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

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

, 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

, 192.0 psi)

Limit

1000 kPa

(10.0 kg/cm

, 142.2 psi)

Max. difference between any

two cylinders

100 kPa

(1.0 kg/cm

, 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

(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

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

Related Topics

Popular Owner Manuals

Latest Owner Manuals