1998-2003 Suzuki Alto 4 Door Engine Mechanical (F8B Engine) User Manual
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Engine Mechanical (F8B Engine) for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

6A
ENGINE MECHANICAL (F8B ENGINE) 6A-1
SECTION 6A
ENGINE MECHANICAL
(F8B ENGINE)
CONTENTS
GENERAL DESCRIPTION 6A- 2. . . . . . . . . . . . . .
Engine 6A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 6A- 3. . . . . . . . . . . . . . . . . . .
ENGINE SERVICES NOT REQUIRING
ENGINE REMOVAL 6A- 4. . . . . . . . . . . . . . . . . . . .
DISMOUNTING ENGINE 6A- 5. . . . . . . . . . . . . . . .
ENGINE DISASSEMBLY
6A- 8. . . . . . . . . . . . . .
INSPECTION OF ENGINE COMPONENTS 6A-18
Cylinder Head 6A-18. . . . . . . . . . . . . . . . . . . . . . .
Rocker-Arm Shaft and Rocker Arms 6A-20. . . .
Valve Guides 6A-21. . . . . . . . . . . . . . . . . . . . . . . .
Valves 6A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seats 6A-22. . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs 6A-24. . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 6A-25. . . . . . . . . . . . . . . . . . . . . . .
Piston and Piston Rings 6A-26. . . . . . . . . . . . . .
Connecting Rods 6A-28. . . . . . . . . . . . . . . . . . . .
Connecting-Rod Big End Bearings 6A-28. . . . .
Crankshaft 6A-30. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Journal Bearings 6A-31. . . . . . . . . .
Flywheel 6A-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seals 6A-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Timing Pulleys 6A-33. . . . . . . .
Oil Pump 6A-33. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REASSEMBLY
6A-34. . . . . . . . . . . . . .
Crankshaft 6A-34. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Housing 6A-35. . . . . . . . . . . . . . . . . . . . .
Oil Pump 6A-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and Piston Rings 6A-36. . . . . . . . . . . . . .
Connecting Rods 6A-38. . . . . . . . . . . . . . . . . . . .
Oil Pump Strainer 6A-38. . . . . . . . . . . . . . . . . . . .
Oil Pan 6A-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel 6A-39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A-39. . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A-42. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker-Arm Shafts 6A-42. . . . . . . . . . . . . . . . . . .
Timing Belt Inside Cover Stud Bolts 6A-43. . . .
Crankshaft Timing Belt Guide 6A-43. . . . . . . . . .
Camshaft and Crankshaft Timing Belt
Pulleys 6A-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 6A-43. . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Gear Case 6A-45. . . . . . . . . . . . . . . .
Fuel Pump 6A-45. . . . . . . . . . . . . . . . . . . . . . . . . .
Generator 6A-45. . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Disc and Cover 6A-45. . . . . . . . . . . . . . . .
Distributor 6A-45. . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash (Clearance) Adjustment 6A-45. . . .
MOUNTING ENGINE
6A-46. . . . . . . . . . . . . . . . .
MAINTENANCE SERVICES 6A-48. . . . . . . . . . .
Water Pump Belt 6A-48. . . . . . . . . . . . . . . . . . . . .
Ignition Timing 6A-48. . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance (Lash) 6A-48. . . . . . . . . . . . . . .
Oil Pump Discharge Pressure
Measurement 6A-50. . . . . . . . . . . . . . . . . . . . . .
Compression Pressure Measurement 6A-51. . .
Vacuum Measurement 6A-52. . . . . . . . . . . . . . . .
Engine Oil 6A-53. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Filter 6A-53. . . . . . . . . . . . . . . . . . . . .
Engine Coolant 6A-53. . . . . . . . . . . . . . . . . . . . . .
Exhaust Line and Muffler 6A-53. . . . . . . . . . . . . .
Oil Filter Cap 6A-53. . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS
6A-54. . . . .
SPECIAL TOOLS 6A-54. . . . . . . . . . . . . . . . . . .
6A-2 ENGINE MECHANICAL (F8B ENGINE)
GENERAL DESCRIPTION
Engine
The engine is a water-cooled, in-line 3 cylinders,
4-stroke cycle gasoline unit with its S.O.H.C. (single
overhead camshaft) valve mechanism arranged for
“V”-type valve configuration.
The single overhead camshaft (S.O.H.C.) is mounted
over the cylinder head; it is driven from crankshaft
through timing belt. Unlike conventional overhead
valve (O.H.V.) engines, this engine has no pushrods.
Thus, drive for valve is more direct and enables the
valves to follow the crankshaft without any delay.
ENGINE MECHANICAL (F8B ENGINE) 6A-3
Engine Lubrication
The oil pump is of a internal gear type, and mounted on
the crankshaft at the crankshaft pulley side.
Oil is drawn up through the oil pump strainer and
passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
In one path, oil reaches the crankshaft journal bear-
ings.
Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting
passages drilled in the crankshaft, and then injected
from a small hole provided on the big end of connecting
rod to lubricate piston, rings, and cylinder wall.
In another path, oil goes up to the cylinder head and lu-
bricates rocker arms, valves and camshaft, etc., after
passing through the internal oilway of rocker arm
shafts.
An oil relief valve is provided on the oil pump. This
valve starts relieving oil pressure when the pressure
comes over about 3.3 kg/cm
2
(46.9 psi, 330 kPa). Re-
lieved oil drains back to the oil pan.
6A-4 ENGINE MECHANICAL (F8B ENGINE)
ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL
The following parts or components do not require engine removal to receive services (replacement, inspection or
adjustment):
Part or Component
Nature of Service
1. Spark plug Replacement or inspection
2. Distributor Replacement, inspection or adjustment
3. Exhaust manifold Replacement or inspection
4. Oil filter Replacement
5. Oil pressure unit Replacement
6. Cylinder head cover Replacement
7. Rocker shaft Replacement or inspection
8. Rocker-arm Replacement or inspection
9. Rocker-arm spring Replacement or inspection
10. Cam shaft Replacement or inspection
11. Cylinder head Replacement or inspection
12. Radiator Replacement or inspection
13. Distributor gear case Replacement
14. Camshaft timing belt pulley Replacement or inspection
15. Crankshaft timing belt pulley Replacement or inspection
16. Timing belt Replacement or inspection
17. Fuel pump Replacement
18. Throttle body Replacement, inspection
19. Intake manifold Replacement
20. Generator Replacement or inspection
21. Starter motor Replacement or inspection
22. Water pump belt Replacement, inspection or tension adjustment
23. Water pump Replacement
24. Pulleys (crank, water pump) Replacement
25. Timing belt cover Replacement
26. Water hose Replacement or inspection
DISMOUNTING ENGINE
1) Release fuel pressure in fuel feed line, refer to Section 6.
2) Disconnect negative cable at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove front bumper, refer to Section 9.
5) Drain cooling system.
WARNING:
To help avoid danger of being burned, do not remove
drain plug and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
6) Remove radiator with cooling fan and reserve tank, refer to Sec-
tion 6B.
7) Remove air cleaner assembly (1) with air cleaner hose (2) and
breather hose (3).
8) Disconnect following cables.
D Accelerator cable from throttle body
D Clutch cable from clutch release lever
D Speedometer cable from transmission case
9) Disconnect following hoses.
D Radiator outlet hose from outlet pipe
D Radiator inlet hose from thermostat cap
D Heater inlet and outlet hoses from heater unit (if equipped)
D Fuel return and inlet hoses from pipes
D Canister purge hose from canister purge control valve
ENGINE MECHANICAL (F8B ENGINE) 6A-5
10) Disconnect the following electric wires.
D Radiator fan
D Distributor (High-tension cord and terminal)
D Starter motor
D Generator
D Back-up light switch
D Oil pressure switch
D Oxygen sensor
D ECT sensor
D Right side of engine harness
D Ground wire from cylinder block
D Ground wire from transmission case
D A/C compressor (if equipped)
11) Remove exhaust center pipe.
12) Disconnect gear shift control shaft (1) and extension rod (2)
from transmission case.
13) Drain engine and transmission oil.
14) Remove stabilizer bar, refer to Section 3D.
15) Disconnect right and left drive shaft joints from differential side
gear snap rings.
6A-6 ENGINE MECHANICAL (F8B ENGINE)
16) Draw right and left drive shafts out of differential side gears.
NOTE:
Be careful not to damage brake flexible hose.
17) Remove water pump and A/C compressor belts (if equipped).
