NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY (NUST)

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING

SPRING 2023
ME-431 IC ENGINE AND POWERPLANT LAB

Disassembly and Assembly of intake and exhaust manifolds and cylinder head
of Suzuki ST30 engine.
S.NO NAME TEAMWORK INDIVIDUAL TOTAL
ASSESSMENT
1 Daniyal Safi
2 Muhammad Ali Ijaz
3 Ali Raza
4 Malik Hamza Farooq
 1. Title:
Disassembly and Assembly of intake and exhaust manifolds and cylinder head of Suzuki ST30
engine.

2. Objectives:
The process of disassembling and assembling the intake and exhaust manifolds as well as the
cylinder head for the Suzuki ST30 engine.

3. Apparatus:
Suzuki ST30 engine, Screwdriver set, T-spanner, Combination spanner set.

4. Disassembly and Assembly procedure:

Disassembly Procedure:
• Disconnect the negative battery cable.
• Drain the radiator coolant and remove the upper hose.
• Remove the throttle body and air cleaner assembly.
• Fuel injectors should be removed after disconnecting the fuel lines.
• Remove the intake manifold bolts and manifold.
• Remove the exhaust manifold bolts and manifold.
• Remove the rocker cover bolts and cover.
• Remove the camshaft holder bolts and holder.
• Remove the camshaft sprocket bolts and sprocket.
• Remove the timing belt cover bolts and cover.
• Loosen the timing belt tensioner bolt and remove the belt.
• Remove the cylinder head bolts in the proper sequence and remove the head.

Assembly Procedure:
• Thoroughly clean the cylinder head, intake manifold, and exhaust manifold mating surfaces.
• Place the new cylinder head gasket onto the engine block.
• Install the cylinder head onto the block and tighten the bolts in the specified sequence to
the specified torque.
• Install the timing belt and adjust the tensioner.
• Install the camshaft sprocket and torque the bolts to the specified value.
• Install the camshaft holder and torque the bolts to the specified value.
• Install the rocker cover and torque the bolts to the specified value.
• Install the exhaust manifold and torque the bolts to the specified value.
• Install the intake manifold and torque the bolts to the specified value.

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 • Install the fuel injectors and connect the fuel lines.
• Install the air cleaner assembly and throttle body.
• Install the upper radiator hose and refill the cooling system with coolant.
• Reconnect the negative battery cable.
• Start the engine and check for leaks or abnormal noises.
Tools:
To disassemble and assemble the distributor, self-starter, and generator of a Suzuki ST30 3-
cylinder two-stroke spark ignition engine, the following specific tools are required:
• A socket set and wrenches of various sizes for removing bolts and nuts.
• Pliers for removing and installing various clips and connectors.
• Screwdrivers of various sizes for removing and installing screws.
• A timing light for setting the ignition timing.
• A multimeter for testing electrical components.
• Puller tools for removing the distributor rotor and pulleys.
• A torque wrench for tightening bolts to the correct specification.
• A bearing puller and installer for removing and installing bearings.
• A seal puller and installer for removing and installing seals.
• A feeler gauge for checking valve clearance.
It's worth noting that not all of these tools may be required for every step of the disassembly and
assembly process. Consult the engine's service manual for specific instructions and tool
requirements.

5. Observations:
As they regulate the flow of air and exhaust gases into and out of the combustion chamber, the
intake and exhaust manifold and cylinder head are essential to the engine's correct operation.
The rocker arms, valves, and valve springs that are crucial for controlling the flow of fuel and air
through the engine may also be found in the cylinder head.
It is important to separate the head and remove the cylinder head bolts in the correct order in
order to reach these parts. The cylinder head is a fragile part that needs careful handling during
this process to prevent damage, so proper care and attention should be given. Before
reassembling the engine, the cylinder head can be cleaned, and examined for wear and tear or
corrosion and any required repairs or replacements can be made.

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 Cylinder Head

Cooling Fan

Alternator

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Maintenance issues with the cylinder head, intake and exhaust manifolds, and manifolds
frequently arise. Leaks from the exhaust system, worn or broken valve parts, and carbon build-
up on the valves or cylinder head are a few examples of these issues. If these issues are not fixed,
the engine may perform worse, use less gasoline, or perhaps stop working altogether.
Thankfully, many issues have fixes that will improve engine performance. Repairing worn-out or
broken valve parts, for instance, can improve engine performance and prevent further engine
damage. While removing carbon build-up from the cylinder head and valves can improve engine
performance and breathing, sealing exhaust leaks can improve fuel economy and reduce harmful
emissions. To ensure that the engine performs smoothly and effectively, it's crucial to remain on
top of these maintenance difficulties.

6. Measurements

Parameters Value
Inlet Valve length end-end (mm) 125.10
Inlet Valve diameter (mm) 7.92
Inlet Valve mass (g) 116.75
Outlet Valve length end-end (mm) 127.74
Outlet Valve diameter (mm) 7.97
Outlet Valve mass (g) 95.85
Pushrod diameter (mm) 8.99
Pushrod length end-end (mm) 276.00
Inlet manifold end diameter (mm) 46.22
Exhaust manifold end diameter (mm) 37.40

7. Discussion:
Students can learn about the crucial parts of the engine that control the flow of exhaust and
intake air by disassembling and reassembling the Suzuki ST30 engine's cylinder head and intake
and exhaust manifold. Also, they can learn how to recognize and fix typical issues. It could be
able to repair individual parts, such as valves or rocker’s arms, or take care of particular problems,
such as exhaust leaks or carbon buildup, without completely disassembling the engine. Poor
engine performance or even engine failure can be caused by problems including exhaust leaks,
carbon build-up, or worn or damaged valve components. To avoid these problems, routine
maintenance activities including checking for and replacing worn or damaged parts, fixing
exhaust leaks, or removing carbon build-up should be carried out.

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 8. Safety Precautions:
During the dismantling and assembly procedure, several safety precautions were implemented.
We wore safety gloves and goggles to protect our hands and eyes from potential cuts from debris
and sharp edges. In order to stop the engine from falling or toppling over, we also securely
secured it. We exercised caution when handling the battery and emptying the engine oil to avoid
any spills or leaks. Finally, we made sure that any used oil and other hazardous trash were
properly disposed of.

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