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

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

Related Topics

Engine Mechanical (F8B Engine)
General Description Engine Services Not Requiring Engine Removal Dismounting Engine Inspection of Engine Components Engine Reassembly Mounting Engine Maintenance Services Required Service Materials Special Tools

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