When removing A/C compressor belt, first remove water pump
pulley.
18) Recover refrigerant from refrigeration system by using recov-
ery and recycling equipment, refer to Section 1B (if equipped).
19) Disconnect suction and discharge hoses from compressor, re-
fer to Section 1B (if equipped).
NOTE:
Cap open fittings immediately to keep moisture out of
system.
20) Remove A/C compressor, upper and lower bracket (if
equipped).
21) Check to ensure all hoses, electric wires and cables are dis-
connected from engine and transmission.
22) Set a piece of wire across the hook on intake manifold and
transmission case so that engine can be lifted by using chain
block.
23) Remove transmission left side mounting and mounting brack-
et.
24) Remove bolts securing engine member to make engine ready
for removal.
25) Lower engine assembly together with transmission and en-
gine member out of vehicle slowly and carefully.
ENGINE MECHANICAL (F8B ENGINE) 6A-7
ENGINE DISASSEMBLY
NOTE:
D Observe critically before starting to remove a component or
part by loosening bolts, nuts and the like. What you may
find before and during disassembly is valuable information
necessary for successful reassembly.
D Be careful in handling aluminum-alloy parts. They are soft-
er than steel or cast-iron parts and their finished surfaces
more easily take scratch marks.
D Have trays and pans ready for setting aside the disas-
sembled parts in an orderly manner. Place the parts in the
trays and pans in such a way that they can be readily identi-
fied. Put match marks or tags on them, as necessary, so that
they will go back to where they came from.
Carry out engine disassembly in the following sequence:
1) Remove starter motor, engine mounting with engine member
and clutch housing lower plate, and loosen the transmission se-
curing bolts after removing the radiator outlet pipe.
2) Take off transmission from cylinder block.
3) Remove clutch cover (1) and clutch disc by using special tool.
Special Tool
(A): 09924-17810
6A-8 ENGINE MECHANICAL (F8B ENGINE)
4) Remove distributor cap (2) and then remove distributor assem-
bly (1).
5) Remove distributor case (1).
6) Remove generator (1), refer to Section 6H.
7) Remove generator brackets (1).
ENGINE MECHANICAL (F8B ENGINE) 6A-9
8) Remove crank pulley (1) similarly, by using special tool hitched
to flywheel (2) so that crankshaft will not turn.
Special Tool
(A): 09924-17810
9) Remove water pump pulley and then remove timing belt cover
(1).
10) Remove timing belt tensioner (1) after removing a part of ten-
sioner spring from water pump securing bolt.
11) Remove timing belt (1).
6A-10 ENGINE MECHANICAL (F8B ENGINE)
12) Remove camshaft timing belt pulley, by using special tool at-
tached, as shown, to lock camshaft.
Special Tool
(A): 09930-40113
13) Similarly remove crankshaft timing belt pulley (1).
14) After removing pulley key, take out timing belt guide (1).
15) Remove timing belt inside cover (1).
16) Remove water pump case (1).
ENGINE MECHANICAL (F8B ENGINE) 6A-11
17) Remove exhaust manifold covers (1) and exhaust manifold
(2).
18) Remove oil filter by using special tool.
NOTE:
Be careful not to spill the oil when removing filter.
Special Tool
(A): 09915-47310
19) Disconnect PCV outlet hose (1) and bypass hose (2).
20) Remove intake manifold (1) with throttle body (2).
21) Remove intake manifold plate (1).
6A-12 ENGINE MECHANICAL (F8B ENGINE)
22) Remove water inlet pipe (1).
23) Remove cylinder head cover (1).
24) Loosen valve adjusting screws (1) fully.
Leave the screws in place.
25) Loosen rocker arm shaft securing screws (1).
26) While drawing out rocker arm shaft (1), separate valve rocker
arms (2) and rocker arm springs.
ENGINE MECHANICAL (F8B ENGINE) 6A-13
27) Remove camshaft thrust plate (1), and draw camshaft (2) out
toward distributor gear case side.
28) Remove cylinder head (1).
a) Using special tool (valve lifter) to compress valve spring
and then remove valve cotters (1) by using special tool
(Forceps). Release special tool, and remove valve spring
(2) and valves (3).
Special Tool
(A): 09916-14510
(B): 09916-48210
(C): 09916-84511
b) Remove valve stem oil seal (1) from valve guide by using
flat head rod (2) or the like, and then valve spring seat (3).
NOTE:
Do not reuse oil seal once disassembled. Be sure to
use new oil seal when assembling.
c) Using special tool, drive valve guide out from combustion
chamber side to valve spring side.
NOTE:
Do not reuse valve guide once disassembled.
Be sure to use new valve guide (Oversize) when assem-
bling.
Special Tool
(A): 09916-44511
6A-14 ENGINE MECHANICAL (F8B ENGINE)
NOTE:
Place disassembled parts except valve stem oil seal and
valve guide in order, so that they can be installed in their
original positions.
29) Remove flywheel by using special tool as shown.
Special Tool
(A): 09924-17810
30) Remove oil level gauge and then remove oil pan (1).
31) Remove oil pump strainer (1).
32) Remove connecting rod caps (1).
33) Install guide hose (1) over threads of rod bolts.
This is to prevent damage to bearing journal and cylinder wall
when removing connection rod.
ENGINE MECHANICAL (F8B ENGINE) 6A-15
34) Decarbon top of cylinder bore, before removing piston from
cylinder.
35) Push piston and connecting rod assembly out through the top
of cylinder bore.
CAUTIONS:
D Before pushing piston out, scribe cylinder number
on its crown.
D Be sure to identify each bearing cap for its con-
necting rod by using cylinder number. Set cap and
rod aside in combination.
a) From each piston, ease out piston pin circlips (1), as
shown.
b) Force piston pin (1) out.
36) Remove oil pump case (1).
6A-16 ENGINE MECHANICAL (F8B ENGINE)
a) Remove oil pump gear plate (1).
b) Take out inner gear (2) and outer gear (1).
37) Remove oil seal housing (1).
38) Remove crankshaft bearing caps (1), and take out crankshaft
(2).
ENGINE MECHANICAL (F8B ENGINE) 6A-17
INSPECTION OF ENGINE
COMPONENTS
NOTE:
D During and immediately after disassembly, inspect cylinder
block and head for evidence of water leakage or damage
and, after washing them clean, inspect more closely.
D Wash all disassembled parts clean, removing grease,
slime, carbon and scales, before inspecting them to deter-
mine whether repair is necessary or not.
Be sure to de-scale the water jackets.
D Use compressed air to clear internal oil holes and pas-
sages.
D Do not disturb the set combinations of valves, bearings and
bearing caps, etc.
Have the sets segregated and identified.
Cylinder head
D De-carbon cylinder head:
Deposits of carbon will be found on its combustion chamber sur-
faces and exhaust ports. Remember, overheating tendency and
loss of output are often due to excessive carbon accumulation.
De-carbon valves, too.
NOTE:
Do not use any sharp-edged tool to scrape off carbon. Be
careful not to scuff or nick metal surfaces when de-carbon-
ing. This applies to valves and valve seats, too.
6A-18 ENGINE MECHANICAL (F8B ENGINE)
D Distortion of gasketed surface:
Using a straightedge and thickness gauge, check the flatness at
a total of 6 locations. If the limit, stated below, is exceeded, cor-
rect the gasketed surface with a surface plate and abrasive pa-
per of about # 400 (waterproof silicon carbide abrasive paper):
place the paper on and over the surface plate, and rub the gas-
keted surface against the paper to grind off high spots. Should
this fail to reduce the thickness gauge readings to within the limit,
replace the cylinder head.
Leakage of combustion gases from this gasketed joint is often
due to warped gasketed surface; such leakage results in re-
duced power output and hence a higher cost of fuel per kilome-
ter.
D Distortion of manifold seating faces:
Check the seating faces of cylinder head for manifolds, using a
straightedge and thickness gauge, in order to determine wheth-
er these faces should be corrected or the cylinder head re-
placed.
Checking exhaust manifold seating face
Checking intake manifold seating face
ENGINE MECHANICAL (F8B ENGINE) 6A-19
Limit of distortion 0.05 mm (0.002 in.)
Limit of distortion 0.10 mm (0.004 in.)
Rocker-arm shaft and rocker arms
D Wear:
Check these parts for wear and, as necessary, replace them.
The extent of wear is determined on the basis of two readings,
one on rocker arm I.D. and the other on shaft diameter.
