Engine Identification: Warning

2002 Suzuki Esteem GL
2001-02 ENGINES 1.8L 4-Cylinder
2001-02 ENGINES
1.8L 4-Cylinder
ENGINE IDENTIFICATION
NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.
Vehicle Engine Code is stamped on left rear portion of cylinder block bellhousing. The first 3 characters of
Engine Identification Code identifies engine type and size.
ENGINE IDENTIFICATION CODE

Application VIN
Esteem 4
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
NOTE: Engine uses hydraulic lifters. Adjustment is not required.
TROUBLE SHOOTING
To trouble shoot mechanical engine components, see ENGINE MECHANICAL in GENERAL TROUBLE
SHOOTING article in GENERAL INFORMATION.
REMOVAL & INSTALLATION
WARNING: Always relieve fuel pressure before disconnecting any fuel injection-
related component. DO NOT allow fuel to contact engine or electrical
components.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Place mating marks on engine hood and other major
assemblies before removal.
FUEL PRESSURE RELEASE
1. Ensure engine is cold. Place transmission in Neutral (M/T) or Park (A/T). Set parking brake, and block
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drive wheels. Remove fuel pump relay. Fuel pump relay is located in relay box on left side of engine
compartment. See Fig. 1.
2. Remove fuel tank filler cap to release pressure. Reinstall filler cap. Start engine, and idle until engine
dies. Crank engine 2 or 3 times to ensure lines are empty. Turn ignition off.
3. Upon completion of service, reinstall fuel pump relay.
Fig. 1: Locating Fuel Pump Relay

Courtesy of SUZUKI OF AMERICA CORP.
ENGINE
CAUTION: When raising or supporting engine or automatic transmission, DO NOT

use a jack under oil pan. Damage to oil pump and pick-up screen could
result.
Removal
1. Relieve fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable.
Disconnect windshield washer hose. Mark and remove hood. Remove air cleaner and duct hoses. Drain
transmission oil, engine oil and cooling system. Remove radiator with cooling fan.
2. Disconnect accelerator cable at throttle body. On automatic transmission models, disconnect gear select
cable from transmission. On manual transmission models, disconnect shift/select cable and clutch cable
from transmission. Remove clutch slave cylinder from transmission, and wire aside.
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3. Mark and disconnect all wiring harness connectors from engine and transmission. Mark and remove fuel
and vacuum hoses from engine. Remove coolant and heater hoses.
4. Remove engine undercovers. Disconnect exhaust pipe from exhaust manifold. Without disconnecting
hoses, remove power steering pump and A/C compressor, and wire aside.
5. Remove axle shaft joints from transmission differential gear. Remove center bearing support.
NOTE: It is not necessary to remove axle shafts from steering knuckles if

removing engine and transmission as a single unit.
6. Attach lifting device to engine. Remove mounting member from front member and suspension frame. See
Fig. 2. Remove left and right engine mounts. Lower engine and transmission from vehicle.
Installation
Lift engine and transmission into engine compartment. Install left and right engine mounts. Install mounting
member to front member and suspension frame. See Fig. 2. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. Remove lifting device. When installing axle shaft, push each axle shaft into differential
so that snap ring engages with differential gear and center bearing support. To complete installation, reverse
removal procedure. Refill cooling system, engine oil, and transmission with proper fluids.
Fig. 2: Exploded View Of Engine Mounting Frame

Courtesy of SUZUKI OF AMERICA
INTAKE MANIFOLD
Removal
1. Relieve fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Drain
cooling system. Disconnect intake air temperature sensor. Remove air cleaner and intake and outlet hoses.
2. Disconnect accelerator cable. Label and disconnect all electrical connections from intake manifold,
injectors and throttle body. Label and disconnect vacuum hoses from intake manifold.
3. Disconnect coolant pipe and hoses from intake manifold, throttle body and cylinder head. Remove fuel
supply and return lines from fuel delivery pipe. Remove throttle body. Disconnect intake manifold front
and rear stiffeners. See Fig. 3.
4. Remove EGR pipe. Remove intake manifold-to-cylinder head bolts. Remove intake manifold and gasket.
Remove remaining components from intake manifold as required.
Installation
To install, reverse removal procedure. Use NEW gaskets. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. Adjust all control cables and fill cooling system.
Fig. 3: Exploded View Of Intake Manifold & Components

EXHAUST MANIFOLD
Removal
1. Disconnect negative battery cable. Disconnect oxygen sensor connector and remove from bracket.
Remove exhaust manifold upper and lower covers. Remove oxygen sensor.
2. Remove right side engine undercover. Remove exhaust pipe-to-manifold bolts. Remove front and rear
exhaust pipe stiffeners. Remove exhaust pipe from exhaust manifold. Remove air cleaner and
intake/outlet hoses.
3. Detach power steering reservoir from inner fender. Disconnect A/C magnetic clutch and oxygen sensor
connectors and detach wiring harness hold-down clamps. Support engine and remove right side engine
mount and bracket. Remove exhaust manifold-to-cylinder head bolts. Remove exhaust manifold and
gasket.
Installation
To install, reverse removal procedure. Use NEW exhaust manifold gasket. Tighten bolts to specification. See
TORQUE SPECIFICATIONS.
CYLINDER HEAD COVER
Removal & Installation
Disconnect negative battery cable. Remove ignition coil cover. Disconnect and remove ignition coils. Remove
oil dipstick. Disconnect breather hose and PCV hose from cylinder head cover. Remove cylinder head cover. To
install, reverse removal procedure. Apply sealant to cylinder head and cover. See Fig. 4.
Fig. 4: Installing Cylinder Head Cover

