service manual susuki baleno sy418

62G00-0B-6-1S

Before draining engine oil, check engine for oil leakage. If any evi-dence of leakage is found, make sure to correct defective part beforeproceeding to following work.1) Drain engine oil by removing drain plug.2) After draining oil, wipe drain plug clean. Reinstall drain plug, and

tighten it securely as specified below.

Tightening Torque(a): 35 N·m (3.5 kg-m, 25.5 lb-ft)1. Oil pan

2. Oil drain plug 62G00-0B-3S2, (a)

62G00-0B-6-2S

3) Loosen oil filter by using oil filter wrench (Special tool).

Special Tool(A): 09915-47330

1 . Oil filter 62G00-0B-4S

62G00-0B-6-3S

4) Apply engine oil to new oil filter O-ring.5) Screw new filter on oil filter stand by hand until filter O-ring contacts

mounting surface.

CAUTION:To tighten oil filter properly, it is important to accuratelyidentify the position at which filter O-ring first contactsmounting surface.

62G00-0B-5S

62G00-0B-6-4S

6) Tighten filter 3/4 turn from the point of contact with mounting sur-face using an oil filter wrench.

Special Tool(A): 09915-47330

Tightening Torque(a): 14 N·m (1.4 kg-m, 10.5 lb-ft)

62G00-0B-6S

62G00-0B-6-5S

7) Replenish oil until oil level is brought to FULL level mark on dipstick.(about 5.2 liters or 11.0/7.1 US/Imp pt.). Filler inlet is at the top ofcylinder head cover.

8) Start engine and run it for three minutes. Stop it and wait another3 minutes before checking oil level. Add oil, as necessary, to bringoil level to FULL level mark on dipstick.

1. Low level mark2. Full level mark

1

2

62G00-0B-7S

0B-6 MAINTENANCE AND LUBRICATION

62G00-0B-7-1S

NOTE:Engine oil capacity is specified as left table.However, note that amount of oil required when actuallychanging oil may somewhat differ from data in left table de-pending on various conditions (temperature, viscosity, etc.).

9) Check oil filter and drain plug for oil leakage.

about 0.3 liters(0.6/0.5 US/imp pt.)

Engine oil capacity

Oil pan capacity

Oil filter capacity

Others

Total

about 0.2 liters(0.4/0.3 US/Imp pt.)



62G00-0B-7-2S

ITEM 1-3Cooling System, Hoses and Connections Inspection1) Visually inspect cooling system hoses for any evidence of leakage

and cracks. Examine them for damage, and check connectionclamps for tightness.

2) Replace all hoses which show evidence of leakage, cracks or otherdamage. Replace all clamps which cannot maintain proper tight-ness.

1. Radiator cap2. Clamp

3. Reservoir tank hose4. Inlet hose

1 3

2 4

62G00-0B-8S

62G00-0B-7-3S

3) Clean frontal area of radiator core.4) Test system and radiator cap for proper pressure holding capacity,

110 kPa (1.1 kg/cm2 , 15.6 psi).If replacement cap is needed, use a cap designed for cooling sys-tem of this vehicle.

5) Check coolant level and concentration.Add if necessary.Refer to COOLANT LEVEL of SECTION 6B for procedure of levelcheck.1. Full level mark

2. Low level mark 62G00-0B-9S

62G00-0B-7-4S

ITEM 1-4Engine Coolant Change

WARNING:To help avoid danger of being burned, do not remove radia-tor cap while engine and radiator are still hot. Scalding fluidand steam can be blown out under pressure if cap is takenoff too soon.

62G00-0B-7-5S

1) Remove radiator cap when engine is cool.2) Loosen radiator drain plug to drain coolant.3) Remove reservoir tank and drain.4) Tighten drain plug securely. Also install reservoir tank.5) Fill radiator with specified amount of coolant, and run engine for 2

or 3 minutes at idle. This drives out any air which may still betrapped within cooling system. STOP ENGINE. Add coolant asnecessary until coolant level reaches filler throat of radiator. Rein-stall radiator cap.121. Radiator

2. Radiator drain plug 62G00-0B-10S

MAINTENANCE AND LUBRICATION 0B-7

62G00-6A3-24-1S

DISASSEMBLY� Disassemble oil pump.

1. Hexagon wrench

1

62G00-6A3-63S

62G00-6A3-24-2S

INSPECTION� Check outer rotor, inner rotor and oil pump cases for excessive wear

or damage.� Check relief valve for excessive wear or damage.

NOTE:If any repair is required on outer rotor, inner rotor and oil pumpcases, replace them as an assembly.

1. Oil pump case No.12. Oil pump case No.23. Outer rotor4. Relief valve5. Relief spring6. Retainer

62G00-6A3-64S

13

2

4

5

6

62G00-6A3-24-3S

� Measure free length and tension of oil relief spring.

Item Standard

Spring free length 63.5 mm(2.5 in.)

Spring preload

86.0 N for52.0 mm8.6 kg for52.0 mm19.0 lb/2.05 in.

62G00-6A3-65S

62G00-6A3-24-5S

� Measure clearance of oil pump rotor and oil pump case.

