cam SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

A: Valve spring retainer side
B: Valve spring seat side
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-51
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 oil 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:

Do not reuse seal once disassembled. Be sure to install
new seal.

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 (1) end) and bottom
end (small-pitch (2) end). Be sure to position spring in place with
its bottom end (small-pitch end) facing the bottom (valve spring
seat side).
8) Using special tools (Valve lifter), compress valve spring and fit
two valve cotters (1) into groove in valve stem.
Special Tool
(A): 09916-14510
(B): 09916-14910
(C): 09916-84511

A: Crankshaft pulley side
B: Flywheel side
A: Camshaft pulley side
B: CMP sensor case side
6A1-52 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
9) Install rocker arms, washers, rocker arm shaft and camshaft as
previously outlined.
10) Install CMP sensor case, intake manifold and exhaust man-
ifold.
INSTALLATION
1) Remove oil gasket and oil on mating surfaces and install new
head gasket (1) as shown in figure, that is, “TOP” mark provided
on gasket comes to crankshaft pulley side, facing up (toward cyl-
inder 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): 3.5 N
.m (0.35 kg-m, 2.5 lb-ft)
3) Apply engine oil to cylinder head bolts and tighten them gradual-
ly as follows.
a) Tighten all bolts to 35 N
.m (3.5 kg-m, 25.0 lb-ft) according to
numerical order in figure.
b) In the same manner as in a), tighten them to 55 N
.m
(5.5 kg-m, 40.0 lb-ft).
c) Loosen all bolts until tightening torque is reduced to 0 (zero)
in reverse order of tightening.
d) In the same manner as in a), tighten them to 35 N
.m
(3.5 kg-m, 25.0 lb-ft).
e) In the same manner as in a) again, tighten them to specified
torque.
Tightening Torque
(a): 68 N
.m (6.8 kg-m, 49.5 lb-ft)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-53
4) Reverse removal procedure for installation.
5) Adjust water pump drive belt tension by referring to “ENGINE
COOLING” section.
6) Adjust power steering pump belt tension or A / C compressor
belt tension, if equipped.
Refer to Section 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) Confirm that ignition timing is within specification.
13) Verify that there is no fuel leakage, coolant leakage and ex-
haust gas leakage at each connection.

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. connecting rod bearing cap nut
: Do not reuse
: Tightening Torque
: Apply engine oil to sliding
: surface of each part.
6
10
6A1-54 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS
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 cylin-
der.
8) Push piston and connecting rod assembly out through the top of
cylinder bore.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-55
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.

Ease out piston pin circlips (1), as shown.

Force piston pin out.
CLEANING
Clean carbon from piston head and ring grooves, using a suitable
tool.

“a”: 50 mm (1.96 in.)
“b”: 95 mm (3.74 in.)
“a”: 23 mm (0.91 in.)
6A1-56 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSPECTION
Cylinders

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.

Using a cylinder gauge, measure cylinder bore in thrust and axial
directions at two positions as shown in figure.
If any of the following conditions is noted, rebore cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions exceeds taper lim-
it.
3) Difference between thrust and axial measurements exceeds
out-of-round limit.
Cylinder bore dia. limit: 74.15 mm (2.9196 in.)
Tapper and out-of-round limit: 0.10 mm (0.0039 in.)
NOTE:
If any one of four cylinders has to be rebored, rebore all four
to the same next oversize. This is necessary for the sake of
uniformity and balance.
Pistons

Inspect piston for faults, cracks or other damaged.
Damaged or faulty piston should be replaced.

Piston diameter:
As indicated in figure, piston diameter should be measured at a
position 23 mm (0.91 in.) from piston skirt end in the direction per-
pendicular to piston pin.
Standard73.970 – 73.990 mm
(2.9122 – 2.9130 in.)
Piston
diameterOversize:
0.25 mm
(0.0098 in.)74.220 – 74.230 mm
(2.9220 – 2.9224 in.)
0.50 mm
(0.0196 in.)74.470 –74.480 mm
(2.9319 – 2.9323 in.)

“a”: 23 mm (0.91 in.)
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-57

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: 0.02 – 0.04 mm (0.0008 – 0.0015 in.)
NOTE:
Cylinder bore diameters used here are measured in thrust
direction at two positions.

Ring groove clearance:
Before checking, piston grooves must be clean, dry and free of
carbon.
Fit new piston ring (1) into piston groove, and measure clearance
between ring 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

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.

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.
Item
StandardLimit
Piston clearance in
small end0.003 – 0.016 mm
(0.0001 – 0.0006 in.)0.05 mm
(0.0020 in.)
Small-end bore:
19.003 – 19.011 mm (0.7482 – 0.7486 in.)
Piston pin dia.:
18.995 – 19.000 mm (0.7478 – 0.7480 in.)

1. Cylinder block
“a”: 120 mm (4.72 in.)
6A1-58 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
Piston Rings
To measure end gap, insert piston ring (3) into cylinder bore and
then measure the gap by using thickness gauge (2).
If measured gap is out of specification, replace ring.
NOTE:
Decarbon and clean top of cylinder bore before inserting pis-
ton ring.
Item
StandardLimit
Piston
Top ring0.15 – 0.30 mm
(0.0059 – 0.0118 in.)0.7 mm
(0.0275 in.)
Piston
ring end
gap
2nd ring0.2 – 0.35 mm
(0.0079 – 0.0137 in.)0.7 mm
(0.0275 in.)
ga
Oil ring0.2 – 0.7 mm
(0.0079 – 0.0275 in.)1.7 mm
(0.0669 in.)
Connecting Rod

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 connecting rod.
Item
StandardLimit
Big-end side
clearance0.10 – 0.20 mm
(0.0039 – 0.0078 in.)0.35 mm
(0.0137 in.)

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.)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-59
Crank Pin and Connecting Rod Bearings

Inspect crank pin for uneven wear or damage. Measure crank pin
for out-of-round or taper with a micrometer. If crank pin is dam-
aged, or out-of-round or taper is out of limit, replace crankshaft or
regrind crank pin to undersize and use undersize bearing.
Connecting rod bearing size
Crank pin diameter
Standard41.982 – 42.000 mm
(1.6528 – 1.6535 in.)
0.25 mm (0.0098 in.)41.732 – 41.750 mm
(1.6430 – 1.6437 in.)
Out-of-round and taper limit: 0.01 mm (0.0004 in.)

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 under-
size bearing has the stamped number (US025) on its backside as
indicated in figure, but standard size one has no number.

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 applying
engine oil to rod bolts, tighten cap nuts to specified torque. DO
NOT turn crankshaft with gaging plastic installed.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

1 or 2
Piston
No.1 Cylinder
No.2 Cylinder
No.3 Cylinder
No.4 Cylinder
Crank
pulley
side
Flywheel
side
6A1-60 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
5) Remove cap and using a scale (2) on gaging plastic (1) enve-
lope, measure gaging plastic width at the widest point (clear-
ance).
If clearance exceeds its limit, use a new standard size bearing
and remeasure clearance.
Item
StandardLimit
Bearing
clearance0.020 – 0.050 mm
(0.0008 – 0.0019 in.)0.080 mm
(0.0031 in.)
6) If clearance can not be brought to within its limit even by using
a new standard size bearing, regrind crankpin to undersize
and use 0.25 mm undersize bearing.
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 stamped number 1 or 2 as shown. It represents
outer diameter of piston.
b) There are also stamped numbers of 1 and 2 on the cylinder block
as shown. The first number represents inner diameter of No.1
cylinder, the second number of No.2 cylinder, the third number
of No.3 cylinder and the fourth number of No.4 cylinder.