sa915 4.205~14,050 | 44, 100~H1, 116 42.995 1sCylinder Head (2-Valve) Rocker Arm Shaft Inspection Use a dial gage to check diameter for warp age Maximum allowance 0.12 (mm) Roker Acm and Roker Arm Shaft Clearance Rocker Arm and Shaft clearence Allowance 0.008-0,040 Replace 0.06 Valve Stem & Guide Measurmen ‘Allowance | Limit] 5.465~5.400 | — 5.450~5.405 | — Si00~5.512 | 5,54 s.200~5.512 | 5.54 ‘Bice & Guide Cleareuce (on) ex | ooss~n0s | ou TN | o.c20~0,050 | 007Cylinder Head (2-Valve) Ifa bore gage i not available, itis posible tose a dail gage. Use the diagram to the right as an example. If the play between the stem and the guide IN 044 EX 0s Place a Valve in a V block, and using a dial gage rotute valve Maximum alloran Valve to Valve Seat face IN 13-45(mm) I. Valve Seat Angle} EX 13-1.5(mm) /*Use exttcam caution when cutting valve tis recommended to start with a small Finally with 485 degree cuter. [is recommended to shop for this opera #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 spec* Manifold Face (Cylinder Head) Use a straight edge bar and a fecler gage. Allowance 0.10(mm) Out of range, have face milled at a machine shop*Cylinder Head (2-Valve) Assembly 1. Before installation of new valve guides use a Hmm reamer, Use the proper tools as displayed in the box to the left. Install guides, **Nowe-if a guide bas been removed for any reason ist be replaced with a new guide.* Oversize Guides (mm) 0.03 foveubricate new seals with clean engine oilCylinder Head (2-Valve) Assembly 6. Lubricate valve with engine oil and slide into ‘guide. Make sure guide slides without restriction, 7, See chart on left or proper spring seating 1 Lange Phe =T 3: ale Spring retin side 2 Seal Pitch 4. Vuive Spring Seat side 8. Using a valve compeessor, install valve keepets ily ubricate camshaft with engine oil stall, Tang 10. Install rocker arm shaft. Make sure tang is i the correct direction as noted in the diageam on the left.Cylinder Head (2-Valve) ‘Assembly Intake Manifold Side Install ew head gone, Follow the dgram onthe let for guide. SM otto sk F ol g| *De note sealan "Make sure all surfaces are elean™ Tstall head assembly ‘Torque to (kguem) 550-600 Follow torque sequence on the chart to the left ‘Assemble remaining parts asin previous section of this chapter, zBCylinder Head (4-Valve) Yokohama Motors 4. Camshaft 2. Valve rocker intake No.1 Arm . eee i $ teerfen Neti ; itor i wa acl ; Le te ee Revomal 1. Drain coolant system 2. Remove service cover io Camshaft holder (09917-68220) 17. Disconnect accelerator eable 8. Remove timing belt (see previous steps) 9, Disconnect Electrical eonmectors 10, Remove camshaft timing pulley UL. Remove timing belt inside cover 12, Remove exhaust center pipe 13. Remove exhaust manifold 14 Remove cylinder headCylinder Head (4-Valve) Disassembly Remove Rocker Atm Shatt Remove Intake Rocker Am ‘Cammsalt Caps Camshate Remove Cylinder head Bolts (8) Remove Cylinder Head Using a spring compressor remove valves *Spring under extreme pressute, always "use proper saftey glasses ‘Yokohama MoroesCylinder Head (4-Valve) Inspection Tale guide remover nome a Using an appropsiate tool, emove valve guides Note-Never re-use valve guides* Camshaft Warp Ave Using a dail gage, check the camshaft Allowance: Below 0.10 (mm) heck the camshaft housing caps for scratchesyct. f visable damage exivt-replace*™Cylinder Head (4-Valve) Inspection Re-insert camshaft into head and torque caps ‘Torque (kg-em) 90-100 Make sure camshat is well viled* Using Platigage, cheek clearance Allesance (045-87 (enm) Limit 0.12¢mm) Rocke Arm FOO stent See Rocker Arm Shaft Clearance ie Allowance 0.008-0.040(a088) Limit 0.006(n)cy Valve Inspection inder Head (4-Valve) Valve Stem | IN Diameter | Ex Valve Guide | IN | S.000~8012] 5.04 Inner Dia Ex | So0~s, 012) 5.04 IN |aom~a, 07] a7 ‘Stem Guide | | —| EX | 0.055~0, 052] 0.09 Tf a hore gage is not available, use a dailgaze as inthe example to the left IN 0.14(mm) EX 0.8(mm) Using « V-Block and a dail gage check valve face Limit= 0.08(enm)Cylinder Head (4-Valve) Suefaces 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 [J tn | ti toner) sz9 [ate Valve Spring(snn) - | Outer 38.6 3 [Vale Spring Pressure hy /A1, 5) « BCylinder Head (4-Valve) 1. 10.5imm Reamer (09916-37320) 2. Vale guide installer handle 3. Valve guide guide Assembly Using a 105(mm) reamer, ream out guide holes ‘Warm cplinder head o between 80-100 degrees Ces Une proper valve guide installation took *#Note-Never resus vale guides Maximum oversize guide use: 0.05(enm) ‘Ate guide installation, use aSmm reamee 9 clean ‘guide holes ‘Make sare no shavings ae let i the holesValve Spring Assembly 1. Lange Pitch Side 2. Small Pitch Side 3. Valve Spring Retainer Side 44 Valve Spring Seat Side ‘Assemble Springs and valves using spring compressor ‘asshownCylinder Head (4-Valve) Assembly Install head gasket using the diagram on the lef ‘*Make sure the gasket is oil free and clean Do not use sealant on the head gasker* TcFlexagon wrench Cylinder Head Torque 600-650(kg.cm) Arm 2. Pivot 1. Timing Pulley Key 2. Oil Seal | camshaft Torque Spee (gem) 90-120Cylinder Head (4-Valve) Assembly Assemble Rocker Arms ‘Timing Belt Inside Cover (kgsem) 90-120 *Do not over torque Set Camshaft pulley torque (kgsem) 500-600 Assemble accessories and attachments (| SetWalve Lash To Spee (see previous) Camshaft Holder wert | aPiston & Rings-Connecting Rod-Cylinder 2 Piston Diagram 660ce 2 Valve and 4 Valve 1. Top Ring. 2 2nd Ring 3. Oi Ring 4. Piston Ring **Note-When removing pistons place vacume hose ot fel hove over the bolt ends to prevent cylinder ‘wall scratches during removal Cylinder Diageam Top q After piston removal check for lip to deteemine ‘excessive wearing. Excessive wearing will equi ‘evlinder boring, Oversize pistons and rings are , available in 0.28(mm) of maximum 0.50 (nim) sizes. Use the chart om the left to determine diameter limits, The following charts and diagrams provide the correct sizes per boring requirmentsPiston & Rings-Connecting Rod-Cylinder Cylinder Bore Measurements Cylinder Bore Inside Diameter: 65,070(mm) Taper Limit: 0.10(mm) Note: IF one oF more inders ae ot of round of Limi aletinders mst be bored tothe same Piston Size “Allowance 61, 965~04. 