NOTE:
Use a micrometer on rocker-arm shaft and a bore gauge
rocker arm. The difference between the two readings is the
arm-to-shaft clearance on which a limit is specified. If the
limit is exceeded, replace shaft or arm, or both.
D Rocker-arm shaft deflection:
Using “V” blocks and a dial gauge, check the shaft for straight-
ness in terms of deflection.
If the limit is exceeded, replace it.
D Wear of rocker-arm and adjusting screw:
If the tip (1) of adjusting screw (2) is badly worn, replace the
screw. The arm must be replaced if its cam-riding face (3) is
badly worn.
D Visually examine each rocker-arm spring for evidence of break-
age or weakening. Be sure to replace springs found in bad condi-
tion.
6A-20 ENGINE MECHANICAL (F8B ENGINE)
Item Standard Limit
Rocker arm I.D.
15.000 – 15.018 mm
(0.590 – 0.591 in.)
–––––
Rocker arm shaft dia.
14.983 – 14.994 mm
(0.589 – 0.590 in.)
–––––
Arm to shaft clearance
0.006 – 0.035 mm 0.070 mm
Arm
-
to
-
shaft
clearance
(0.0002 – 0.0014 in.) (0.0028 in.)
Deflection limit 0.06 mm (0.0024 in.)
Valve guides
D Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to determine the stem clearance in the
guide. Be sure to take a reading at more than one place along
the length of each stem and guide.
If the bore gauge is not available, check the end deflection of the
valve stem in place with a dial gauge rigged. Move the stem end
in the directions (4) (5) and determine whether replacement is
necessary or not, by referring to these limiting values:
Valves
D Inspect each valve for wear, burn or distortion at its face and
stem and, as necessary, replace it.
D Measure the thickness “a” of valve head. If the limit given to this
thickness is exceeded, the valve must be replaced.
Valve head thickness “a”
ENGINE MECHANICAL (F8B ENGINE) 6A-21
Item Standard Limit
Valve stem
In
6.965 – 6.980 mm
(0.274 – 0.275 in.)
–––––
diameter
Ex
6.950 – 6.970 mm
(0.273 – 0.274 in.)
–––––
Valve guide
In
7.000 – 7.015 mm
g
I.D.
Ex
(0.275 – 0.276 in.)
–––––
Stem-to-guide
In
0.020 – 0.050 mm
(0.0008 – 0.0020 in.)
0.07 mm
(0.0028 in.)
g
clearance
Ex
0.030 – 0.065 mm
(0.0012 – 0.0025 in.)
0.09 mm
(0.0035 in.)
Valve stem end
Intake 0.12 mm (0.0047 in.)
deflection
Exhaust 0.16 mm (0.0063 in.)
Standard Limit
Intake 0.6 mm (0.024 in.)
.
–
.
Exhaust 0.7 mm (0.028 in.)
D Check the end face of each valve stem for wear. This face meets
the rocker arm intermittently in operation, and might become
concaved or otherwise irregular. As necessary, smoothen the
end face with an oil stone and, if this grinding removes the end
stock by as much as 0.5 mm (0.0196 in.) (as measured from the
original face), replace the valve.
D Check each valve for radial runout with a dial gauge and “V”
block. The object of this check is to determine whether the valve
stem is true and square relative to the head.
If the limit is exceeded, do not attempt to correct the stem; re-
place the valve, instead.
Valve seats
D Seating contact width:
Produce a contact pattern on each valve in the usual manner,
namely, by giving a uniform coat of marking compound (Red-
lead paste) to the valve seat and by rotatingly tapping the seat
with the valve head. The valve lapper (the tool used in valve lap-
ping) must be used.
The pattern produced on the seating face of the valve must be
a continuous ring without any break, and the width “a” of the pat-
tern must be within the stated range.
CAUTION:
The valves to be checked and serviced for seating width
and contact pattern must be those found satisfactory in
regard to stem clearance in the guide and also the re-
quirements stated in the preceding part titled VALVES.
6A-22 ENGINE MECHANICAL (F8B ENGINE)
Limit on stock allowance of
valve stem end face
0.5 mm (0.0196 in.)
Limit on valve head radial
runout
0.08 mm (0.0031 in.)
“
a
”
Standard seating width
revealed by contact
p
at-
Intake
1.3 – 1.5 mm
“a”
revealed
by
contact
at
-
tern on valve face
Exhaust
(0.05 – 0.06 in.)
D Valve seat repair:
A valve seat not producing a uniform contact with its valve or
showing a width of the seating contact that is off the specified
range must be repaired by regrinding or by cutting and regrind-
ing and finished by lapping.
1) EXHAUST VALVE SEAT: Use a valve seat cutter to make
three cuts in the order illustrated in figure. Three cutters must
be used: the first for making the 155 angle, the second for
making the 755 angle and the last for making the 455 seat
angle. The third cut must be made to produce the desired
seat width.
2) INTAKE VALVE SEAT: The cutting sequence is the same as
for exhaust valve seats but the second angle differs, as will
be noted in figure.
3) VALVE LAPPING: Lap the valve on the seat in two steps, first
with a coarsesize lapping compound applied to the face and
the second with a fine-size compound, each time using a
valve lapper according to the usual lapping method.
NOTE:
D After lapping, wipe the compound off the valve face
and seat, and produce a contact pattern with a marking
compound (red-lead paste). Check to be sure that the
contact is centered widthwise “a” on the valve seat
and that there is no break in the contact pattern ring.
D Be sure to check and, as necessary, adjust the valve
clearance after re-installing the cylinder head and
valve mechanism.
ENGINE MECHANICAL (F8B ENGINE) 6A-23
Seat width for exhaust valve
seat
1.3 – 1.5 mm
(0.0512 – 0.0591 in.)
Seat width for intake valve
seat
1.3 – 1.5 mm
(0.0512 – 0.0591 in.)
Valve springs
D Referring to the criterion data given below, check to be sure that
each spring is in sound condition, free of any evidence of break-
age or weakening. Remember, weakened valve springs can be
the cause of chatter, not to mention the possibility of reducing the
power output due to gas leakage caused by decreased seating
pressure.
D Spring squareness:
Use a square and surface plate to check each spring for square-
ness in terms of the clearance between the end of valve spring
and the square. Valve springs found to exhibit a larger clearance
than the limit must be replaced.
Camshaft
A noisy engine or an engine producing not enough power is fre-
quently due to its camshaft excessively worn or bent or bowed. The
wear could occur on its cams and journals.
D Camshaft runout:
Hold the camshaft between two center points, with a dial gauge
rigged up to measure its runout. Replace the camshaft if the
amount of runout so measured exceeds the limit.
D Cam wear:
Measure the height “a” of each cam. If any of the micrometer
readings taken is down to or less than the limit, replace the cam-
shaft.
6A-24 ENGINE MECHANICAL (F8B ENGINE)
Item Standard Limit
Valve spring free
length
48.9 mm
(1.925 in.)
47.6 mm
(1.874 in.)
Valve spring pre-
load
23.6 – 27.6 kg
for 40 mm
(52.0 – 60.8 Ib/1.57 in.)
22.0 kg
for 40 mm
(48.5 Ib/1.57 in.)
Valve spring squareness limit 2.0 mm (0.079 in.)
Camshaft runout limit 0.10 mm (0.0039 in.)
Cam height “a” Standard Limit
Intake cam
36.152 mm 36.100 mm
Exhaust cam
36 5
(1.423 in.)
36 00
(1.421 in.)
Pump drive cam
33.300 mm
(1.311 in.)
33.000 mm
(1.299 in.)
D Thrust clearance:
Using a thickness gauge (1), measure this clearance as shown
in figure, at the thrust plate. If the limit is exceeded, replace thrust
plate or camshaft.
D Journal wear:
Measure the journal diameter in two directions at two places to
obtain four readings on each journal; and check the journal bores
with a bore gauge, producing four readings on each. From these
readings, compute the radial clearance (camshaft journal clear-
ance). If the service limit is exceeded by any of the computed ra-
dial clearances, replace the camshaft and, as necessary,
cylinder head, too.
“A” : Camshaft pulley side
“B” : Fuel pump side
Cylinder block
D Distortion of gasketed surface:
By the same method that is prescribed for checking the distortion
of the gasketed surface of the cylinder head, check the top face
of the cylinder block for distortion and, if the distortion is found
to exceed the limit, machine the face with a surface grinder.