CYLINDER HEAD
Removal
1. Relieve fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Drain
cooling system and engine oil. Remove ignition coil cover. Remove air cleaner and intake and outlet
hoses. Disconnect accelerator cable from throttle body and bracket. Label and remove all hoses, fuel lines
and electrical connectors from cylinder head, intake manifold and exhaust manifold. Remove cylinder
head cover. See CYLINDER HEAD COVER.
2. Remove engine undercovers. Remove intake manifold rear stiffener. Disconnect coolant pipe from intake
manifold. Remove timing chain cover. See TIMING CHAIN COVER. Remove first timing chain. See
1ST TIMING CHAIN & CHAIN TENSIONER. Remove camshafts and valve lash adjusters. See
CAMSHAFTS & VALVE LASH ADJUSTERS.
3. Disconnect exhaust pipe from exhaust manifold and remove stiffeners. Remove right side engine mount
and bracket. Remove power steering pump and generator from power steering pump bracket. Remove
power steering pump bracket. Loosen cylinder head bolts in sequence. Remove 6-mm bolt. See Fig. 5.
Remove cylinder head with intake and exhaust manifolds attached.
Fig. 5: Cylinder Head Bolt Removal Sequence

Inspection
1. Check cylinder head for evidence of water leakage or damage. Clean carbon from combustion chambers.
Check cylinder head for cracks in intake and exhaust ports, combustion chambers and head surface.
2. Check for head warpage. If warpage exceeds specification, cylinder head should be machined or replaced.
See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
3. Check intake and exhaust manifold seating surfaces on cylinder head for warpage. Warpage limit for
manifold seating surfaces is .004" (.10 mm). If warpage exceeds specification, machine or replace
cylinder head.
Installation
1. To install, reverse removal procedure. Use NEW cylinder head and manifold gaskets. Tighten cylinder
head bolts to 39 ft. lbs (53 N.m) in proper sequence. See Fig. 6.
2. Tighten cylinder head bolts to 61 ft. lbs (83 N.m) in proper sequence. Loosen all bolts in sequence, until
torque is reduced to zero. See Fig. 5.
3. Retighten cylinder head bolts to 27 ft. lbs. (37 N.m) using proper sequence. See Fig. 6. Finish tightening
cylinder head bolts to 76 ft. lbs. (103 N.m). Tighten 6-mm bolt on side of cylinder head to 97 INCH lbs.
(11 N.m). To complete installation, reverse removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS.
Fig. 6: Cylinder Head Bolt Tightening Sequence

TIMING CHAIN COVER
Removal
1. Disconnect negative battery cable. Drain engine oil and coolant. Remove air cleaner and intake and outlet
hoses. Remove radiator hoses. Remove radiator cooling fan. Remove right side engine undercover.
Remove generator belt.
2. Remove crankshaft pulley bolt. Using Puller (09944-36011) and Attachment (09926-58010) remove
crankshaft pulley. Remove oil pan and oil pump screen. See OIL PAN. With lifting device, support
engine. Remove engine front torque bushing, rear engine mount and rear mounting bracket. See Fig. 2
3. Without disconnecting refrigerant lines, remove A/C compressor and bracket, and suspend aside. Remove
power steering fluid reservoir from inner fender and suspend aside. Disconnect oxygen sensor. Remove
right side engine mount. With lifting device, raise engine to allow removal of water pump pulley,
generator belt idler pulley, generator belt tensioner and timing chain cover.
4. Remove cylinder head cover. See CYLINDER HEAD COVER. Remove timing chain cover bolts and
nut and remove timing chain cover.
Installation
To install, reverse removal procedure. Drive in NEW oil seal until flush with cover. Apply sealant to mating
surface along edge of engine block and at cylinder block-to-cylinder head mating surfaces. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
2ND TIMING CHAIN & CHAIN TENSIONER
Removal
1. Disconnect negative battery cable. Drain engine oil and coolant. Remove oil pan and oil pump screen.
See OIL PAN. Remove cylinder head cover. See CYLINDER HEAD COVER.
2. Remove timing chain cover. See TIMING CHAIN COVER. Align sprocket timing marks with timing
marks on block. See Fig. 7. Ensure key on crankshaft sprocket is pointing up.
3. Remove timing chain No. 2 tensioner adjuster by turning intake camshaft slightly counterclockwise while
pushing back chain tensioner shoe. Remove intake and exhaust camshaft sprocket bolts. Remove
camshaft sprockets and 2nd timing chain.
CAUTION: DO NOT turn camshafts more than 15 degrees, or crankshaft more than 90
degrees in either direction from aligned position after timing chain is
removed. Doing so could damage pistons and/or valves.
Installation
1. Install camshaft sprockets, and align all sprocket timing marks with timing marks on block. See Fig. 7.
Ensure key on crankshaft sprocket is pointing up, arrow on idler sprocket points up, and camshaft knock-
pins are aligned with marks on cylinder head.
2. Install 2nd timing chain by aligning Yellow link on timing chain with arrow on idler sprocket. Align Dark
Blue links on 2nd timing chain with marks on camshaft sprockets.
3. Push tensioner plunger back into tensioner body, and insert a push pin into timing chain tensioner to
ensure plunger does not come out. Install timing chain tensioner with gasket and tighten to specification.
See TORQUE SPECIFICATIONS.
4. Remove push pin from timing chain tensioner. Turn crankshaft clockwise 2 rotations, then align timing
marks. Ensure timing marks are aligned. Apply oil to timing chains, tensioners, sprockets, and guides. To
complete installation, reverse removal procedure.
Fig. 7: Aligning 2nd Timing Chain & Sprockets

1ST TIMING CHAIN & CHAIN TENSIONER
Removal
2. Remove timing chain cover. See TIMING CHAIN COVER. Align timing marks. See Fig. 8. Ensure key
on crankshaft sprocket is pointing up.
3. Remove 2nd timing chain and chain tensioner. See 2ND TIMING CHAIN & CHAIN TENSIONER.
Remove 1st timing chain guide, timing chain tensioner adjuster, and timing chain tensioner. Remove idler
sprocket and 1st timing chain. Remove crankshaft sprocket.
Installation
1. Install crankshaft sprocket, ensuring key on crankshaft is pointing up. See Fig. 8. Apply oil to idler
sprocket shaft and bushing and install idler sprocket. Install first timing chain by aligning Dark Blue link
on timing chain with mark on idler sprocket.
2. Align Yellow link on timing chain with mark on crankshaft sprocket. Install timing chain No. 1 tensioner.
While holding release latch on tensioner adjuster, press plunger back into tensioner adjuster body, and
insert a push pin to hold latch in place.
3. Install timing chain No. 1 tensioner adjuster, and tighten to specification. See TORQUE
SPECIFICATIONS. Remove push pin from tensioner adjuster latch. Install timing chain guide. Ensure
Dark Blue link and Yellow link on timing chain are aligned with respective timing marks. To complete
installation, reverse removal procedure.
Fig. 8: Aligning 1st Timing Chain & Sprockets

CAMSHAFT & VALVE LASH ADJUSTERS
Removal
2. Remove timing chain cover. See TIMING CHAIN COVER. Align timing marks. Remove 2nd timing
chain and chain tensioner. See 2ND TIMING CHAIN & CHAIN TENSIONER. Remove camshaft
position sensor from end of camshaft.
3. To secure work for the following steps, reinstall frame mounting member, front torque bushing, rear
engine mount and mounting bracket. Turn crankshaft clockwise 90 degrees so crankshaft key is pointing
to 3 o'clock position.
4. Note position of camshaft bearing caps. Remove camshaft bearing cap bolts in reverse order of tightening
sequence. See Fig. 10. Remove camshaft bearing caps and camshafts.
5. Remove valve lash adjusters. Completely immerse valve lash adjusters in clean engine oil to keep them
from collapsing. DO NOT apply force to body of adjuster. DO NOT place adjuster on its side or with
bucket body facing up.
Installation
1. Fill valve lash adjuster pockets on cylinder head with clean engine oil. Ensure oil comes out of oil
passages. Install valve lash adjusters into cylinder head.
2. Ensure key on crankshaft sprocket is pointing up and aligned with timing mark. Lubricate camshafts and
install, ensuring knock out pins align with timing marks. See Fig. 7.
3. Apply sealant to exhaust camshaft rear bearing cap sealing surface. See Fig. 9. Check position of
camshaft bearing caps and install. Bearing caps are marked with an "I" for intake camshaft and "E" for
exhaust. Ensure arrow on caps point toward timing chain.
4. Lubricate camshaft bearing cap bolts and gradually tighten 2 or 3 times in sequence until specified torque
is reached. See Fig. 10 and TORQUE SPECIFICATIONS. To complete installation, reverse removal
procedure.
CAUTION: DO NOT turn camshafts or start engine for at least 30 minutes after
installing valve lash adjusters and camshafts. Operating engine within 30
minutes may cause valve and/or piston damage.
NOTE: If air is trapped in valve lash adjuster, valve may make a tapping sound when
engine is operated. To correct this condition, run engine for 30 minutes at 2000
RPM to purge air from valve lash adjuster. If condition is not corrected, replace
defective valve lash adjuster(s).
Fig. 9: Exhaust Camshaft Bearing Cap Sealing Surface

Fig. 10: Camshaft Bearing Cap Bolt Tightening Sequence

WATER PUMP
Removal
1. Disconnect negative battery cable. Drain cooling system. Remove radiator hose from thermostat housing.
Remove heater outlet pipe bolt. Remove drive belts.
2. Remove radiator and cooling fan. Remove water pump pulley. Remove A/C compressor from bracket
leaving hoses attached. Remove and discard 4 water pump attaching bolts. Remove water pump. DO
NOT lose dowel pin when removing pump.
Installation
To install, reverse removal procedure. Ensure all mating surfaces are clean. Use NEW water pump mounting
bolts, gasket and "O" ring.
NOTE: For further information on cooling systems, see SPECIFICATIONS and

ELECTRIC COOLING FANS articles in ENGINE COOLING.
OIL PAN
Removal
1. Remove oil dipstick. Raise and support vehicle. Drain engine oil. Remove engine under covers. Remove
exhaust pipe from manifold. Attach lifting device and support engine. Remove frame mounting member.
Remove flywheel lower cover.
2. Remove oil pan bolts and lower oil pan from vehicle. Remove oil pump screen.
Installation
Apply continuous bead of sealant to oil pan and install. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. To complete installation, reverse removal procedure.
OVERHAUL
NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.
CYLINDER HEAD
Disassembly
1. Remove cylinder head. See CYLINDER HEAD under REMOVAL & INSTALLATION. Remove fuel
injectors. Remove intake and exhaust manifolds. Remove thermostat housing. Remove camshafts. See
CAMSHAFT & VALVE LASH ADJUSTERS under REMOVAL & INSTALLATION.
2. Using Valve Spring Compressor (09916-14510) and Valve Lifter Attachment (09916-14910), compress
valve springs and use tweezers to remove valve keepers. See Fig. 11. Remove valve spring retainers,
springs, spring seats, valves and valve seals. Keep all components in order for reassembly reference.
Reassembly
To assemble, reverse disassembly procedure. Ensure valve springs are installed with close coiled (small pitch)
end down, toward cylinder head.
Fig. 11: Removing Valve Keepers

Valve Springs
Check valve springs for damage. Use a square, flat surface plate to check spring squareness. Using a valve
spring tester, check valve spring preload pressure. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS. Replace any weak or out-of-square springs.
Valve Stem Oil Seals
Use Handle (09916-58210) and Valve Stem Seal Installer (09917-98221) to install valve stem seals. Place new
lubricated valve stem seal on valve stem seal installer and press seal onto valve guide using hand pressure only.
When installer bottoms on head, seal is properly positioned. Avoid twisting seals during installation.
Valve Guides
1. Check valve stem-to-guide clearance. If clearance exceeds specification, replace with oversize valve
guide. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
2. Use Valve Guide Remover (09916-44910) to drive out old guide. Ream guide bore in cylinder head with
11-mm Reamer (09916-38210) and Handle (09916-34542). Heat cylinder head to 176-212°F (80-100°C).
3. Using Valve Guide Installer (09917-87810) and Handle (09916-58210), drive in new oversize valve
guide until valve guide installer contacts cylinder head.
4. Check valve guide installed height. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Ream NEW valve guide with 6-mm Reamer (09916-37810) and Handle (09916-34542). Clean valve
guide bore after reaming.
Valve Seats
1. Inspect valve seats for damage or wear. If valve seat rework is necessary, use cutters to obtain required
angles. On exhaust valve seats, first cut should be 15 degrees. Second cut should be 45 degrees to obtain
correct seat angle.
2. On intake valve seats, first cut should be 15 degrees. Second cut should be 60 degrees, and third cut
should be 45 degrees to obtain correct seat angle. After cutting valve seats to correct angles, lap valve
seats.
Valves
1. Remove carbon deposits. Inspect for wear, burns or distortion, at face and stem. Replace as necessary.
Measure valve head margin. Check valve stem end for pitting or wear.
2. Valve stem end may be resurfaced if not too much material is removed from valve length. Measure valve
length. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
1. Remove cylinder head. See CYLINDER HEAD under REMOVAL & INSTALLATION. Remove oil
pump. See OIL PUMP under ENGINE OILING.
2. Ensure pistons, connecting rods and rod caps are marked for reassembly reference. Clean carbon from top
of cylinder bores. Remove connecting rod caps. Install protective hose over connecting rod studs.
3. Push connecting rod and piston assembly out through top of cylinder block. Remove piston rings.
Remove wrist-pin circlips and push piston wrist-pin out by hand.
4. Check piston wrist pin-to-bore fit. Wrist pin should push into piston smoothly by hand, at room
temperature. When assembling, apply engine oil to outside of wrist pin and to wrist pin bore. Install
piston wrist pin with opening in circlips facing down.
Fitting Pistons
1. Check cylinder bore for damage, wear and taper. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS to determine if block must be rebored.
2. Standard pistons are identified by numerical marks ("1" or "2") stamped on piston crown. Cylinder bore
diameters are indicated by colored marks (Red or Blue) on cylinder block. See Fig. 12. To check outside
diameter of piston, measure piston at a point 1.04" (26.4 mm) from bottom of skirt and at 90 degrees to
pin bore.
3. Pistons are available in .0098" (.25 mm) and .0196" (.50 mm) oversizes. Select oversize piston according
to cylinder wear. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.
4. When installing piston into cylinder, ensure piston numerical mark corresponds with cylinder bore
colored mark to provide correct piston-to-cylinder clearance. See Fig. 12. See CYLINDER BLOCK
table under ENGINE SPECIFICATIONS.
Fig. 12: Matching Pistons To Cylinders

