1998-2003 Suzuki Alto 4 Door Engine Mechanical (F8D Engine) User Manual
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Engine Mechanical (F8D Engine) for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

6A1
ENGINE MECHANICAL (F8D ENGINE) 6A1-1
SECTION 6A1
ENGINE MECHANICAL
(F8D ENGINE)
CONTENTS
GENERAL DESCRIPTION 6A1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 6A1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 6A1- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 6A1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Check 6A1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check 6A1- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check 6A1- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash (Clearance) 6A1- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Filter 6A1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover 6A1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 6A1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Oil Pump Strainer 6A1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 6A1-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arms, Rocker Arm Shaft and Camshaft 6A1-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head 6A1-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Rings, Connecting Rods and Cylinders 6A1-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL 6A1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly 6A1-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A1-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS 6A1-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 6A1-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE:
For what each abbreviation stands for (i.e., full term), refer to SECTION 0A.
The engine is a water-cooled, in line 3 cylinders, 4
stroke cycle gasoline unit equipped with its S.O.H.C.
(Single Overhead Camshaft) valve mechanism ar-
ranged for “V”-type valve configuration and 12 valves
(IN 2 and EX 2/one cylinder).
The single overhead camshaft is mounted over the
cylinder head: it is driven from crankshaft through tim-
ing belt and opens and closes its valves via the rocker
arms.
6A1-2 ENGINE MECHANICAL (F8D ENGINE)
GENERAL DESCRIPTION
ENGINE
The oil pump for pressure-feeding lubrication oil to the running parts of the engine is of an internal gear type, in
which an outer ring-like gear is internally meshed with an inner gear, there being a separating crescent-like stator
between the two. The pump is mounted on the front end of the engine, and is driven by the crankshaft.
The oil pump lifts oil through the strainer and discharges it under pressure, forcing the oil through the oil filter. The
filtered oil flows into two paths inside the cylinder block. In one path, oil reaches the crankshaft journal bearings
and big-end bearings on crankpins. Some of this oil goes to the connecting-rod small ends and lubricates piston
pins there and also the walls of cylinder bores.
In the other path, oil goes up to the cylinder head and enters the oil gallery of rocker arm shafts to lubricate the
sliding parts of these shafts and also journals of the camshaft.
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). Relieved oil flows back to the oil pan.
ENGINE MECHANICAL (F8D ENGINE) 6A1-3
ENGINE LUBRICATION
ON-VEHICLE SERVICE
COMPRESSION CHECK
Check 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 high-tension cords (1) and all spark plugs referring to
Section 6F.
5) Disconnect ignition coil wire harness at coupler (1).
WARNING:
Failure in disconnecting the coupler can cause spark
to occur in engine room possibly resulting in a dan-
gerous explosion.
6) Install special tool (Compression gauge) into spark plug hole.
Special Tool
(A): 09915-64510-001
(B): 09915-64510-002
(C): 09915-64530
(D): 09915-64550
7) Disengage clutch (to lighten starting load on engine) and de-
press accelerator pedal all the way to make throttle valve full-
open.
6A1-4 ENGINE MECHANICAL (F8D ENGINE)
8) Crank engine with fully charged battery, and read the highest
pressure on compression gauge.
NOTE:
For measuring compression pressure, crank engine at
least 250 r/min. by using fully charged battery.
ENGINE VACUUM CHECK
The engine vacuum that develops in the intake line is a good indi-
cator of the condition of the engine. The vacuum checking proce-
dure is as follows:
1) Warm up engine to normal operating temperature.
NOTE:
After warming up engine, place transmission gear shift le-
ver in “Neutral” and set parking brake and block drive
wheels.
9) Carry out steps 5) through 7) on each cylinder to obtain three
readings.
10) After checking, install spark plugs and high-tension cords (1)
and connect injector and ignition coil wire harness connector
securely.
ENGINE MECHANICAL (F8D ENGINE) 6A1-5
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)
2) With engine stopped, disconnect canister purge control vacu-
um hose from canister purge control valve and connect 3-way
joint, hose and special tool (vacuum gauge and joint) to canister
purge control valve and vacuum hose disconnected.
Special Tool
(A): 09915-67310
(B): 09918-08210
SUZUKI GENUINE PARTS
(C): Hose 09343-03087
(D): 3-way joint 09367-04002
3) Run engine at specified idle speed, and read vacuum gauge.
Vacuum should be within following specification.
Vacuum specification (at sea level):
at specified idling speed
53.7 – 60.4 kPa (40 – 45 cmHg, 15.7 – 17.7 )
4) After checking, connect vacuum hose to canister purge control
valve.
OIL PRESSURE CHECK
NOTE:
Prior to checking oil pressure, check following items.
D Oil level in oil pan.
If oil level is low, add oil up to Full level hole on oil level
gauge.
D Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in MAINTE-
NANCE SERVICE of Section 0B.
D Oil leaks.
If leak is found, repair it.
1. Full level hole
2. Low level hole
6A1-6 ENGINE MECHANICAL (F8D ENGINE)
1) Hoist vehicle. Remove oil pressure switch from cylinder block.
2) Install special tool (Oil pressure gauge) to vacated threaded
hole. Then lower vehicle.
Special Tool
(A): 09915-77310
(B): 09915-78211
3) Start engine and warm it up to normal operating temperature.
NOTE:
Be sure to place transmission gear shift lever in “Neutral”
and set parking brake and block drive wheels.
4) After warming up, raise engine speed to 4,000 r/min and mea-
sure oil pressure.
Oil pressure specification:
300 – 450 kPa (3.0 – 4.5 kg/cm
2
, 42.7 – 64.0 psi) at 4,000
r/min (rpm)
5) Stop engine and remove oil pressure gauge.
6) Before reinstalling oil pressure switch (1), be sure to wrap its
screw threads with sealing tape and tighten switch to specified
torque.
NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.
Tightening Torque
(a): 14 N
.
m (1.4 kg-m, 10.5 lb-ft)
7) Start engine and check oil pressure switch for oil leakage.
8) Stop engine and connect terminal to pressure switch terminal.
ENGINE MECHANICAL (F8D ENGINE) 6A1-7
VALVE LASH (CLEARANCE)
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to CYLINDER HEAD
COVER in this section.
3) Remove distributor cap (1), rotor (2) and cover (3).
4) Using 17 mm wrench, turn crankshaft pulley clockwise until lug
of signal rotor aligned to CMP sensor as shown in figure.
5) If signal rotor is positioned as shown in figure (i.e. No.1 piston
is at top dead center of compression stroke), check valve lashes
at valves (1) and (4).
A: Top dead center of No.1 piston
B: Top dead center of No.2 piston
C: Top dead center of No.3 piston
6) If valve lash is out of specification, adjust it to specification by
turning adjusting screw after loosening lock nut.
After adjustment, tighten lock nut to specified torque while hold-
ing adjusting screw stationary, and then make sure again that
valve lash is within specification.
Special Tool
(A): 09917-18210
Tightening Torque
(a): 12 N
.
m (1.2 kg-m, 9.0 lb-ft)
6A1-8 ENGINE MECHANICAL (F8D ENGINE)
Valve
clearance
When cold
(Coolant tempera-
ture is 15 – 255C
or 59 – 775F)
When hot
(Coolant tempera-
ture is 60 – 685C
or 140 – 1545F)
clearance
specifica-
tion
Intake
0.13 – 0.17 mm
(0.005 – 0.007 in.)
0.15 – 0.19 mm
(0.006 – 0.007 in.)
Exhaust
0.13 – 0.17 mm
(0.005 – 0.007 in.)
0.14 – 0.18 mm
(0.006 – 0.007 in.)
7) After checking and adjusting valve lashes at valves (1) and (4),
rotate crankshaft pulley clockwise until lug “C” of signal rotor
aligned to CMP sensor and check the same valves at (3) and
(6). Adjust them as necessary.
8) After checking and adjusting valve lashes at valves (3) and (6),
rotate crankshaft pulley clockwise until lug “B” of signal rotor
aligned to CMP sensor and check the same valves at (2) and
(5). Adjust them as necessary.
A: Top dead center of No.1 piston
B: Top dead center of No.2 piston
C: Top dead center of No.3 piston
AIR CLEANER FILTER
REMOVAL AND INSTALLATION
1) Remove air cleaner case bracket bolts (1).
2) Remove air cleaner case clamps (2).
3) Remove air cleaner filter from case.
4) Check air cleaner filter for dirt.
5) If necessary, blow off dust by compressed air from air outlet side
of air cleaner filter.
If excessively dirty, replace filter.
6) Reverse removal procedure for installation.
ENGINE MECHANICAL (F8D ENGINE) 6A1-9
CYLINDER HEAD COVER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove high-tension cords.
3) Disconnect PCV valve and breather hoses from head cover.
4) Remove cylinder head cover.
