check engine SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

6A-12 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
1. Camshaft allowable turning range – – – By timing
mark, within 90 from “V” mark on head cover on
both right and left.
2. Crankshaft allowable turning range – – – by punch
mark, within 90 from arrow mark on oil pump case
on both right and left.
CAUTION:
After timing belt is removed, never turn camshaft and crank-
shaft independently more than such an extent as shown be-
low. If turned, interference may occur among piston and
valves, and parts related to piston and valves may be dam-
aged.
12) Remove tensioner, tensioner plate, tensioner spring and
spring damper.
INSPECTION

Check timing belt for wear or crack. Replace it as necessary.

Check tensioner for smooth rotation and rattle.
INSTALLATION
1) Install tensioner plate (1) to tensioner (2).
Insert lug (3) of tensioner plate into hole (4) of tensioner.
2) Install tensioner (2) and tensioner plate (3).
Do not tighten the tensioner bolt (1) and stud by wrench yet.
Hand tighten only at this time.
Check to ensure that plate movement in arrow direction as
shown in figure causes tensioner to move in the same direction.
If no associated movement between plate and tensioner occurs,
remove tensioner and plate again and reinsert the plate lug into
tensioner hole.

1. Crank timing belt pulley bolt
Direction of crankshaft
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-13
3) Check that timing mark (3) on camshaft timing belt pulley (1) is
aligned with “V” mark (2) on cylinder head cover (4). If not, align
two marks by turning camshaft but be careful not to turn it more
than its allowable turning range which is described on previous
page.
4) Check that punch mark (2) on crank timing belt pulley (4) is
aligned with arrow mark (3) on oil pump case. If not, align two
marks by turning crankshaft but be careful not to turn it more
than its allowable turning range which is described on previous
page.
5) With two sets of marks aligned, install timing belt (1) on two pul-
leys in such a way that the drive side of belt is free of any slack,
and with tensioner plate pushed up by finger.
And then install tensioner spring and spring damper (2) as
shown in figure, and handtighten tensioner stud.
NOTE:

When installing timing belt, match arrow mark (
) on
timing belt with rotating direction of crankshaft.

In this state, No.1 piston is at top dead center of compres-
sion stroke.
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 (1) first and then tensioner bolt
(2) 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): 27 N
.m (2.7 kg-m, 19.5 lb-ft)

ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-17
INSPECTION
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
housings.
Check clearance by using gaging plastic (1). The procedure is as
follows.
1) Clean housings and camshaft journals.
2) Make sure that all valve lash adjusters are removed and install
camshaft to cylinder head.
3) Place a piece of gaging plastic the full width of journal of cam-
shaft (parallel to camshaft).
4) Install housings as outlined on the following page and evenly
torque housing bolts to specified torque. Housings MUST be
torqued to specification in order to assure proper reading of
camshaft journal clearance.
NOTE:
Do not rotate camshaft while gaging plastic is installed.
5) Remove housing, and using scale (2) on gaging plastic envel-
op, measure gaging plastic width at its widest point.
JournalStandardLimitJournal
clearance0.040 – 0.082 mm
(0.0016 – 0.0032 in.)0.12 mm
(0.0047 in.)
If measured camshaft journal clearance exceeds limit, mea-
sure journal (housing) bore and outside diameter of camshaft
journal. Replace camshaft or cylinder head assembly which-
ever the difference from specification is greater.
Item
Standard
Camshaft journalNo.126.000 – 26.021 mm
(1.0236 – 1.0244 in.)
j
bore dia.No.2 &
No.330.000 – 30.021 mm
(1.1811 – 1.1819 in.)
Camshaft journalNo.125.939 – 25.960 mm
(1.0212 – 1.0220 in.)
j
O.D.No.2 &
No.329.939 – 29.960 mm
(1.1787 – 1.1795 in.)

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.
6A-18 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
1) Before installing valve lash adjuster to cylinder head, fill oil pas-
sage of cylinder head (1) with engine oil according to the follow-
ing procedure.
Pour engine oil through camshaft journal oil holes (2) and check
that oil comes out from oil holes in sliding part of valve lash ad-
juster.
2) Install lash adjuster to cylinder head.
Apply engine oil around valve lash adjuster and then install it to
cylinder head.
3) Install camshaft to cylinder head.
After applying engine oil to camshaft journal and all around cam,
set camshaft to cylinder head so that camshaft timing belt pulley
pin hole (1) in camshaft is at lower position.
4) Install camshaft housing to camshaft and cylinder head.

Apply engine oil to sliding surface of each housing against
camshaft journal.

