Engine 1.6L Diagnostics
Contents
1. Seat Correction Angles On intake and exhaust valves use 15 degr stone to narrow seat and 45 degr stone to widen seat VALVE TRAIN Rocker Arm Shaft Assembly Check rocker arm to shaft oil clearance Maximum clearance is 0035 09 Check rocker arm shaft runout Rocker arm shaft runout limit is 008 20 mm on 16 valve or 004 10 mm on all others Lash Adjusters If tip of rocker arm adjusting screw is worn replace screw If cam riding face of rocker arm is badly worn replace rocker arm CYLINDER BLOCK ASSEMBLY Piston amp Rod Assembly 1 Remove cylinder head See CYLINDER HEAD under REMOVAL amp INSTALLATION Remove oil dipstick guide oil pan and screen See OIL PAN under REMOVAL amp INSTALLATION 2 Ensure pistons connecting rods and rod caps are marked for reassembly reference Remove carbon from top of cylinder bores Remove connecting rod caps Install protective hose over connecting rod bolts 3 Remove connecting rod and piston assembly through top of cylinder block Mark cylinder number on piston crown Remove piston rings 4 Remove circlips and push piston pin out by hand 5 Check piston pin to bore fit Pin should press in piston smoothly by hand at room temperature When assembling apply engine oil to outside of pin and to piston pin bore 6 Position piston upward Install circlips and piston pin Install circlips with opening facing either up or down2. Fitting Pistons 1 Check cylinder bore for damage wear and taper See CYLINDER BLOCK under CYLINDER BLOCK ASSEMBLY under OVERHAUL See CYLINDER BLOCK table under ENGINE SPECIFICATIONS to determine if block must be rebored 2 Pistons are available in 0098 25 mm and 0197 50 mm oversizes Check outside diameter of piston Measure at a point 63 16 0 mm from bottom of skirt and at 90 degrees to pin bore 3 Standard pistons are available in 2 sizes Piston diameter is determined by numerical mark 1 or 2 stamped on piston crown See Fig 7 4 Cylinder bore diameter is determined by numerical mark 1 or 2 stamped on cylinder block Numerical marks on cylinder block read left to right indicate bore sizes of cylinders No 1 2 3 and 4 respectively See Fig 7 5 When installing piston into cylinder ensure piston numerical mark matches cylinder bore numerical mark to provide correct piston to cylinder clearance 1 6L 4 CYL VIN dArticle Text n 81995 Suzuki EsteenFor Xeon Copyright 19 Identification Mark 90H08900 Fig 7 Matching Pistons To Cylinders Courtesy of Suzuki of America Corp Piston Rings 1 Install rings with R RN or T mark facing upward Install oil ring spacer first then rails Position piston ring gaps See Fig 8 Lubricate all internal surfaces with engine oil before installation 2 Ensure arrow on piston head faces front of engi
3. transmission and engine oil axles See AXLE SHAFTS FWD artic 6 Attach hoist to engine On all models drain Disconnect ball joints and remove drive le in DRIVE AXLES section Disconnect crossmember from frame rails Disconnect left and right side engine mounts Lower engine and transmission as an assembly Installation Raise engine transmission unit into vehicle Install engine transmission mountings to brackets Install bolts into frame brackets Tighten bolts to specification See TORQUE SPECIFICATIONS To complete installation reverse removal procedure INTAKE MANIFOLD Removal 1 Release fuel pressur Disconnect negative battery cable intake hoses and air breather hoses WARNING To avoid severe burns S DO NOT FUEL PRESSURE RELEASE Drain cooling system Remove air remove radiator drain plug or cap while engine and radiator are still hot 2 Remove air cleaner assembly Label and disconnect all electrical connections from intake body Label and disconnect vacuum hoses from intake manifold 3 Disconnect coolant hoses and remove upper radiator hose from delivery pipe Disconnect al 4 Remove intake manifol manifold injectors and throttle from manifold and throttle body Remove fuel supply and return lines ll control cables ld to cylinder head bolts Remove intake manifold and throttle
4. stamped on cylinder block mating surface See Fig 11 PISTONS PINS amp RINGS SPECIFICATIONS PISTONS PINS RINGS TABLE Application In mm Pistons Clearance sis 0008 0016 02 04 Diameter 1 e te Mat ado ee 2 9520 2 9524 74 980 74 990 Be o thd A Av 2 9516 2 9520 74 970 74 980 Pins Diameter Vi is a date a ds 7478 7480 18 995 19 000 PISEONCELTE ero e AS ti Slip ROA CEIT erase E OA A A O Slip Rings No 1 End Gap Standard iris daba ts 0079 0138 20 35 Service LIME ads 0276 70 Side Clearance 0012 0028 030 070 No 2 End Gap Standard ass stu bet ack eee ese eke 0079 0138 20 35 Service LIMIT Ci a Seed 0276 70 Side Clearance 0008 0024 02 06 No 3 Oil End Gap Standardo AE wheter is id Seer 0079 0276 20 70 Service Limit A ia 0669 1 7 1 Piston diameter is determined by numerical mark 1 or 2 stamped on piston See Fig 8 VALVES amp VALVE SPRINGS SPECIFICATIONS VALVES amp VALVE SPRINGS TABLE Application Specification Intake Valves Seat Angles 4 ka sake dba Eb A A A Meath ee ates 45 Valve Head Thickness Standard amenas A ER NTE a SC 03 047 8 1 2 mm Service LAME a o ia 024 6 mm Stem Diameter 2152 2157 5 465 5 480 mm Exhaust Valves Seat Angle T Teeni bis baga A A A IES es ae 45 Valve Head Thickness Standard mia e ek ias la 03 047 8 1 2 mm Service LIMIE aii i