ENGINE MECHANICAL (F8B ENGINE) 6A-25
Item Standard Limit
Thrust clearance
0.050 – 0.150 mm
(0.002 – 0.006 in.)
0.300 mm
(0.012 in.)
Item Standard Limit
Journal clearance
0.050 – 0.091 mm
(0.0020 – 0.0036 in.)
0.15 mm
(0.0060 in.)
Camshaft journal dia. Journal bore dia.
(a)
43.425 – 43.450 mm
(1.710 – 1.711 in.)
43.500 – 43.516 mm
(1.712 – 1.713 in.)
(b)
43.625 – 43.650 mm
(1.718 – 1.719 in.)
43.700 – 43.716 mm
(1.720 – 1.721 in.)
(c)
43.825 – 43.850 mm
(1.725 – 1.726 in.)
43.900 – 43.916 mm
(1.728 – 1.729 in.)
(d)
44.025 – 44.050 mm
(1.733 – 1.734 in.)
44.100 – 44.116 mm
(1.736 – 1.737 in.)
Distortion of
Standard Limit
Distortion
of
gasketed surface
0.03 mm
(0.0012 in.)
0.05 mm
(0.0020 in.)
D Cylinder bore:
Using a cylinder bore gauge, measure the diameter of each bore
in two directions, longitudinal and transverse, at three places,
top, middle and bottom, to obtain a total of 6 readings. On the ba-
sis of these readings taken on each bore, determine whether the
maximum difference in diameter between any two bores ex-
ceeds the limit. If the limit, stated below, is exceeded or if the
bore wall is badly scored or burned, re-bore all cylinders to the
next oversize and use oversize pistons in engine reassembly.
When replacing the pistons or installing oversize pistons, be
sure that the piston-to-cylinder clearance comes within the
stated range:
CAUTION:
If any one of the three cylinders has to be re-bored, re-
bore the three to the same next oversize. This is neces-
sary for the sake of uniformity and balance.
Piston and piston rings
D Piston diameter:
Piston-to-cylinder clearance, mentioned above, is equal to the
bore diameter minus the piston diameter, which is to be mea-
sured by measuring at the level of the piston in the direction
transverse to piston pin axis, as shown in below figure. This level
from the skirt end is 30 mm (1.18 in.) high.
“a”. 30 mm (1.18 in.)
6A-26 ENGINE MECHANICAL (F8B ENGINE)
Piston oversize
0.25 mm (0.0098 in.)
Piston
oversize
0.50 mm (0.0196 in.)
Wear limit on bore 0.05 mm (0.0020 in.)
Piston-to-cylinder clearance
0.045 – 0.055 mm
(0.0018 – 0.0022 in.)
Standard
68.450 – 68.475 mm
(2.6949 – 2.6959 in.)
Piston diameter
Oversize:
0.25 mm
(0.0098 in.)
68.720 – 68.740 mm
(2.7055 – 2.7063 in.)
0.50 mm
(0.0196 in.)
68.970 – 68.990 mm
(2.7154 – 2.7161 in.)
D Inspect the outer surface of each cylinder for evidence of burn
and for scratch or groove marks. Minor flaws can be removed by
grinding with fine-grain sandpaper.
D De-carbon the piston crown and ring grooves, using a soft-metal
scraping tool.
D Ring clearance in the groove:
Using a thickness gauge (1), check each piston ring (2) in its
groove for side clearance and, if the limit stated below is exceed-
ed, measure the groove width and ring width to determine
whether the piston or the ring or both have to be replaced.
D Piston ring end gap:
To measure the end gap, insert the piston ring (2) into the cylin-
der bore, locating it at the lowest part of the bore and holding it
true and square; then use a thickness gauge (1) to measure the
gap. If the gap measured exceeds the limit, replace the ring.
“a”: 120 mm (4.72 in.)
ENGINE MECHANICAL (F8B ENGINE) 6A-27
Item Standard Limit
Ring clearance
Top ring
0.03 – 0.07 mm
(0.0012 – 0.0028 in.)
0.12 mm
(0.0047 in.)
g
in the groove
2nd ring
0.02 – 0.06 mm
(0.0008 – 0.0024 in.)
0.10 mm
(0.0039 in.)
Piston ring
Top ring
1 47 1 49 mm (0 0579 0 0587 in )
Pi
s
t
on r
i
ng
thickness
2nd ring
1
.
47
–
1
.
49
mm
(0
.
0579
–
0
.
0587
in
.
)
thickness
Oil ring 0.45 mm (0.0177 in.)
Ring
Top ring 1.52 – 1.54 mm (0.0598 – 0.0606 in.)
g
groove
2nd ring 1.51 – 1.53 mm (0.0594 – 0.0602 in.)
width
Oil ring 2.81 – 2.83 mm (0.1106 – 0.1114 in.)
Item Standard Limit
Top ring
0.15 – 0.30 mm
(0.006 – 0.012 in.)
0.7 mm
(0.028 in.)
Piston ring end gap
2nd ring
0.10 – 0.30 mm
(0.004 – 0.012 in.)
0.7 mm
(0.028 in.)
Oil ring
0.20 – 0.70 mm
(0.008 – 0.028 in.)
1.8 mm
(0.040 in.)
Connecting rods
D Big-end thrust clearance:
Check the big end of each connecting rod for thrust clearance,
with the rod fitted and connected to its crank pin in the normal
manner. If the clearance measured is found to exceed the limit,
the connecting rod or the crankshaft, whichever is responsible
for the excessive clearance, must be replaced.
D Connecting rod alignment:
Mount the connecting rod on the aligner to check it for bow and
twist and, if the limit is exceeded, replace it.
D Inspect the small end of each connecting rod for wear and evi-
dence of crack or any other damage, paying particular attention
to the condition of its bush. Check the piston pin clearance in the
small end. Replace the connecting rod if its small end is badly
worn or damaged or if the clearance checked exceeds the limit.
Connecting-rod big end bearings
D Inspect the bearing shells for signs of fusion, pitting, burn or flak-
ing and observe the contact pattern. Bearings found in defective
condition through this inspection must be replaced.
CAUTION:
Bearing shells are not meant to be repaired by scrap-
ing or grinding with sandpaper or by any machining.
The remedy is to replace them.
6A-28 ENGINE MECHANICAL (F8B ENGINE)
Item Standard Limit
Big-end thrust clearance
0.10 – 0.20 mm
(0.004 – 0.008 in.)
0.30 mm
(0.012 in.)
(1) Width of big end
21.95 – 22.00 mm
(0.864 – 0.866 in.)
(2) Width of crank pin
22.10 – 22.15 mm
(0.870 – 0.872 in.)
Limit on bow 0.05 mm (0.002 in.)
Limit on twist 0.10 mm (0.004 in.)
Item Standard Limit
Pin clearance in small
end
0.003 – 0.016 mm
(0.0001 – 0.0006 in.)
0.05 mm
(0.0020 in.)
Small-end I.D.
16.003 – 16.011 mm
(0.6300 – 0.6304 in.)
Piston pin dia.
15.995 – 16.000 mm
(0.6297 – 0.6299 in.)
D Crankpin-to-bearing clearance:
Check this clearance by using gaging plastic (1). Here’s how to
use gaging plastic:
1) Prepare, by cutting, a length of gaging plastic roughly equal
to bearing width and place it axially on crankpin, avoiding the
oil hole.
2) Make up the big end in the normal manner, with bearing
shells in place and by tightening the cap to the specification.
NOTE:
Never rotate crankshaft or turn connecting rod when a
piece of gaging plastic is in the radial clearance.
Tightening Torque
(a): 30 N·m (3.0 kg-m, 22.0 Ib-ft)
NOTE:
When fitting bearing cap to crankpin, be sure to discrimi-
nate between its two ends, right and left.
3) Remove the cap, and measure the width of flattened gaging
plastic (1) piece with the gaging plastic envelope scale (2).
This measurement must be taken at the widest part.
4) If the limit, indicated above, is exceeded, re-grind the crank-
pin to the undersize and use the undersize bearing, both of
which are stated below:
Where undersize bearings are used, the clearance specifica-
tion is slightly lenient:
ENGINE MECHANICAL (F8B ENGINE) 6A-29
Item Standard Limit
Crankpin-to-bearing
clearance
0.020 – 0.040 mm
(0.0008 – 0.0016 in.)
0.080 mm
(0.0031 in.)
Bearing size Crankpin diameter
Standard
37.982 – 38.000 mm
(1.4953 – 1.4960 in.)