INSTALLATION
1) Install O-rings (2) and cylinder head cover gasket (1) to cylinder
head cover (3).
D Apply sealant to cylinder head cover gasket and cylinder
head side seal (4) indicated part.
“A”: sealant: 99000-31150
D Apply grease to O-rings.
“B”: grease: 99000-25010
NOTE:
Be sure to check each of these parts for deterioration or
any damage before installation and replace if found defec-
tive.
2) Install cylinder head cover to cylinder head and tighten cover
bolts to specified torque.
Tightening Torque
(a): 11 N
.
m (1.1 kg-m, 8.0 lb-ft)
NOTE:
When installing cylinder head cover, use care so that cylin-
der head cover gasket, cylinder head side seal or O-rings
will not get out of place or fall off.
3) Install high-tension cords.
4) Connect PCV valve and breather hoses to head cover.
5) Connect negative cable at battery.
6A1-10 ENGINE MECHANICAL (F8D ENGINE)
1. Intake manifold
2. Throttle body
3. Gasket
4. Fuel pressure regulator
5. Fuel delivery pipe
6. Fuel injector
7. Stiffener
: Tightening Torque
: Do not reuse
REMOVAL
1) Relieve fuel pressure according to fuel pressure relief proce-
dure described in Section 6.
2) Disconnect negative cable at battery.
3) 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.
4) Remove air cleaner case (1).
5) Disconnect following electric lead wires:
D Injectors lead wires at the coupler
D Canister purge control valve
D Throttle position sensor/Idle air control valve
D Pressure sensor
ENGINE MECHANICAL (F8D ENGINE) 6A1-11
THROTTLE BODY AND INTAKE MANIFOLD
6) Disconnect accelerator cable from throttle body.
7) Disconnect following hoses:
D Canister purge hose from canister purge control valve
D Engine cooling water (coolant) hoses from throttle body
D PCV hose from intake manifold
D Fuel return and inlet hoses from each pipe
8) Remove intake manifold stiffener (1).
9) Remove intake manifold (2) with throttle body (3) from cylinder
head, and then its gasket (4).
INSPECTION
D Using a straight edge and thickness gauge, check surface at a
total of 6 locations. If distortion limit, given below, is exceeded,
correct gasketed surface or replace intake manifold.
Limit of distortion: 0.05 mm (0.002 in.)
INSTALLATION
Reverse removal procedure for installation noting the followings.
D Use new intake manifold gasket.
D Tighten bolts and nuts to specified torque.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
D Adjust accelerator cable play, referring to Section 6E.
D Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
D Refill cooling system, referring to Section 6B.
D Adjust water pump drive belt tension, referring to Section 6B.
D Upon completion of installation, turn ignition switch ON but en-
gine OFF and check for fuel leaks.
D Finally, start engine and check for engine coolant leaks.
6A1-12 ENGINE MECHANICAL (F8D ENGINE)
1. Exhaust manifold
2. Exhaust manifold cover
3. Gasket
4. Oxygen sensor
5. Exhaust manifold bolt and nut
6. Exhaust pipe bolt
: Tightening Torque
: Do not reuse
WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system cools down.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect oxygen sensor coupler (if equipped).
3) Remove exhaust manifold covers of exhaust manifold.
4) Remove exhaust pipe from exhaust manifold.
5) Remove exhaust manifold and its gasket from cylinder head.
ENGINE MECHANICAL (F8D ENGINE) 6A1-13
EXHAUST MANIFOLD
INSTALLATION
1) Install new gasket (1) to cylinder head.
2) Install exhaust manifold (2).
Tighten bolts and nuts to specified torque.
Tightening Torque
(a): 23 N
.
m (2.3 kg-m, 17.0 lb-ft)
3) Install pipe gasket and install exhaust pipe to exhaust manifold.
Before installing pipe gasket, check it for deterioration or dam-
age, and replace as necessary.
Tighten pipe fasteners to specified torque.
Tightening Torque
(b): 55 N
.
m (5.5 kg-m, 40.0 lb-ft)
4) Install upper cover (3) to exhaust manifold.
5) Connect oxygen sensor connector (4) and fit connector to
bracket.
6) Connect negative cable at battery.
7) Check exhaust system for exhaust gas leakage.
6A1-14 ENGINE MECHANICAL (F8D ENGINE)
1. Timing belt
2. Tensioner
3. Crank shaft pulley
4. Camshaft timing belt pulley
5. Camshaft timing pulley
6. Tensioner bolt
7. Pulley bolt
8. Inside cover
9. Outside cover seal
10. Outside cover
: Tightening Torque
: Do not reuse
REMOVAL
1) Disconnect negative cable at battery.
2) Remove air cleaner case and hose.
3) Remove water pump drive belt (1) and water pump pulley (2).
4) Remove A/C compressor belt (3), if equipped.
5) Remove clutch housing lower plate (1).
6) Remove crankshaft pulley (1) with crankshaft locked.
ENGINE MECHANICAL (F8D ENGINE) 6A1-15
TIMING BELT AND BELT TENSIONER
7) Remove timing belt outside cover.
8) For installation of timing belt, align 4 timing marks (1), (2), (3),
(4) as shown in figure by turning crankshaft.
9) Remove timing belt tensioner (5) and timing belt (6).
CAUTION:
D After timing belt is removed, never turn camshaft
and crankshaft independently more than such an
extent as shown in figure. If turned, interference
may occur among piston and valves, and parts re-
lated to piston and valves may be damaged.
D Never bend timing belt.
1. Camshaft allowable turning range By timing mark,. . .
within 90_ from timing mark on timing belt inside cover on
both right and left.
2. Crankshaft allowable turning range By timing mark,. . .
within 90_ from timing mark on oil pump case on both right
and left.
INSPECTION
D Inspect timing belt for wear or crack.
Replace it as necessary.
6A1-16 ENGINE MECHANICAL (F8D ENGINE)
D Inspect tensioner for smooth rotation.
INSTALLATION
1) Install crank pulley key (2) to crankshaft.
Install crankshaft timing belt pulley (1) to crankshaft, if removed.
2) Install tensioner (2).
Do not tighten tensioner bolt (1) with wrench yet. Hand tighten
only at this time.
3) Check that timing mark (1) on camshaft timing belt pulley is
aligned with mark (2) on timing belt inside cover. If not, align two
marks by turning camshaft but be careful not to turn it more than
its allowable turning range which is described on previous page.
4) Check that punch mark (2) on crankshaft timing belt pulley is
aligned with arrow mark (1) on oil pump case. If not, align two
marks by turning crankshaft but be careful not to turn it more
than its allowable turning range which is described on previous
page.
ENGINE MECHANICAL (F8D ENGINE) 6A1-17
5) Check to ensure that valve clearance is adjusted correctly.
6) Remove spark plugs.
7) Install timing belt.
With two sets of marks (1), (2) and (3), (4) aligned, install timing
belt on two pulleys in such a way that drive side (5) of belt is free
from any slack.
NOTE:
D When installing timing belt, match arrow mark ( ê ) on
timing belt with rotating direction (6) of crankshaft.
8) Attach hexagon wrench (1) to belt tensioner hole and adjust belt
tension to specified.
(a) Move tensioner till timing belt tension is specification by
turning hexagon wrench clockwise as shown in figure and
measure timing belt tension by using special tool.
Special Tool
(A): 09919-56010
Belt tension under pressure 7 kg or 15.5 Ib
“a”: 10.5 mm (0.413 in.) New belt. . .
12.0 mm (0.472 in.) Reuse belt. . .
(b) Tighten tensioner bolt.
Tightening Torque
(a): 19 N
.
m (1.9 kg-m, 14.0 lb-ft)
(c) To take up slack of timing belt, turn crankshaft two rotations
clockwise.
Then confirm again that two sets of marks are aligned re-
spectively. And confirm belt tension again as previously
outlined.
NOTE:
Perform step 8) repeatedly, after loosen tensioner bolt,
if belt tension is out of standards.
6A1-18 ENGINE MECHANICAL (F8D ENGINE)
9) Install spark plugs.
10) Install timing belt outside cover.
Before installing, make sure that seal is between water pump
and oil pump case.
Tightening Torque
(a): 11 N
.
m (1.1 kg-m, 8.0 lb-ft)
11) Install crankshaft pulley (1).
Install crankshaft timing belt pulley with crankshaft locked, and
tighten pulley bolts to specified torque.
Tightening Torque
(a): 84 N
.
m (8.4 kg-m, 61.0 lb-ft)
12) Install A/C compressor belt (3), if equipped.
Adjust its belt tension, referring to Section 0B.
13) Install water pump pulley (1) and water pump drive belt (2).
Adjust water pump drive belt tension, referring to Section 6B.
14) Install air cleaner case and hose.
15) Connect negative cable at battery.
ENGINE MECHANICAL (F8D ENGINE) 6A1-19
OIL PAN AND OIL PUMP STRAINER
1. Oil pan:
Apply SUZUKI BOND No. 1207C
99000-31150 to mating surface.