5. arms and shaft See ROCKER ARM amp VALVE LASH ADJUSTER under REMOVAL amp INSTALLATION 2 Use Valve Spring Compressor 09916 14510 and Valve Lifter Attachment 09916 14910 to compress valve spring Use Forceps 09916 84510 to remove retainer locks See Fig 6 Remove retainers springs valve stem oil seals spring seats and valves Keep all components in order for reassembly reference Cylinder Head Reassembly To assemble reverse disassembly procedure Ensure valve springs are installed with close coiled small pitch end down toward cylinder head Valve Spring Retainer Remover Valve Cotters o Valve Spring Compressor 90H00346 Fig 6 Removing Valve Lock Courtesy of Suzuki of America Corp Valve Springs Check valve springs for damage Use a square and flat surface plate to check spring squareness Maximum out of square is 079 2 00 mm Using valve spring tester check valve spring preload pressure See VALVES amp VALVE SPRINGS table under ENGINE SPECIFICATIONS Replace any weak or out of square springs NOTE DO NOT reuse old valve stem oil seals Valve Stem Oil Seals Place NEW lubricated stem seal on valve guide Use Valve Stem Seal Installer 09916 58210 Press seal on valve guide using hand pressure only When installer bottoms on head seal is properly positioned Avoid twisting seals during installation Valve Guides 1 Check valve stem to guide
6. battery cable 2 Raise vehicle and remove fender apron extension by pushing center pin into clip DO NOT push in too far as pin may fall into fender Loosen generator and remove water pump pulley and belt 3 Remove crankshaft pulley Remove timing belt cover Align all sprocket timing marks with timing marks on engine See Fig 4 Move up and secure timing belt tensioner 4 If timing belt is to be reused mark belt with an arrow indicating direction of rotation Remove timing belt from camshaft and crankshaft sprockets CAUTION DO NOT turn crankshaft more than 90 degrees in either direction from aligned position Doing so could damage piston s and or valve s by interference Also DO NOT bend timing belt Installation 1 Loosen all valve adjusting screws fully before installing timing belt Allow camshaft to rotate freely during belt tension adjustment Align timing mark on camshaft sprocket with V mark on timing belt inner cover See Fig 4 2 Turn crankshaft clockwise until punch mark on crankshaft sprocket is aligned with arrow mark on oil pump With timing marks aligned install timing belt Ensure direction arrow mark on timing belt is pointed in direction of crankshaft rotation Ensure drive side of belt is free of slack 3 Move tensioner plate up with finger pressure and loosely secure tensioner bolt Turn crankshaft 2 revolutions clockwise to remove all slack from belt Tighten tensioner nut and then tensioner
7. bearing caps and camshaft Remove rocker arm shaft plug and timing belt inside cover 6 Remove intake rocker arms with clip from rocker arm shaft Remove rocker arm shaft bolts Push rocker arm shaft slightly to rear and remove O ring from shaft Remove exhaust rocker arms and springs while pushing rocker arm shaft toward front of engine Installation 1 To install reverse removal procedure Install NEW O ring on rear of rocker arm shaft Ensure flat surface of rocker arm shaft is facing down and is parallel with cylinder head gasket mating surface Tighten camshaft bearing caps in 3 or 4 steps in sequence finishing with final torque specification See Fig 5 See TORQUE SPECIFICATIONS 2 Intake rocker shaft has a 55 14 mm stepped end Exhaust rocker shaft has a 59 15 mm stepped end Ensure intake rocker shaft stepped end faces front of engine and exhaust rocker shaft stepped end faces rear of engine Adjust valve clearance S VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS 1 6L 4 CYL VIN 0Artic 94147116 Fig 5 Camshaft Bearing Cap Bolt Tightening Sequence Courtesy of Suzuki of America Corp CAMSHAFT Removal For camshaft removal see ROCKER ARM amp VALVE LASH ADJUSTER CAUTION Hydraulic valve lash adjusters cannot be disassembled or repaired DO NOT apply force to adjuster body If removed keep immersed in container of clean e
