Block SUZUKI SWIFT 2000 1.G SF310 Service Service Manual

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.

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.

8. Heater inlet hose
9. Heater outlet hose
10. Radiator
11. Oil cooler (A / T only)
12. Engine
13. ECT sensor1. Radiator inlet hose
2. Radiator outlet hose
3. Water intake pipe
4. Thermostat
5. Water pump
6. IAC valve (throttle body)
7. Breather pipe (air cleaner
outlet hose)
6B-2 ENGINE COOLING
GENERAL DESCRIPTION
COOLING SYSTEM CIRCULATION
During engine warm-up (thermostat closed), the water pump discharges coolant into the water jacket chamber
adjacent to No.1 cylinder. Coolant then flows through the cylinder block and the cylinder heat. Coolant then returns
to the water pump through intake manifold, heater inlet hose, heater unit, heater outlet hose, and water intake pipe.
During normal temperatures (thermostat open), coolant takes the same basic route but is now allowed to flow past
the thermostat, the inlet hose and the radiator, and then back to the water pump through the outlet hose and the
water intake pipe.

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.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-9
1. Throttle body
2. Fuel feed hose
NOTE:
Before starting engine, place transmission gear shift lever in
“Neutral” (shift selector lever to “P” range for A/T model), and
set parking brake and block drive wheels.
1) Warm up engine to normal operating temperature.
2) Set tachometer.
3) Check idle speed with A/C OFF.
If idle speed is not within specified range, check idle speed con-
trol system and any other system and parts which might affect
idle speed. Refer to “Engine Diagnosis of Section 6” for inspec-
tion.
Engine idle speed: 850
50 r/min
NOTE:
Idle speed is not adjustable manually. If it is out of its speci-
fied range, there is a faulty condition somewhere. Check
each of related systems and parts.
AIR AND FUEL DELIVERY SYSTEM
FUEL PRESSURE
INSPECTION
1) Relieve fuel pressure, referring to Section 6.
2) Separate air cleaner assembly from throttle body and shift its
position.
3) Disconnect fuel feed hose from throttle body.
CAUTION:
A small amount of fuel may be released after fuel line is
disconnected.
In order to reduce chance of personal injury, cover fitting
to be disconnected with a shop cloth. Place that cloth in
an approved container when disconnection is com-
pleted.
4) Connect special tools and hose between throttle body and fuel
feed pipe as shown in figure, and clamp hoses securely to en-
sure no leaks occur during checking.
Special Tool
(A): 09912-58441
(B): 09912-58431
(C): 09912-58490
5) Install air cleaner assembly to throttle body and cylinder head
cover.

6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
IDLE SPEED / IDLE AIR CONTROL (IAC) DUTY
INSPECTION
Before idle speed / IAC duty check, make sure of the following.

Lead wires and hoses of Electronic Fuel Injection and engine
emission control systems are connected securely.

Accelerator cable has some play, that is, it is not tight.

Valve lash is checked and adjusted according to maintenance
schedule.

Ignition timing is within specification.

All accessories (wipers, heater, lights, A / C, etc.) are out of ser-
vice.

Air cleaner has been properly installed and is in good condition.

No abnormal air inhaling from air intake system.
After above items are all confirmed, check idle speed and IAC duty
as follows.
NOTE:
Before starting engine, place transmission gear shift lever in
“Neutral” (shift selector lever to “P” range for A / T vehicle),
and set parking brake and block drive wheels.
1) Connect SUZUKI scan tool (1) to DLC with ignition switch OFF,
if it is available.
2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC duty” as follow:
Select “Data List” mode on scan tool to check “IAC duty” and en-
gine speed.
Special Tool
(A): 09931-76011 (SUZUKI scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16 / 14 pin DLC cable)
If duty and/or idle speed is out of specifications, inspect idle air
control system referring to Diagnostic Flow Table B-4 IDLE AIR
CONTROL SYSTEM CHECK in Section 6.
ENGINE IDLE SPEED AND IAC DUTY
A/C OFFA/C ON
M / T vehicle750±50 r / min (rpm)875±50 r/minA / T vehicle
at P/N range750 ±50 r/min (rpm)
8 – 25 or *8 – 35%
875 ±50 r/min
(rpm)
NOTE:
Duty values with (*) are applicable to vehicle used at high
altitude (higher than 2,000 m or 6,560 ft).
4) Check that 875 ± 50 r / min. idle speed is obtained with lighting
switch ON and heater blower switch in 2 – 4 position.
If not, check “Electric load (+)” circuit and “Heater blower switch
signal” circuit referring to “ELECTRONIC CONTROL SYSTEM”
in this section and idle air control system.
5) Check that specified engine idle speed is obtained with A / C ON
if vehicle is equipped with A / C.
If not, check A / C ON signal circuit.

