lock SUZUKI SWIFT 2000 1.G SF310 Service Repair Manual

1. Clamp
1. Long bolt
2. Short bolt
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-23
6) To take up slack of timing belt, turn crankshaft two rotations
clockwise after installing it. After making sure that belt is free
from slack, tighten tensioner stud first and then tensioner bolt
to each specified torque.
Then confirm again that two sets of marks are aligned respec-
tively.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
7) 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)
8) With crankshaft locked, remove crankshaft timing belt pulley
bolt (4).
9) Install crankshaft pulley (2).
Fit hole of pulley to pin (1) on crankshaft timing belt pulley, and
tighten pulley bolts (3) to specified torque.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
10) With crankshaft locked using flat end rod or the like, tighten
crankshaft timing belt pulley bolt (4).
Tightening Torque
(b): 130 N
.m (13.0 kg-m, 94.0 lb-ft)
11) Clamp harness securely.

2. O-ring
6A1-26 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
6) Remove oil pan (3) and then oil pump strainer (1).
CLEANING

Clean mating surfaces of oil pan and cylinder block.
Remove oil, old sealant, and dusts from mating surfaces and oil
pan inside.

Clean oil pump strainer screen.
INSTALLATION
1) Apply sealant to oil pan mating surface continuously as shown
in figure.
“A” Sealant: 99000-31150
Sealant amount
Width “a”: 4 mm, 0.16 in.
Height “b”: 2 mm, 0.08 in.
2) Install O-ring (2) into cylinder block securely as shown in figure.
Install oil pump strainer (1) to cylinder block.
Tighten strainer bolt first and then bracket bolt to specified
torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
After fitting oil pan (3) 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)

1. Rotor plate
2. Inner rotor:
Apply thin coat of engine oil.
3. Outer rotor:
Apply thin coat of engine oil.
4. Gasket
5. Pin
6. Pin
7. Relief valve:
Apply thin coat of engine oil.
8. Spring
9. Retainer
10. Retainer ring
11. Front oil seal:
Apply engine oil to contact
part of crankshaft with oil seal lip.
12. Plate screw
13. Bolt (short)
14. Bolt (long)
: Tightening Torque
: Do not reuse
6A1-28 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
OIL PUMP
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing belt as previously outlined.
3) Remove generator and its bracket.
NOTE:
When installing bracket, fasten nut (A) first.
4) Remove power steering pump bracket or A / C compressor
bracket, if equipped.
NOTE:
When installing bracket, fasten bolt (B) first.
5) Remove oil pan and oil pump strainer as previously outlined.
6) Remove crankshaft timing belt pulley (3).
Lock crankshaft inserting flat end rod or the like (1) between fly-
wheel ring gear and transmission case.
With crankshaft locked, remove crankshaft timing belt pulley
bolt (2).

(a)
1. Oil pump
1. No. 1 bolts (short)
2. No. 2 bolts (long)
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-31
4) Install rotor plate. Tighten 5 screw securely.
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 lb-ft)
5) Apply engine oil to guide seal (3) and install guide seal and guide
(2).
INSTALLATION
1) Install two oil pump pins 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, and apply engine oil to special tool.
Special Tool
(A): 09926-18210
3) Install oil pump to cylinder block.
As there are 2 types of oil pump bolts, refer to figure for their cor-
rect use and tighten them to specified torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
4) Install rubber seal between oil pump and water pump.

6A1-32 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
5) Install timing pulley key (2) and crank timing belt pulley (3) and
crankshaft pulley pin (1). Refer to figure for proper installation
of these parts.
With crankshaft locked using flat end rod or the like (5), tighten
crank timing belt pulley bolt (4) to specified torque.
Tightening Torque
(a): 130 N
.m (13.0 kg-m, 94.0 lb-ft)
6) Install timing belt, tensioner, oil pump strainer, oil pan and other
parts as previously outlined.
7) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
8) Adjust water pump drive belt tension referring to Section 6B.
9) Adjust power steering pump belt tension or A / C compressor
belt tension, if equipped.
Refer to Section 0B.
10) Refill engine with engine oil referring to “ENGINE OIL
CHANGE” in Section 0B.
11) Connect negative cable at battery.
12) After completing installation, check oil pressure by running en-
gine.

1. Camshaft
2. Camshaft oil seal
3. Rocker arm shaft
4. O-ring
5. Rocker shaft bolt
6. Rocker arm (IN)
7. Rocker arm No.1 (EX)
8. Rocker arm No.2 (EX)
9. Valve adjusting screw
10. Valve adjusting screw
11. Clip
12. Lock nut
13. Rocker arm spring
: Tightening Torque : Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-33
ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing belt as previously outlined and remove camshaft
timing belt pulley (1) by using special tool.
Special Tool
(A): 09917-68221
3) Remove cylinder head cover as previously outlined.

1. Oil plug
6A1-34 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
4) Disconnect CMP sensor coupler from CMP sensor.
5) Remove CMP sensor case (1) from cylinder head.
Place a container or rag under CMP sensor case, for a small
amount of oil flows out during removal of case.
6) After loosening all valve adjusting screw lock nuts (2), turn ad-
justing screws (1) back all the way to allow all rocker arms (3) to
move freely.
7) Remove camshaft housing and camshaft.
NOTE:
To remove camshaft housing bolts, loosen them in such or-
der as indicated in figure, a little at a time.
8) Remove timing belt inside cover (2).
9) Remove intake rocker arm (1) with clip (2) from rocker arm shaft
(3).
NOTE:
Do not bend clip when removing intake rocker arm.

EX IN
2. Rocker arm shaft
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-35
10) Remove rocker arm shaft bolts (1).
11) Remove exhaust rocker arms (1) and rocker arm spring (2) by
pulling out rocker arm shaft to battery side after removing bat-
tery.
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: 0.10 mm (0.004 in.)

6A1-36 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
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.
Item
StandardLimit
Rocker arm l.D.15.996 – 16.014 mm
(0.629 – 0.630 in.)———
Rocker arm shaft dia.15.969 – 15.984 mm
(0.6287 – 0.6293 in.)———
Arm-to-shaft clearance0.012 – 0.045 mm
(0.0005 – 0.0018 in.)0.09 mm
(0.0035 in.)
Cam Wear
Using a micrometer, measured height of cam. If measured height
is below limit, replace camshaft.
Cam height
StandardLimit
Intake cam36.184 – 36.344 mm
(1.4246 – 1.4309 in.)36.084 mm
(1.4206 in.)
Exhaust cam35.900 – 36.060 mm
(1.4134 – 1.4197 in.)35.800 mm
(1.4094 in.)
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.

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.