985 Piston Oversize 0.28 | 65, 215~85, 235 Oversize 050 | 65, 465~05. 485 1.50 Piston Rings 1. Piston Ring 2. Thickness Gage Ring Clearance Chart * iston Ring] me Fo ai Clearance |Piston & Rings-Connecting Rod-Cylinder Piston Pin Connecting Rod Side Clearence Measure Ring End Gap Before installing new piston rings, che ‘must be checked. 1. Cylinder Block. 2, Feeler Gage 3. Piston Ring **Note: Check from top 10 bottom of eylinder* Piston Pin and Piston Bows Clearance ‘Owe 17, 09518, 000 15,9051, 000) Piston Boss | 18,008~18,014 - Taner Dia | 6.00816. 014) Connecting Rod Clearance Allowance: 0.10.2(mm)Piston & Rings-Connecting Rod-Cylinder Connecting Rod Alighment ee Jt 2 rod knocking moive was detected before disassembly this text should be preformed "| Bend Rae Faire @ 0,08(me) ‘Twist Rate Failure (@0.10(een) ‘Aligament Machine Connecting Rod Beatings ‘Note: Do Not Remove Old Bearings With Sharp Tools Damage Will Occure™ "Note: Always replace both upper and lower hearing as ase "Note: If an ieegularty is indicated, meas the ensnk jouenal with a ierometer® “Note: Only stindard (STD) replacement beatings available* ‘Warning: Do not route the crankshaft while suaging material is heeween the bearing and journal Bearing Clearance Measurement Clearance Allow 0.020.0.040(am) Beating Size Normak STD ‘Crankshaft (mm) 35.982-36,00 I Plastigage 2. Seale Bearing Cap Torque (kgem) 310-350Piston & Rings-Connecting Rod-Cylinder Connecting Rod Alighment z [tf a rod knocking noise was detceted before disassembly this test should he preformed ® Bend Rate Failure @ 0,05(mm) ‘Tost Rate Failure (@0.10(em) Alignment Machine Connecting Rod Bearings Note: Do Not Remove Old Bearings With Sharp Tools Damage Will Occure* "Note: Always replace both upper and lower beating as asset "Note: If am irregulary is indicated, measute the crank journal with a micrometer™ “Note: Only standard (STD) replacement beatings available ‘Warning: Do not rotate the crankshaft while ‘aging material is between the Dearing and journal Bearing Clearance Measurement Clearance Allowance — 0.020-0.040(am) Bearing Size Normal: STD (Crankshaft (mm) 35.982-36.00 1 Plastigage 2, Seale Bearing Cap Torque (kg.cm) 310-350Piston & Rings-Connecting Rod-Cylinder Piston Assembly — Note: Alway ton rings Install the conaceting rod tothe piston, making sute the piston disection arrow on the piston facing the front of the engine. 1. Piston Make sure the piston pin is well lubricated, install retaining, * 2. Arrow w Front | clips and verify they are well seated, 3. Connecting Rod 4. Oil Hole (lacing Tatas) Piston Ring Chart z 1. Top Compression Ring 2 Secondary Compression Ring cD 3.011 Ring Ring Gap Locatio Use the chaet wo the left for Ring Gap Direction 1. Arrow (Pointing to font of engine) 2. Top Compression Rin 3. Second Compression Ring 4.01 Ring 5. Intake diecetion 6. Exhaust direction 7.45 degrees 8. Oil Ring 1. Guide Hose wo protect journalMain Bearing-Crankshaft, Cylinder Block 1. Cylinder Block. 