Suzuki Esteem, Swift 1994-02

Rocker Arms & Shafts

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Removal & Installation



Only the 1.3L engine uses rocker arms/shafts. On the 1.6L engine, the camshaft directly actuates the valves.

The 1.3L and 1.6L engines use rocker arms/shafts. On the 1.8L engine, the camshaft directly actuates the valves.

1.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system into a re-sealable container.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Cylinder head cover from the cylinder head
     
    Camshaft Position (CMP) sensor coupler from the CMP sensor
     
    High tension cords and couplers from the coil assemblies
     
    Ignition coil from the exhaust manifold side
     
    CMP case from the cylinder head
     

  6.  
  7. Loosen all valve adjusting screw lock nuts, turn the adjusting screws back all the way to allow the rocker arms to move freely.
  8.  
  9. Remove or disconnect the following:

    Camshaft housing and the camshaft
     
    Timing belt inside cover
     
    Intake rocker arm with the clip from the rocker arm shaft. Make sure not to bend the clip when removing the intake rocker arm
     
    Rocker arm shaft bolts
     
    Exhaust rocker arms and spring by pulling out the shaft on the battery side. If necessary, remove the battery for clearance.
     

  10.  
  11. Inspect the rocker arms and shafts for wear and/or damage and replace parts as necessary.
    1. If the tip of the valve lash adjuster is badly worn, replace the adjuster.
    2.  

  12.  

To install:

  1. Apply engine oil to the rocker arms and the rocker arm shafts.
  2.  
  3. Install or connect the following:

    O-ring on the shaft
     
    Rocker arm shaft with its holes facing up
     
    Rocker arm (exhaust side) and the rocker arm spring
     
    Rocker arm shaft bolts and tighten the bolts to 96 inch lbs. (11 Nm)
     

  4.  
  5. Pour a small amount of engine oil into the arm pivot holding part of the shaft.
  6.  
  7. Install or connect the following:

    Rocker arm (intake side), with the clips to the rocker arm shaft
     
    Camshaft and housing
     
    Camshaft oil seal
     
    Timing belt inside cover
     
    Camshaft timing belt pulley, while fitting the pin on the camshaft into the slot. Tighten the pulley bolt to 43 ft. lbs. (60 Nm).
     
    Timing belt
     
    Remaining components in the reverse order of removal.
     

  8.  
  9. Check the ignition timing.
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system into a re-sealable container.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Cylinder head cover from the cylinder head
     
    Camshaft Position (CMP) sensor connector from the CMP sensor
     
    High tension cords and connectors from the coil assemblies
     
    Ignition coil from the exhaust manifold side
     
    CMP case from the cylinder head
     

  6.  
  7. Loosen all valve adjusting screw lock nuts, turn the adjusting screws back all the way to allow the rocker arms to move freely.
  8.  
  9. Remove or disconnect the following:

    Camshaft housing and the camshaft
     
    Timing belt inside cover
     
    Intake rocker arm with the clip from the rocker arm shaft. Make sure not to bend the clip when removing the intake rocker arm
     
    Rocker arm shaft bolts
     
    Exhaust rocker arms and spring by pulling out the shaft on the battery side. If necessary, remove the battery for clearance.
     

  10.  
  11. Inspect the rocker arms and shafts for wear and/or damage and replace parts as necessary.
    1. If the tip of the valve lash adjuster is badly worn, replace the adjuster.
    2.  

  12.  

To install:

  1. Apply engine oil to the rocker arms and the rocker arm shafts.
  2.  
  3. Install or connect the following:

    O-ring on the shaft
     
    Rocker arm shaft with its holes facing up
     
    Rocker arm (exhaust side) and the rocker arm spring
     
    Rocker arm shaft bolts and tighten the bolts to 96 inch lbs. (11 Nm)
     

  4.  
  5. Pour a small amount of engine oil into the arm pivot holding part of the shaft.
  6.  
  7. Install or connect the following:

    Rocker arm (intake side), with the clips to the rocker arm shaft
     
    Camshaft and housing
     
    Camshaft oil seal
     
    Timing belt inside cover
     
    Camshaft timing belt pulley, while fitting the pin on the camshaft into the slot. Tighten the pulley bolt to 43 ft. lbs. (60 Nm).
     
    Timing belt
     
    Remaining components in the reverse order of removal.
     

  8.  
  9. Check the ignition timing.
  10.  

1.6L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    After the timing belt is removed, never turn the camshaft and crankshaft independently more than 90° in either direction. If turned, interference may occur among the piston and valves causing possible damage to the effected parts.