Piston Rings
1. Install rings with "R" or "RN" mark facing up. Install oil ring spacer. Install rails, and position piston ring
gaps 45 degrees apart. Lubricate all internal surfaces with engine oil before installation.
2. Ensure arrow on top of piston points to front of engine and that the "77E" mark on connecting rod faces
front of engine. Using a ring compressor, install piston and rod assemblies.
Rod Bearings
1. Inspect crankshaft journals for wear, taper and out-of-round condition. If specifications are exceeded, use
undersize bearings, grind journals to undersize or replace crankshaft. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
2. Inspect rod bearing shells for signs of fusion, pitting, burning or flaking. Standard bearings are unmarked.
Undersized bearings have a Red mark painted on edge of bearing. Undersize bearing thickness is .0632-
.0635" (1.605-1.613 mm) at center of bearing. Check rod bearing clearance using Plastigage. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
3. Check connecting rod side clearance. Standard connecting rod side play is .010-.015" (.25-.38 mm), with
a service limit of .0177" (.45 mm).
Crankshaft & Main Bearings
1. Loosen crankshaft lower crankcase bolts in proper sequence and remove crankshaft. See Fig. 16. Inspect
journals for wear, taper and out-of-round condition. Use Plastigage to check bearing clearance. If
specifications are exceeded, use undersize bearings, grind crankshaft journals to undersize or replace
crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
2. Standard and undersize main bearings are available in 5 different sizes and are color-coded to indicate
size. See UNDERSIZE BEARINGS. See COLOR CODE FOR STANDARD MAIN BEARINGS
table. Upper bearing half has an oil groove and must be installed to cylinder block. Lower bearing half
without oil groove is installed to lower crankcase housing. Bearing No. 1 is at crankshaft pulley end of
engine. Bearing No. 5 is at flywheel end of engine.
3. Main bearing journal diameter is indicated by numerical marks ("1", "2" or "3") stamped on crankshaft
web No. 2. See Fig. 13. The numerical marks on crankshaft web No. 2 read left to right, and indicate
journal diameters of bearings No. 1, 2, 3, 4 and 5. See CRANKSHAFT MAIN BEARING JOURNAL
DIAMETERS table.
4. Main bearing bore diameter, with bearing removed, is indicated by letters ("A", "B" or "C") stamped on
corresponding bearing bore on lower crankcase housing. See Fig. 14. See MAIN BEARING BORE
DIAMETERS table.
5. Determine NEW standard bearing by using numerical marks on crankshaft webs and letters stamped on
lower crankcase mating surface. See STANDARD MAIN BEARING APPLICATIONS table.
6. Fit main bearings with oil groove into cylinder block, and bearings without oil grove into lower crankcase
housing. Coat bearings with oil, and place crankshaft in cylinder block. Install NEW "O" ring to cylinder
block, and apply sealant to lower crankcase mating surface as shown in illustration. See Fig. 15. Install
lower crankcase housing to cylinder block and tighten bolts to specification and in sequence. See Fig. 17.
Fig. 13: Locating Main Bearing Journal Diameter On Crankshaft Web No. 2
Fig. 14: Locating Main Bearing Bore Diameter Letters Stamped On Lower Crankcase Housing
Fig. 15: Identifying Lower Crankcase Sealant Application Areas

CRANKSHAFT MAIN BEARING JOURNAL DIAMETERS

Numbers Stamped On Web No. 2 In. (mm)
"1" 2.2832-2.2834 (57.993-57.998)
"2" 2.2830-2.2832 (57.988-57.993)
"3" 2.2828-2.2829 (57.983-57.986)
MAIN BEARING BORE DIAMETERS

Letters Stamped On Block In. (mm)
"A" 2.4409-2.4411 (62.000-62.004)
"B" 2.4412-2.4414 (62.006-62.012)
"C" 2.4414-2.4416 (62.012-62.017)
COLOR CODE FOR STANDARD MAIN BEARINGS

Paint Color Thickness - In. (mm)
Green .0783-.0785 (1.989-1.994)
Black .0785-.0786 (1.994-1.996)
No Paint .0786-.0787 (1.996-2.000)
Yellow .0787-.0789 (2.000-2.004)

Blue .0788-.0790 (2.002-2.007)
STANDARD MAIN BEARING APPLICATIONS

Letter Stamped On Lower
Crankcase Housing (Cap Bore Number Stamped On Crank
Diameter) Web No.2 (Journal Diameter) Standard Bearing Color to Use
"A" "1" Green
"A" "2" Black
"A" "3" No Paint
"B" "1" Black
"B" "2" No Paint
"B" "3" Yellow
"C" "1" No Paint
"C" "2" Yellow
"C" "3" Blue
COLOR CODE FOR UNDERSIZE MAIN BEARINGS

Paint Color Thickness - In. (mm)
Green & Red .0833-.0834 (2.115-2.118)
Black & Red .0834-.0835 (2.118-2.121)
Red Only .0835-.0837 (2.121-2.126)
Yellow & Red .0836-.0838 (2.123-2.129)
Blue & Red .0837-.0839 (2.126-2.131)
UNDERSIZE MAIN BEARING APPLICATIONS