2. Oil pump strainer
3. Seal
4. Drain plug gasket
5. Drain plug
6. Oil pan bolt and nut
7. Strainer bolt
: Tightening Torque
: Do not reuse
1) Drain engine oil by removing drain plug (1).
2) Remove clutch housing lower plate (1).
3) Disconnect exhaust pipe from exhaust manifold.
4) Remove oil pan (2) and then oil pump strainer (1).
6A1-20 ENGINE MECHANICAL (F8D ENGINE)
CLEANING
D Clean mating surfaces of oil pan and cylinder block.
Remove oil, old sealant, and dusts from mating surfaces and oil
pan inside.
D Clean oil pump strainer screen.
INSTALLATION
1) Apply sealant to oil pan mating surface continuously as shown
in figure.
“A” Sealant: 99000-31150
ENGINE MECHANICAL (F8D ENGINE) 6A1-21
2) Install oil pump strainer (1) and oil pan (2).
Install new O-ring (3) to oil pump strainer in the position as
shown in figure.
Install strainer to cylinder block, then tighten strainer bolt to spe-
cified torque.
Tightening Torque
(a): 11 N
.
m (1.1 kg-m, 8.0 lb-ft)
After fitting oil pan to cylinder block, run in securing bolts and
start tightening at the center: move wrench outward, tightening
one bolt at a time.
Tighten bolts to specified torque.
Tightening Torque
(b): 11 N
.
m (1.1 kg-m, 8.0 lb-ft)
(b)
3) Install new gasket and drain plug (1) to oil pan.
Tighten drain plug (1) to specified torque.
Tightening Torque
(a): 50 N
.
m (5.0 kg-m, 36.5 lb-ft)
4) Install clutch (torque converter) housing lower plate.
5) Connect exhaust manifold pipe to exhaust manifold.
6) Refill engine with engine oil, referring to item ENGINE OIL
CHANGE in Section 0B.
7) Verify that there is no engine oil leakage and differential oil leak-
age at each connection.
6A1-22 ENGINE MECHANICAL (F8D ENGINE)
OIL PUMP
: Tightening Torque
: Do not reuse
1. Rotor plate:
Apply thin coat of engine oil.
2. Outer rotor:
Apply thin coat of engine oil.
3. Inner rotor:
Apply thin coat of engine oil.
4. Gasket
5. Pin
6. Oil seal:
Apply thin coat of engine oil.
7. Relief valve
8. Spring
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing belt as previously outlined.
3) Remove generator (1) and its bracket (2).
4) Remove A/C compressor (3) and its bracket (4) (if equipped).
5) Remove camshaft timing pulley (5) by using special tool.
Special Tool
(A): 09917-68221
6) Remove timing belt inside cover (6).
7) Remove oil pan and oil pump strainer as previously outlined.
8) Remove oil pump assembly (7) after removing bolts.
DISASSEMBLY
1) Remove rotor plate (1).
ENGINE MECHANICAL (F8D ENGINE) 6A1-23
INSPECTION
D Check oil seal lip for fault or other damage. Replace as neces-
sary.
Special Tool
(A): 09913-75520
NOTE:
When installing oil seal, press-fit it till its end face is flush
with oil pump case end face.
D Check outer and inner rotors, rotor plate, and oil pump case for
excessive wear or damage.
MEASUREMENT
D Radial clearance
Check radial clearance between outer rotor (1) and case (2), us-
ing thickness gauge.
If clearance exceeds its limit, replace outer rotor or case.
Limit on radial clearance between outer rotor and case:
0.320 mm (0.0126 in.)
D Side clearance
Using straight edge and thickness gauge, measure side clear-
ance.
Limit on side clearance: 0.17 mm (0.0067 in.)
ASSEMBLY
1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip
portion, and inside surfaces of oil pump case and plate.
3) Install outer and inner rotors to pump case.
4) Install rotor plate. Tighten screws to specified torque.
After installing plate, check to be sure that gears turn smoothly
by hand.
Tightening torque
(a): 11 N·m (1.1 kg-m, 8.0 Ib-ft)
6A1-24 ENGINE MECHANICAL (F8D ENGINE)
INSTALLATION
1) Install two oil pump pins (2) and oil pump gasket to cylinder
block. Use a new gasket.
2) To prevent oil seal lip from being damaged or upturned when
installing oil pump to crankshaft, fit special tool (Oil seal guide)
to crankshaft (1), and apply engine oil to special tool.
Special Tool
(A): 09926-18210
3) Install oil pump to cylinder block.
Tightening Torque
(a): 11 N
.
m (1.1 kg-m, 8.0 lb-ft)
4) Install rubber seals (1) between oil pump and water pump.
5) Install timing belt, tensioner, oil pump strainer, oil pan and oth-
er parts as previously outlined.
6) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
7) Adjust water pump drive belt tension, referring to Section 0B.
8) Adjust A/C compressor belt tension, if equipped. Refer to Sec-
tion 0B.
9) Refill engine with engine oil, referring to item ENGINE OIL
CHANGE in Section 0B.
10) Connect negative cable at battery.
11) Verify that there is no coolant leakage and each oil leakage at
each connection.
12) After completing installation, check oil pressure by running en-
gine.
ENGINE MECHANICAL (F8D ENGINE) 6A1-25
1. Camshaft
2. Camshaft oil seal
3. Rocker arm shaft
4. Rocker shaft bolt
5. Rocker arm No.1 (IN)
6. Rocker arm No. 2 (IN)
7. Valve adjusting screw
8. Camshaft housing:
Apply SUZUKI BOND No.1207C
to mating surfaces of housing No.1.
9. Lock nut
10. Rocker arm (EX)
11. Rocker arm spring
: Tightening Torque
: Do not reuse
: Apply engine oil to sliding surface of each part.
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing belt as previously outlined.
3) Remove camshaft timing belt pulley (1) by using special tool
and then remove timing belt inside cover (2).
Special Tool
(A): 09917-68221
4) Remove cylinder head cover as previously outlined.
5) After loosening all valve adjusting screw lock nuts (2), turn ad-
justing screws (1) back all the way to allow all rocker arms to
move freely.
6) Remove rocker arm shaft bolts (1).
6A1-26 ENGINE MECHANICAL (F8D ENGINE)
ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT
7) Remove rocker arm shaft (1) with intake rocker arms (2) and
rocker arm spring (3).
8) Remove camshaft housing (1), camshaft (2) and distributor. For
distributor removal, refer to Section 6F.
NOTE:
To remove camshaft housing bolts, loosen them in such or-
der as indicated in figure, a little at a time.
9) Remove exhaust rocker arms.
INSPECTION
Adjusting Screw and Rocker Arm
If tip of adjusting screw (1) is badly worn, replace it.
Rocker arm (2) must be replaced if its cam-riding face (3) is badly
worn.
Rocker Arm Shaft Runout
Using “V” blocks and dial gauge, check runout. If runout exceeds
its limit, replace rocker arm shaft.
Runout limit: 0.06 mm (0.0024 in.)
ENGINE MECHANICAL (F8D ENGINE) 6A1-27
Rocker Arm-to-Rocker Arm Shaft Clearance
Using a micrometer and a bore gauge, measure rocker shaft dia.
and rocker arm l.D.
Difference between two readings is arm-to-shaft clearance on
which a limit is specified.
If limit is exceeded, replace shaft or arm, or both.
Cam Wear
Using a micrometer, measured height of cam. If measured height
is below limit, replace camshaft.
Camshaft Runout
Hold camshaft between two “V” blocks, and measure runout by us-
ing a dial gauge.
If runout exceeds the limit, replace camshaft.
Runout limit: 0.10 mm (0.0039 in.)
Camshaft Journal Wear
Check camshaft journals and camshaft housings for pitting,
scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head with
housing. Never replace cylinder head without replacing housing.
6A1-28 ENGINE MECHANICAL (F8D ENGINE)
Item Standard Limit
Rocker arm I.D.
15.985 – 16.005 mm
(0.629 – 0.630 in.)
–––––
Rocker arm shaft dia.
15.965 – 15.980 mm
(0.6285 – 0.6291 in.)
–––––
Arm-to-shaft clearance
0.005 – 0.040 mm
(0.0002 – 0.0016 in.)
0.06 mm
(0.0024 in.)
Cam height Standard Limit
Intake cam
30.406 – 30.566 mm
(1.1971 – 1.2034 in.)
30.362 mm
(1.1954 in.)
Exhaust cam
29.719 – 29.879 mm
(1.1700 – 1.1763 in.)
29.676 mm
(1.1683 in.)
Check clearance by using gaging plastic.
The procedure is as follows.
1) Clean housing and camshaft journals.
2) Install camshaft to cylinder head.
3) Place a piece of gaging plastic the full width of journal of cam-
shaft (parallel to camshaft).
