engine SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

2. Scale
1. Paint
6A1-74 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
4) From numerals stamped on crank webs (1) of No.2 and No.3 cyl-
inders and the alphabets stamped on mating surface of cylinder
block, determine new standard bearing to be installed to journal,
by referring to table given below.
For example, if numeral stamped on crank web is “1” and alpha-
bet stamped on mating surface is “B”, install a new standard
bearing painted in “Black” to its journal.
Numeral stamped on crank web
(Journal diameter)
123
Alphabet stamped
ti f
AGreenBlackColorless
on mating surface
(Bearing capboreBBlackColorlessYellow(Bearing ca bore
dia.)CColorlessYellowBlue
New standard bearing to be installed.
5) Using gaging plastic (1), check bearing clearance with newly se-
lected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and
recheck clearance.
6) When replacing crankshaft or cylinder block due to any reason,
select new standard bearings to be installed by referring to nu-
merals stamped on new crankshaft or alphabets stamped on
mating surface of new cylinder block.
UNDERSIZE BEARING (0.25 mm):

0.25 mm undersize bearing is available, in five kinds varying in
thickness.
To distinguish them, each bearing is painted in the following col-
ors at such position as indicated in figure.
Each color represents the following thicknesses at the center of
bearing.
Color painted
Bearing thickness
Green & Red2.121 – 2.125 mm
(0.0835 – 0.0836 in.)
Black & Red2.124 – 2.128 mm
(0.0836 – 0.0837 in.)
Red only2.127 – 2.131 mm
(0.0837 – 0.0838 in.)
Yellow & Red2.130 – 2.134 mm
(0.0838 – 0.0839 in.)
Blue & Red2.133 – 2.137 mm
(0.0839 – 0.0840 in.)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-75

If necessary, regrind crankshaft journal and select under-size
bearing to use with it as follows.
1) Regrind journal to the following finished diameter.
Finished diameter: 44.732 – 44.750 mm
(1.7611 – 1.7618 in.)
2) Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicular
to each other in order to check for out-of-round.
3) Using journal diameter measured above and alphabets
stamped on mating surface of cylinder block, select an under-
size bearing by referring to table given below.
Check bearing clearance with newly selected undersize bear-
ing.
Measured journal diameter
44.744 – 44.750 mm
(1.7616 – 1.7618 in.)44.738 – 44.744 mm
(1.7613 – 1.7616 in.)44.732 – 44.738 mm
(1.7611 – 1.7613 in.)
Alphabets stampedAGreen & RedBlack & RedRed only
on mating surfaceBBlack & RedRed onlyYellow & Red
of cylinder block
CRed onlyYellow & RedBlue & Red
Undersize bearing to be installed
Rear Oil Seal
Carefully inspect oil seal (1) for wear or damage. If its lip is worn or
damaged, replace it.
For oil seal installation, press-fit rear oil seal (1) so that oil seal
housing (2) end face is flush with oil seal end face.

“a”: 23 mm (0.91 in.)
6A1-76 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
Flywheel

If ring gear is damaged, cracked or worn, replace flywheel.

If the surface contacting clutch disc is damaged, or excessively
worn, replace flywheel.

Check flywheel for face runout with dial gauge.
If runout exceeds its limit, replace flywheel.
Limit on runout: 0.2 mm (0.0078 in.)
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed surface
for distortion and, if flatness exceeds its limit, correct it.
Item
StandardLimit
Flatness0.03 mm
(0.0012 in.)0.06 mm
(0.0024 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must also
be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Size
Piston diameter
O / S 0.2574.220 – 74.230 mm
(2.9220 – 2.9224 in.)
O / S 0.5074.470 – 74.480 mm
(2.9319 – 2.9323 in.)
3) Using micrometer, measure piston diameter.
4) Calculate cylinder bore diameter to be rebored.
D = A + B – C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.02 – 0.04 mm
(0.0008 – 0.0015 in.)
C: Allowance for honing = 0.02 mm (0.0008 in.)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-77
5) Rebore and hone cylinder to calculated dimension.
NOTE:
Before reboring, install all main bearing caps in place and
tighten to specification to avoid distortion of bearing bores.
6) Measure piston clearance after honing.
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 such combination and make
sure that each part goes back to where it came from, when
installing.
1) Install main bearings to cylinder block.
One of two halves of main bearing (2), has an oil groove (3).
Install it to cylinder block (1), and the other half without oil groove
to bearing cap.
Make sure that two halves are painted in the same color.
2) Install thrust bearings (1) to cylinder block between No.2 and
No.3 cylinders. Face oil groove (2) sides to crank webs.

1. Short bolts
2. Long bolts
6A1-78 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
3) Install crankshaft to cylinder block.
4) Install bearing cap to cylinder block, making sure to point arrow
mark (on each cap) to crankshaft pulley side. Fit them sequen-
tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side.
After installing bearing cap stiffeners, tighten bearing cap bolts
in such order as shown in figure a little at a time and repeat it till
they are tightened to specified torque.
Tightening Torque
(a): 54 N
.m (5.4 kg-m, 39.0 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turning it by 8.0 N
.m (0.8 kg-m, 5.8
lb-ft) torque or below.
5) Install new gasket and oil seal housing.
Do not reuse gasket removed in disassembly. Apply engine oil
to oil seal lip before installation. Tighten housing bolts to specifi-
cation.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
NOTE:
As there are 2 types of housing bolts, refer to figure for their
correct use.
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.
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 or drive plate, and torque its
bolts to specification.
Special Tool
(A): 09924-17810
Tightening Torque
(a): 78 N
.m (7.8 kg-m, 56.5 lb-ft) (Flywheel bolts)
(a): 95 N
.m (9.5 kg-m, 69.0 lb-ft) (Drive plate bolts)

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.

1. 09915-64510-001
Compression gauge
2. 09915-64510-002
Connector
3. 09915-64530
Hose
4. 09915-67010
Attachment
09915-67311
Vacuum gauge09918-08210
Vacuum gauge hose joint09915-77311
Oil pressure gauge
09917-18211
Tappet adjuster wrench09919-16020
17 mm socket09926-18210
Oil seal guide (Vinyl resin)09917-68221
Camshaft pulley holder
1. 09916-14510
Valve lifter
2. 09916-14910
Valve lifter attachment
09916-84511
Forceps09916-44910
Valve guide remover09916-34542
Reamer handle
09916-38210
Reamer (11 mm)09916-58210
Valve guide installer handle09916-56011
Valve guide installer
attachment09916-34550
Reamer (5.5 mm)
6A1-80 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
SPECIAL TOOLS

09917-98221
Valve stem seal installer09916-77310
Piston ring compressor09924-17810
Flywheel holder09915-47330
Oil filter wrench
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-81
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
SealantSUZUKI BOND NO.1207C
(99000-31150)
Mating surfaces of cylinder block and oil pan.
SealantSUZUKI BOND NO.1215
(99000-31110)
Mating surfaces of camshaft housings (No.6).

Mating surfaces of CMP sensor case and cylinder
block.

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.

6B
ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
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
GENERAL DESCRIPTION6B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS6B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE6B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant6B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Flush and Refill 6B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE6B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Water Pipes or Hoses6B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat6B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump6B-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .