Oil SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-39

Indicates position from timing
belt side. Install in numerical
order starting from timing belt
side.

Indicates direction of housing.
Install so that arrow is directed
toward timing belt side.

Embossed marks are provided on each camshaft housing, in-
dicating position and direction for installation.
Install housing as indicated by these marks.

As camshaft housing No. 1 retains camshaft in proper position
as to thrust direction, make sure to first fit No. 1 housing to No.
1 journal of camshaft securely.

After applying engine oil to housing bolts, tighten them tempo-
rarily first. Then tighten them by the following sequence as in-
dicated in figure.
Tighten a little at a time and evenly among bolts and repeat
tightening sequence three to four times before they are tight-
ened to specified torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
7) Install camshaft oil seal (1).
After applying engine oil to oil seal lip, press-fit camshaft oil seal
till oil seal surface becomes flush with housing surface.
8) Install timing belt inside cover.
9) Install camshaft timing belt pulley (1) to camshaft while fitting pin
(2) on camshaft into slot at “E” mark.

6A1-40 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
1. O-ring2
10) Using special tool, tighten pulley bolt to specified torque.
Tightening Torque
(a): 60 N
.m (6.0 kg-m, 43.5 lb-ft)
Special Tool
(A): 09917-68221
11) Install belt tensioner, timing belt, outside cover, crankshaft
pulley and water pump belt as previously outlined.
12) After applying sealant to part “A” as shown in figure, install
CMP sensor case (2) (Distributorless ignition coil case) to cyl-
inder head and tighten its fixing bolts to specified torque.
“A” Sealant: 99000-31110
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
13) Adjust valve clearance as previously outlined.
14) Install cylinder head cover and air cleaner outlet hose.
15) Check to ensure that the following parts are back in place:

Ignition coil assemblies

High tension cords

CMP sensor coupler

Couplers to ignition coil assembly

Other removed parts which have not been reinstalled
16) Connect negative cable at battery.
17) Confirm that ignition timing is within specification referring to
Section 6F.

: Do not reuse
1. Valve cotters
2. Valve spring retainer
3. Valve spring:
be sure to position
spring in place with its
bottom end (small-pitch
end) facing the bottom
(valve spring seat side).
4. Valve stem seal
5. Valve spring seat
6. Exhaust valve
7. Intake valve
8. Cylinder head bolt
9. Camshaft housing bolt10. Camshaft housing:
Apply sealant to mating surface of
No.1 and No.6 housings.
11. Valve guide
12. Oil venturi plug
13. Cylinder head gasket:
“TOP” mark provided on gasket comes to
crankshaft pulley side, facing up
(toward cylinder head side).
14. Dowel pin
: Tightening Torque
: Apply engine oil to sliding
: surfaces of each part.
3.5 N.m (0.35 kg-m)
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-41
VALVES AND CYLINDER HEAD
REMOVAL
1) Relieve fuel pressure according to procedure described in Sec-
tion 6.
2) Disconnect negative cable at battery.
3) Drain cooling system.
4) Remove air cleaner outlet hose as previously outlined.

6A1-42 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)

Ignition coil assembly

Ground wires from
intake manifold

EVAP canister purge
valve

ECT sensor
Injectors, TP sensor and
IAC valve wires at the
coupler

Heated oxygen sensor 1

MAP sensor
5) Remove intake manifold rear stiffener (1) and generator adjust
arm reinforcement (2) from intake manifold.
6) Disconnect the following electric wires:
and then release above wire harnesses from clamps.
7) Disconnect the following hoses:

Brake booster hose (1)

EVAP canister purge hose (3) from purge valve

Radiator inlet hose

Heater inlet hose

IAC valve outlet (2)
8) Disconnect fuel feed (2) and return hoses (3) from fuel delivery
pipe (1).

3
2. Breather hose
3. PCV valve4. High-tension cords
5. Ignition coil assembly
6. Ignition coil coupler
A: Camshaft pulley side
B: CMP sensor case side
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-43
9) Remove cylinder head cover (1) as previously outlined.
Loosen all valve lash adjusting screws fully.
10) Remove timing belt and camshaft as previously outlined.
11) Disconnect exhaust pipe from exhaust manifold and remove
exhaust manifold stiffener (if equipped).
12) Loosen cylinder head bolts in such order as indicated in figure
and remove them.
13) Check all around cylinder head for any other parts required to
be removed or disconnected and remove or disconnect what-
ever necessary.
14) Remove cylinder head with intake manifold, exhaust manifold
CMP sensor case, using lifting device if necessary.

6A1-44 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
DISASSEMBLY
1) For ease in servicing cylinder head, remove CMP sensor case,
intake manifold with throttle body and exhaust manifold from cyl-
inder head.
2) Remove rocker arms and washers by pulling its shaft out to
transmission side.
3) Using special tools (Valve lifter), compress valve springs and
then remove valve cotters (1) by using special tool (Forceps) as
shown.
Special Tool
(A): 09916-14510
(B): 09916-14910
(C): 09916-84511
4) Release special tool, and remove spring retainer and valve
spring.
5) Remove valve from combustion chamber side.
6) Remove valve stem oil seal (1) from valve guide, and then valve
spring seat (2).
NOTE:
Do not reuse oil seal once disassembled. Be sure to use
new oil seal when assembling.
7) Using special tool (Valve guide remover), drive valve guide out
from combustion chamber side to valve spring side.
Special Tool
(A): 09916-44910
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.
8) Place disassembled parts except valve stem seal and valve
guide in order, so that they can be installed in their original posi-
tion.

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)

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.