4) Install camshaft housing, referring to the following page.
5) Tighten camshaft housing bolts in such order as indicated in fig-
ure a little at a time till they are tightened to specified torque.
Tightening Torque
(a): 11 N
.
m (1.1kg-m, 8.0 lb-ft)
NOTE:
Do not rotate camshaft while gaging plastic is installed.
6) Remove housing and using scale (1) on gaging plastic (2) enve-
lope, measure gaging plastic width at its widest point.
If measured camshaft journal clearance exceeds limit, measure
journal (housing) bore and outside diameter of camshaft jour-
nal. Replace camshaft or cylinder head assembly whichever
the difference from specification is greater.
ENGINE MECHANICAL (F8D ENGINE) 6A1-29
Standard Limit
Journal
clearance
0.045 – 0.087 mm
(0.0018 – 0.0034 in.)
0.12 mm
(0.0047 in.)
Item Standard
Camshaft Journal bore dia.
27.000 – 27.021 mm
(1.0630 – 1.0638 in.)
Camshaft journal O.D.
26.934 – 26.955 mm
(1.0603 – 1.0612 in.)
INSTALLATION
1) Fill small amount of engine oil into arm pivot holding part of cylin-
der head. Install rocker arm (exhaust side) (1).
2) Apply engine oil to cams and journals on camshaft and put cam-
shaft on cylinder head. Install camshaft housing to camshaft
and cylinder head.
D Apply engine oil to sliding surface of each housing against
camshaft journal.
D Apply sealant to mating surface of No.1 housing (1) which will
mate with cylinder head.
“A” Sealant: 99000-31150
D Embossed marks are provided on each camshaft housing,
indicating position and direction for installation.
Install housing as indicated by these marks.
D As camshaft housing No. 1 retains camshaft in proper posi-
tion as to thrust direction, make sure to first fit No. 1 housing
to No. 1 journal of camshaft securely.
D Indicates position from timing
belt side. Install in numerical
order starting from timing belt
side.
D Indicates direction of housing.
Install so that arrow is directed
toward timing belt side.
D After applying engine oil to housing bolts, tighten them tem-
porarily first. Then tighten them by following sequence as in-
dicated in figure.
Tighten a little at a time and evenly among bolts and repeat
tightening sequence three to four times before they are
tightened to specified torque.
Tightening Torque
(a): 11 N
.
m (1.1 kg-m, 8.0 lb-ft)
3) Install new camshaft oil seal (1).
After applying engine oil to oil seal lip, press-fit camshaft oil seal
till oil seal surface becomes flush with housing surface.
4) Install distributor, refer to Section 6F.
6A1-30 ENGINE MECHANICAL (F8D ENGINE)
5) Apply engine oil to rocker arm shaft and rocker arms.
6) Install rocker arm shaft, rocker arm (intake side) and rocker
arm spring.
7) Install rocker arm shaft bolts and tighten them to specified
torque.
Tightening Torque
(a): 22 N
.
m (2.2 kg-m, 16.0 lb-ft)
8) Install camshaft timing belt inside cover.
9) Install camshaft timing belt pulley to camshaft while fitting pin
on camshaft into slot.
10) Using special tool, tighten pulley bolt to specified torque.
Tightening Torque
(a): 54 N
.
m (5.4 kg-m, 39.0 lb-ft)
Special Tool
(A): 09917-68221
11) Install belt tensioner, timing belt, outside cover, crankshaft
pulley, A/C compressor belt (if equipped) and water pump belt
as previously outlined.
12) Adjust valve clearance as previously outlined.
13) Install cylinder head cover.
14) Connect negative cable at battery.
15) Confirm that ignition timing is within specification referring to
Section 6F.
ENGINE MECHANICAL (F8D ENGINE) 6A1-31
1. Valve cotters
2. Valve spring retainer
3. Valve spring
4. Valve stem seal
5. Valve spring seat
6. Exhaust valve
7. Intake valve
8. Cylinder head
9. Cylinder head gasket
10. Oil venturi plug
11. Cylinder head bolt
12. Oil gallery plug
: Tightening Torque
: Do not reuse
: Apply engine oil.
REMOVAL
1) Relieve fuel pressure according to fuel pressure relief proce-
dure described in Section 6.
2) Disconnect negative cable at battery.
3) Drain cooling system.
4) Remove cylinder head cover as previously outlined.
Loosen all valve lash adjusting screws fully.
6A1-32 ENGINE MECHANICAL (F8D ENGINE)
VALVES AND CYLINDER HEAD
5) Remove timing belt, timing belt inside cover rocker arm shaft
with, intake rocker arms, exhaust rocker arms and camshaft as
previously outlined.
6) Disconnect exhaust pipe from exhaust manifold.
7) Loosen cylinder head bolts in such order as indicated in figure
and remove them.
8) Check all around cylinder head for any other parts required to
be removed or disconnected and remove or disconnect what-
ever necessary.
9) Remove cylinder head with intake manifold and exhaust man-
ifold.
DISASSEMBLY
1) For ease in servicing cylinder head, remove intake manifold, ex-
haust manifold and thermostat case from cylinder head.
2) Using special tool (Valve lifter), compress valve springs and
then remove valve cotters by using special tool (Forceps) as
shown.
Special Tool
(A): 09916-14510
(B): 09916-14910
3) Release special tool, and remove spring retainer and valve
spring.
4) Remove valve from combustion chamber side.
ENGINE MECHANICAL (F8D ENGINE) 6A1-33
5) Remove valve stem oil seal (1) from valve guide, and then valve
spring seat (2).
NOTE:
Do not reuse oil seal once disassembled. Be sure to use
new oil seal when assembling.
6) Using special tool (Valve guide remover), drive valve guide out
from combustion chamber side to valve spring side.
Special Tool
(A): 09916-44910
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.
7) Place disassembled parts except valve stem seal and valve
guide in order, so that they can be installed in their original posi-
tion.
INSPECTION
Valve Guides
Using a micrometer and caliper gauge, take diameter readings on
valve stems and guides to check stem-to-guide clearance.
Be sure to take reading at more than one place along the length of
each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
If caliper gauge is not available, check end deflection of valve stem
with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end deflection.
If deflection exceeds its limit, replace valve stem and valve guide.
6A1-34 ENGINE MECHANICAL (F8D ENGINE)
Item Standard Limit
Valve stem
In
5.465 – 5.480 mm
(0.2152 – 0.2157 in.)
–––
diameter
Ex
5.440 – 5.455 mm
(0.2142 – 0.2148 in.)
–––
Valve guide
In
5.500 – 5.512 mm
I.D.
Ex
(0.2166 – 0.2170 in.)
–––
Stem-to-guide
In
0.020 – 0.047 mm
(0.0008 – 0.0018 in.)
0.07 mm
(0.0027 in.)
clearance
Ex
0.045 – 0.072 mm
(0.0018 – 0.0028 in.)
0.09 mm
(0.0035 in.)
Valve stem end deflection limit
In 0.14 mm (0.005 in.)
Valve
stem
end
deflection
limit
Ex 0.18 mm (0.007 in.)
Valves
D Remove all carbon from valves.
D Inspect each valve for wear, burn or distortion at its face and
stem end, as necessary, replace it.
D Measure thickness of valve head. If measured thickness ex-
ceeds limit, replace valve.
1. Valve head thickness
2. 45_
D Inspect valve stem end face for pitting and wear. If pitting or wear
is found there, valve stem end may be resurfaced, but not so
much as to grind off its chamfer. When it is worn so much that
its chamfer is gone, replace valve.
D Seating contact width:
Create contact pattern on each valve in the usual manner, i.e.,
by giving uniform coat of marking compound to valve seat and
by rotatingly tapping seat with valve head. Valve lapper (tool
used in valve lapping) must be used.
Pattern produced on seating face of valve must be a continuous
ring without any break, and the width “a” of pattern must be within
specified range.
ENGINE MECHANICAL (F8D ENGINE) 6A1-35
Valve head thickness
Standard Limit
IN
0.8 – 1.2 mm
0.6 mm (0.024 in.)
EX
(0.03 – 0.047 in.)
0.7 mm (0.027 in.)
Standard seating width revealed
In
1.80 – 2.20 mm
(0.0709 – 0.0866 in.)
g
by contact pattern on valve face
Ex
1.65 – 2.05 mm
(0.0650 – 0.0807 in.)
D Valve seat repair:
A valve seat not producing a uniform contact with its valve or
showing width of seating contact that is out of specified range
must be repaired by regrinding or by cutting and regrinding and
finished by lapping.
1) EXHAUST VALVE SEAT: Use valve seat cutter (1) to make
two cuts as illustrated in figure. Two cutters must be used: the
first for making 15_ angle, and the second for making 45_
angle. The second cut must be made to produce desired seat
width.
Seat width for exhaust valve seat:
1.65 – 2.05 mm (0.0650 – 0.0807 in.)