Radial ClearanceCheck radial clearance between outer rotor and case, using thick-ness gauge.If clearance exceeds its limit, replace outer rotor or case.

Limit on radial clearance betweenouter rotor and case: 0.15 mm (0.0059 in.)

1. Oil pump case No.12. Outer rotor3. Inner rotor4. Thickness gauge

1

4

3

2

62G00-6A3-66S

6A3-24 ENGINE MECHANICAL

62G00-6A3-30-1S

INSTALLATION

Reverse removal sequence to install timing chain cover noting follow-ing points.1) Apply sealant “A” to area as shown in figure.

“A”: Sealant 99000-31150

1. Timing chain cover2. Cylinder head3. Cylinder block

CAUTION:When raising engine, be careful not to raise it excessivelyand not to cause transmission to contact body, steeringgear box, etc.

62G00-6A3-82S

62G00-6A3-30-3S

2) Apply engine oil to oil seal lip, then install timing chain cover.Tighten bolts and nut to specified torque.

NOTE:Before installing timing chain cover, check that pin is securelyfitted.

Tightening Torque(a): 11.0 N·m (1.1 kg-m, 8.0 lb-ft)

1. Timing chain cover2. Nut3. Bolt

2

3

1

62G00-6A3-83S

62G00-6A3-30-5S

3) Install generator belt idler pulley.Tighten nut to specified torque.

Tightening Torque(a): 45 N·m (4.5 kg-m, 33.0 lb-ft)

4) Install generator belt tensioner.Tighten bolts to specified torque.

Tightening Torque(b): 25 N·m (2.5 kg-m, 18.5 lb-ft)

5) Install water pump pulley.

1. Generator beltidler pulley

2. Generator belttensioner

3. Water pump pulley

1

2

3(a)

(b)

62G00-6A3-79S


62G00-6A3-69-1S

5) Remove cap and using a scale on gaging plastic envelope, mea-sure gaging plastic width at the widest point (clearance).If clearance exceeds its limit, use a new standard size bearing andremeasure clearance.

Item Standard

Bearingclearance

0.045 – 0.063 mm(0.0018 – 0.0025 in.)

Limit

0.08 mm(0.0031 in.)

1. Gaging plastic2. Scale 62G00-6A3-197S

62G00-6A3-69-2S

6) If clearance can not be brought to within its limit even by using anew standard size bearing, regrind crank pin to undersize and use0.25 mm undersize bearing.

Item Standard

Bearingclearance

0.038 – 0.083 mm(0.0015 – 0.0033 in.)

Limit

0.091 mm(0.0036 in.)

ENGINE MECHANICAL 6A3-69

62G00-6A3-83-1S

5) Remove lower crankcase and using scale on gaging plastic envel-op, measure gaging plastic width at its widest point. If clearance ex-ceeds its limit, replace bearing. Always replace both upper andlower inserts as a unit.A new standard bearing may produce proper clearance. If not, it willbe necessary to regrind crankshaft journal for use of 0.25 mm un-dersize bearing.After selecting new bearing, recheck clearance.Bearing Clearance

Standard: 0.032 – 0.052 mm (0.0013 – 0.0020 in.)Limit: 0.060 mm (0.0023 in.)

1. Gaging plastic2. Scale

62G00-6A3-233S

62G00-6A3-83-3S

Selection of main bearingsSTANDARD BEARING:If bearing is in malcondition, or bearing clearance is out of specifica-tion, select a new standard bearing according to following procedureand install it.1) First check journal diameter. As shown in figure, crank web No.2

has stamped numbers.Three kinds of numbers (“1”, “2” and “3”) represent following journaldiameters.

Stamped numbers on crank web No.2 represent journal diametersmarked with an arrow in figure respectivery.For example, stamped number “1” indicates that correspondingjournal diameter is 57.994 – 58.000 mm.

Stamped numbers Journal diameter

57.994 – 58.000 mm(2.2832 – 2.2834 in.)57.988 – 57.994 mm(2.2830 – 2.2832 in.)57.982 – 57.988 mm(2.2828 – 2.2829 in.)

1

2

3

1. Crankshaft pulley side2. Flywheel side3. Crankshaft web No.2

62G00-6A3-234S


62G00-6A3-84-1S

2) Next, check crankcase (bearing cap) bore diameter without bear-ing. On lower crankcase five alphabets are stamped as shown infigure. Three kinds of alphabets (“A”, “B” and “C”) represent following capbore diameters.

Stamped alphabets on lower crankcase represent crankcase borediameter marked with an arrow in figure respectivery.For example, stamped alphabet “A” indicates that correspondingbearing cap bore diameter is 62.000 – 62.006 mm.

Stamped alphabetBearing cap bore diameter

(without bearing)62.000 – 62.006 mm(2.4409 – 2.4411 in.)62.006 – 62.012 mm(2.4412 – 2.4414 in.)62.012 – 62.018 mm(2.4414 – 2.4416 in.)