Apply sealant to mating surface of No.1 and No.3 housings
which will mate with cylinder head.
“A”: Sealant 99000-31110

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

6A-20 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
CAUTION:

Don’t turn camshaft or start engine (i.e., valves should not be operated) for about half an hour after
reinstalling hydraulic valve lash adjusters and camshaft. As it takes time for valves to settle in place,
operating engine within half an hour after their installation may cause interference to occur between
valves and piston.

If air is trapped in valve lash adjuster, valve may make tapping sound when engine is operated after
valve lash adjuster is installed. In such a case, run engine for about half an hour at about 2,000 – 3,000
r / min., and then air will be purged and tapping sound will cease. Should tapping should not cease,
it is possible that valve lash adjuster is defective. Replace it if defective.
If defective adjuster can’t be located by hearing among 6 of them, check as follows.
1) Stop engine and remove cylinder head cover.
2) Push adjuster downward by hand (with less than 15 kg or 33 lbs force) when cam crest is not on
adjuster to be checked and check if clearance exists between cam and adjuster. If it does, adjuster
is defective and needs replacement.
VALVE LASH ADJUSTER NOISE DIAGNOSIS
In case of the followings, valve lash adjuster noise may be caused by air trapped into valve lash adjusters.

Vehicle is left for 24 hours or more.

Engine oil is changed.

Hydraulic lash adjuster is replaced or reinstalled.

Engine is overhauled.
If noise from valve lash adjusters is suspected, perform the following checks.
1) Check engine oil for the followings.

Oil level in oil pan
If oil level is low, add oil up to Full level hole on oil level gauge.

Oil quality
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to Section 0B.

Oil leaks
If leak is found, repair it.

Oil pressure (refer to Oil Pressure Check in this section)
If defective pressure is found, repair it.
2) Run engine for about half an hour at about 2,000 to 3,000 r / min., and then air will be purge and tapping sound
will cease.
3) Should tapping sound not cease, it is possible that hydraulic valve lash adjuster is defective.
Replace it if defective.
If defective adjuster can’t be located by hearing among 16 of them, check as follows.
a) Stop engine and remove cylinder head cover.
b) Push adjuster downward by hand (with less than 20 kg or 44 lbs. Force) when cam crest is not on adjuster
to be check if clearance exists between cam and adjuster.
If it does, adjuster is defective and needs replacement.

1. Cylinder head
2. Cylinder head bolt
3. Valve guide
4. Cylinder head gasket:
“TOP” mark provided on
gasket comes to crankshaft
pulley side, facing up
(toward cylinder head side).
5. Pin
6. Camshaft
7. Valve lash adjuster
8. Valve cotters
9. Valve spring retainer
10. Valve spring:
Be sure to position spring in place with
its bottom end (small-pitched) facing the
bottom (valve spring seat side).11. Valve stem seal
12. Valve spring seat
13. Exhaust valve
14. Intake valve
15. Oil seal
16. Gasket
17. Camshaft housing bolt: Tightening Torque
: Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-21
VALVES AND CYLINDER HEAD
INSPECTION
Valve Guides
Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to check stem-to-guide clearance.
Be sure to take reading at more than one place along the length of
each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Item
StandardLimit
Valve stemIn5.457 – 5.480 mm
(0.2148 – 0.2157 in.)———
diameterEx5.440 – 5.455 mm
(0.2142 – 0.2148 in.)———
Valve guide
I.D.In &
Ex5.500 – 5.512 mm
(0.2165 – 0.2170 in.)———
Stem-to-
guide
In0.020 – 0.055 mm
(0.0008 – 0.0021 in.)0.07 mm
(0.0027 in.)
guide
clearanceEx0.045 – 0.072 mm
(0.0018 – 0.0028 in.)0.09 mm
(0.0035 in.)

6A-22 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
Valve Springs

Referring to data given below, check to be sure that each spring
is in sound condition, free of any evidence of breakage or weak-
ening. Remember, weakened valve springs can cause chatter,
not to mention possibility of reducing power output due to gas
leakage caused by decreased seating pressure.
Item
StandardLimit
Valve spring
free length42.29 mm
(1.6649 in.)41.0 mm
1.6142 in.)
Valve spring
preload
209 – 235 N
(20.9 – 23.5 kg) at
32.6 mm (46.1 –
51.8 lb at 1.28 in.)187 N (18.7 kg)
at 32.6 mm
(41.2 lb at 1.28 in.)

Spring squareness:
Use a square and surface plate to check each spring for square-
ness in terms of clearance between end of valve spring and
square. Valve spring found to exhibit a larger clearance than limit
must be replaced.
Valve spring
2 0 mm (0 079 in )g
squareness limit.2.0 mm (0.079 in.)

