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Engine Specification Maruti

This document provides specifications for the engine of a Maruti-800, including: - It is a 3-cylinder, 4-stroke, water-cooled engine with a displacement of 796cm3. - It produces 39.5 horsepower at 5500 rpm and 6 kg-m of torque at 3000 rpm. - The dismantling and cleaning process includes removing components like the timing belt, camshaft, crankshaft, cylinder head, valves and pistons. The assembling process reverses this to rebuild the engine.

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5K views4 pages

Engine Specification Maruti

This document provides specifications for the engine of a Maruti-800, including: - It is a 3-cylinder, 4-stroke, water-cooled engine with a displacement of 796cm3. - It produces 39.5 horsepower at 5500 rpm and 6 kg-m of torque at 3000 rpm. - The dismantling and cleaning process includes removing components like the timing belt, camshaft, crankshaft, cylinder head, valves and pistons. The assembling process reverses this to rebuild the engine.

Uploaded by

Parama Guru
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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ENGINE SPECIFICATION MARUTI 800

TYPE

: Four stroke cycle, water cooled

NUMBER OF CYLINDER

: 3

BORE

: 68.5 mm

STROKE

: 72.0 mm

PISTON DISPLACEMENT VOLUME

: 796 cm

COMPRESSION RATIO

: 8.7:1

HORSE POWER

: 39.5 at 5500 rpm

TORQUE

: 6 kg m at 3000 rpm

MAXIMUM RPM

: 5500

FIRING ORDER

: 132

LUBRICATION SYSTEM

: Wet sump

CARBURETTOR

: Mikuni - Two barrel down draft

AIR CLEANER

: Polyester, fiber element (Dry type)

IGNITION TIMING

: 7 BTDC, Below 900 rpm

DISMANTLING, CLEANING, INSPECTION AND ASSEMBLING OF


MARUTI 800 ENGINE.
DISMANTLING:
1. Remove drain plug and drain out engine oil.
2. Remove fuel pump.
3. Ease out water pump pulley
4. Remove crank pulley with a lever attached to flywheel so that crankshaft will not turn.
5. Remove outside cover on timing belt.
6. Remove timing belt tensioner after removing the tensioner spring from the water
pump securing bolts.
7. Remove timing belt.
8. Remove the camshaft timing belt pulley by locking the camshaft.
9. Similarly remove the crankshaft timing belt pulley.
10. After removing the pulley key take out timing belt guide.
11. Take down timing belt inside cover.
12. Remove alternator bracket.
13. Remove water pump case.
14. Take off exhaust manifold cover and exhaust manifold.
15. Remove oil filter.
16. Draw the by-pass hose from intake manifold.
17. Take down inlet manifold.
18. Remove water inlet pipe.
19. Take off cylinder head cover.
20. Loosen the 6 valve adjusting screws fully, leaving the screws in place.
21. Loosen rocker arm shaft securing screws. (There are 8 screws)
22. While drawing out rocker arm shaft, separate valve rocker arms and rocker arm springs.

23. Remove camshaft thrust plate and draw shaft out towards distributor gear case side.
24. Remove cylinder head.
25. a) Use valve lifter to compress the valve spring in order to free valve retainers by
removing the cone locks. Then remove the valve spring and valves.
26. Remove the flywheel.
27. Take down oil pan.
28. Remove oil pump strainer.
29. Remove 3 connecting rod caps.
30. Install guide hose over threads of rod bolts. This to prevent damage to bearing journal
and cylinder wall when removing connecting rod.
31. Push piston and connecting rod assembly out through the top of cylinder bore.
32. Remove oil pump case.
33. Remove oil pump gear plate.
34. Take out inner gear and outer gear.
35. Remove oil seal housing.
36. Remove crankshaft bearing caps and take out crankshaft.

ASSEMBLING PROCEDURE FOR MARUTI 800


(Be ready with kit, Anabond or Suzuki bond or sealant lubricating oil, cleaning oil or
kerosene)
1. Keep the cylinder block up side down. Lubricate and fix the main journal bearings. Place
the crankshaft in right position. Then fix the crankshaft bearing caps with arrow mark facing
the crank pulley side as in fig. Tighten the bearing cap bolts to a torque of 4.3 4.8 kg-m
using torque wrench in the sequence given in fig. (1). Dont forget to fix the thrust bearings
in No.3 cylinder. Check the smooth rotation of crankshaft.
2. Then fix the oil seal housing on the flywheel side with new gasket.
3. Apply Suzuki bond on the mating surfaces around the oil discharging port of both the oil
pump case and the cylinder block. Install oil pump and check to be sure that oil seal lip is
not up turned. Install lit on crank pulley side with gasket.
4. Keep the cylinder block in side position. Before pinning piston to connecting rod oil the
small end and pin holes. Before fitting rings to piston check for first ring with RN mark and
2nd one with R mark as in fig.(2). After mounting the three rings distribute their end gaps to
different sides.

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