2) INTAKE VALVE SEAT: Cutting sequence is the same as for
exhaust valve seats (1).
Seat width for intake valve seat:
1.80 – 2.20 mm (0.0709 – 0.0866 in.)
3) VALVE LAPPING: Lap valve on seat in two steps, first with
coarse size lapping compound applied to face and the se-
cond with fine-size compound, each time using valve lapper
according to usual lapping method.
Cylinder Head
D Remove all carbon from combustion chambers.
NOTE:
Do not use any sharp-edged tool to scrape off carbon. Be
careful not to scuff or nick metal surfaces when decarbon-
ing. The same applies to valves and valve seats, too.
D Check cylinder head for cracks in intake and exhaust ports, com-
bustion chambers, and head surface.
6A1-36 ENGINE MECHANICAL (F8D ENGINE)
D Flatness of gasketed surface:
Using a straightedge and thickness gauge, check surface at a
total of 6 locations. If distortion limit, given below, is exceeded,
correct gasketed surface with a surface plate and abrasive pa-
per of about #400 (Waterproof silicon carbide abrasive paper):
place paper on and over surface plate, and rub gasketed surface
against paper to grind off high spots. Should this fail to reduce
thickness gauge readings to within limit, replace 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.
Limit of distortion: 0.05 mm (0.002 in.)
D Distortion of manifold seating faces:
Check 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 cylinder head replaced.
Limit of distortion: 0.10 mm (0.004 in.)
Valve Springs
D Referring to data given below, check to be sure that each spring
is in sound condition, free of any evidence of breakage or weak-
ening. Remember, weakened valve springs can cause chatter,
not to mention possibility of reducing power output due to gas
leakage caused by decreased seating pressure.
ENGINE MECHANICAL (F8D ENGINE) 6A1-37
Item Standard Limit
Valve spring
free length
37.09 mm
(1.460 in.)
36.2 mm
(1.4252 in.)
Valve spring
preload
13.3 – 15.7 kg for 32.0 mm
(29.3 – 34.6 lb/1.26 in.)
13.0 kg for 32.0 mm
(28.7 lb/1.26 in.)
D Spring squareness:
Use a square and surface plate to check each spring for square-
ness in terms of clearance between end of valve spring and
square. Valve springs found to exhibit a larger clearance than
limit given below must be replaced.
Valve spring squareness limit “a”: 2.0 mm (0.079 in.)
ASSEMBLY
1) Before installing valve guide into cylinder head, ream guide hole
with special tool (10.5 mm reamer) so remove burrs and make
it truly round.
Special Tool
(A): 09916-34542
(B): 09916-37320
2) Install valve guide to cylinder head.
Heat cylinder head uniformly at a temperature of 80 to 100_C
(176 to 212_F) so that head will not be distorted, and drive new
valve guide into hole with special tools. Drive in new valve guide
until special tool (Valve guide installer) contacts cylinder head.
After installing, make sure that valve guide protrudes by 13.0
mm (0.51 in.) from cylinder head.
Special Tool
(C): 09916-57340
(D): 09916-58210
NOTE:
D Do not reuse valve guide once disassembled.
Install new valve guide (Oversize).
D Intake and exhaust valve guides are identical.
Valve guide oversize: 0.03 mm (0.0012 in.)
Valve guide protrusion “a” (In and Ex): 13.0 mm (0.51 in.)
3) Ream valve guide bore with special tool (5.5 mm reamer).
After reaming, clean bore.
Special Tool
(A): 09916-34542
(B): 09916-34550
6A1-38 ENGINE MECHANICAL (F8D ENGINE)
4) Install valve spring seat to cylinder head.
5) Install new valve stem seal (1) to valve guide.
After applying engine oil to seal and spindle of special tool
(Valve guide installer handle), fit stem seal to spindle, and then
install seal to valve guide by pushing special tool by hand.
After installing, check to be sure that seal is properly fixed to
valve guide.
Special Tool
(A): 09917-98221
(B): 09916-58210
NOTE:
D Do not reuse valve stem seal once disassembled. Be
sure to install new 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 by hand. Tapping or hitting special tool may cause
damage to seal.
6) Install valve to valve guide.
Before installing valve to valve guide, apply engine oil to stem
seal, valve guide bore, and valve stem.
7) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end) (1) and bottom
end (small-pitch end) (2). Be sure to position spring in place with
its bottom end (small-pitch end) facing the bottom (valve spring
seat side).
8) Using special tool (Valve lifter), compress valve spring and fit
two valve cotters into groove in valve stem.
Special Tool
(A): 09916-14510
(B): 09916-14910
ENGINE MECHANICAL (F8D ENGINE) 6A1-39
9) Install rocker arms, springs and rocker arm shaft as previously
outlined.
10) Install intake manifold, exhaust manifold and thermostat case.
INSTALLATION
1) Remove old gasket and oil on mating surfaces and install new
head gasket as shown in figure, that is, “TOP” mark (1) pro-
vided on gasket comes to crankshaft pulley side (2), facing up
(toward cylinder head side).
2) Check to make sure that oil jet (venturi plug) is installed and
if it is, that it is not clogged.
When installing it, be sure to tighten to specified torque.
Tightening Torque
(a): 5 N
.
m (0.5 kg-m, 4.0 lb-ft)
3) Apply engine oil to cylinder head bolts and tighten them gradu-
ally as follows.
(1) Tighten all bolts to 30 N
.
m (3.0 kg-m, 22.0 lb-ft) according
to numerical order in figure.
(2) In the same manner as in (1), tighten them to 48 N
.
m (4.8
kg-m, 35.0 lb-ft).
(3) Loosen all bolts to 0 N·m (0 kg-m, 0 lb-ft) reversing to nu-
merical order in figure.
(4) In the same manner as in (1) again, tighten them to 48 N·m
(4.8 kg-m, 35.0 lb-ft).
(5) In the same manner as in (1) again, tighten them to speci-
fied torque.
Tightening Torque
(b): 60 N
.
m (6.0 kg-m, 43.5 lb-ft)
6A1-40 ENGINE MECHANICAL (F8D ENGINE)
4) Reverse removal procedure for installation.
5) Adjust water pump drive belt tension, referring to Section 6B.
6) Adjust A/C compressor belt tension, if equipped. Refer to sec-
tion 0B.
7) Adjust intake and exhaust valve lashes as previously outlined.
8) Adjust accelerator cable play. Refer to Section 6E.
9) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
10) Refill cooling system referring to Section 6B.
11) Connect negative cable at battery.
12) Verify that there is no fuel leakage, coolant leakage and ex-
haust gas leakage at each connection.
13) Confirm that ignition timing is within specification referring to
Section 6F.
ENGINE MECHANICAL (F8D ENGINE) 6A1-41
PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS
1. Top ring
2. 2nd ring
3. Oil ring
4. Piston
5. Connecting rod
6. Connecting rod bearing cap
7. Connecting rod bearing
8. Piston pin
9. Piston pin circlip
10. Bearing cap nut
: Tightening Torque
: Apply engine oil to sliding surface of each part.
REMOVAL
1) Remove cylinder head from cylinder block as previously out-
lined.
2) Drain engine oil.
3) Remove oil pan and oil pump strainer as previously outlined.
4) Mark cylinder number on all pistons, connecting rods and rod
bearing caps, using silver pencil or quick drying paint.
5) Remove rod bearing caps.
6) Install guide hose (1) over threads of rod bolts. This is to prevent
damage to bearing journal and rod bolt threads when removing
connecting rod.
7) Decarbon top of cylinder bore before removing piston from cyl-
inder.
8) Push piston and connecting rod assembly out through the top
of cylinder bore.
6A1-42 ENGINE MECHANICAL (F8D ENGINE)
DISASSEMBLY
1) Using piston ring expander, remove two compression rings (Top
and 2nd) and oil ring from piston.
2) Remove piston pin from connecting rod.
D Ease out piston pin circlips (1), as shown.
D Force piston pin out.
CLEANING
Clean carbon from piston head and ring grooves, using a suitable
tool.
ENGINE MECHANICAL (F8D ENGINE) 6A1-43
INSPECTION
Cylinders
D Inspect cylinder walls for scratches, roughness, or ridges which
indicate excessive wear. If cylinder bore is very rough or deeply
scratched, or ridged, rebore cylinder and use oversize piston.
D Using a cylinder gauge, measure cylinder bore in thrust and ax-
ial directions at two positions as shown in figure.
If any of following conditions is noted, rebore cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions exceeds taper
limit.
3) Difference between thrust and axial measurements exceeds
out-of-round limit.
Cylinder bore dia. limit: 68.57 mm (2.6996 in.)
Taper and out-of-round limit: 0.10 mm (0.0039 in.)
NOTE:
If any one of three cylinders has to be rebored, rebore all
three to the same next oversize. This is necessary for the
sake of uniformity and balance.
1. 50 mm (1.96 in.)