1. Rear mounting
2. Left mounting
3. Left mounting bracket
4. Right mounting
5. Right mounting bracket
For M / T model
For A / T model
1. Rear mounting
2. Rear mounting No.2
bracket
3. Rear mounting No.1
bracket
4. Left mounting No.1
bracket
5. Stopper6. Left mounting
7. Left mounting No.2
bracket
8. Right mounting bracket
9. Right mounting
10. Torque rod bracket
11. Stiffener
12. Torque rod
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-25
11) Disconnect the following cables.

Accelerator cable from throttle body.

Clutch cable from transmission. (For M / T model)

Gear select cable and oil pressure control cable from trans-
mission. (For A / T model)

Speedometer cable from transmission.
12) Hoist vehicle.
13) Remove fender apron extensions.
14) Remove exhaust pipe from exhaust manifold (or WU-TWC).
15) Remove gear shift control shaft from transmission and remove
extension rod. (For M / T model)
16) Drain engine oil and transmission oil.
17) Remove drive shaft joints from differential gears of transmis-
sion.
Refer to Section 4 (DRIVE SHAFT) for procedure to disconnect
drive shaft joints.
For engine and transmission removal, it is not necessary to re-
move drive shafts from steering knuckle.
18) Remove A / C compressor (if equipped) from compressor
bracket with hose still attached.
NOTE:
Suspend removed A / C compressor at a place where no
damage will be caused during removal / installation of en-
gine with transmission.
19) Remove engine rear torque rod bracket from transmission.
(For A / T model)
20) Lower vehicle.
21) Install lifting device.
22) Remove rear mounting from body.
23) Remove left side engine mounting and bracket. (For M / T mod-
el)
Remove left mounting from body. (For A / T model)
24) Remove right side engine mounting from its bracket.
25) Before removing engine with transmission, recheck to make
sure all hoses, electric wires and cables are disconnected from
engine and transmission.
26) Remove engine with transmission from body.

2. Upper half of bearing
(a)
6A-28 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
NOTE:

All parts to be installed must be perfectly clean.

Be sure to oil crankshaft journals, journal bearings, thrust
bearings, crankpins, connecting rod bearings, pistons, pis-
ton rings and cylinder bores.

Journal bearings, bearing caps, connecting rods, rod bear-
ings, rod bearing caps, pistons and piston rings are in com-
bination sets. Do not disturb combination and try to see that
each part goes back to where it came from, when installing.
1) Fit main bearings to cylinder block (1).
Among two halves of main bearing, one halt has oil groove (3).
Install this half with oil groove to cylinder block, and another half
without oil groove to bearing cap.
Make sure that two halves are painted in the same color.
2) Fit thrust bearings (1) to cylinder block between No.2 and No.3
cylinders. Face oil groove (2) sides to crank webs.
3) Put crankshaft on cylinder block.
4) Fit bearing caps sequentially in ascending order, 1, 2, 3 and 4,
starting from pulley side. Be sure to point arrow mark (2) (on
each cap) to crankshaft pulley side (1).
Gradual and uniform tightening is important for bearing cap
bolts. Make sure that four caps become tight equally and pro-
gressively till specified torque is attained.
Tightening Torque
(a): 53 N
.m (5.3 kg-m, 38.5 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turned by hand.

ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-29
5) Install oil seal housing and its gasket.
Install new gasket. Do not reuse gasket removed in disassem-
bly. Oil lip portion of oil seal before installing. Tighten housing
bolts to specification.
After installing oil seal housing, gasket edges might bulge out;
if so, cut them off to make them flush with cylinder block and
oil seal housing.
Tightening Torque
(b): 12 N
.m (1.2 kg-m, 9.0 lb-ft)
6) Install oil pump.
Refer to item “Oil pump” for installation of oil pump.
7) Install flywheel (M / T model) or drive plate (A / T model).
Using special tool, lock flywheel and torque its bolts (1) to spec-
ification.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N
.m (7.8 kg-m, 56.5 lb-ft)
8) Install pistons and connecting rods as previously outlined.
9) Install oil pump strainer and oil pan.
10) Install cylinder head assembly to cylinder block (1).
Before installing cylinder head assembly to cylinder block,
install check valve (2) into oil gallery in cylinder block, directing
slit of valve toward top of cylinder block.
NOTE:
Tighten cylinder head bolts to specified torque as pre-
viously outlined.
Whenever installing cylinder head to new cylinder block,
use following procedure to tighten cylinder head bolts.

Tighten cylinder head bolts to specified torque as pre-
viously outlined and loosen them once till tightening
torque becomes “zero”. And then torque them to specifi-
cation again.
11) Install crankshaft timing belt pulley, timing belt, crankshaft
pulley, water pump pulley, etc., as previously outlined.
12) Install clutch to flywheel (M / T model).
For clutch installation, refer to Section 7C.
13) Install engine with transmission to body as previously outlined.