Letter Stamped on 2.2734-2.2736" (57.744- 2.2731-2.2733" (57.737- 2.2729-2.2731" (57.732-
Lower Crankcase 57.749 mm) Journal 57.742 mm) Journal 57.737 mm) Journal
Diameter Bearing Color Diameter Bearing Color Diameter Bearing Color
"A" Green & Red Black & Red Red Only
"B" Black & Red Red Only Yellow & Red
"C" Red Only Yellow & Red `Blue & Red
Undersize Bearings
1. Undersize main bearings are available in 5 different sizes and are color coded to indicate size. See
COLOR CODE FOR UNDERSIZE BEARINGS table.
2. If regrinding crankshaft is necessary, ensure finished journal diameter is within a range of 2.2729-
2.2736" (57.732-57.749 mm). Using micrometer, measure re-ground journal diameter. Using journal
diameter and letters stamped on lower crankcase housing, select undersize bearing. See UNDERSIZE
MAIN BEARING APPLICATIONS table. Use Plastigage to ensure correct clearance of installed
undersize bearing.
Thrust Bearing
1. With lower crankcase housing installed, check crankshaft thrust clearance (end play) using a dial
indicator.
2. Standard thrust bearing thickness is .984" (2.50 mm). Oversize thrust bearing thickness is .1009" (2.563
mm). If clearance exceeds specification, replace thrust bearing. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Cylinder Block
Inspect block for distortion of deck surface. Inspect block and cylinders for cracks, scratches and other defects.
Measure cylinder bores at 2 levels for wear, taper and out-of-round condition. If bore wear, taper or out-of-
round condition exceeds specification, rebore cylinders. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS.
Fig. 16: Loosening Crankshaft Bearing Bolts

Fig. 17: Tightening Crankshaft Bearing Bolts

ENGINE OILING
ENGINE LUBRICATION SYSTEM
A force-feed type lubrication system is used. The oil pump is a trochoid-type pump mounted on forward portion
of crankshaft. Oil is drawn up through oil screen, passed through oil pump, and then oil filter. See Fig. 18. The
filtered oil flows through 2 passages in cylinder block. One passage supplies oil to crankshaft and pistons, and
the other passage supplies oil to cylinder head, valves and camshafts.
Fig. 18: Cross Sectional View Of 1.8L Engine Oiling System

Courtesy of SUZUKI MOTOR CORPORATION
Crankcase Capacity
Total oil capacity, including filter, is 5.3 qts. (5L). Check dipstick to verify oil level is correct.
Oil Pressure
Normal oil pressure is 55.5-66.8 psi (3.9-4.7 kg/cm2 ) at 4000 RPM.
OIL PUMP
Removal & Disassembly
1. Disconnect negative battery cable. Drain engine oil. Remove oil pan and oil pump screen. See OIL PAN
under REMOVAL & INSTALLATION. Remove oil pump sprocket cover. DO NOT remove oil pump
sprocket from pump, as oil pump may be damaged. Remove oil pump with sprocket, from lower
crankcase.
2. Remove pump assembly bolts, and remove inner and outer oil pump rotors. Remove retainer, relief spring
and relief valve.
Inspection
1. Inspect inner and outer rotors and oil pump housing for cracks, wear or damage. Ensure relief valve slides
smoothly in bore. Inspect pressure relief spring for damaged coils.
2. Using a feeler gauge, measure radial and side clearance of pump rotors and pump case. If clearance
exceeds specification, replace outer rotor or case. See OIL PUMP SPECIFICATIONS table.
Reassembly & Installation
1. Ensure rotors are assembled in same direction as originally installed. Apply thin coat of engine oil to
inner and outer rotors and inside surfaces of oil pump case. Install inner and outer rotors.
2. Ensure rotors turn freely by hand after pump is assembled. Install oil pump, and tighten bolts to
specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.
OIL PUMP SPECIFICATIONS

Clearance In. (mm)
Radial .0059 (.150)
Side .0043 (.109)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Compressor Bracket Bolts 47 (64)
Camshaft Sprocket Bolts 57 (77)
Connecting Rod Cap Nut 33 (45)
Crankshaft Pulley Bolt 110 (150)
Cylinder Head Bolts
Step 1 (1) 39 (53)
Step 2 61 (83)
Step 3 (2)
Step 4 27 (37)
Step 5 76 (103)
Step 6 (3)
Engine Side Mounting Bracket Bolts 40 (54)