2. 90 mm (3.54 in.)
Pistons
D Inspect piston for faults, cracks or other damaged.
Damaged or faulty piston should be replaced.
D Piston diameter:
As indicated in figure, piston diameter should be measured at a
position (1) 20 mm (0.79 in.) from piston skirt end in the direction
perpendicular to piston pin.
6A1-44 ENGINE MECHANICAL (F8D ENGINE)
Standard
68.465 – 68.485 mm
(2.6955 – 2.6962 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
(2.7153 – 2.7161 in.)
D Piston clearance:
Measure cylinder bore diameter and piston diameter to find their
difference which is piston clearance. Piston clearance should be
within specification as given below. If it is out of specification, re-
bore cylinder and use oversize piston.
Piston clearance : 0.025 – 0.045 mm (0.0009 – 0.0017 in.)
NOTE:
Cylinder bore diameters used here are measured in thrust
direction at two positions.
“a”: 20 mm (0.79 in.)
D Ring groove clearance:
Before checking, piston grooves must be clean, dry and free of
carbon.
Fit new piston ring into piston groove, and measure clearance
between ring (1) and ring land by using thickness gauge (2).
If clearance is out of specification, replace piston.
Ring groove clearance:
Top:0.03 – 0.07 mm (0.0012 – 0.0027 in.)
2nd:0.02 – 0.06 mm (0.0008 – 0.0023 in.)
Piston Pin
D Check piston pin, connecting rod small end bore and piston bore
for wear or damage, paying particular attention to condition of
small end bore bush. If pin, connecting rod small end bore or pis-
ton bore is badly worn or damaged, replace pin, connecting rod
or piston.
D Piston pin clearance:
Check piston pin clearance in small end. Replace connecting
rod if its small end is badly worn or damaged or if measured
clearance exceeds limit.
Small-end bore:
16.003 – 16.011 mm (0.6300 – 0.6303 in.)
Piston pin dia.:
15.995 – 16.000 mm (0.6297 – 0.6299 in.)
ENGINE MECHANICAL (F8D ENGINE) 6A1-45
Item Standard Limit
Piston clearance
in small end
0.003 – 0.016 mm
(0.0001 – 0.0006 in.)
0.05 mm
(0.0020 in.)
Piston Rings
To measure end gap, insert piston ring (2) into cylinder bore and
then measure the gap by using thickness gauge (1).
If measured gap is out of specification, replace ring.
NOTE:
Decarbon and clean top of cylinder bore before inserting pis-
ton ring.
“a”: 120 mm (4.72 in.)
Connecting Rod
D Big-end side clearance:
Check big-end of connecting rod for side clearance, with rod
fitted and connected to its crank pin in the normal manner. If
measured clearance is found to exceed its limit, replace con-
necting rod.
D Connecting rod alignment:
Mount connecting rod on aligner to check it for bow and twist
and, if limit is exceeded, replace it.
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)
6A1-46 ENGINE MECHANICAL (F8D ENGINE)
Item Standard Limit
Top ring
0.12 – 0.26 mm
(0.0047 – 0.0102 in.)
0.7 mm
(0.0275 in.)
Piston ring
end gap
2nd ring
0.12 – 0.26 mm
(0.0047 – 0.0102 in.)
0.7 mm
(0.0275 in.)
Oil ring
0.2 – 0.7 mm
(0.0079 – 0.0275 in.)
1.8 mm
(0.0709 in.)
Item Standard Limit
Big-end side
clearance
0.10 – 0.20 mm
(0.0039 – 0.0079 in.)
0.35 mm
(0.0137 in.)
Crank Pin and Connecting Rod Bearings
D Inspect crank pin for uneven wear or damage. Measure crank
pin for out-of-round or taper with a micrometer. If crank pin is
damaged, or out-of-round or taper is out of limit, replace crank-
shaft or regrind crank pin referring to following step 6) of Rod
bearing clearance.
Out-of-round limit
(difference between A and B): 0.01 mm (0.0004 in.)
Taper limit
(difference between a and b): 0.01 mm (0.0004 in.)
D Rod bearing:
Inspect bearing shells for signs of fusion, pitting, burn or flaking
and observe contact pattern. Bearing shells found in defective
condition must be replaced.
Two kinds of rod bearing are available; standard size bearing
and 0.25 mm undersize bearing. To distinguish them, 0. 25 mm
undersize bearing has the stamped number (US025) on its
backside as indicated in figure, but standard size one has no
number.
D Rod bearing clearance:
1) Before checking bearing clearance, clean bearing and crank
pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gaging plastic (1) to full width of crankpin as
contacted by bearing (parallel to crankshaft), avoiding oil
hole.
4) Install rod bearing cap (1) to connecting rod.
When installing cap, be sure to point arrow mark (2) on cap
to crankshaft pulley side (3), as shown in figure. After apply-
ing engine oil to rod bolts, tighten cap nuts to specified torque.
DO NOT turn crankshaft with gaging plastic installed.
Tightening Torque
(a): 30 N
.
m (3.0 kg-m, 22.0 lb-ft)
ENGINE MECHANICAL (F8D ENGINE) 6A1-47
Connecting rod bearing size Crank pin diameter
Standard
37.982 – 38.000 mm
(1.4953 – 1.4960 in.)
0.25 mm (0.0098 in.) undersize
37.732 – 37.750 mm
(1.4855 – 1.4862 in.)
5) Remove cap and using a scale on gaging plastic envelope,
measure gaging plastic (1) width at the widest point (clearance).
If clearance exceeds its limit, use a new standard size bearing
and remeasure clearance.
6) If clearance can not be brought to within its limit even by using
a new standard size bearing, replace crankshaft or regrind
crankpin to undersize as follows.
– Install 0.25 mm undersize bearing to connecting rod big end.
– Measure bore diameter of connecting rod big end.
– Regrind crankpin to following finished diameter.
– Confirm that bearing clearance is within above standard val-
ue.
Finished
crankpin
dia.
=
Measured big end
bore dia. (including
undersize bearing)
0.030 mm
(0.0012 in.)
–
ASSEMBLY
NOTE:
Two sizes of piston are available as standard size spare part
so as to ensure proper piston-to-cylinder clearance. When
installing a standard size piston, make sure to match piston
with cylinder as follows.
a) Each piston has painted color red or blue (2) as shown. It repre-
sents outer diameter of piston.
b) There are paints (1) on the cylinder block as shown. The color
(red or blue) of each paint represents cylinder bore diameter.
The first paint from crank pulley side represents inner diameter
of No.1 cylinder, the second paint of No.2 cylinder, the third paint
of No.3 cylinder.
c) Painted color on piston and cylinder block should correspond.
That is, install blue color painted piston to cylinder which is iden-
tified with blue paint and a red color painted piston to cylinder
with red paint.
6A1-48 ENGINE MECHANICAL (F8D ENGINE)
Item Standard Limit
Bearing
clearance
0.020 – 0.040 mm
(0.0008 – 0.0016 in.)
0.065 mm
(0.0026 in.)
Piston Cylinder
Piston to cylinder
Outer diameter
Color
(paint)
Bore diameter
Piston
-
to
-
c
y
linder
clearance
68.475 – 68.485 mm
(2.6959 – 2.6962 in.)
Red
68.51 – 68.52 mm
(2.6973 – 2.6976 in.)
0.02 – 0.04 mm
(0.0008 –
0.0015 in.)
68.465 – 68.475 mm
(2.6955 – 2.6959 in.)
Blue
68.50 – 68.51 mm
(2.6968 – 2.6973 in.)
0.02 – 0.04 mm
(0.0008 –
0.0015 in.)
1) Install piston pin to piston (1) and connecting rod:
After applying engine oil to piston pin and piston pin holes in pis-
ton and connecting rod, fit connecting rod to piston as shown in
figure and insert piston pin to piston and connecting rod, and
install piston pin circlips (3).
NOTE:
Circlip should be installed with its cut part facing either up
or down as shown in figure.
The oil hole (2) should come on intake side
2) Install piston rings to piston:
D As indicated in figure, 1st and 2nd rings have “RN”, “T” or “R”
mark (1) respectively. When installing these piston rings to
piston, direct marked side of each ring toward top of piston.
D 1st ring differs from 2nd ring in thickness, shape and color of
surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.
D When installing oil ring, install spacer first and then two rails.
3) After installing three rings (1st, 2nd and oil rings), distribute their
end gaps as shown in figure.
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and
oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap
6. Intake side
7. Exhaust side
INSTALLATION
1) Apply engine oil to pistons, rings, cylinder walls, connecting rod
bearings and crankpins.
NOTE:
Do not apply oil between connecting rod and bearing or be-
tween bearing cap and bearing.
2) Install guide hoses over connecting rod bolts.
These guide hoses protect crankpin and threads of rod bolt from
damage during installation of connecting rod and piston assem-
bly.