0.25 mm
undersize
37.732 – 37.750 mm
(1.4855 – 1.4862 in.)
0.50 mm
undersize
37.482 – 37.500 mm
(1.4757 – 1.4764 in.)
Radial clearance for
undersize bearing
0.020 – 0.070 mm
(0.0008 – 0.0028 in.)
Crankshaft
D Runout:
Check the crankshaft for runout and if the dial gauge reading ex-
ceeds the limit, replace the crankshaft.
NOTE:
Measure the runout at the center journal. Rotate the crank-
shaft slowly.
D Crankshaft thrust play:
Measure this play with crankshaft set in the cylinder block in the
normal manner, that is, with the thrust bearing fitted and the
bearing caps installed. Tighten bearing cap bolts to specified
torque. Use a dial gauge to read the displacement in axial
(thrust) direction of the crankshaft. If the limit is exceeded, re-
place thrust bearing with new standard one or oversize one to
obtain standard thrust play.
Tightening Torque
(a): 46 N·m (4.6 kg-m, 33.5 Ib-ft)
D Out-of-round and taper (uneven wear):
An unevenly worn crankshaft journal or crankpin shows up as a
difference in diameter at a cross section or along its length (or
both). This difference, if any, is to be determined from microme-
ter readings taken as shown in figure.
If any of the journals or crankpins is badly damaged or if the
amount of uneven wear in the sense explained above exceeds
the limit, repair (by re-grinding) or replace the crankshaft.
NOTE:
Where journal or crankpin re-grinding is necessary, finish
the diameter to the size necessary for the undersize bear-
ing. (Refer to Crankpin-to-bearing clearance of previous
page.)
6A-30 ENGINE MECHANICAL (F8B ENGINE)
Limit on crankshaft runout 0.06 mm (0.002 in.)
Item Standard Limit
Crankshaft thrust play
0.13 – 0.28 mm
(0.005 – 0.011 in.)
0.35 mm
(0.014 in.)
Thickness of
Standard
2.500 mm
(0.0984 in.)
Thi
c
k
ness o
f
crankshaft
Oversize:
0.125 mm 2.563 mm
crankshaft
thrust bearing
Oversize:
(0.0049 in.) (0.1009 in.)
thrust
bearing
Oversize:
0.250 mm
(0.0098 in.)
2.625 mm
(0.1033 in.)
Limit on uneven wear 0.01 mm (0.0004 in.)
Crankshaft journal bearings
D Inspect the bearing shells for signs of fusion, pitting, burn or flak-
ing and observe the contact pattern. Defective shells must be re-
placed.
CAUTION:
As in the case of connecting-rod bearings, the journal
bearing shells are not meant to be repaired by scrap-
ing or grinding with sandpaper or by any machining.
D Journal-to-bearing clearance:
Check this clearance by using gaging plastic. The following
method is based on the use of gaging plastic:
1) Cut the gaging plastic stock to the required length (equal to
the width of the bearing), and place it axially on the journal,
avoiding the oil hole.
2) Mount the crankshaft in the usual manner, tightening the
bearing caps to the specified torque value. (It is assumed that
a gaging plastic piece is pinched at each journal.)
Do not rotate the crankshaft when gaging plastic is in.
Tightening Torque
(a): 46 N·m (4.6 kg-m, 33.5 Ib-ft)
CAUTION:
Each of the four bearing caps has an arrow marked
on it. Be sure to position each cap with its arrow
pointing to crankshaft pulley side and to match it
(by the cylinder number) to its journal. Remember,
the three cylinders are numbered, 1, 2 and 3, as
counted from crankshaft pulley side.
“A” : Crankshaft pulley side
“B” : Flywheel side
3) Remove the caps. By referring to the envelop scale, measure
the width of the widest part of the piece, and determine wheth-
er the radial clearance checked (obtained from the gaging
plastic piece) is within the limit.
ENGINE MECHANICAL (F8B ENGINE) 6A-31
Item Standard Limit
Journal-to-bearing
clearance
0.020 – 0.040 mm
(0.0008 – 0.0016 in.)
0.080 mm
(0.003 in.)
4) If the limit is exceeded, re-grind the journals to the undersize
and use the undersize bearing.
Flywheel
D Inspect the friction surface – the surface in contact with clutch
disc – for wear and damage. Most of surface flaws, if any, can be
removed by simple machining. A badly damaged flywheel must
be replaced.
D Face runout:
Check the flywheel for face runout with a dial gauge, as shown
in figure. Be sure that the runout is less than the limit.
D Ring gear tooth wear:
Inspect the teeth for wear and for evidence of crack, chipping or
any other damage. Replace the ring gear if its teeth are found in
bad condition.
Oil seals
Carefully inspect the oil seals removed in disassembly, examining
the lip portion (1) of each oil seal for wear and damage. Use of new
oil seals in reassembly is recommended.
6A-32 ENGINE MECHANICAL (F8B ENGINE)
Bearing size Journal diameter
Standard
49.982 – 50.000 mm
(1.9678 – 1.9685 in.)
0.25 mm undersize
49.744 – 49.750 mm
(1.9584 – 1.9587 in.)
0.50 mm undersize
49.494 – 49.500 mm
(1.9486 – 1.9488 in.)
Radial clearance for undersize
bearing
0.020 – 0.070 mm
(0.0008 – 0.0028 in.)
Limit on runout 0.2 mm (0.008 in.)
Timing belt and timing pulleys
Inspect the belt and pulleys for wear, cracks and signs of failure.
Replace them as necessary.
CAUTION:
D Do not bend the belt. Keep away oil and water from the
belt. The belt must be kept clean.
D The pulleys and belt tensioner, too, must be kept clean
and free of oil and water.
Oil pump
1) Inspect oil seal lip for fault or other damage.
Replace as necessary.
2) Inspect outer and inner gears, gear plate, and oil pump case for
excessive wear or damage.
D Radial clearance:
Check radial clearance between outer gear (2) and case (3), us-
ing thickness gauge (1).
If clearance exceeds its limit, replace outer gear or case.
D Side clearance:
Using straight edge and thickness gauge, measure side clear-
ance.
ENGINE MECHANICAL (F8B ENGINE) 6A-33
Item Standard Limit
Radial clearance between
outer gear and case
0.12 – 0.20 mm
(0.005 – 0.008 in.)
0.3 mm
(0.012 in.)
Item Standard Limit
Side clearance
0.045 – 0.120 mm
(0.0018 – 0.0047 in.)
0.17 mm
(0.0067 in.)
ENGINE REASSEMBLY
NOTE:
D All parts to be used in reassembly must be perfectly clean.
D Oil the sliding and rubbing surfaces of engine parts just be-
fore using them in reassembly. Use engine oil (Refer to Sec-
tion 0B).
D Have the liquid packing ready for use. SUZUKI BOND No.
1215 is specified for the liquid. Use it wherever its use is
specified in order to ensure leak-free (oil and water) work-
manship of reassembly.
D There are many running clearances. During the course of
engine reassembly, be sure to check these clearances, one
after another, as they form.
D Gaskets, O-rings and similar sealing members must be in
perfect condition. For these members, use replacement
parts in stock.
D Tightening torque is specified for important fasteners –
bolts and nuts in the main – of the engine and other compo-
nents. Use torque wrenches and constantly refer to the spe-
cified values given in the text of this manual.
D Do not disregard the match marks provided on parts. Some
of them are those given at the time of disassembly.
D There are many sets of parts. Crankshaft bearings, con-
necting rods, pistons, etc., are in combination sets. Do not
disturb the combinations and try to see that each part goes
back to where it came from.
Engine reassembly is the reverse of engine disassembly as far as
sequence is concerned, but there are many reassembling steps
that involve measures necessary for restoring the engine as close
to the factory-assembled condition as possible. Only those steps
will be dealt with.
Crankshaft
Be sure to oil crankshaft journal bearings as shown.
6A-34 ENGINE MECHANICAL (F8B ENGINE)
Thrust bearings (1) for the crankshaft are an item prone to escape
the attention: be careful not to leave them out. These bearings go
into place with their oil groove side facing the crank web.
Be sure to oil crankshaft journals as shown.
When fitting crankshaft bearing caps to journals after setting the
crankshaft in place, be sure to point the arrow mark (on each cap)
to crankshaft pulley side. Fit them sequentially in the ascending or-
der, 1, 2, 3 and 4, starting from pulley side.
Tightening Torque
(a): 46 N·m (4.6 kg-m, 33.5 Ib-ft)
Gradual and uniform tightening is important for bearing cap bolts.