7B-32 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC)
STALL TEST
This test is to check overall performance of automatic transmission
and engine by measuring stall speed at D and R ranges.
Be sure to perform this test only when transmission fluid is at normal
operating temperature (70–80C / 158–176F) and its level is be-
tween FULL HOT and LOW HOT. (Refer to “Fluid level” in this sec-
tion.)
CAUTION:
Do not run engine at stall more than 5 seconds continuous-
ly, for oil temperature may rise excessively high.
1) Install tachometer.
2) Apply parking brake and block vehicle wheels.
3) Start engine with selector lever shifted to P range.
4) Depress brake pedal.
5) Shift selector lever to D range and depress accelerator pedal ful-
ly while watching tachometer. Read engine rpm quickly when it
has become constant (stall speed).
6) Release accelerator pedal immediately after stall speed is
checked.
7) In the same way, check stall speed at R range.
8) Stall speed should be within following specification.
Stall speed: 2,500 – 2,900 r / min
(For both G10 and G13 engine models)
9) Possible causes for out-of-specification stall speed are as fol-
lows. Check each part which is suspected to be the cause.
Stall speed measured
Possible causes
Lower than specification
Engine output insufficient

Torque converter defective
Higher than specification in
D range
Forward clutch slippage

One-way clutch defective
Higher than specification in
R range
Direct clutch slippage

1st-reverse brake slippage

1. Front drive shaft (LH)
2. Oil pan
AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-33
LINE PRESSURE TEST
This test is to check oil pressure system for operation by measuring
oil pressure in oil pressure line. Make sure to perform this test only
when transmission fluid is at normal operating temperature.
NOTE:

Make sure that transmission fluid level is between FULL HOT
and LOW HOT marks on oil level gauge at normal operating
temperature which corresponds to 70–80C (155–176F) of
fluid. (Refer to “Fluid level” in this section.)

Check that transmission is free from fluid leakage.
1) With engine at stop, remove plug and connect oil pressure
gauge to plug hole.
Special Tool
(A): 09925-37811-001
2) Install tachometer.
3) Apply parking brake and block vehicle wheels.
4) With selector lever shifted to P range, start engine.
5) Depress brake pedal fully.
6) Shift selector lever to D range and check oil pressure with engine
running at idling speed and at stall speed respectively.
7) Repeat the same check as in step 6) with selector lever shifted
to R range.
CAUTION:
Do not run engine at stall more than 5 seconds continu-
ously, for oil temperature may rise excessively high.
8) If line pressure is within respective specification in table below,
oil pressure system is in good condition.
[G10 Engine Model]
Engine speedLine pressureEngine s eedD rangeR range
Idling speed
200 – 390 kPa
2.0 – 3.9 kg / cm2
28.4 – 55.5 psi
540 – 780 kPa
5.4 – 7.8 kg / cm2
76.8 – 110.9 psi
Stall speed
390 – 590 kPa
3.9 – 5.9 kg / cm2
55.5 – 83.9 psi
880 – 1230 kPa
8.8 – 12.3 kg / cm2
125.1 – 174.9 psi
[G13 Engine Model]
Engine speedLine pressureEngine s eedD rangeR range
Idling speed
260 – 460 kPa
2.6 – 4.6 kg / cm2
37.0 – 65.4 psi
660 – 900 kPa
6.6 – 9.0 kg / cm2
93.9 – 128.0 psi
Stall speed
660 – 850 kPa
6.6 – 8.5 kg / cm2
93.9 – 120.9 psi
1330 kPa or more
13.3 kg / cm2 or more
189.0 psi or more