8. body and gasket Remove remaining components from intake manifold as required 1 6L 4 CYL VIN OArticle Installation To install reverse removal procedure Use NEW gaskets Tighten bolts to specification See TORQUE SPECIFICATIONS Adjust all control cables and fill cooling system EXHAUST MANIFOLD Removal 1 Disconnect negative battery cable Remove air cleaner assembly if necessary Disconnect oxygen sensor wire connector 2 Disconnect exhaust pipe from exhaust manifold Remove exhaust manifold cover Remove exhaust manifold stiffener Remove exhaust manifold to cylinder head bolts Remove exhaust manifold and gasket Installation To install reverse removal procedure Use NEW exhaust manifold gasket Tighten bolts to specification See TORQUE SPECIFICATIONS CYLINDER HEAD Removal 1 Release fuel pressure S FUEL PRESSURE RELEASE Disconnect negative battery cable Drain cooling system and remove necessary coolant hoses from cylinder head Remove intake manifold brace Label and remove hoses lines and electrical connectors from cylinder head intake manifold and exhaust manifold Disconnect exhaust pipe from exhaust manifold and remove brace 2 Removing exhaust and intake manifolds is not necessary Remove rocker arm cover Fully loosen all rocker arm adjustment screws Remove timing belt See TIMING BELT Remove air conditioner compressor and or generator adjusting arm from cylinder he
9. 1 6L 4 CYL VIN 0 Article Text 1995 Suzuki Esteem For Xeon Copyright O 1998 Mitchell Repair Information Company LLC Tuesday December 02 2003 06 52PM ARTICLE BEGINNING 1995 96 ENGINES Suzuki 1 6L 4 Cylinder Esteem PLEASE READ THIS FIRST NOTE For repair procedures not ENGINE OVERHAUL GENERAL INFORMATION section ENGINE IDENTIFICATION Engine code is stamped on bellhousing exhaust side Vehicle stamped on a metal tag attached to pillar The sixth character of VIN ENGINE ID E TABLE Application Esteem ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT 1 Disconnect negative bat Remove right side inner fender apro visible Align crankshaft p belt cover 2 Remove distributor cap covered in this article INFORMATION article see in GENERAL rear portion of cylinder block at Identification Number VIN is left side of instrument panel near identifies engine model ENTIFICATION CODE tery cable Remove rocker cover n extension to make timing marks ulley timing mark with TDC mark on timing Ensure rotor is pointing upward toward distributor hold down bolt and to No 1 terminal of distributor cap If not correctly oriented rotate crankshaft 360 degrees 3 Measure clearance between adjustment screw and valve stem using thickness gauge Check intake and 2 and exhaust valve clearance o crankshaft
10. 2 56 018 Identifying Main Bearing Color Codes Standard Bearing Courtesy of Suzuki of America Corp Color 9618563 Marks Identifying Main Bearing Color Codes Undersiz Courtesy of Suzuki of America Corp COLOR COD E FOR STANDARD B Color Pai nted EARINGS TABLE Bearing Thickness In 0786 0787 1 996 2 0787 0788 1 999 2 O 0788 0789 2 002 2 0789 0790 2 005 2 0790 0791 2 008 2 1 6L 4 CYL VIN 0Article Text p STANDARD BEARING APPLICATION TABLE Letter Stamped Numbers Stamped On Block On Crankshaft Webs Color TA Cana la ah ie grade Sad Sd a s eee E W i AE Green PAM Da GD soars MZ cpa Sete aed ee Black PAM ameno E dE Se Ske E e SO er ege No Paint EE Tiger tak e Black BM Tetange do mada tase a DT Leners arate No Paint IER Cara tech ane TES erg he WM dd ene TI e Oyen ER Ee Yellow VCR abalar ms A SR ae ea Soa Cie ea Settee ots No Paint TOM amarelos ser eat EE DEN rasas dren Braue LN Yellow CEN Le EE UE ee E Blue Undersize Bearings 1 Bearings are available in 010 25 mm undersize Undersize bearing thickness is determined by 2 color marks See Fig 11 See COLOR CODE FOR UNDERSIZE BEARINGS table 2 Use journal finished diameters 2 0367 2 0373 51 732 51 747 mm and letters stamped on cylinder block mating surface to determine correct undersize bearing for replacement See UNDERSIZE BEARING APPLICATION table 3 Use Plastigag
11. Intake Valve Valve Guide I D 2165 2170 5 500 5 512 mm Valve Guide Installed Height 45 11 5 mm Valve Stem To Guide Oil Clearance msc 0008 0020 020 047 mm Service Limit amina seg do ae 0027 07 mm Exhaust Valve Valve Guide I D 2165 2170 5 500 5 512 mm Valve Guide Installed Height 45 11 5 mm Valve Stem To Guide Oil Clearance eri avos 0018 0028 045 072 mm Service Limit ao sets Sots ai ete ees 0035 09 mm CAMSHAFT SPECIFICATIONS CAMSHAFT TABLE Application In mm Bore Diameter 1 1024 1 1032 28 000 28 021 Journal Diameter 1 1000 1 1008 27 939 27 960 Journal RUNGU Aira GSS Zen ee Si Siti 0039 10 Lobe Height Exhaust Standard 1 4313 1 4376 36 356 36 516 Exhaust Service Limit 1 4273 36 256 Intake Standard 1 4240 1 4303 36 171 36 331 Intake Service Limit 1 4201 36 071 Oil Clearance 16 Valve Standard 0016 0032 040 082 16 Valve Service Limit o o ooooooooooooo o 0047 12 ROCKER ARM amp ROCKER ARM SHAFT SPECIFICATIONS ROCKER ARM amp ROCKER ARM SHAFT TABL E Application In mm Rocker Arm Inside Diameter 6293 6301 15 985 16 005 Rocker Arm Shaft Outside Diameter Et a SEM totes 6287 6293 15 969 15 984 Rocker Arm To Shaft Oil Clearance Standard animais EA e Suas 0005 0018 012 045 S
12. TIONS Crankshaft amp Main Bearings 1 Remove engine or engine and transmission See ENGINE under REMOVAL amp INSTALLATION Separate transmission from engine Remove timing belt sprockets pulley and tensioner See TIMING BELT under REMOVAL amp INSTALLATION 2 Remove flywheel and oil pan Remove rear main oil seal housing Remove connecting rod caps Remove main bearing caps Remove crankshaft 3 Inspect journals for wear taper and out of round condition If specifications are exceeded grind journals to undersize or replace crankshaft See CRANKSHAFT MAIN amp CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS 4 Standard main bearings are color coded See Fig 11 Upper half of bearing has an oil groove An arrow mark and number are embossed on each main bearing cap 5 Ensure arrow mark on main bearing cap faces toward crankshaft pulley Bearing No 1 is at crankshaft pulley end of engine Bearing No 5 is at flywheel end of engine 6 Main bearing journal diameter is determined by numerical mark 1 2 or 3 stamped on crankshaft webs of cylinders No 2 and 3 See Fig 9 7 The numerical marks on crankshaft web read left to right indicate journal diameters of bearings No 1 2 3 4 and 5 respectively 8 Determine bearing cap bore diameter with bearing removed Bearing cap bore diameter is determined by letter A B or C stamped on cylinder block mating surfac
13. ad if equipped 3 Loosen cylinder head bolts in reverse order of tightening sequence See Fig 2 Loosen head bolts in 2 or 3 steps to prevent cylinder head warpage Remove head bolts Using a lifting device remove cylinder head with intake and exhaust manifolds attached Inspection 1 Check cylinder head for evidence of water leakage or damage Remove carbon from combustion chambers Check cylinder head for cracks in intake and exhaust ports combustion chambers and head surface 2 Check head warpage at 6 locations If warpage exceeds specification cylinder head should be machined or replaced See CYLINDER HEAD table under ENGINE SPECIFICATIONS 3 Check intake and exhaust manifold seating faces on cylinder head for warpage Warpage limit for manifold seating faces is 004 10 mm If warpag xceeds specification machine or replace cylinder head Installation To install cylinder head reverse removal procedure Use NEW head and manifold gaskets Tighten cylinder head bolts to specification in 3 steps using proper sequence SeeFig 2 or 8 See TORQUE SPECIFICATIONS Adjust valve clearance S VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS E 94847010 Fig 2 Cylinder Head Bolt Tightening Sequence Courtesy of Suzuki of America Corp FRONT COVER OIL SEAL 1 6L 4 CYL VIN 0Article Text p 31995 Suzuki EsteenFor Xeon Copyright 1998 Mitch
14. bolt See TORQUE SPECIFICATIONS Ensure timing mark re aligned Install timing belt outer 1 6b 4 GYL MIN 0Article ext p 4 905SuzubkEsteenton Xeon NOG 4489 Mitchell Repair Information Come removal procedure to complete installation Adjust valve clearance See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS Timing Marks a Timing Belt Tensioner id Timing Marks 8 DIRECTION OF CRANKSHAFT ROTATION 91F00435 Fig 4 Aligning Timing Belt amp Tensioner Typical SOHC Courtesy of Suzuki of America Corp ROCKER ARM amp VALVE LASH ADJUSTER Removal 1 Disconnect negative battery cable Remove front grille Remove hood lock and hood lock support member and disconnect lead wire from horn Push center pin of clips to release grille clips 2 Drain cooling system Remove radiator cooling fan and shroud Remove A C condenser and compressor if equipped leaving hoses connected Remove air cleaner assembly and rocker arm cover 3 Remove water pump belt and pulley Remove timing belt See TIMING BELT Use Camshaft Pulley Holder 09917 68220 to secure camshaft pulley Remove camshaft sprocket bolt and sprocket 4 Loosen all valve adjustment lock nuts and valve adjusting screws to allow rocker arms to move freely 5 Loosen camshaft bearing caps in reverse order of tightening sequence See Fig 5 Loosen bolts in 2 or 3 steps Remove camshaft
15. cket bolts if equipped 2 Raise vehicle and drain engine oil Remove oil dipstick and oil pan Remove oil pump pick up screen Lock crankshaft with Gear Stopper 09927 56010 installed at flywheel ring gear With crankshaft locked remove timing belt pulley Remove oil pan and oil pump strainer pickup Remove oil pump assembly Remove dip stick guide Remove oil pump rotor plate 3 Mark outer gear with felt pen for reassembly reference Remove inner and outer oil pump gears Remove plug relief spring and relief valve Inspection 1 Inspect oil pump housing for cracks or damage Inspect oil screen for clogging or damage Inspect oil screen O ring Ensure relief valve slides smoothly in bore Inspect pressure relief spring for damaged coils 2 Inspect oil pump gears for wear or damage Using a feeler gauge measure radial and side clearance See Figs 14 and 22 If clearance exceeds specification replace outer rotor or case See OIL PUMP SPECIFICATIONS table OIL PUMP SPECIFICATIONS TABLE Radial Clearance Side Clearance Application In mm In mm All Models sarasin ss 0122 4310 ci 0059 150 Reassembly amp Installation 1 Ensure gears are assembled in same direction as originally installed Apply thin coat of engine oil to inner and outer rotors lip portion of oil seal and inside surfaces of oil pump case and plate Install inner and outer rotors 2 Install gear plate E
16. clearance If clearance exceeds specification replace with oversize valve guide S CYLINDER HEAD table under ENGINE SPECIFICATIONS 2 Use Valve Guide Remover 09916 44910 Drive out old guide 3 Ream guide bore in cylinder head with 11 mm Reamer 09916 38210 Heat cylinder head to 176 212 F 80 100 C 4 Using Valve Guide Installer Attachment 09916 58210 for SOHC drivq OL ACYL VIN TOA rticlecText tp 77995 Soup EstetarFarsXedA e Copyright 1998 Mitchell Repair ex ead contacts cylin 5 Valve guide protrusion is 45 11 5mm Ream valve guide with 5 5 mm Reamer 09916 34550 6 Clean valve guide bore after reaming Install valve and ensure valve stem oil clearance is correct See CYLINDER HEAD table Valve Seat Inspect valve seats for damage or wear If valve seat rework is necessary use 2 cutters to obtain required angles On intake and exhaust valves first cut should be 15 degrees Second cut should be 45 degrees to obtain correct seat angle After cutting valve seats to correct angles lap valve seat Valves 1 Remove carbon deposits Inspect for wear burns or distortion at face and stem Replace as necessary Measure valve head margin Check valve stem end for pitting or wear 2 Measure valve length Valve stem end may be resurfaced if no more than 19 4 8 mm is removed from valve length See VALVES amp VALVE SPRINGS table under ENGINE SPECIFICATIONS
17. ds specification replace thrust bearing See CRANKSHAFT MAIN amp CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS Cylinder Block 1 Inspect block for distortion of deck surface Warpage limit is 0012 0024 03 06 mm Inspect block for cracks scratches and other defects Measure bores at 3 levels for wear taper and out of round condition 2 If bore wear taper or out of round exceed specification rebore cylinders See CYLINDER BLOCK table under ENGINE SPECIFICATIONS ENGINE OILING ENGINE LUBRICATION SYSTEM A force feed type lubrication system is used The oil pump is a trochoid type pump mounted on the forward portion of the crankshaft 4c6Lr4 lt CYI5 VIN 0Article Text p 121995 Suzuki EsteerrFor Xeon Copyright 1998 Mitchell Repair Information Con W li 90A00349 Fig 13 Cross Sectional View Of Engine Oil Circuit Typical Courtesy of Suzuki of America Corp Crankcase Capacity Crankcase capacity including filter is 3 5 gts 3 3L Check dipstick to verify oil level is correct Oil Pressure Normal oil pressure is 46 9 61 2 psi 3 3 4 3 kg cm at 4000 RPM OIL PUMP Removal amp Disassembly 1 Disconnect negative battery cable Remove radiator cooling fan shroud water pump pulley and drive belt Remove timing belt cover timing belt and tensioner S TIMING BELT under REMOVAL amp INSTALLATION Remove generator and bracket and air conditioner compressor bra
18. e See Fig 10 See appropriate BEARING CAP BORE DIAMETERS table 9 The letters stamped on cylinder block mating surface read left to right indicate cap bore diameters of bearing caps No 1 2 3 4 and 5 respectively Five standard main bearing sizes are available Bearing thickness is determined by color code See Fig 11 See COLOR CODE FOR STANDARD BEARINGS table 10 Use numerical marks on crankshaft webs and letters stamped on cylinder block mating surface to determine correct replacement bearing See STANDARD BEARING APPLICATION table as A as EE Dam a SI o BCBA e Stamped Numbers 90B08902 Fig 9 Locating Numerical Marks On Crankshaft Webs SOHC Courtesy of Suzuki of America Corp CRANKSHAFT JOURNAL DIAMETERS TABLE Numbers Stamped On Webs In mm E tee 2 0470 2 0472 51 994 52 000 1 6L 4 CYL VIN 0Article Te HSH e Sach par Geet a dd 2 0468 2 0470 51 988 51 994 WC NEE an steko 2 0465 2 0468 51 982 51 988 31 23 ST OSD isl IC the Stamped Letters 90D08903 Fig 10 Locating Letters Stamped On Cylinder Block Courtesy of Suzuki of BEARING CAP BORE DIAMETERS TABLE America Corp Letters Stamped On Block Fig 11 Fig 12 96118562 2 2047 2 2050 2 2050 2 2052 2 2052 2 2054 In Color Mark mm 56 000 56 006 56 006 56 012 56 01
19. e to ensure correct clearance of installed undersize bearing Lubricate bearings before installing Tighten bolts to specification in 3 steps Tighten main bearing caps in following order center cap No 2 cap No 4 cap front cap and rear cap See TORQUE SPECIFICATIONS COLOR CODE FOR UNDERSIZE BEARINGS TABLE Color Painted Thickness In mm Green E REG cai Diet else ef re 0835 0836 2 121 2 125 Black Beet ae ms ela aes eis ees 0836 0837 2 124 2 128 Red Only naa 0837 0838 2 127 2 131 Yellow GREG er Ee ee 0838 0839 2 130 2 134 Blue e REA eric due aa 0839 0840 2 133 2 137 UNDERSIZE BEARING APPLICATION TABL E Measured Journal Letter Stamped Diameter In mm On Block Color DESLEAL DIAS rr TATS beis daa Green Red 51 744 51 750 PB uer ed Ae ee Black amp Red DCM ma Md ate E ain eas Red Only 20369 202 EE EEN Black amp Red 51 738 51 744 HS ek ee ae dass Red Only AI a RER E E ERS Yellow amp Red 270367 200369 is TATI e oi Red Only 51 732 51 78 ET nen venia SAS Yellow amp Red UC aed ea ds Ue ON A Blue amp Red Thrust Bearing 1 With crankshaft bearing caps installed check thrust clearance end play using dial gauge to read displacement in axial thrust direction of crankshaft 2 Standard thickness of thrust bearing is 0984 2 50 mm Oversize thrust bearings are available in increments of 0049 125 mm If clearanc xcee