Make sure that the four caps become tight equally and uniformly
progressively to the stated torque value.
NOTE:
After tightening cap bolts, check to be sure that crankshaft ro-
tates smoothly when turned over by hand.
“A” : Crankshaft pulley side
“B” : Flywheel side
Oil seal housing
This housing demands a new gasket: do not reuse the gasket re-
moved in disassembly. After bolting the housing to the block, the
gasket edges might bulge out; if so, cut off the edges to make the
joint seam flat and smooth: use a sharp knife.
NOTE:
Just before mounting the housing, oil the lip portion of the oil
seal.
ENGINE MECHANICAL (F8B ENGINE) 6A-35
Oil Pump
NOTE:
Reassemble components of oil pump assembly according to
following procedure, if disassembled.
a) Wash, clean and then dry all disassembled parts.
b) Apply thin coat of engine oil to inner and outer gears, oil seal lip
portion, and inside surfaces of oil pump case and plate.
c) Install outer and inner gears to pump case.
d) Install gear plate.
e) After installing plate, check to be sure that gears turn smoothly
by hand.
1) Install two oil pump pins (2) and oil pump gasket to cylinder
block. Use new gasket.
2) To prevent oil seal lip from being damaged or upturned when
installing oil pump to crankshaft (1), fit oil seal guide (special
tool) to crankshaft, and apply engine oil to it.
Special Tool
(A): 09926-18210
3) Before fitting the pump case, apply sealant to mating surfaces
around the oil discharging port of both the oil pump case and the
cylinder block, install oil pump to crankshaft and cylinder block.
After installing oil pump, check to be sure that oil seal lip is not
upturned, and then remove special tool.
“A”: Sealant 99000-31110
4) Edge of oil pump gasket might bulge out: if it does, cut bulge off
with a sharp knife, making edge smooth and flush with end
faces of the pump case and cylinder block.
Piston and piston rings
POSITION OF PISTON RELATIVE TO CONNECTING ROD: The
arrow (1) on the crown points to crankshaft pulley side, and the oil
hole (2) comes on intake port side.
NOTE:
Before pinning piston to connecting rod, oil the small end and
pin holes.
“A” : Flywheel side
“B” : Crankshaft pulley side
6A-36 ENGINE MECHANICAL (F8B ENGINE)
Before fitting rings to piston, check to be sure that first ring (1) has
RN mark and second ring (2) R mark. After mounting the three
rings, distribute their end gaps as illustrated in figure. Remember,
the marked side of each ring (1st and 2nd) comes on top side.
NOTE:
After fitting the rings, oil them in the grooves.
3. Oil ring
4. Arrow mark
5. Crankshaft pulley
side
6. 1st ring end gap
7. 2nd ring end gap
and oil ring
spacer gap
8. Oil ring lower rail
gap
9. Oil ring upper rail
gap
10. Intake side
11. Exhaust side
After covering the connecting rod bolts with plastic or rubber pipes
(1) as shown in figure, use special tool (piston ring compressor),
is mandatory in inserting pistons into cylinder block. Using this spe-
cial tool, feed the piston and connecting rod combination into the
bore from the upper side of cylinder block.
Special Tool
(A): 09916-77310
Pay attention to these reminders:
D Point the piston crown arrow to pulley side.
D Be sure that the number (marked on the crown at the time of dis-
assembly) tallies with the cylinder number.
D Liberally oil the big-end bearings before fitting them to crank-
pins.
D Oil the bore just before feeding in the piston.
CAUTION:
When inserting the piston and connecting rod com-
bination into the cylinder bore, care must be taken to
ensure the big end section of the connecting rod and
the connecting rod bolts do not contact the cylinder
wall nor the crankshaft journal, otherwise damage can
occur.
“A”: Crankshaft pulley side
“B”: Flywheel side
ENGINE MECHANICAL (F8B ENGINE) 6A-37
Connecting rods
Two stoppers (1), (2) determine the position of each big-end bear-
ing cap relative to the big end. At the time of installing these caps,
be sure to locate stopper (1) of cap in the direction of stopper (2).
NOTE:
The two stoppers do not coincide in longitudinal direction:
the coincidence is meant in the direction shown in figures.
After fitting all three big-end bearing caps, start tightening them uni-
formly, being sure to equalize tightness between right and left on
each cap. The sequence here is similar to that for crankshaft bear-
ing caps.
Tightening Torque
(a): 30 N·m (3.0 kg-m, 22.0 Ib-ft)
Oil pump strainer
Bear in mind that O-ring (1) is often forgotten and left out in reas-
sembly. Absence of this ring defeats the purpose served by the
strainer.
Oil pan
1) After fitting the oil pan to the block, run in the securing bolts and
start tightening at the center: move the wrench outward, tight-
ening one bolt at a time.
Tighten bolts to specified torque.
Tightening Torque
(a): 5 N·m (0.5 kg-m, 4.0 Ib-ft)
6A-38 ENGINE MECHANICAL (F8B ENGINE)
2) Install new gasket and drain plug to oil pan.
Tighten drain plug to specified torque.
Tightening torque for drain plug:
50 N·m (5.0 kg-m, 36.5 Ib-ft)
Flywheel
1) Check to be sure that locating pin (1) is studded in the crank-
shaft.
2) Install flywheel to crankshfat by using special tool hitched to fly-
wheel so that crankshaft will not turn.
Special tool:
09924-17810
Tightening Torque for flywheel bolt:
43 N·m (4.3 kg-m, 31.5 Ib-ft)
Cylinder head
NOTE:
D Do not reuse valve guide once disassembled. Install new
valve guide (Oversize).
D Intake and exhaust valve guide are identical.
1) Install new valve guide into cylinder head.
a) Before installing new valve guide into cylinder head, ream
guide hole with special tool (12 mm reamer) to remove burrs,
making sure that guide hole diameter after reaming comes
within specified range.
b) Install valve guide to cylinder head.
Heat cylinder head uniformly at a temperature of 80 to 1005C
(176 to 2125F), using care not to distort head, and drive new
valve guide into hole with special tools.
Drive in new valve guide until valve guide installer (Special
tool) contacts cylinder head. After installation, make sure
that valve guide protrudes “a” by 14.0 mm (0.551 in.) from
cylinder head.
Special Tool
(A): 09916-37310
(B): 09917-88210
(C): 09916-57321
ENGINE MECHANICAL (F8B ENGINE) 6A-39
Valve guide oversize 0.03 mm (0.001 in.)
Valve guide protrusion (In and Ex) 14.0 mm (0.551 in.)
Valve guide hole Dia. (In & Ex)
12.030 – 12.048 mm
(0.4736 – 0.4743 in.)
c) Ream valve guide (1) bore with special tool (7 mm reamer).
After reaming, clean bore.
Special Tool
(A): 09916-34520
2) Install valve spring seat to cylinder head.
3) Install new valve stem seal (1) to valve guide.
After applying engine oil to seal and spindle of special tool
(valve stem seal installer), fit oil seal to spindle, and then install
seal to valve guide by pushing special tool by hand.
After installation, check to be sure that seal is properly fixed to
valve guide.
Special Tool
(A): 09917-98210
NOTE:
D Do not reuse oil seal disassembled. Be sure to install
new oil seal.
D When installing, never tap or hit special tool with a ham-
mer or else. Install seal to guide only by pushing special
tool with hand. Tapping or hitting special tool may cause
damage on seal.
4) Install valve to valve guide.
Before installing valve to valve guide, apply engine oil to stem
seal, valve guide bore, and valve stem.
5) Install spring and spring retainer.
Each valve spring has top end (large-pitch end) and bottom end
(small-pitch end). Be sure to position spring in place with its bot-
tom end (small-pitch end) down to valve spring seat side.
1. Large-pitch
2. Small-pitch
3. Valve spring retainer side
4. Valve spring seat side
6A-40 ENGINE MECHANICAL (F8B ENGINE)
6) Using special tool (Valve lifter), compress valve spring and fit
two valve cotters (1) to groove provided in valve stem.
Special Tool
(A): 09916-14510
(B): 09916-48210
(C): 09916-84511
2. Valve spring retainer
7) Be sure that locating pins (3) are in place and then install new
head gasket, in such a way that “TOP” mark (1) provided on the
gasket comes crankshaft pulley side, facing up (toward cylinder
head side), “IN” mark (2) comes on intake manifold side and
“EX” mark comes on exhaust side.