Engine-To-Transmission Bolts 66 (89)
Exhaust Manifold Bolt 37 (50)
Exhaust Manifold Stiffener (4) 37 (50)
Exhaust Pipe 37 (50)
Flex Plate/Flywheel Bolts 51 (69)
Generator Belt Idler Pulley Bolt 33 (45)
Generator Belt Tensioner Bolts 18 (24)
Intake Manifold Bolt 17 (23)
Intake Manifold Stiffener (4) 37 (50)
Lower Crankcase-To-Cylinder Block (Main Bearing Cap) Bolts
8-mm Bolt 20 (27)
10-mm Bolt 43 (58)
Oil Pan Drain Plug 26 (35)
Oil Pump Mounting Bolts 20 (27)
Oil Pump Relief Valve Plug 21 (28)
Timing Chain (1st) Tensioner Nut 18 (24)
Timing Chain (2nd) Tensioner Adjuster Nut (5)
33 (45)
Torque Converter Bolts 14 (19)
Transmission Stiffener Bolts 37 (50)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolts 97 (11)
Oil Pan Bolts 97 (11)
Oil Pump Sprocket Cover Bolts 97 (11)
Oil Strainer Bolts 97 (11)
Timing Chain Cover Bolts 97 (11)
Timing Chain (No.1) Guide 80 (9)
Throttle Body Bolts 115 (13)
Valve Cover Nuts 97 (11)
(1) Follow tightening procedure listed under CYLINDER HEAD under REMOVAL &
INSTALLATION. See Fig. 6. Tighten 6-mm bolt to 96 INCH lbs. (11 N.m).
(2) Loosen bolts in sequence, until torque is reduced to zero (0). See Fig. 5.
(3) Tighten 6 mm bolt on side of cylinder head to 96 INCH lbs (11 N.m).
(4) Tighten smaller bolts to 18 ft. lbs. (25 N.m).
(5) Tighten smaller bolts to 96 INCH lbs. (11 N.m).
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
Displacement 109.8 Cu. In. (1.8L)
Compression Pressure (1)
Standard 199 psi (14 kg/cm2 )
Minimum Limit 170 psi (12 kg/cm2 )
Maximum Variation 14.2 psi (1.0 kg/cm2 )
Fuel System SFI
(1) Check while cranking engine at 250 RPM or more.
CONNECTING RODS SPECIFICATIONS
CONNECTING RODS
Application In. (mm)
Pin Bore .8269-.8272 (21.003-21.011)
Maximum Bend .002 (.05)
Maximum Twist .0039 (.099)
Side Play
Standard .0099-.0150 (.251-.381)
Service Limit .0177 (.450)
CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Crankshaft
End Play
Standard .0039-.0138 (.009-.350)
Runout .0023 (.058)
Main Bearings
Journal Diameter (1)
"1" 2.2832-2.2834 (57.993-57.998)
"2" 2.2830-2.2832 (57.988-57.993)
"3" 2.2828-2.2829 (57.983-57.986)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance
Standard .0010-.0018 (.025-.046)
Main Bearing Cap Bore Diameter (2)
"A" 2.4409-2.4411 (62.000-62.004)
"B" 2.4412-2.4414 (62.006-62.012)
"C" 2.4414-2.4416 (62.012-62.017)
Connecting Rod Bearings
Standard Journal Diameter 1.9768-1.9685 (50.210-50.000)
Undersize Journal Diameter
.25 mm 1.9580-1.9586 (49.733-49.748)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance
Standard .010-.0150 (.250-.381)
(1) Main bearing journal diameter is indicated by numerical mark ("1", "2" or "3") stamped on crankshaft
web No. 2. See Fig. 13.
(2) Main bearing cap bore diameter is indicated by letter ("A", "B" or "C") stamped on cylinder block.
See Fig. 14.
PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS
PISTONS, PINS & RINGS

Pistons
Clearance .0008-.0015 (.020-.038)
Standard Diameter (1)
"1" 3.3063-3.3066 (83.980-83.988)
"2" 3.3059-3.3062 (83.970-83.977)
Oversize Diameter
.0098" (.25 mm) 3.3157-3.3165 (84.219-84.239)
.0196" (.50 mm) 3.3256-3.3263 (84.470-84.488)
Pins
Diameter .8267-.8268 (20.998-21.001)
Piston Fit Slip
Rod Fit .0001-.0005 (.003-.013)
Rings
No. 1
End Gap
Standard .0079-.0137 (.201-.348)

Side Clearance .0012-.0027 (.030-.069)
No. 2
End Gap
Standard .0138-.0196 (.351-.498)
Side Clearance .0008-.0023 (.020-.058)
No. 3 (Oil)
End Gap
Standard .0079-.0275 (.201-.700)
Service Limit .0709 (1.801)
Side Clearance .0024-.0059 (.061-.150)
(1) Piston diameter is determined by numerical mark ("1" or "2") stamped on top of piston.
ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS
VALVES & VALVE SPRINGS

Intake Valves
Seat Angle 45°
Valve Head Thickness
Standard .039" (.99 mm)
Service Limit .024" (.61 mm)
Stem Diameter .2348-.2354" (5.964-5.979 mm)
Exhaust Valves
Seat Angle 45°
Valve Head Thickness
Standard .047" (1.19 mm)
Stem Diameter .2339-.2344" (5.941-5.954 mm)
Valve Springs
Inner Spring Free Length
Standard 1.4204" (36.078 mm)
Service Limit 1.3780" (35.001 mm)
Outer Spring Free Length
Standard 1.5921" (40.439 mm)
Service Limit 1.5440" (39.218 mm)
Out-Of-Square .079" (2.01 mm)
Lbs. @ In. (kg @ mm)
Inner Valve Spring Preload
Standard 15.2-17.4 @ 1.08 (6.9-7.9 @ 27.4)
Service Limit 13.6 @ 1.08 (6.2 @ 27.4)