20. ed leaving hoses connected 2 Remove pump pulley Ensure No 1 piston is at TDC of compression stroke Remove crankshaft pulley bolts and crankshaft pulley Remove timing belt cover tensioner and timing belt See TIMING BELT Remove dipstick and tube Remove generator mounting bracket Remove water pump 1 6L 4 CYL MIN 0Article Text p 6 995 Suzuki EsteenFor Xeon Copyright O 1998 Mitchell Repair Information Comp To install reverse removal procedure Ensure all mating surfaces are Clean Use NEW water pump gasket and NEW dipstick tube O ring NOTE For further information on cooling systems see COOLING SYSTEM SPECIFICATIONS ENGINE COOLING FANS article in ENGINE COOLING section OIL PAN Removal Raise and support vehicle Drain engine oil Remove engine undercovers Remove exhaust pipe No 1 Remove transmission stiffener Support engine transmission assembly Remove crossmember Remove crankshaft position sensor from oil pan Remove oil pan nuts and bolts Remove oil pan then oil pump strainer Installation To install reverse removal procedure Install oil pan using silicone type sealant Tighten bolts to specification See TORQUE SPECIFICATIONS OVERHAUL CYLINDER HEAD Cylinder Head Disassembly 1 Remove cylinder head See CYLINDER HEAD under REMOVAL amp INSTALLATION Remove intake and exhaust manifolds Remove camshaft See CAMSHAFT Remove rocker
21. ell Repair Information Come Removal 1 Remove water pump crankshaft pulley and generator Remove timing belt cover and timing belt See TIMING BELT 2 Drain engine oil Remove oil dipstick and oil pan Remove oil pump pick up screen Remove oil pump assembly Remove oil pump rotor plate 3 Using felt pen mark outer gear for reassembly reference Remove inner and outer oil pump gears Remove plug relief spring and relief valve Drive out oil seal Installation 1 Drive in NEW oil seal Ensure gears are assembled in same direction as originally installed Apply thin coat of engine oil to lip portion of oil seal and inside surfaces of oil pump case and plate Install inner and outer rotors 2 Install rotor plate Tighten 5 screws Install 2 oil pump pins NEW dipstick O ring NEW seal for oil pick up tube and NEW oil pump gasket Use Oil Seal Guide 09926 18210 to prevent damage to oil seal during installation of oil pump See Fig 3 3 Apply engine oil to guide and install oil pump Install dipstick guide with NEW seal Install oil pan using silicone type sealant To complete installation reverse removal procedure Tighten bolts to specification See TORQUE SPECIFICATIONS Oil Pump Pin Crankshaft Oil Seal Guide SS BO 90G08909 Fig 3 Installing Oil Seal Guide Courtesy of Suzuki of America Corp TIMING BELT Removal 1 Disconnect negative
22. engine 2 or 3 times to ensure lines are empty Reconnect fuel pump relayconnector Fuel Pump Relay 95E32361 Fig 1 Locating Fuel Pump Relay Courtesy of Suzuki of America Corp ENGINE CAUTION When raising or supporting engine or automatic transmission for any reason DO NOT use a jack under oil pan Damage to oil pump and pick up strainer could result NOTE Remove engine and transmission as an assembly Engine and transmission assembly must be lowered from vehicle Removal FUEL PRESSURE RELEASE 1 Release fuel pressure S Disconnect battery cables Mark and remove hood Drain coolant and remove radiator hoses 2 Disconnect cooling fan wires Remove air cleaner assembly Remove radiator and cooling fan as an assembly Disconnect fuel lines and heater hoses Identify engine 3 Disconnect accelerator cable at throttle body On M T mark and remove vacuum lines and hoses at models disconnect clutch cable at transmission On A T models disconnect gear select cable from transmission On all models label and disconnect all engine and transmission wiring 4 Raise vehicle Remove right and left engine undercovers Disconnect exhaust pipe at manifold Loosen A C compressor pivot bolt Remove A C drive belt and compressor mounting bracket if equipped 5 On A T models disconnect gearshift control shaft and gearshift extension rod at transaxle 1
23. ervice LINIE rias a ed 0035 09 Rocker Arm Shaft Runout o o oooooooooooooooo o 008 20 1 6L 4 CYL VIN OArticle Text p 17 995 Suzuki EsteenFor Xeor END OF ARTICLE 1 6L 4 CYL VIN OArticle Text p 18 995 Suzuki EsteenFor Xeon Copyright 1998 Mitchell Repair Information Con