8) Install cylinder head onto cylinder block.
9) Apply engine oil to cylinder head bolts and tighten them gradual-
ly as follows.
a) Tighten all bolts to 34 N·m (3.4 kg-m, 24.5 Ib-ft) according to
numerical order in figure.
b) In the same manner as a), tighten them to 54 N·m (5.4 kg-m,
39.0 Ib-ft).
c) Loosen all bolts to 0 N·m (0 kg-m, 0 Ib-ft), reversing to numer-
ical order in figure.
d) In the same manner as a) again, tighten them to 54 N·m (5.4
kg-m, 39.0 Ib-ft).
e) In the same manner as a) again, tighten them to specified
torque.
Tightening Torque
(a): 68 N·m (6.8 kg-m, 49.5 Ib-ft)
ENGINE MECHANICAL (F8B ENGINE) 6A-41
Camshaft
The camshaft goes into cylinder head from distributor gear case
side. Before inserting it, be sure to oil its journals.
Be careful not to leave out the thrust plate (1) when installing the
camshaft. After setting this shaft in place, with its thrust plate prop-
erly fitted, turn the shaft by hand to be sure it rotates smoothly.
Rocker-arm shafts
1) Apply engine oil to rocker arms and rocker arm shafts.
2) Install rocker arms, springs and rocker arm shafts.
The two rocker-arm shafts are identical, there being no need to dis-
tinguish between the two. However, each shaft takes but one posi-
tion in place. See figure.
D On the intake side (1), the stepped end (3) comes on camshaft
pulley side (5).
D On the exhaust side (2), the stepped end (4) comes on flywheel
side (6).
As to the positions of rocker arms and springs on each rocker-arm
shaft, refer to figure. “Camshaft pulley side” is meant by “1”; “distrib-
utor gear side” by “2”.
NOTE:
When installing rocker-arm shafts, be sure to have valve ad-
justing screws loosened fully but do not remove then.
6A-42 ENGINE MECHANICAL (F8B ENGINE)
Timing belt inside cover
When reinstalling the inside cover (1) to cylinder head, apply seal-
ant to the threads of upper side screws (2) as shown, because the
bolt holes for the two extend into the interior of cylinder head.
“A” Sealant 99000-31110
Crankshaft timing belt guide
This guide takes its position on crankshaft as shown in figure. Re-
member, one side of this guide (3) faces the cylinder block and the
other side faces the timing belt pulley (2): the former side being dis-
tinct from the latter.
1. Crankshaft pulley
Camshaft and crankshaft timing belt pulleys
These pulleys have a punch-mark (1) to show that the marked side
faces the timing belt outside cover. When installing each pulley, di-
rect this mark to timing belt outside cover side.
Tighten camshaft pulley bolt to specified torque.
Tightening Torque for camshaft pulley bolt:
55 N·m (5.5 kg-m, 40.0 Ib-ft)
2 Keyway
Timing belt
A certain sequence must be followed installing the timing belt.
Here’s the sequence:
1) Put the tensioner and the spring together before installing them
as one to the timing belt cover. Tighten the bolts to the extent that
the tensioner can be moved by hand easily.
NOTE:
When carrying out the above job, make sure to loosen each
lock nut and then each valve clearance adjusting screw so
that the camshaft and the pulley can rotate freely.
ENGINE MECHANICAL (F8B ENGINE) 6A-43
2) Timing belt inside cover has an embossed mark (4).
Turn camshaft timing belt pulley to the position where punch-
mark (1) meets mark (4).
3) The inside cover has another embossed mark (5). Turn crank-
shaft to match key-way (3) and punch-mark (2) of crankshaft
timing belt pulley to mark (5).
4) You now have the two pulleys correctly related to each other in
angular sense. Under this condition, put on the timing belt in
such a way that portion of belt indicated as (6) is free of any
slack.
NOTE:
When installing timing belt, match arrow mark ( ê ) on tim-
ing belt with rotating direction of crankshaft.
5) After putting the belt, hook the spring on the water pump secur-
ing bolt as shown in figure. The spring, with its own tension, ad-
just the belt tension to the specified value. Rotate the crankshaft
clockwise fully twice and tighten the bolt (7) first and then the
bolt (8).
Tightening Torque
(a): 19 N·m (1.9 kg-m, 14 Ib-ft)
CAUTION:
After setting the belt tensioner, turn crankshaft 2 rota-
tions in clockwise direction to see if marks (1) (3) (4)
(5) and crankshaft keyway (2) locate themselves on
the same straight line. If they do not line up straight,
the foregoing procedure must be repeated to satisfy
this requirement.
6A-44 ENGINE MECHANICAL (F8B ENGINE)
Crank Pulley
Install crank shaft pulley (1) by using special tool hitched to fly-
wheel (2) so that crakshaft will not turn.
Special tool
(A): 09924-17810
Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 Ib-ft)
Distributor gear case
Bolts (1) are for securing this gear case to the cylinder block. When
installing the case, be sure to apply sealant to the threads of these
bolts.
“A”: Sealant 99000-31110
Generator
The water pump drive belt, by which the generator too is driven,
must be tensioned to the specification after the alternator is
installed. Check the tension at the middle point of the belt between
water pump pulley and alternator pulley. To vary the tension for ad-
justment, displace the alternator in place.
For belt tension specification, refer to MAINTENANCE SERVICE
of SECTION 0B in this manual.
Clutch disc and cover
Install clutch disc and cover.
For installation, refer to SECTION 7A CLUTCH in this manual and
torque each bolt to specification.
Distributor
Install distributor to case.
For installation, be sure to refer to SECTION 6F IGNITION SYS-
TEM in this manual.
NOTE:
Check and adjust ignition timing with engine installed to car
body and after installing and connecting all necessary parts.
For procedure, refer to SECTION 6F IGNITION SYSTEM in this
manual.
Valve lash (clearance) adjustment
Adjust valve lash of all intake and exhaust valves to specification,
referring to description on valve lash in following item ENGINE
MAINTENANCE SERVICE in this section.
ENGINE MECHANICAL (F8B ENGINE) 6A-45
MOUNTING ENGINE
1) Install transmission to engine.
Tightening Torque
(a): 50 N·m (5.0 kg-m, 36.5 Ib-ft)
2) Install engine member to engine and then install engine assem-
bly to vehicle.
Install transmission left side mounting to transmission case and
body.
3) Install A/C compressor, upper and lower bracket and then con-
nect suction and discharge hoses to A/C compressor (if
equipped). Refer to Section 1B.
4) Install A/C compressor belt (3) and adjust its tension, refer to
Section 1B (if equipped).
5) Install water pump belt (1) after installed water pump pulley (2)
and adjust its tension, refer to Section 0B.
6A-46 ENGINE MECHANICAL (F8B ENGINE)
6) Install right and left drive shafts, refer to Section 4.
7) Install stabilizer bar, refer to Section 3D.
8) Connect gear shift control shaft and extension rod to transmis-
sion case.
9) Install exhaust center pipe.
Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 Ib-ft)
(b): 55 N·m (5.5 kg-m, 40.0 Ib-ft)
10) Refill transmission gear oil, refer to Section 0B.
11) Connect cables, hoses, wires and couplers which were dis-
connected in dismounting engine procedure.
D Adjust accelerator play, refer to Section 6E1.
D Adjust clutch pedal free travel, refer to Section 7C.
12) Install air cleaner assembly with air cleaner hose and breather
hose.
13) Install radiator with cooling fan and reserve tank, refer to Sec-
tion 6B.
14) Install engine hood and connect windshield washer hose.
15) Install front bumper.
16) Connect negative cable at battery.
17) Refill engine with engine oil, refer to Section 0B.
18) Refill cooling system with coolant, refer to Section 6B.
19) Evacuate and charge A/C system, refer to Section 1B (if
equipped).
20) Upon completion of installation, verify that there is no fuel,
coolant, transmission oil, engine oil or exhaust gas leakage at
each connection.
21) Check ignition timing and adjust it as necessary, refer to Sec-
tion 6F1.
ENGINE MECHANICAL (F8B ENGINE) 6A-47
MAINTENANCE SERVICES
Water pump belt
Adjust the belt tension as outlined in the SECTION 0B MAINTE-
NANCE SERVICE.
Ignition timing
Refer to SECTION 6F IGNITION SYSTEM.
