Adjust SUZUKI SWIFT 2000 1.G SF310 Service User Guide

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-71
INSPECTION
STEPACTIONYESNO
1Was “ENGINE DIAG. FLOW TABLE” performed?Go to Step 2.Go to “ENGINE
DIAG. FLOW
TABLE“.
2Is there DTC other than Fuel system (DTC P0171 / P0172)
and misfire (DTC P0300-P0304)?Go to applicable
DTC Diag.
Flow Table.Go to Step 3.
3Check Ignition System.
1) Remove spark plugs and check them for;

Air gap: 1.0 – 1.1 mm (0.040 – 0.043 in.) See Fig. 1.

Carbon deposits

Insulator damage

Plug type
If abnormality is found, adjust, clean or replace.
2) Disconnect all injector connectors. See Fig. 2.
3) Connect spark plugs to high tension cords and then ground
spark plugs.
4) Crank engine and check that each spark plug sparks.
Are above check results satisfactory?Go to Step 4.Check ignition
system parts
(Refer to Section
6F1).
4Check Fuel Pressure (Refer to Section 6E2 for details).
1) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge. See Fig. 3.
3) Check fuel pressure.
With fuel pump operating
and engine at stop : 270 – 310 kPa, 2.7 – 3.1 kg / cm
2,
38.4 – 44.0 psi.
At specified idle speed : 200 – 240 kPa, 2.0 – 2.4 kg / cm
2,
28.4 – 34.1 psi.
Is measured value as specified?
Go to Step 5.Go to Diag. Flow
Table B-3 fuel
pressure check.
5Check Fuel Injectors and Circuit.
1) Using sound scope (1) or such, check operating sound of
each injector (2) when engine is running. Cycle of
operating sound should very according to engine speed.
See Fig 4.
If no sound or an unusual sound is heard, check injector
circuit (wire or coupler) or injector.
2) Turn ignition switch OFF and disconnect a fuel injector
connector.
3) Check for proper connection to fuel injector at each
terminal. See Fig. 5.
4) If OK, then check injector resistance.
Injector Resistance: 12 – 13 ohm at 20C (68F)
5) Carry out steps 1) and 3) on each injector.
6) Check each injector for injected fuel volume referring to
Section 6E2. See Fig. 6.
Injected Fuel Volume: 38 – 48 cc / 15 sec (1.28 / 1.34 –
1.62 / 1.69 US / Imp. oz / 15 sec)
7) Check each injector for fuel leakage after injector closed.
Fuel Leakage: Less than 1 drop / min.
Is check result in step 1) and 3) to 7) satisfactory?Go to Step 6.Check injector
circuit or replace
fuel injector(s).

6A
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-1
SECTION 6A
ENGINE MECHANICAL
(G10, 1-CAM 6-VALVES ENGINE)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
ON-VEHICLE SERVICE6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Hydraulic Valve Lash Adjuster 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash Adjuster Noise Diagnosis 6A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Piston Rings, Connecting Rods and Cylinders 6A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Ground
1. Throttle body
2. ISC actuator
coupler
3. TP sensor
coupler
4. Fuel injector
coupler
5. EFE heater
coupler
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-7
INSTALLATION
1) Install throttle body to intake manifold. (Refer to Section 6E.)
2) Install intake manifold gasket to cylinder head. Use a new gas-
ket.
3) Install intake manifold (1) with throttle body to cylinder head.

Install clamps (3) as shown in figure, and tighten bolts and
nuts to specification.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Connect breather hose to PCV valve.
5) Connect vacuum hoses.
6) Connect coolant hoses.
7) Connect fuel return and feed hoses to throttle body.
8) Connect electric lead wire.
9) Connect accelerator cable to throttle body.
10) Install air cleaner assembly to throttle body.
11) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
12) Refill cooling system.
13) Connect negative cable at battery.
14) Upon completion of installation, start engine and check for fuel
leaks and engine coolant leaks.
After warming up engine, adjust accelerator cable play to spec-
ification according to description in Section 6E.