5. Theust Bearing 2. Front Main Seal 6, rear Oil Seal 3. Main Bearing 7. Oil Seal Housing Gasket 4. Crankshaft 8. Oil Seal Housing 9. Input Shaft Bearing 10. Flywheel Yokohama MotorsMain Bearing- ‘Thrust Bearing 1 Thus Bear ‘Crankshaft, Clyinder Block Crankshaft Inspection “Note: Before removing crankshaft veify previous torque setting were correct Follow the torque sequence guild to the left “Torque should be (kyzem) 550-600 Remove Crankshaft Crankshaft Journal Taper/Out of rowmd Limit Using a dial gage check the crankshaft The test should involve minimum 3 tuens per Journal Out of round Lis 03(anem) Inspect theuse bearings for unusval wate, Remove theust hearings and discard. Not: Do not re-use cheust bearings Replace with new beatingsMain Bearing-Crankshaft, Cylinder Block Crankshaft Inspection Bearing torque (kg.cm) 550-600 (Cranckshaft End-Play Allowance: 0.13-0.28(mm) Using a micrometer, check journal taper Crankshaft Journal STD 43.982-44.000(mm) Journal Taper Allowance: 0.01(mm) Re-Install Crankshaft and torque to Spec ‘Torque (kg.cm) 580-600 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 Ka Cylinder Block Deck Cheek Install new rear oil seal “Note: Take cuation not to damage seal Lip Flywheel Roundness Cheek Limit (on) 0.2 lywhecl Torque: (ke.em) 400-450 Using a straight edge bar and a fecler gage check hhead deck for levelness Allowance: 0.05(enm) ‘Out of spec, have deck resurfacedEngine Related Diagrams & Part Numbers Engine Gasket See 10) L finserssi Gasket Set Engine 2 wisesiwol — Gasher Cynder Head 5 wnssiie2 —— Grket Cylinder Head Cover 4 #S1-71G00 Gasket nce Mio I 5 HiausssFO0 Gk Exnunt Mastek! Sy 8 HIME ORing > pn 7 mraestra Gantt = of 8. BIOI9-76G00 Gaskets Oi! Pomp s 9. RITE. Gasket Water Pap [10.417 rso.ni7 Cashes Water ner H-MISGLT9G00 Guket Thrtle Body 12-#16559.7600 —Graket: Oil Fier Adapter Cae (4D) Poy Bisbee — Gakee ba tatty ‘omg Guin oe7Cems AX Ring Se: Piston STD Ring Sets Piston O8: 030 Pisens st TILAHO-0A0 Gon Rod Bening STD. 0-040 Dsm-tato025 earec tien I dopa 12 aaseeibor 1S Law-siHon —Crunlohat Paley 1 us-e0no0 Crankshaft Pulley Bok (Cranks AY) Pat MUSL-TaBOL Housing Oil Seal po Shot 24d, maven Spring inst (AT) DS-IPRLANOT Hele Akcenscr Line (LEN) Ces (0N)Combat (To) ML, MOSOES0 Ring Set: Piston STD DIL-6aDSI-028 Phase: OS 028 Ver) DAML eAsis {21N-69051-050 Paton OS 080 1AISL-S1AS0 Paton Pun (TN) 4 OSELINOOS Snap Ring 51. 1200-76650 Connecting Rod Assembly (T) 52, 2460-60451 Connesting Red sem (¥ 6 o7ise.a8083 Nur Ta, IRIKAHOLON® Con Roa Bearing (1) 72. DUIAIOSLONe Con Ree Bean 78. wniisisors Beanngs Undersin 25 (1) bestsiwsiaas 21-500 fazatentts0 D3O1-I8I00N0 eowng St Creakshat SED (T &V) Bearing US 038 (Task) The Booring F2S Tine Bearing 12.868 ML ogmaiss0a Oiled ts ‘Cena (Turbo) 2. e1siDe1 Taming Bek Paley 1. Lowi ——Ceankshalt Paley M4 ossHLSiUS9 ey 15, 1200-40000 Crank ily Bk 16 0785-00005 Oil Seatenains 1 UAB OilSea| Dat 1. orpz90s3 Screw 20. onto Pin 21 120078190 Fipwhest 22 Us10097 Bole att 2. 12625-70800 Bearings Input Shalt 2 eit-a6ns Pint) 242. 