09160-12090 Suzuki WASHER

2-12.2 Turn the crankshaft in the direction of engine rotation until the valves opposite the cylinder to be adjusted overlap.Fig. 2-1 and table below
2-2 Note for Refitment:The exhaust valve is left-hand as viewed from the exhaust air side.Fig. 2-2
2-33. Release locknut of adjusting screw and adjust rocker arm/valve stem clearance.Retighten locknut.Fig. 2-34. Recheck clearance and readjust if necessary.
2-45. Apply sealing compound to new gaskets for rocker chamber cover(s) and fit cover(s).Fig. 2-4 Checking The Compression Pressure
The specified pressure applies to min. 150/min starting speed of engine and 20°C reference temperature at sea-level. Prior to checking, run up engine briefly to medium speed, so the combustion chamber will be sufficiently sealed by an oil film. Perform check at zero delivery of injection pump.
2-51. Remove injector and in its place insert and secure adapter with seal.Fig. 2-5, left Attention:In the case of FL 912 W, remove heater plug and in its place insert adapter for compression pressure recorder.Fig. 2-5, right
2-62. Connect compression pressure gauge.Fig. 2-6
2-73. Take the compression pressure reading.Fig. 2-7
2-8 Important:Check that the individual compression pressures are within the range specified and about equal for all cylinders. Any deviations in pressure between cylinders should not exceed 15%.Fig. 2-8Determining TDC With Setting Device
1. Remove No. 1 rocker chamber cover.2. Turn crankshaft until valves overlap, then give crankshaft another half turn.
2-93. Mount setting device. Using pressure screw of device, press down one rocker arm through 5-6 mm.Fig. 2-9
2-104. Fit dial gauge with preload.Fig. 2-10
2-115. Secure graduated scale to V-belt pulley and fix pointer to dowel sleeve.Fig. 2-11 If engine is installed in vehicle, use graduated dial segment No. 100940.6. Set pointer to "O" on scale.7. Turn crankshaft carefully in nominal direction until piston pushes up the valve. Slowly turn farther until gauge pointer changes the direction. Set gauge at "O"8. Turn back crankshaft through about one revolution of gauge pointer, then again in original direction up to 0, 1 mm (10 graduations) from O-position. Read crankshaft position from scale and record.9. Turn crankshaft in running direction beyond "O" through about one revolution of the gauge and turn back up to 0.1 mm (10 graduations) before "0".10. Read crankshaft position again from scale and record. The middle of the two crankshaft positions is the TDC (=OT) mark.11. Turn crankshaft so that the mark found agrees with the pointer. The piston is now in TDC position.
2-1212. Set pointer to "0" position of scale.Fig. 2-12Determining TDC W/O Graduated Scale
2-13Mounted are tuning unit No. 100640 and dial gauge No. 100400. Dial gauge is pre-tensioned.Fig. 2-131. Extend dowel sleeve by a piece of wire.2. Turn crankshaft carefully in normal direction until piston pushes up the valve. Slowly turn farther until gauge pointer changes the direction. Set gauge at "0".
2-143. Turn back crankshaft through about one revolution of gauge pointer, then again in original direction up to 0.1 mm (10 graduations) from 0-position. Provide an V-belt pulley a mark agreeing with dowel sleeve.Fig. 2-144. Turn crankshaft in running direction beyond "0" through about one revolution of the gauge and turn back up to 0.1 mm (10 graduations) before "0". Provide second mark on belt pulley.
2-155. Measure and mark the half-way position between the two marks.Fig. 2-15 The mid-way mark will be the dead centre mark. When it is opposite the retainer sleeve, cylinder 1 will be in the top dead centre position.Checking Beginning Of Delivery (FB) (by H.P. test unit or hand pump)
The TDC (=OT) has been determined. The graduated scale is secured to the belt pulley, the pointer to the dowel sleeve.
2-161. Turn the crankshaft backwards through 90 deg., then in the direction of engine rotation until the indicator points to the value given in the specifications for the FB point ahead of the zero position.Fig. 2-16 The piston of cylinder 1 will be exactly at the FB point.1. Connect the pressure line of the high-pressure tester.
2-172. Dismantle the fuel filter. Disassemble the fuel line of cylinder 1 connecting with the pumping element and the leak-off line connecting with the fuel-injection pump cover. Plug the leak-off hole and connect the pressure line of the instrument to the threaded sleeve for the fuel filter.Fig. 2-17
2-18 The hand pump can also be used if a blanking cover with hollow screw instead of the delivery pipe with H.P. unit is provided. The hollow screw can be fabricated locally (see drawing on last page).Fig. 2-183. Connect the overflow pipe with funnel and the return line to the stub for the fuel line to cylinder 1.F2/3/4/5/6L (with Bosch injection pump):
2-193.1. Disconnect inlet pipe and backleakage pipe. Plug up one of the ports (arrow) and connect delivery pipe of test pump to second port.Fig. 2-194. Turn the crankshaft in the direction opposite that of engine rotation through 90 deg. from the point of fuel delivery (FB).
2-20
2-214.1. Switch on H.P. unit (F2L with Deutz injection pump) or operate H.P. hand pump (F2/3/4/5/6L with Bosch injection pump), until fuel comes out of the overflow pipe. Turn crankshaft slowly in normal direction, until only droplets come out at intervals of 5-8 seconds.Fig. 2-20 and 2-21
2-225. Check that FB mark on belt pulley agrees with pointer, so that the fuel delivery timing is correct.Fig. 2-226. Turn off the high-pressure tester.7. If necessary, correct the point of fuel delivery in accordance with the separate instructions. Note that the procedure is not the same for all types of engine.Setting Beginning Of Delivery (FB) (As from 3-cylinder engine)
1. Turn the crankshaft in the direction opposite to that of engine rotation, through 90 deg. from the point of fuel delivery (FB) and then in the direction of engine rotation until the FB mark on the vee-belt pulley registers with th