Get Engine Mechanical (F8D Engine) -> Unit Repair Overhaul Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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

49.994 – 50.000 mm

(1.9683 – 1.9685 in.)

49.988 – 49.994 mm

(1.9680 – 1.9683 in.)

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)

54.000 – 54.006 mm

(2.1260 – 2.1262 in.)

54.006 – 54.012 mm

(2.1262 – 2.1265 in.)

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.

Green

Black

Colorless

Black

Colorless

Yellow

Colorless

Yellow

Blue

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

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

Engine Mechanical (F8D Engine) -> Unit Repair Overhaul for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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