A

B

C

1. Crankshaft pulley side2. Flywheel side

62G00-6A3-235S

62G00-6A3-84-4S

3) There are five kinds of standard bearings differing in thickness. Todistinguish them, they are painted in following colors at the positionas indicated in figure.Each color indicates following thickness at the center of bearing.

62G00-6A3-236S

Color painted Bearing thickness

1.990 – 1.994 mm(0.0783 – 0.0785 in.)

1.993 – 1.997 mm(0.0785 – 0.0786 in.)

1.996 – 2.000 mm(0.0786 – 0.0787 in.)

Green

Black

Colorless (no paint)

1.999 – 2.003 mm(0.0787 – 0.0788 in.)

Yellow

2.002 – 2.006 mm(0.0788 – 0.0790 in.)

Blue

1. Paint


62G00-6A3-85-1S

4) From number stamped on crank web No.2 and alphabets stampedon lower crankcase, determine new standard bearing to beinstalled to journal, by referring to table shown below.For example, if number stamped on crank web No.2 is “1” and al-phabet stamped on lower crankcase is “B”, install a new standardbearing painted in “Black” to its journal.

Number stamped on crank web(Journal diameter)

1 2 3

Alphabetstampedon lowercrankcase(Cap bore dia.)

A

B

C

Green

Black

Colorless

Black

Colorless

Yellow

Colorless

Yellow

Blue

New standard bearing to be installed.

62G00-6A3-85-3S

5) Using gaging plastic, check bearing clearance with newly selectedstandard bearing.If clearance still exceeds its limit, use next thicker bearing and re-check clearance.If clearance can not be still brought to within its limit even by usinga new standard size bearing, regrind crank pin to under size anduse 0.25 mm undersize bearing.

Crankshaft journal diameter (0.25 mm undersize):57.732 – 57.750 mm (2.2729 – 2.2736 in.)

6) When replacing crankshaft or cylinder block and lower crank casedue to any reason, select new standard bearings to be installed byreferring to number stamped on new crankshaft or alphabetsstamped on new lower crankcase.

1. Gaging plastic2. Scale

62G00-6A3-237S



SPECIAL TOOLS

62G00-6A3-277S

09911-97710Oil seal guide

09911-97810Oil seal installer

62G00-6A3-254S

09913-75510Bearing installer

62G00-6A3-255S 09915-47330Oil filter wrench

62G00-6A3-256S

1. 09915-64510-001Compression gauge

2. 09915-64510-002Connector

3. 09915-64530Hose

4. 09915-67010Attachment

62G00-6A3-257S

09915-67310Vacuum gauge

62G00-6A3-258S

1. 09915-77310Oil pressure gauge

2. 09915-78211Oil pressure gauge attachment

62G00-6A3-259S

1. 09916-14510Valve lifter

2. 09916-14910Valve lifter attachment

62G00-6A3-260S

09916-34542Reamer handle

62G00-6A3-261S

09916-37810Reamer (6 mm)

62G00-6A3-262S 09916-38210Reamer (11 mm)

62G00-6A3-263S09916-44910Valve guide remover

62G00-6A3-264S

09916-58210Valve guide installer handle

62G00-6A3-265S

09916-77310Piston ring compressor

62G00-6A3-266S09916-84510Forceps

62G00-6A3-267S

09917-68221Camshaft lock holder

62G00-6A3-269S

62G00-6A3-91-1S

62G00-6E2-34-1S

RADIATOR FAN CONTROL SYSTEMThis system controls operation (ON/OFF) of the radiator fan motor.Radiator fan motor is turned ON and OFF by its relay which ECM con-trols.Radiator fan motor is turned ON/OFF under following engine coolanttemp.

Engine coolant temperature

OFF�ON

ON�OFF below 98�C (208�F)

above 94�C (201�F)

Radiatorfan motor

1. Radiator fan motor2. Radiator fan control relay3. ECM4. Main relay5. Engine coolant temp. (ECT sensor)

62G00-6E2-37S

4 25

31

Gr

R/B

D8 P/G BI/R

BW

R

D20B11

B/W

D1/D12

62G00-6E2-34-3S

AIR CONDITIONING (A/C) ON SIGNAL OUTPUT FOR A/CAMPLIFIER (VEHICLE WITH A/C ONLY)ECM outputs A/C ON signal (one of the signals for A/C amplifier to con-trol the air conditioner) to A/C amplifier when A/C signal inputted toECM and conditions listed below are satisfied.

Throttle position sensor output voltage (throttle valve opening) : below 4.0VEngine coolant temp : below 110 �C (230�F)Engine speed : between 600 r/min and 5,900 r/min.

1. ECM2. A/C amplifier3. TP sensor4. CMP sensor5. ECT sensor6. Engine start signal7. A/C signal8. A/C ON signal9. Sensed information

60G00-6E1-43S

D19

B13

6E2-34 ELECTRONIC FUEL INJECTION SYSTEM

Prepared by

Overseas Service Department

1st Ed. December, 19952nd Ed. Oct., 2001

Printed in Japan

404Printing:

service manual susuki baleno sy418

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