Oil pump SUZUKI SWIFT 2000 1.G SF310 Service Owner's Manual

INFORMATION SENSORS
-1. MAP sensor
-2. TP sensor
-3. IAT sensor
-4. ECT sensor
-5. Heated oxygen sensor-1
5-1. Heated oxygen sensor-2
-6. VSS (A / T)
-7. Transmission range switch (A / T)
-8. Battery
-9. CMP sensor
-10. CKP sensor
-11. Fuel level sensor (gauge) (in fuel tank)
-12. PSP switch
-13. A / C control module (if equipped)
-14. VSS (speedometer) (M / T)OTHERS
A: ECM (PCM)
B: Main relay
C: EVAP canister
D: Data link connector CONTROL DEVICES
a: Fuel injector
b: EVAP canister purge valve
c: Fuel pump relay
d: EGR valve (step motor)
e: Malfunction indicator lamp
f: Ignition coil assembly
g: Radiator fan control relay
h: IAC valve
6-1-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
COMPONENT LOCATION

1.“V” mark on cylinder head cover
2. Timing mark on camshaft timing belt pulley
3. Arrow mark on oil pump case
4. Punch mark on crankshaft timing belt pulley
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-11
8) Loosen crankshaft pulley bolts (1) and remove crankshaft
pulley (2).
9) Remove timing belt outside cover (1).
10) Align 4 timing marks as shown in figure to facilitate its installa-
tion.
11) Loosen tensioner bolt (3) and stud (4), and remove belt (1) from
crankshaft timing belt pulley and camshaft timing belt pulley af-
ter pushing up the tensioner plate (2) fully by finger as shown
figure.
CAUTION:
Never bend timing belt.

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)

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.

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.

1. Cylinder block
2. Front oil seal
3. Main bearing
4. Bearing cap
5. Cap washer
6. Cap bolt
7. Timing pulley key
8. Crankshaft
9. Thrust bearing:
Set oil grooves of bearing to weds.
10. Rear oil seal
11. Pin
12. Oil seal housing gasket
13. Oil seal housing
14. Housing bolt
15. Input shaft bearing
16. Flywheel
17. Flywheel bolt
: Tightening Torque
: Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
78 N.m (7.8 kg-m)
12 N
.m (1.2 kg-m)
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-27
MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK
REMOVAL
1) Remove engine with transmission from body as previously out-
lined.
2) Remove transmission from engine, and then remove clutch and
flywheel (drive plate for A / T).
3) Remove water pump belt, generator bracket, crankshaft pulley,
timing belt, and crankshaft timing belt pulley etc.
4) Remove cylinder head assembly.
5) Remove oil pan and oil pump strainer.
6) Remove pistons and connecting rods.
7) Remove oil pump and oil seal housing.
8) Remove main bearing caps and crankshaft.

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.

6A1
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-1
SECTION 6A1
ENGINE MECHANICAL
(G13B, 1-CAM 16-VALVES ENGINE)
WARNING:
For vehicles equipped with Supplement 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 or 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).
CONTENTS
GENERAL DESCRIPTION6A1- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine6A1- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication6A1- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block6A1- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings 6A1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Rings, Piston Pins and Connecting Rods 6A1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Value Train 6A1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON VEHICLE SERVICE6A1- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Check6A1- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A1- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A1- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash (Clearance)6A1- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Element6A1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Outlet Hose6A1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A1-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A1-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Oil Pump Strainer 6A1-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump6A1-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arms, Rocker Arm Shaft and Camshaft 6A1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A1-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Rings, Connecting Rods and Cylinders 6A1-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A1-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A1-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A1-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A1-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A1-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS6A1-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE:
For what each abbreviation stands for (i.e., full term), refer to SECTION 0A.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-3
ENGINE LUBRICATION
The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side.
Oil is drawn up through oil pump strainer and passed through pump to oil filter.
The filtered oil flows into two paths in cylinder block. In one path, oil reaches crankshaft journal bearings.
Oil from crankshaft journal bearings is supplied to connecting rod bearings by means of intersecting passages
drilled in crankshaft, and then injected from a small hole provided on big end of connecting rod to lubricate piston,
rings, and cylinder wall.
In another path, oil goes up to cylinder head and lubricates camshaft journals, rocker arms, camshaft, etc., passing
through oil gallery in rocker arm shaft.
An oil relief valve is provided on oil pump. This valve starts relieving oil pressure when the pressure comes over
about 400 kPa (4.0 kg / cm
2, 56.9 psi). Relieved oil drains back to oil pan.