Outer Valve Spring Preload
Standard 33.9-39.2 @ 1.25 (15.4-17.8 @ 31.8)
Service Limit 30.4 @ 1.25 (13.8 @ 31.8)
CYLINDER BLOCK SPECIFICATIONS
CYLINDER BLOCK
Cylinder Bore
Standard Diameter (1)
Red 3.3075-3.3078 (84.011-84.018)
Blue 3.3071-3.3074 (84.000-84.008)
Maximum Taper .004 (.10)
Maximum Out-Of-Round .004 (.10)
Maximum Deck Warpage .0024 (.061)
(1) Cylinder bore diameter is determined by color mark (Red or Blue) on cylinder block. See Fig. 12.
CYLINDER HEAD SPECIFICATIONS
CYLINDER HEAD
Maximum Warpage
Head-To-Block .002" (.05 mm)
Manifold-To-Head .004" (.10 mm)
Valve Seats
Seat Angle 45°
Seat Width .0433-.0512" (1.1-1.3 mm)
Valve Guides
Intake Valve
Valve Guide I.D. .2362-.2366" (6.000-6.010 mm)
Valve Guide Installed Height .53" (13.5 mm)
Valve Stem-To-Guide Oil Clearance
Standard .0008-.0018" (.020-.046 mm)
Exhaust Valve
Valve Guide I.D. .2362-.2366" (6.000-6.010 mm)
Valve Guide Installed Height .53" (13.5 mm)
Valve Stem-To-Guide Oil Clearance
Standard .0018-.0028" (.046-.071 mm)
CAMSHAFT SPECIFICATIONS
CAMSHAFT
Bore Diameter 1.0236-1.0249 (26.000-26.032)
Journal Diameter 1.0220-1.0228 (25.959-25.979)
Journal Runout .0039 (.099)
Lobe Height
Intake
Standard 1.5906-1.5969 (40.401-40.561)
Service Limit 1.5828 (40.203)
Exhaust
Standard 1.5744-1.5780 (39.990-40.081)
Service Limit 1.5666 (39.792)
Oil Clearance
Standard .0008-.0029 (.020-.074)

Engine Identification: Warning

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Engine Identification: Warning

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2002 Suzuki Esteem GL

2001-02 ENGINES 1.8L 4-Cylinder

ENGINE IDENTIFICATION CODE

NOTE: Engine uses hydraulic lifters. Adjustment is not required.

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

FUEL PRESSURE RELEASE

miércoles, 24 de febrero de 2021 10:43:20

Fig. 1: Locating Fuel Pump Relay

CAUTION: When raising or supporting engine or automatic transmission, DO NOT

NOTE: It is not necessary to remove axle shafts from steering knuckles if

Fig. 2: Exploded View Of Engine Mounting Frame

Fig. 3: Exploded View Of Intake Manifold & Components

CYLINDER HEAD COVER

Removal & Installation

Fig. 4: Installing Cylinder Head Cover

Fig. 5: Cylinder Head Bolt Removal Sequence

Fig. 6: Cylinder Head Bolt Tightening Sequence

TIMING CHAIN COVER

specification. See TORQUE SPECIFICATIONS.

2ND TIMING CHAIN & CHAIN TENSIONER

Fig. 7: Aligning 2nd Timing Chain & Sprockets

1ST TIMING CHAIN & CHAIN TENSIONER

Fig. 8: Aligning 1st Timing Chain & Sprockets

CAMSHAFT & VALVE LASH ADJUSTERS

Fig. 9: Exhaust Camshaft Bearing Cap Sealing Surface

Fig. 10: Camshaft Bearing Cap Bolt Tightening Sequence

NOTE: For further information on cooling systems, see SPECIFICATIONS and

Fig. 11: Removing Valve Keepers

Valve Stem Oil Seals

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

table under ENGINE SPECIFICATIONS.

Fig. 12: Matching Pistons To Cylinders

Crankshaft & Main Bearings

Fig. 15: Identifying Lower Crankcase Sealant Application Areas

CRANKSHAFT MAIN BEARING JOURNAL DIAMETERS

MAIN BEARING BORE DIAMETERS

COLOR CODE FOR STANDARD MAIN BEARINGS

Yellow .0787-.0789 (2.000-2.004)

STANDARD MAIN BEARING APPLICATIONS

COLOR CODE FOR UNDERSIZE MAIN BEARINGS

UNDERSIZE MAIN BEARING APPLICATIONS

Fig. 16: Loosening Crankshaft Bearing Bolts

Fig. 17: Tightening Crankshaft Bearing Bolts

Fig. 18: Cross Sectional View Of 1.8L Engine Oiling System

Normal oil pressure is 55.5-66.8 psi (3.9-4.7 kg/cm2 ) at 4000 RPM.

Removal & Disassembly

Reassembly & Installation

OIL PUMP SPECIFICATIONS

Engine Side Mounting Bracket Bolts 40 (54)

CONNECTING RODS SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

Service Limit .0276 (.701)

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS