Cylinder head torque SUZUKI SWIFT 2000 1.G SF310 Service Owner's Manual

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-37
Check clearance by using gaging plastic.
The procedure is as follows.
1) Clean housing and camshaft journals.
2) 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 camshaft housing referring to “INSTALLATION” of the fol-
lowing page.
5) Tighten camshaft housing bolts in such order as indicated in fig-
ure a little at a time till they are tightened to specified torque.
Tightening Torque
(a): 11 N
.m (1.1kg-m, 8.0 lb-ft)
NOTE:
Do not rotate camshaft while gaging plastic is installed.
6) Remove housing and using scale (2) on gaging plastic (1) enve-
lope, measure gaging plastic width at its widest point.
StandardLimit
Journal
clearance0.040 – 0.082 mm
(0.0016 – 0.0032 in.)0.12 mm
(0.0047 in.)
If measured camshaft journal clearance exceeds limit, measure
journal (housing) bore and outside diameter of camshaft journal.
Replace camshaft or cylinder head assembly whichever the dif-
ference from specification is greater.
Item
Standard
Camshaft Journal bore dia.28.000 – 28.021 mm
(1.1024 – 1.1031 in.)
Camshaft journal O.D.27.939 – 27.960 mm
(1.1000 – 1.1008 in.)

A: Timing belt side
B: Flywheel side
6A1-38 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSTALLATION
1) Apply engine oil to rocker arm shaft and rocker arms.
2) Check O-ring for damage or deterioration. Install O-ring to rock-
er arm shaft.
3) Install rocker arm shaft (3) with shaft bolt holes (4) facing up,
rocker arm (exhaust side) (2) and rocker arm spring (1).
4) Install rocker arm shaft bolts and tighten them to specified
torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
5) Fill small amount of engine oil into arm pivot holding part (3) of
rocker arm shaft. Install rocker arm (intake side) (1) with clips (2)
to rocker arm shaft.
6) Apply engine oil to cams and journals on camshaft and put cam-
shaft on cylinder head. 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.6 housing which will
mate with cylinder head.
“A” Sealant: 99000-31110

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.

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.

A: Crankshaft pulley side
B: Flywheel side
6A1-62 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSTALLATION OR CONNECTION
1) Apply engine oil to pistons, rings, cylinder walls, connecting rod
bearings and crankpins.
NOTE:
Do not apply oil between connecting rod and bearing or be-
tween bearing cap and bearing.
2) Install guide hoses over connecting rod bolts.
These guide hoses protect crankpin and threads of rod bolt from
damage during installation of connecting rod and piston assem-
bly.
3) When installing piston and connecting rod assembly into cylin-
der bore, point arrow mark on piston head to crankshaft pulley
side.
4) Install piston and connecting rod assembly into cylinder bore.
Use special tool (Piston ring compressor) to compress rings.
Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until all
piston rings have entered cylinder bore.
Special Tool
(A): 09916-77310
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side (3).
Tighten cap nuts to specification.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-79
8) Install pistons and connecting rods as previously outlined.
9) Install oil pump strainer and oil pan as previously outlined.
10) Install cylinder head assembly to cylinder block as previously
outlined.
11) Install camshaft, crankshaft timing belt pulley, timing belt,
crankshaft pulley, water pump pulley, etc., as previously out-
lined.
12) Install clutch to flywheel (for M / T vehicle). For clutch installa-
tion, refer to “CLUTCH” section.
13) Install engine mountings and brackets.
Refer to tightening torque for INSTALLATION of “ENGINE AS-
SEMBLY” in this section.
14) Install engine with transmission to vehicle as previously out-
lined.

6A1-82 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
TIGHTENING TORQUE SPECIFICATIONS
FASTENING PARTSTIGHTENING TORQUEFASTENING PA R T SN.mkg-mlb-ft
Oil pressure switch131.39.5
Valve adjusting screw lock nuts121.29.0
Cylinder head cover bolts111.18.0
Intake manifold bolts and nuts232.317.0
Timing belt tensioner stud111.18.0
Timing belt tensioner bolt252.518.0
Timing belt cover bolts and nut111.18.0
Exhaust manifold bolts and nuts323.223.5
Crankshaft pulley bolt161.611.5
Crankshaft timing belt pulley bolt13013.094.0
Exhaust pipe nuts and bolts505036 5Exhaust manifold stiffener nut505.036.5
Oil pump strainer bolt and stay bolt111180Oil pan bolts and nuts111.18.0
CKP sensor bolt101.07.5
Oil pan drain plug505.036.0
Oil pump rotor plate screws111180Oil pump case bolts111.18.0
Camshaft housing bolts111180Rocker arm shaft bolts111.18.0
Camshaft timing belt pulley bolt606.043.5
Cylinder head venturi plug3.50.352.5
Cylinder head bolts686.849.0
Connecting rod bearing cap nuts353.525.5
Crankshaft main bearing cap bolts545.439.0
Flywheel bolts787.856.5
Drive plate bolts959.569.0
Engine mounting & bracket bolts and nutsRefer to INSTALLATION of
ENGINE ASSEMBLY in this section.

ENGINE COOLING 6B-9
WATER PUMP
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Remove timing belt and tensioner according to procedure de-
scribed in “TIMING BELT AND TENSIONER” of Section 6A or
6A1.
4) Remove water pump belt adjusting arm.
5) Remove water pump assembly (1).
INSPECTION
NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes abnormal noise, replace
it.
INSTALLATION
1) Install new pump gasket to cylinder block.
2) Install water pump to cylinder block.
Tightening Torque
(a): 12 N
.m (1.2 kg-m, 9.0 lb-ft)
3) After installing water pump, install rubber seal (1) between water
pump and oil pump, and another between water pump and cylin-
der head.
4) Install timing belt tensioner, timing belt and timing belt outside
covers according to procedure described in “TIMING BELT AND
TENSIONER” of Section 6A or 6A1.
NOTE:
Special care must be used when installing belt tensioner
and timing belt.
Torque each bolt and nut to specification.
Before installing outside covers, check to make sure that
cover seal is fitted in groove of each cover properly.