24. ion is not available at time of publication CRANKSHAFT MAIN amp CONNECTING ROD BEARINGS SPECIFICATIONS CRANKSHAFT MAIN amp CONNECTING ROD BEARINGS TABLE Application In mm Crankshaft End Play Standard gs Boletos So Se So A Oe 004 012 11 31 Service LIMPE A EEN A eek a a A e 015 38 RUTIQUE pcs Sa Se E Dai A Ree RSS SS 002 06 Main Bearings Journal Diameter 1 EE esse bie pa se aida AS gi ee a eS 2 0470 2 0472 51 994 52 000 VD Ad O eo aes 2 0468 2 0470 51 988 51 994 WENN 2 0465 2 0468 51 982 51 988 Journal QuE 0OE RoOUNd asda pn See EE E 0004 010 Journal Taper spenst eso WINS io a 0004 010 Oil Clearance Standard camila Meteo Balas 0008 0016 020 040 Service LIMIE eri A a a 0024 060 Main Bearing Cap Bore Diameter 2 TAT a is AE a 2 2047 2 2050 56 000 56 006 A E DE SS DL es 2 2050 2 2052 56 006 56 012 A aaa ter eon 2 2052 2 2054 56 012 56 018 4 6L 4 CYL VIN OArticle Text p Connecting Rod Bearings Journal Diameter 1 7316 1 7323 43 982 44 000 Journal QUE OL ROUNA suas ear ato os sobra Pe 0004 010 Journal Taper ies e AN ea 0004 010 Oil Clearance Standardi rta Ss cass tee ets 0008 0020 020 050 Servic DIMI tir id as 0031 080 1 Main bearing journal diameter is determined by numerical mark 1 2 or 3 stamped on crankshaft web 2 Main bearing cap bore diameter is determined by letter A B or C
25. ne Ensure oil hole in connecting rod faces intake side of engine Install cylinder head oil pick up screen and oil pan To complete installation reverse removal procedure CAUTION Install spacer gap more than 45 degrees from side rail gaps Rails should turn smoothly when installed t INTAKE SIDE Oil Ring End Gap Nos Ring End Gap Arrow Mark No 2 DCH Ring End Gap Oil Ring End Gap Oil Ring Spacer Gap EXHAUST SIDE Piston Identification Mark lt i EsteenFor Xeon Copyright 1998 Mitchell Repair Information Comp A No t Ring Mark MANOBRA Fig 8 Positioning Piston Ring Gaps Courtesy of Suzuki of America Corp Rod Bearings 1 Inspect journals for wear taper and out of round If specifications are exceeded grind journals to undersize or replac crankshaft See CRANKSHAFT MAIN amp CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS 2 Inspect bearing shells for signs of fusion pitting burning or flaking Observe contact pattern Standard bearings are unmarked Undersized bearings are stamped US025 on back of bearing to indicate 010 25 mm undersize 3 Check bearing clearance using Plastigage See CRANKSHAFT MAIN amp CONNECTING ROD BEARINGS table Standard connecting rod side play is 0039 0078 10 20mm with a service limit of 0138 35 mm 4 To install reverse removal procedure Tighten rod nuts to specification See TORQUE SPECIFICA
26. ngine oil Inspection 1 Check cam lobes and journals for wear and damage Use Plastigage to check bearing clearance If wear exceeds specification repair or replace as necessary See CAMSHAFT table under ENGINE SPECIFICATIONS 2 Use dial indicator and V blocks to measure camshaft runout at center of shaft If wear exceeds specification repair or replace as necessary See CAMSHAFT table Installation Lubricate camshaft lobes and camshaft bearing journals Install camshaft and NEW oil seal in cylinder head Install camshaft sprocket Ensure camshaft sprocket timing marks align with timing marks on cylinder head See Fig 4 To complete installation reverse removal procedure REAR CRANKSHAFT OIL SEAL Removal Remove engine or engine and transmission See ENGINE Separate transmission from engine Remove flywheel Remove oil seal housing Remove seal Inspect oil seal housing for wear or damage Repair or replace as necessary Installation Install oil seal in housing Apply oil to seal lip Install oil seal housing with NEW gasket Tighten housing bolts to specification See TORQUE SPECIFICATIONS table Oil seal housing gasket will bulge after mounting bolts have been tightened Trim excess gasket material even with oil pan gasket surface WATER PUMP Removal 1 Drain cooling system Disconnect negative battery cable Remove drive belts Remove A C compressor if equipp
27. nsure gears turn freely by hand after gear plate is installed Install oil pump pins NEW dipstick O ring NEW seal for4 BH ACYEVIN PACA ext no APIS Sar ukMEstethForSdon Copyright 1998 Mitchell Rep Guide 09926 18210 to prevent damage to oil seal during instal lation of oil pump 3 Apply engine oil to guide and install pump Install dipstick guide with NEW seal Install oil pan using silicone type sealant Tighten bolts to specification See TORQUE SPECIFICATIONS Inner Rotor 98E 18568 Fig 14 Checking Oil Pump Radial Clearance Courtesy of Suzuki of America Corp Straightedge Feeler Gauge 96F 18569 Fig 15 Checking Oil Pump Side Clearance Courtesy of Suzuki of America Corp TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS TABL E Application Ft Lb Generator Mount Adjusting Bolts 13 21 Generator Pulley Bolt Mina ets aos aaa ste eR ae Sle aes Camshaft Sprocket Bot ee NNN NN erde eee ies 41 47 Connecting Rod Cap Nut o oooooooooooooooo o 24 27 Crankshaft Main Bearing Cap Bolt 37 42 Crankshaft P lley Bolt nesses ae mesas Alt Crankshaft Sprocket Bolt EE 77 85 LOOT ek E a eile A oe Ee tn bind Se e Ee 77 85 Cylinder Head Bolt 1 tdi praia acabe ceda SUBS So 48 52 Drive Plate To Torque Converter Bolt Engine Mounts To BLoCk aaa ie siste aerea