205-0409 Spring Fin 6t4 (AT) BE TSDETAAON “Nernst esl s78$mm (LENE) Cea (Tao)CombatVibes 4) 1 wate ss, 2 was 77G00 > DetcaiDen 10, basse IAS Comshateares (a0) Cami Combi OilSeal S896 Sate Hock Aem N Shatle Hosker An Ne Rocher Arm take Ned Rocker Ar: Take No.2 Rocker Arm xl Adjustment Ser Inte Adjustment Ser Washer Maher fotake Nahe: Essa oie Reopen (Vibe) Seat Vake Spring tees (bso) : ‘tee 3 Sante ie Commas Soo : ikea i ae, irae i nee Reansscneen oe cove 3S, ‘orem flan isomt Ckt msn Himsa See ee é %Timing Ba) Timing Bek (Lato) eowoctcios 5. eomecoste? Tang Bel (Tato)Iowa Mani Tete Boa (4¥) 5. msso-00203 & buat 3. Is-coRts0 sisson 1. bance 20. BRET7GID 21 3907242 8 Tota Maitld/Throte Boxy (4) Intake Monod Gok Intake Manifold Site Su Rade Sng Tene Grok Surge Tank Bait Bak hte Body Assembly Tv Boas Postion Senor Peeves Senne “Thre Contd nae Maniord/ The Body (AN) Past 2 26. 1s12L-7760 SL scons 32, wtoLazuo St Thesn-sorm0 Se esau Intake Monier / vie Boy (48) Pat 2 Gasket Tote Hoy Clip iter Prewure Senor Puig ODSIntake Maniotl/Phvte Boy (arto) Water Pomp (At) Dep take Manieata/Toroe sense 21 wes0-iB00 22 wuss-Lame 28 Be0sor 26 autos ‘Winer Pump (At) Sonatas etn wast) 7 anenaaias le Body (Tuo) Tce Meniits Gane: Intake Marl Sta Boe Nut Bait tle Bay Asoo Thole Postion Sensor Pressure Sensor Thro Body Gusher, Bat Kater net Water Pomp Se (Assembly) Gasket Water Pomp Sra ae Boat Wer Pomp PaesTbecharger (Tho) rsso6128 ori 3, nsse0g33 Tuwbchaeger (Tues) ‘Turbocharger (Tao) Tecate ssaransi dvorsane Tsosoltst 95-60 AL anssonsss irbochange (Teebo) 32 amssanrsaat (ossets7Shol He: $8 Nahe: Way Solenid Nie: ir Bypass Bat ‘cip cup 5Vay Joint Check Vike GimpLat ‘ait Trbochager Teck) “Turbosarger Vin) Hee: Wastegate (1) More Wastsgat () Pipesee-Water(T) Pipe Sets Wace (0 Pipe il ocak (P) Pipe: Turbo Of Tracke (6) Wier atk Bote(X) Vaion Bot Pipe: Owes BoeConversion Charts CONVERSION OF TORQUE | Convert [ Convert From | To Mukiply | From | To | Multiply Ibn. loz.in. 16 ozin. —[ibin. _|.0625 Ib.in. Ib.ft. .08333 j Ib.ft. Ib. in. 12 Ib.in, — |kg.cm. | 1.1519 kg.cm. Ibn. |. 8681 Ib.in. Ica.m. .011519 lea m. Ib.in. 86.81 7 Ibn. | Nm 133 Nm Ibn. |8.85 Ib.in. | anm 113 dNm |Ib.in. .885 Ib. kgm. 1382 kom. bgt. 7.236 Ib. ft. Nm 1.356 Nm | Ib.ft. | .7376 Nm dNm 10 dNm Nm 10 Nm kg.cm. 10.2 kg.cm. Nm | ooe7 Nm kg.m. 102 kg.m. Nm 9.807Thank you! For More Information on other fine publications check the following resources. www.lulu.com www.amazon.com Automotive Specialty ‘www.yokohamamtots.com Automotive Service Manuals Suzuki Subaru Honda Mitsubishi Daihatsu Toyota Nissan Others‘The Complete F6A Engine Overhaul & Parts Manual VIN Decoding Engine Identification Service Data Intake Manifolds (Turbo-Fuel Injected-Carbureted) Timing Belt Valve Adjustments Oil System & Pump Overhaul Cylinder Head Overhaul Pistons-Connecting Rods-Camshaft Specifications Bearings & Crankshaft Cylinder Block Specifications & Part Numbers Engine Mounts & Frame Diagrams Complete Engine Part Number Guide All this and more in the new Second Edition Version! DE51IV Service & Parts Manual Second Edition DF51V DC51T DD51T DC51B DA52T DB52T some. DA52V