Get Engine Mechanical (F8B Engine) -> Engine Reassembly Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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

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

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