    Negative battery cable
     
    Timing belt
     

  4.  
  5. Using a camshaft sprocket holding tool, hold the sprocket stationary and remove the camshaft sprocket bolt.
  6.  
  7. Remove or disconnect the following:

    Cylinder head cover
     
    Distributor cap and distributor assembly from the engine, if equipped
     
    Ignition coils and the Camshaft Position (CMP) sensor case from the cylinder head with the CMP sensor coupler disconnected
     
    Loosen all of the valve adjusting screw locknuts until the rocker arms move freely
     
    Camshaft housing and camshaft
     
    Rocker arm shaft plug from the cylinder head
     
    Timing belt inner cover-to-cylinder head bolts and the cover
     
    All intake rocker arms and clips from the rocker shaft. Keep all parts in order so they can be reinstalled in their original locations.
     
    6 rocker arm shaft-to-cylinder head bolts. Push the rocker arm shaft through the rear of the cylinder head until the end of the rocker shaft appears.
     
    O-ring from the rear of the rocker arm shaft
     
    Exhaust rocker arms, rocker arm springs and rocker shaft by pulling the rocker arm shaft through the front of the cylinder head. Be sure to keep the parts in order for installation purposes.
     

  8.  
  9. Clean and inspect all parts for wear and/or damage. Replace parts as necessary.
  10.  

To install:

  1. Lubricate the rocker arms and shafts with clean engine oil before installation.
  2.  
  3. Install or connect the following:

    Push the rocker shaft into the front of the cylinder head
     
    Exhaust rocker arms and springs as the rocker arm shaft is being installed into the cylinder head
     
    Push the rocker arm shaft through the rear of the cylinder head
     
    New O-ring onto the rocker shaft
     

  4.  
  5. Rotate the rocker arm shaft so the flat machined surface is horizontal and facing downward, parallel with the cylinder head mating surface and slide the shaft back into the cylinder head.
  6.  
  7. Install or connect the following:
    NOTE
    The camshaft carrier caps are embossed with numbers and arrows to ensure correct assembly. The No. 1 camshaft carrier cap must be installed at the front of the cylinder head with the remaining carrier caps following in numerical order. The directional arrows must always point toward the front of the cylinder head.


    WARNING
    If the camshaft carrier cap bolts are tightened at random, damage to the camshaft may occur.



    6 rocker arm shaft bolts and tighten the rocker arm-to-cylinder head bolts to 96 inch lbs. (11 Nm). Fill the rocker arm shaft bolt holes with clean engine oil.
     
    Intake rocker arms and clips onto the rocker arm shaft
     



    Camshaft

    Click image to see an enlarged view

    Fig. Camshaft carrier cap bolt torque sequence-1.6L engine



    Click image to see an enlarged view

    Fig. Align the dowel pin with the E-slot in the sprocket-1.6L engine

     

  8.  
  9. Lubricate the new camshaft seal lip with clean engine oil
    NOTE
    During camshaft timing belt sprocket installation, align the camshaft dowel pin with the slot in the camshaft timing belt gear designated as E .


    NOTE
    When installing the timing belt, the directional arrows on the timing belt must be matched with the rotation of the crankshaft. If not, excessive wear and timing belt failure may occur.



    New Camshaft seal into the cylinder head until it is flush with the camshaft carrier surface
     
    Timing belt inner cover and tighten the cover-to-cylinder head bolts to 89 inch lbs. (10 Nm)
     
    Rocker arm shaft plug into the cylinder head and tighten to 24 ft. lbs. (33 Nm)
     



    Camshaft sprocket. Using a holding tool to hold the sprocket in place, tighten the camshaft sprocket bolt to 44 ft. lbs. (60 Nm).
     



    Timing belt
     

  10.  
  11. Apply RTV silicone rubber sealant to the surface of the distributor case that mates with the rear of the rocker arm shaft.
  12.  
  13. Install or connect the following:
    NOTE
    With the timing marks aligned on the sprockets and the timing belt installed, the number 4 piston is at Top Dead Center (TDC) of the compression stroke.



    Distributor case and tighten the 3 case-to-cylinder head bolts to 89 inch lbs. (10 Nm), if equipped
     
    CMP sensor case and tighten the bolts to 96 inch lbs. (11 Nm), if equipped
     
    Ignition coil, if equipped
     



    Distributor into the distributor case, if equipped. Be sure the rotor is aligned with the No. 4 tower on the distributor cap.
     
    Distributor cap, if equipped
     

  14.  
  15. Adjust the valve lash.
  16.  
  17. Install or connect the following:

    Cylinder head cover onto the cylinder head, in the reverse order of removal. Clean all sealing surfaces and use a new gasket and O-rings. Tighten the cylinder head cover bolts to 89 inch lbs. (10 Nm).
     
    Negative battery cable
     

  18.  
  19. Start the engine, allow it to reach normal operating temperature and check for leaks.
  20.  
  21. Check and adjust the ignition timing as necessary.
  22.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    After the timing belt is removed, never turn the camshaft and crankshaft independently more than 90° in either direction. If turned, interference may occur among the piston and valves causing possible damage to the effected parts.