ENGINE MECHANICAL (F8D ENGINE) 6A1-49
3) When installing piston and connecting rod assembly into cylin-
der bore, point arrow mark (2) on piston head to crankshaft
pulley side (1).
4) Install piston and connecting rod assembly into cylinder bore.
Use special tool (Piston ring compressor) to compress rings.
Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until all
piston rings have entered cylinder bore.
Special Tool
(A): 09916-77310
5) Install bearing cap:
Point arrow mark (2) on cap (1) to crankshaft pulley side (3).
Tighten cap nuts to specification.
Tightening Torque
(a): 30 N
.
m (3.0 kg-m, 22.0 lb-ft)
6) Reverse removal procedure for installation, as previously out-
lined.
7) Adjust water pump drive belt tension, referring to Section 0B.
8) Adjust A/C compressor belt tension, if equipped. Refer to Sec-
tion 0B.
9) Adjust intake and exhaust valve lashes as previously outlined.
10) Adjust accelerator cable play. Refer to Section 6E.
11) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
12) Refill engine with engine oil, referring to item ENGINE OIL
CHANGE in Section 0B.
13) Refill cooling system referring to Section 6B.
14) Connect negative cable at battery.
15) Verify that there is no fuel leakage, coolant leakage, oil leak-
age and exhaust gas leakage at each connection.
16) Verify that ignition timing is within specification referring to
Section 6F.
6A1-50 ENGINE MECHANICAL (F8D ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Refer to Section 6A.
ENGINE MECHANICAL (F8D ENGINE) 6A1-51
1. Cylinder block
2. Oil filter
3. Main bearing:
Apply engine oil to bearing
inside surfaces.
4. Bearing cap
5. Cap bolt:
Apply engine oil.
6. Timing pulley key
7. Crankshaft:
Apply engine oil to crankshaft
journals.
8. Thrust bearing:
Apply engine oil.
9. Rear oil seal
10. Pin
11. Oil seal housing gasket
12. Oil seal housing
13. Housing bolt
14. Input shaft bearing:
Apply engine oil.
15. Flywheel
16. Flywheel bolt
: Tightening Torque
: Do not reuse
6A1-52 ENGINE MECHANICAL (F8D ENGINE)
MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK
REMOVAL
1) Remove engine assembly with transmission and engine mem-
ber from body as previously outlined.
2) Remove clutch cover, clutch disc and flywheel (1).
Special Tool
(A): 09924-17810
3) Remove crankshaft pulley, timing belt, timing belt inside cover
and crankshaft timing pulley.
4) Remove cylinder head assembly as previously outlined.
5) Remove oil pan and oil pump strainer as previously outlined.
6) Remove oil pump (1).
7) Remove oil seal housing.
8) Remove connecting rod bearing caps.
9) Loosen crankshaft bearing cap bolts in such order as indicated
in figure a little at a time and remove bearing caps.
10) Remove crankshaft from cylinder block.
ENGINE MECHANICAL (F8D ENGINE) 6A1-53
INSPECTION
Crankshaft
Crankshaft runout
Using a dial gauge, measure runout at center journal. Rotate
crankshaft slowly. If runout exceeds its limit, replace crankshaft.
Limit on runout: 0.06 mm (0.0023 in.)
Crankshaft thrust play
Measure this play with crankshaft set in cylinder block in the normal
manner, that is, with thrust bearing (1) and journal bearing caps
installed.
Use a dial gauge to read displacement in axial (thrust) direction of
crankshaft.
If its limit is exceeded, replace thrust bearing with new standard
one or oversize one to obtain standard thrust play.
Out-of-round and taper (uneven wear) of journals
An unevenly worn crankshaft journal shows up as a difference in
diameter at a cross section or along its length (or both). This differ-
ence, if any, is determined by taking micrometer readings.
If any one of journals is badly damaged or if amount of uneven wear
in the sense explained above exceeds its limit, regrind or replace
crankshaft.
Out-of-round limit
(difference between A and B): 0.01 mm (0.0004 in.)
Taper limit
(difference between a and b): 0.01 mm (0.0004 in.)
6A1-54 ENGINE MECHANICAL (F8D ENGINE)
Item Standard Limit
Crankshaft
thrust play
0.11 – 0.31 mm
(0.0044 – 0.0122 in.)
0.35 mm
(0.0138 in.)
Thickness of crank-
Standard
2.500 mm
(0.0984 in.)
shaft thrust bearing
Oversize:
0.125 mm
(0.0049 in.)
2.563 mm
(0.1009 in.)
Main Bearings
General information
D Service main bearings are available in standard size and 0.25
mm (0.0098 in.) undersize, and each of them has 5 kinds of
bearings differing in tolerance.
D Upper half of bearing (2) has oil groove (3) as shown in figure.
Install this half with oil groove to cylinder block (1).
D On each main bearing cap, arrow mark and number are em-
bossed as shown in figure.
When installing each bearing cap to cylinder block, point arrow
mark toward crankshaft pulley side and install each cap from
that side to flywheel side in ascending order of numbers “1”, “2”,
“3” and “4”. Tighten cap bolts to specified torque.
Inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Never replace one half without replacing the other half.
Main bearing clearance
Check clearance by using gaging plastic according to following
procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gaging plastic (1) to full width of bearing (paral-
lel to crankshaft) on journal, avoiding oil hole.
4) Install bearing cap as previously outlined and evenly torque cap
bolts to specified torque.
Bearing cap must be torqued to specification in order to assure
proper reading of clearance.
Tightening Torque
(a): 47 N
.
m (4.7 kg-m, 34.0 lb-ft)
NOTE:
Do not rotate crankshaft while gaging plastic is installed.
ENGINE MECHANICAL (F8D ENGINE) 6A1-55
5) Remove cap and using scale on gaging plastic envelope, mea-
sure gaging plastic (1) width at its widest point. If clearance ex-
ceeds its limit, replace bearing. Always replace both upper and
lower inserts as a unit.
A new standard bearing may produce proper clearance. If not,
it will be necessary to regrind crankshaft journal for use of 0.25
mm undersize bearing.
After selecting new bearing, recheck clearance.
Selection of main bearings
STANDARD BEARING:
If bearing is in malcondition, or bearing clearance is out of specifi-
cation, select a new standard bearing according to following proce-
dure and install it.
1) First check journal diameter by using following procedure.
As shown in figure, crank webs of No.1 cylinder have four
stamped numerals.
Three kinds of numerals (“1”, “2” and “3”) represent following
journal diameters.
The first, second, third and fourth (left to right) stamped numer-
als represent journal diameters at bearing caps “1”, “2”, “3” and
“4” respectively.
For example, in figure, the first (leftmost) numeral “1” indicates
that journal dia. at bearing cap “1” is within 49.994 – 50.000 mm,
and second one “2” indicate that journal dia. at cap “2” is within
49.988 – 49.994 mm.
6A1-56 ENGINE MECHANICAL (F8D ENGINE)
Standard Limit
Bearing clearance
0.020 – 0.040 mm
(0.0008 – 0.0016 in.)
0.065 mm
(0.0026 in.)
Numeral stamped Journal diameter
1
49.994 – 50.000 mm
(1.9683 – 1.9685 in.)
2
49.988 – 49.994 mm
(1.9680 – 1.9683 in.)
3
49.982 – 49.988 mm
(1.9678 – 1.9680 in.)
2) Next, check bearing cap bore diameter without bearing. On
mating surface of cylinder block, four numerals are stamped as
shown in figure.
Three kinds of numerals (1, 2 and 3) represent following cap
bore diameters.
The first, second, third and fourth (left to right) stamped numer-
als represent cap bore diameters of bearing caps “1”, “2”, “3”
and “4”, respectively.
For example, in figure, the first (leftmost) numeral “1” indicates
that cap bore dia. of bearing cap “1” is within 54.000 – 54.006
mm, and the fourth (rightmost) numeral “2” indicates that cap
bore dia. of cap “4” is within 54.006 – 54.012 mm.
3) There are five kinds of standard bearings differing in thickness.
To distinguish them, they are painted in following colors at the
position as indicated in figure.
Each color indicates following thickness at the center of bear-
ing.
ENGINE MECHANICAL (F8D ENGINE) 6A1-57
Numeral stamped
Bearing cap bore diameter
(without bearing)
1
54.000 – 54.006 mm
(2.1260 – 2.1262 in.)
2
54.006 – 54.012 mm
(2.1262 – 2.1265 in.)
3
54.012 – 54.018 mm
(2.1265 – 2.1267 in.)
Color painted Bearing thickness
Green
1.986 – 1.990 mm
(0.0782 – 0.0783 in.)
Black
1.989 – 1.993 mm
(0.0783 – 0.0784 in.)
Colorless
(no paint)
1.992 – 1.996 mm
(0.0784 – 0.0785 in.)
Yellow
1.995 – 1.999 mm
(0.0785 – 0.0787 in.)