28. one complete revolution valve clearance of cylinders No 1 f cylinders No 1 and 3 Turn 360 degrees Check intake valve clearance of cylinders No 3 and 4 and exhaust valve clearance of cylinders No 2 and 4 4 Ensure clearance is within specification See VALVE CLEARANCE SPECIFICATIONS table If clearance adjustment is necessary loosen lock nut and turn adjusting screw Hold adjusting screw while tightening lock nut to 106 INCH lbs 12 N m Recheck clearance VALVE CLEARANCE SPECIFICATIONS TABLE Application In mm Engine Cold Intake Exhaust ooooooooooooo o 009 007 213 218 Engine Hot Intake Exhaust EE 007 008 18 20 REMOVAL amp INSTALLATION label all electrical connectors s before removal Also place NOTE For reassembly reference vacuum hoses and fuel line mating marks on engine hood and other major assemblies before removal WARNING ALWAYS relieve fuel pressure befor injection related component disconnecting any fuel DO NOT allow fuel to contact engine or electrical components FUEL PRESSURE RELEASE 1 Place transmission in Neutral M T or Park A T Set parking brake and block drive wheels 2 Disconnect fuel pump relay connector Fuel pump relay is located in relay box near battery See Fig 1 3 Remove fuel filler cap to release pressure Reinstall fuel filler cap Start engine and idle until engine dies Crank
29. oooooooo o 89 115 10 13 Rocker Arm Shaft Screw acentuar serias vis o 80 106 9 12 Rocker Cover BOLE misses aso as 35 44 4 5 Timing Belt Outer Cover Bolt 80 106 9 12 Timing Belt Tensioner Stud Nut 80 106 9 12 Water Pump Mounting Bolt 80 106 9 12 Water Pump Pulley Bolt 89 115 10 13 1 Tighten in sequence See Fig 2 or 8 ENGINE SPECIFICATIONS GENERAL ENGINE SPECIFICATIONS GENERAL ENGINE SPECIFICATIONS TABLE Application Specification Displacement camisas mas pias ad bo aS 97 0 Cu In 1 61 BOBS EE 2 95 75 0 mm E Lise ita te eee eda Mocha EE 3 54 90 0 mm Compression Ratio Beets aoe eRe a eS Sed Compression Pressure 1 Standard vrai n Dm ads er EEN a 199 psi 14 kg cm EE abas Ae ars Mani ee data dd OS 156 psi 11 kg cm Maximum Variation 14 2 psi 1 kg cm EOL SYSTEM eck A Ee aad a Sp SR hk BAe ee er eee EES SFI Horsepower HR RPM corria o Sd ar 98 6000 Torque Eta thst eRPM a shoo eae sect eege Ale dae os 96 30 00 1 Checked at 250 RPM or higher CONNECTING RODS SPECIFICATIONS CONNECTING RODS TABLE Application In mm Pin BOLO eletre OG eek wae eg 7481 7485 19 003 19 011 Maximum Bend greys dite a dead een eg a pa 0020 05 Maximum TRES sans santa Ba we ba Re a 0039 10 Side Play Standard a ded sigam nvr ahd e bode aoe 0039 0078 10 20 Service Tame EE EES 0138 35 1 Informat
30. rede ere opie ae oles Engine Mounts To Fram resonar da ere hee ee re Sues we Exhaust Manifo la Bolt caps cisnes RE whe ees 13 21 EXNQUSE lt PTPE 1 ii d e ege ierg KES Flywheel Bolt Drive Plate For A T 55 59 Intake Manifold Bolt lua ars alo sas pena EE sae als 13 21 Buel Pesa Flare Nut ia sms Seg wide ete Tate inde ames Or San Drain Plug wene esaeet Goer Te ae 8 AO 22 30 OL Filter Mount cuidas a asa SS Spark PIU aseme pipas air el eet sere er ane a ge fee bee CE ee 15 22 Timing Belt Tensioner Bolt 18 22 Torque Converter BOLES Lim gemea E SEA A hein A ando pelo ds s N m 18 28 82 111 56 64 33 37 50 57 15 18 105 11 105 11 65 7 70 GA a D wen L vVHIWQHI ou 00 allasa TL E N 0048 N U1 wo ATO UTO G A Ur OUTA w o E INCH Lbs N m Camshaft Bearing Cap Bolt 2 80 10 Cooling Fan Nut rer ees silo tees a EE Slee es 71 10 1 6L 4 CYL VIN 0Article Distributor Cases Bolt amena ento ae An side oia ao 71 106 8 12 071 Pan Bolt eres ras a eigenen eben dar o ers 80 106 9 12 Oil Pressure SWIEGH usaria a da ee ere NL 106 133 12 15 011 Pump Mounting BOLE eege ae d hs AE ECH 80 106 9 12 Oil Pump Rotor Plate SCrew os wae CN e 80 106 9 12 011 Pump Strainer Bolt cuecas aeee aes a 80 106 9 12 Oil Seal Housing BOTE excesos E NN as 80 106 9 12 Rear Main Seal Bolt o oooooooo
31. s dida 028 70 mm Stem Diameter 2142 2148 5 440 5 455 mm Valve Springs Free Length Standard ai A ee 1 4500 36 83 mm Service Limit in rs A da 1 4043 35 67 mm QuUE 0fE Square ars ia NEE e ees 079 2 00 mm Lbs In kg Q mm Valve Spring Preload Standard ye pnma ete we 23 6 27 5 1 24 10 7 12 5 31 5 Service Limit oj sue aims ees acs E 20 5 1 24 9 3 31 5 CYLINDER BLOCK SPECIFICATIONS 1 6L 4 CYL VIN 0Article Text p CYLINDER BLOCK TABL Ea Application In mm Cylinder Bore Standard Diameter 1 MAA o EE 2 9531 2 9535 75 010 75 020 DO a A ef ae pa A id te 2 9528 2 9531 75 000 75 010 Maximum Taper ans NR goes tes eel ae ge eh ele nergy dE 0039 10 Maximum OutG Of ROUNG varon o led 0039 10 Maximum Deck Warpage o oooooooooooooo ooo 002 05 1 Cylinder bore diameter is determined by numerical mark 1 or 2 stamped on cylinder block See Fig 8 CYLINDER HEAD SPECIFICATIONS CYLINDER HEAD TABLE Application Specification Maximum Warpage Head To BLOC aii rel WSS NS were 002 05 mm Manifold To Head iso pss as 004 10 mm Valve Seats Intake amp Exhaust Valves Seat AngGle ge nies ee paes Wade Se ee Se Ss le Re Da ea 45 Seat Width its DS eee as 0433 0512 1 1 1 3 mm Valve Guides Valve Stem End Deflection Limit Ereigneis e EOS 006 14 mm GUISE E A is 007 18 mm
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