Valve clearance (lash)
To check and adjust valve clearance with the engine mounted in
place, that is, secured to the chassis, be sure to remove the cylin-
der head cover, so that you can take a good look at rocker arms and
camshaft. Remember, a clearance reading is meaningful only
when it is taken with the rocker arm clear of and not riding on the
cam.
Remove the ignition timing check hole plug provided at the joint be-
tween engine and transmission to gain visual access to the “T”
mark. Turn over crankshaft to index mark (I) to timing match mark
(II), and see if the rocker arms of No. 1 cylinder are off the respec-
tive cam lobes (of camshaft); if so, valves (1) and (2), in figure, are
ready for clearance checking and adjustment: if not, turn over
crankshaft further by 360_ to index mark (I) to mark (II) again. This
360_ turning should bring about the desired state. (in which the two
valves are ready for checking and adjustment).
6A-48 ENGINE MECHANICAL (F8B ENGINE)
Valve
clear-
When cold (Coolant
temperature is 15 –
25_C or 59 – 77_F)
When hot (Coolant
temperature is 60 –
68_C or 140 – 154_F)
ance
specifi-
Intake
0.13 – 0.18 mm
(0.005 – 0.007 in.)
0.15 – 0.19 mm
(0.006 – 0.007 in.)
cation
Exhaust
0.13 – 0.18 mm
(0.005 – 0.007 in.)
0.15 – 0.19 mm
(0.006 – 0.007 in.)
Turn over the crankshaft 2405 from “T” mark, check and adjust the
valves (5) and (6).
Turn over the crankshaft 2405 from “3” mark, check and adjust the
valves (3) and (4).
Measuring valve clearance
Adjusting valve clearance
ENGINE MECHANICAL (F8B ENGINE) 6A-49
Oil pump discharge pressure measurement
NOTE:
Prior to checking oil pressure, check the following.
D Oil level in oil pan.
If level is low, add oil up to Full level hole on oil level gauge.
D Oil quality.
If oil is discolored, or deteriorated, change oil. For particular
oil to be used, refer to table in SECTION 0B MAINTENANCE
SERVICE.
D Oil leak.
If leak is found, repair it.
1) Disconnect lead wire from oil pressure switch.
2) Remove oil pressure switch (1) from cylinder block.
3) Install special tool (oil pressure gauge) to vacated threaded
hole.
Special Tool
(A): 09915-77310
4) Start engine and warm it up to normal operating temperature.
5) After warming up, raise engine speed to 3,000 r/min and mea-
sure oil pressure.
6) After checking oil pressure, stop engine and remove oil pres-
sure gauge.
7) Before reinstalling oil pressure switch, be sure to wrap its screw
threads with sealing tape and tighten switch to specified torque.
Tightening Torque
Oil pressure switch: 14 N·m (1.4 kg-m, 10.5 Ib-ft).
NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut off edge.
8) After installing oil pressure switch, start engine and check
switch for oil leakage.
6A-50 ENGINE MECHANICAL (F8B ENGINE)
Oil pressure
specification
300 – 450 kPa
(3.0 – 4.5 kg/cm
2
, 42.7 – 64.0 psi)
at 3,000 r/min (rpm)
Compression pressure measurement
Check the compression pressure on all three cylinders, as follows:
1) Warm up engine.
2) Stop engine after warming up.
NOTE:
After warming up engine, place transmission gear shift le-
ver in “Neutral” and set parking brake and block drive
wheels.
3) Disconnect fuel injector wire harness connector.
4) Remove front grille, high-tension cords and all spark plugs.
5) Disconnect ignition coil wire harness at coupler.
10) Be sure to install spark plugs, high-tension cords and front
grille.
11) Connect fuel injector and ignition coil wire harness connector
securely.
6) Install special tool (Compression gauge) into spark plug hole.
Special Tool
(A): 09915-64510
7) Disengage the clutch (to lighten starting load on engine), and
depress the accelerator all the way to make the throttle full-
open.
8) Crank the engine with the starter motor, and read the highest
pressure on the compression gauge.
9) Carry out the steps 5) through 7) on each cylinder to obtain
three readings.
NOTE:
For measuring compression pressure, crank engine at
least 400 r/min. by using fully charged battery.
WARNING:
Failure in disconnecting the coupler can cause
spark to occur in engine room possibly resulting in
a dangerous explosion.
ENGINE MECHANICAL (F8B ENGINE) 6A-51
Compression pressure
Standard
1350 kPa
(13.5 kg/cm
2
, 192.0 psi)
Limit
1000 kPa
(10.0 kg/cm
2
, 142.2 psi)
Max. difference between any
two cylinders
100 kPa
(1.0 kg/cm
2
, 14.2 psi)
Vacuum measurement
The vacuum that develops in the intake line is a good indicator of
the condition of the engine.
It is for this reason that the vacuum is measured. The measuring
procedure is as follows:
1) Warm up engine until it is normal operating temperature.
NOTE:
After warming up engine, place transmission gear shft le-
ver in “Neutral” (shift select lever to “P” range for A/T mod-
el), and set parking brake and block drive wheels.
2) With engine stopped, disconnect pressure regulator vacuum
hose (1) from intake manifold (2) and connect 3-way joint,
hoses and special tool (vacuum gauge and joint) between in-
take manifold and vacuum hose disconnected.
Special Tool
(A): 09915-67310
(B): 09918-08210
SUZUKI GENUINE PARTS
(C): 3-way joint 09367-04002
3) Run the engine at the specified idling speed and, under this run-
ning condition, read the vacuum gauge. The vacuum should be
not lower than 53.7 kPa (40 cm Hg, 15.7 in. Hg).
A low vacuum reading means that any combination of the fol-
lowing malconditions is the cause, which must be corrected be-
fore releasing the machine to the customer:
(a) Leaky cylinder head gasket
(b) Leaky intake manifold gasket
(c) Leaky valves
(d) Weakened valve springs
(e) Maladjusted valve clearance
(f) Valve timing out of adjustment
(g) Ignition mistimed
4) After checking, remove vacuum gauge and connect vacuum
hose to intake manifold.
5) Before reinstalling vacuum checking plug, be sure to wrap its
screw threads with sealing tape and tighten plug.
6A-52 ENGINE MECHANICAL (F8B ENGINE)
Standard vacuum
53.7 – 60.4 kPa
(40 – 45 cm Hg, 15.7 – 17.7 in. Hg)
Idling speed
specification
900 r/min (rpm)
(Take vacuum reading at this speed.)
Engine oil
Refer to the SECTION 0B MAINTENANCE SERVICE.
Engine oil filter
The methods of servicing the oil filter are outlined under SECTION
0B MAINTENANCE SERVICE.
Engine coolant
This subject is covered in the SECTION 6B for ENGINE COOLING
SYSTEM.
Exhaust line and muffler
Inspect each exhaust line connection for tightness, and examine
the muffler and other parts for evidence of breakage and leakage
of gases. Repair or replace defective parts, if any.
Oil filler cap
The cap has a packing. Be sure that packing is in good condition,
free of any damage and signs of deterioration, and is tight in place.
If any defective, replace.
ENGINE MECHANICAL (F8B ENGINE) 6A-53
6A-54 ENGINE MECHANICAL (F8B ENGINE)
REQUIRED SERVICE MATERIALS
MATERIAL
RECOMMENDED
SUZUKI PRODUCT
USE
Sealant
SUZUKI BOND No. 1215
(99000-31110)
D Mating surfaces around the oil discharging
port of oil pump case and cylinder block
D Threads of timing belt inside cover stud bolts
D Threads of distributor gear case bolts
SPECIAL TOOLS
09915-47310
Oil filter wrench
09915-77310
Oil pressure gauge
09916-44511
Valve guide remover
09916-77310
Piston ring compressor
09916-37310
12 mm reamer
09916-57321
Valve guide installer handle
09916-34520
7 mm reamer
09916-84511
Forceps
09915-67310
Vacuum gauge
1.09916-14510
Valve lifter
2.09916-48210
Valve lifter attachment
09915-64510
Compression gauge
09917-88210
Valve guide installer attach-
ment
ENGINE MECHANICAL (F8B ENGINE) 6A-55
09924-17810
Flywheel holder
09930-40113
Camshaft lock holder
09926-18210
Oil seal guide (Vinyl resin)
09917-98210
Valve stem seal installer
09918-08210
Vacuum gauge hose joint

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General Description Engine Services Not Requiring Engine Removal Dismounting Engine Engine Disassembly Inspection of Engine Components Engine Reassembly Mounting Engine Maintenance Services Required Service Materials Special Tools

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