    Negative battery cable
     
    Timing belt
     

  4.  
  5. Using a camshaft sprocket holding tool, hold the sprocket stationary and remove the camshaft sprocket bolt.
  6.  
  7. Remove or disconnect the following:

    Cylinder head cover
     
    Distributor cap and distributor assembly from the engine, if equipped
     
    Ignition coils and the Camshaft Position (CMP) sensor case from the cylinder head with the CMP sensor connector disconnected
     
    Loosen all of the valve adjusting screw locknuts until the rocker arms move freely
     
    Camshaft housing and camshaft
     
    Rocker arm shaft plug from the cylinder head
     
    Timing belt inner cover-to-cylinder head bolts and the cover
     
    All intake rocker arms and clips from the rocker shaft. Keep all parts in order so they can be reinstalled in their original locations.
     
    6 rocker arm shaft-to-cylinder head bolts. Push the rocker arm shaft through the rear of the cylinder head until the end of the rocker shaft appears.
     
    O-ring from the rear of the rocker arm shaft
     
    Exhaust rocker arms, rocker arm springs and rocker shaft by pulling the rocker arm shaft through the front of the cylinder head. Be sure to keep the parts in order for installation purposes.
     

  8.  
  9. Clean and inspect all parts for wear and/or damage. Replace parts as necessary.
  10.  

To install:

  1. Lubricate the rocker arms and shafts with clean engine oil before installation.
  2.  
  3. Install or connect the following:

    Push the rocker shaft into the front of the cylinder head
     
    Exhaust rocker arms and springs as the rocker arm shaft is being installed into the cylinder head
     
    Push the rocker arm shaft through the rear of the cylinder head
     
    New O-ring onto the rocker shaft
     

  4.  
  5. Rotate the rocker arm shaft so the flat machined surface is horizontal and facing downward, parallel with the cylinder head mating surface and slide the shaft back into the cylinder head.
  6.  
  7. Install or connect the following:
    NOTE
    The camshaft carrier caps are embossed with numbers and arrows to ensure correct assembly. The No. 1 camshaft carrier cap must be installed at the front of the cylinder head with the remaining carrier caps following in numerical order. The directional arrows must always point toward the front of the cylinder head.


    WARNING
    If the camshaft carrier cap bolts are tightened at random, damage to the camshaft may occur.



    6 rocker arm shaft bolts and tighten the rocker arm-to-cylinder head bolts to 96 inch lbs. (11 Nm). Fill the rocker arm shaft bolt holes with clean engine oil.
     
    Intake rocker arms and clips onto the rocker arm shaft
     



    Camshaft

    Click image to see an enlarged view

    Fig. Camshaft carrier cap bolt torque sequence-1.6L engine



    Click image to see an enlarged view

    Fig. Align the dowel pin with the E-slot in the sprocket-1.6L engine

     

  8.  
  9. Lubricate the new camshaft seal lip with clean engine oil
    NOTE
    During camshaft timing belt sprocket installation, align the camshaft dowel pin with the slot in the camshaft timing belt gear designated as E .


    NOTE
    When installing the timing belt, the directional arrows on the timing belt must be matched with the rotation of the crankshaft. If not, excessive wear and timing belt failure may occur.



    New Camshaft seal into the cylinder head until it is flush with the camshaft carrier surface
     
    Timing belt inner cover and tighten the cover-to-cylinder head bolts to 89 inch lbs. (10 Nm)
     
    Rocker arm shaft plug into the cylinder head and tighten to 24 ft. lbs. (33 Nm)
     



    Camshaft sprocket. Using a holding tool to hold the sprocket in place, tighten the camshaft sprocket bolt to 44 ft. lbs. (60 Nm).
     



    Timing belt
     

  10.  
  11. Apply RTV silicone rubber sealant to the surface of the distributor case that mates with the rear of the rocker arm shaft.
  12.  
  13. Install or connect the following:
    NOTE
    With the timing marks aligned on the sprockets and the timing belt installed, the number 4 piston is at Top Dead Center (TDC) of the compression stroke.



    Distributor case and tighten the 3 case-to-cylinder head bolts to 89 inch lbs. (10 Nm), if equipped
     
    CMP sensor case and tighten the bolts to 96 inch lbs. (11 Nm), if equipped
     
    Ignition coil, if equipped
     



    Distributor into the distributor case, if equipped. Be sure the rotor is aligned with the No. 4 tower on the distributor cap.
     
    Distributor cap, if equipped
     

  14.  
  15. Adjust the valve lash.
  16.  
  17. Install or connect the following:

    Cylinder head cover onto the cylinder head, in the reverse order of removal. Clean all sealing surfaces and use a new gasket and O-rings. Tighten the cylinder head cover bolts to 89 inch lbs. (10 Nm).
     
    Negative battery cable
     

  18.  
  19. Start the engine, allow it to reach normal operating temperature and check for leaks.
  20.  
  21. Check and adjust the ignition timing as necessary.
  22.  

 
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