1. Timing belt
2. Tensioner
3. Tensioner plate
4. Tensioner spring
5. Spring damper
6. Camshaft timing pulley
7. Pin
8. Pulley bolt
9. Seal
10. Inside cover seal
11. Inside cover
12. Outside cover seal
13. Outside cover
14. Tensioner stud
15. Tensioner bolt
16. Tensioner spring screw
: Tightening Torque
6A-10 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
TIMING BELT AND BELT TENSIONER
REMOVAL
1) Disconnect negative cable at battery.
2) Hoist vehicle.
3) Remove clip (2) after pushing center pin, and then remove fend-
er apron extension (1) on right side.
NOTE:
Do not push center pin (3) too far in, or it will fall off into
fender.
4) Remove air cleaner assembly as previously outlined.
5) Remove A / C compressor drive belt, if equipped.
6) Loosen water pump pulley bolts (1).
7) Loosen generator pivot bolts (3) and its adjusting bolt (2) and re-
move water pump belt (4) and its pulley (5).

6A-14 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
7) Install timing belt outside cover.
Before installing, make sure that rubber seal (1) is between wa-
ter pump and oil pump case and another between water pump
and cylinder head.
Tightening Torque
(c): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
8) Install crankshaft pulley (2).
Tighten crankshaft pulley bolts (1).
Tightening Torque
(d): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
9) Install water pump pulley and water pump belt.
Adjust the belt tension to the specification.
Refer to Section 6B for procedure to adjust the belt tension.
10) Install air cleaner assembly.
11) Install fender apron extension of right side.
12) Connect negative cable at battery.

1. Cylinder head cover
2. Gasket
3. Cylinder head
4. Camshaft housing No.1:
Apply sealant 99000-31110 to mating surface.
5. Camshaft housing No.2
6. Camshaft housing No.3:
Apply sealant 99000-31110 to mating surface.
7. Camshaft
8. Oil seal
9. Valve lash adjuster
10. Camshaft housing bolt
1. Crankshaft timing belt pulley: Tightening Torque
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-15
CAMSHAFT AND HYDRAULIC VALVE LASH ADJUSTER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove cylinder head cover as previously outlined.
3) Remove distributor and then its case from cylinder head.
4) Remove crankshaft pulley, timing belt outside cover and timing
belt as previously outlined.
After removing timing belt, set key (2) on crankshaft in position
as shown in figure by turning crankshaft. This is to prevent inter-
ference between valves and piston when reinstalling camshaft.
5) Remove camshaft timing belt pulley (1).
Lock camshaft (2) with a proper size rod (3) inserted into hole (10
mm, 0.39 in.) in it as shown and then loosen camshaft timing belt
pulley bolt.
NOTE:
Mating surfaces of cylinder head and cover must not be
damaged in this work. So, put clean shop cloth (4) between
rod and mating surfaces, and use care not to bump rod
against mating surfaces hard when loosening bolt.

Don’t apply force
6A-16 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
6) Remove camshaft housings from cylinder head.
7) Remove camshaft from cylinder head.
8) Remove valve lash adjuster from cylinder head.
NOTE:

Never disassemble hydraulic valve lash adjuster.

Don’t apply force to body of adjuster, for oil in high pres-
sure chamber in adjuster will leak.

Immerse removed adjuster (2) in clean engine oil (1) and
keep it there till reinstalling it so as to prevent oil leakage.
If it is left in air, place it with its bucket body facing down.
Don’t place on its side or with bucket body facing up.

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.

2. No.2 housing
3. No.3 housing
3. Rod
4. Shop cloth
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-19

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

After applying engine oil to housing bolts, tighten them tem-
porarily first. Then tighten them by following sequence as
shown 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.
Special Tool
(A): 09919-16010
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
5) Install camshaft oil seal.
After applying engine oil to oil seal lip, press-fit camshaft oil
seal till oil seal surface becomes flush with housing surface.
6) Install camshaft timing belt pulley (1) to camshaft (2) after
installing dwell pin to camshaft.
With locking camshaft as shown in figure, tighten pulley bolt to
specified torque.
Tightening Torque
(b): 60 N
.m (6.0 kg-m, 43.5 lb-ft)
7) Install cylinder head cover to cylinder head as previously out-
lined.
8) Install timing belt, timing belt outside cover, crankshaft pulley,
water pump pulley and water pump belt as previously outlined.
9) Install distributor case and distributor.
Refer to Section 6F for installation.
10) Install air cleaner assembly as previously outlined.
11) Connect negative cable at battery.
12) Adjust ignition timing.
Refer to Section 6F for adjustment.