Blue
1.998 – 2.002 mm
(0.0781 – 0.0788 in.)
4) From numerals stamped on crank webs of No.1 and No.2 cylin-
ders and the numerals stamped on mating surface of cylinder
block, determine new standard bearing to be installed to jour-
nal, by referring to table given below.
For example, if numeral stamped on crank web is “1” and nu-
meral stamped on mating surface is “1”, install a new standard
bearing painted in “Green” to its journal.
1
Green
Black
Colorless
2
Black
Colorless
Yellow
3
Colorless
Yellow
Blue
1
2
3
Numeral stamped on crank web
(Journal diameter)
Numeral stamped
on mating surface
(Bearing cap bore
dia.)
New standard bearing to be installed.
5) Using gaging plastic (1), check bearing clearance with newly
selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and
recheck clearance.
6) When replacing crankshaft or cylinder block due to any reason,
select new standard bearings to be installed by referring to nu-
merals stamped on new crankshaft or alphabets stamped on
mating surface of new cylinder block.
UNDERSIZE BEARING (0.25 mm):
D 0.25 mm undersize bearing is available, in five kinds varying in
thickness.
To distinguish them, each bearing is painted in following colors
at such position as indicated in figure.
Each color represents following thickness at the center of bear-
ing.
1. Paint
6A1-58 ENGINE MECHANICAL (F8D ENGINE)
Color painted Bearing thickness
Green & Red
2.111 – 2.115 mm
(0.0831 – 0.0832 in.)
Black & Red
2.114 – 2.118 mm
(0.0832 – 0.0833 in.)
Red only
2.117 – 2.121 mm
(0.0833 – 0.0835 in.)
Yellow & Red
2.120 – 2.124 mm
(0.0835 – 0.0836 in.)
Blue & Red
2.123 – 2.127 mm
(0.0836 – 0.0837 in.)
D If necessary, regrind crankshaft journal and select under-size
bearing to use with it as follows.
1) Regrind journal to following finished diameter.
Finished diameter: 49.732 – 49.750 mm
(1.9580 – 1.9586 in.)
2) Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicular
to each other in order to check for out-of-round.
3) Using journal diameter measured above and numerals
stamped on mating surface of cylinder block, select an under-
size bearing by referring to table given below.
Check bearing clearance with newly selected undersize bear-
ing.
Green & Red
Black & Red
Red only
Black & Red
Red only
Yellow & Red
Red only
Yellow & Red
Blue & Red
1
2
3
Measured journal diameter
Numeral stamped
on mating surface
of cylinder block
Undersize bearing to be installed
49.744 – 49.750 mm
(1.9584 – 1.9587 in.)
49.738 – 49.744 mm
(1.9582 – 1.9584 in.)
49.732 – 49.738 mm
(1.9579 – 1.9582 in.)
Rear Oil Seal
Carefully inspect oil seal (1) for wear or damage. If its lip is worn
or damaged, replace it.
For oil seal installation, press-fit rear oil seal (1) so that oil seal
housing (2) end face is flush with oil seal end face.
ENGINE MECHANICAL (F8D ENGINE) 6A1-59
Flywheel
D If ring gear is damaged, cracked or worn, replace flywheel.
D If the surface contacting clutch disc is damaged, or excessively
worn, replace flywheel.
D Check flywheel for face runout with dial gauge.
If runout exceeds its limit, replace flywheel.
Limit on runout: 0.2 mm (0.0078 in.)
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed surface
for distortion and, if flatness exceeds its limit, correct it.
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must also
be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
3) Using micrometer, measure piston diameter.
“a”: 20 mm (0.79 in.)
4) Calculate cylinder bore diameter to be rebored.
D = A + B – C
D:Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.025 – 0.045 mm
(0.0009 – 0.0017 in.)
C:Allowance for honing = 0.02 mm (0.0008 in.)
6A1-60 ENGINE MECHANICAL (F8D ENGINE)
Item Limit
Flatness
0.05 mm
(0.0020 in.)
Size Piston diameter
O/S 0.25
68.720 – 68.740 mm
(2.7055 – 2.7062 in.)
O/S 0.50
68.970 – 68.990 mm
(2.7154 – 2.7161 in.)
5) Rebore and hone cylinder to calculated dimension.
NOTE:
Before reboring, install all main bearing caps in place and
tighten to specification to avoid distortion of bearing
bores.
6) Measure piston clearance after honing.
INSTALLATION
NOTE:
D All parts to be installed must be perfectly clean.
D Be sure to oil crankshaft journals, journal bearings, thrust
bearings, crankpins, connecting rod bearings, pistons, pis-
ton rings and cylinder bores.
D Journal bearings, bearing caps, connecting rods, rod bear-
ings, rod bearing caps, pistons and piston rings are in com-
bination sets. Do not disturb such combination and make
sure that each part goes back to where it came from, when
installing.
1) Install main bearings to cylinder block (1).
One of two halves of main bearing (2), has an oil groove (3).
Install it to cylinder block, and the other half without oil groove
to bearing cap.
Make sure that two halves are painted in the same color.
2) Install thrust bearings (1) to cylinder block between No.2 and
No.3 cylinders. Face oil groove (2) sides to crank webs.
ENGINE MECHANICAL (F8D ENGINE) 6A1-61
3) Install crankshaft to cylinder block.
4) Install bearing cap to cylinder block, making sure to point arrow
mark (on each cap) to crankshaft pulley side. Fit them sequen-
tially in ascending order, 1, 2, 3 and 4, starting from pulley side.
Tighten bearing cap bolts in such order as shown in figure a little
at a time and repeat it till they are tightened to specified torque.
Tightening Torque
(a): 47 N
.
m (4.7 kg-m, 34.0 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turning it by 7.0 N
.
m (0.7 kg-m, 5.0
lb-ft) torque or below.
5) Install new gasket and oil seal housing.
Do not reuse gasket removed in disassembly. Apply engine oil
to oil seal lip before installation. Tighten housing bolts to specifi-
cation.
Tightening Torque
(a): 11 N
.
m (1.1 kg-m, 8.0 lb-ft)
NOTE:
As there are 2 types (long bolts (1) and short bolts (2)) of
housing bolts, refer to figure for their correct use.
After installing oil seal housing, gasket edges might bulge out;
if so, cut them off to make them flush with cylinder block and oil
seal housing.
6) Install oil pump.
Refer to item OIL PUMP for installation of oil pump.
7) Install flywheel.
Using special tool, lock flywheel, and torque its bolts (1) to spec-
ification.
Special Tool
(A): 09924-17810
Tightening Torque
(a): 42 N
.
m (4.2 kg-m, 30.5 lb-ft)
6A1-62 ENGINE MECHANICAL (F8D ENGINE)
8) Install pistons and connecting rods as previously outlined.
9) Install oil pump strainer and oil pan as previously outlined.
10) Install cylinder head assembly to cylinder block as previously
outlined.
NOTE:
Tighten cylinder head bolts to specified torque as pre-
viously outlined.
11) Install camshaft, crankshaft timing belt pulley, timing belt,
crankshaft pulley, water pump pulley, etc., as previously out-
lined.
12) Install clutch to flywheel. For clutch installation, refer to Section
7C.
13) Install transmission and engine member to engine.
14) Install engine assembly to vehicle as previously outlined.
ENGINE MECHANICAL (F8D ENGINE) 6A1-63
6A1-64 ENGINE MECHANICAL (F8D ENGINE)
REQUIRED SERVICE MATERIALS
MATERIALS
RECOMMENDED
SUZUKI PRODUCT
USE
Sealant
SUZUKI BOND NO. 1207C
(99000-31150)
D Mating surfaces of cylinder block and oil pan.
D Mating surface of camshaft housing No.1.
D Cylinder head cover gasket and cylinder head side seal.
Grease
SUZUKI SUPER GREASE A
(99000-25010)
D O-rings of plug cap.
SPECIAL TOOLS
09913-75520
Bearing installer
1. 09915-64510-001
Compression gauge
2. 09915-64510-002
Connector
3. 09915-64530
Hose
4. 09915-64550
Attachment
09915-67310
Vacuum gauge
09915-77310
Oil pressure gauge
09915-78211
Oil pressure gauge
attachment
09916-14510
Valve lifter
09916-14910
Valve lifter attachment
09916-34542
Reamer handle
09916-34550
Reamer (5.5 mm)
09916-37320
Reamer (10.5 mm)
09916-44910
Valve guide remover
09916-57340
Valve guide installer
attachment
ENGINE MECHANICAL (F8D ENGINE) 6A1-65
09924-17810
Flywheel holder
09918-08210
Vacuum gauge hose joint
09926-18210
Oil seal guide
(Vinyl resin)
09916-77310
Piston ring compressor
09917-18210
Tappet adjuster wrench
09917-68221
Camshaft pulley holder
09917-98221
Valve stem seal installer
09916-58210
Valve guide installer
handle

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