Head SUZUKI SWIFT 2000 1.G SF310 Service Repair Manual

1.“V” mark on cylinder
head cover
2. Timing mark by “E” on
camshaft timing belt pulley
3. Arrow mark on oil
pump case
4. Punch mark on crankshaft
timing belt pulley
4. Tensioner stud
6. Damper
6
6A1-20 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
8) Lock crankshaft inserting flat end rod or the like (2) between fly-
wheel ring gear and transmission case, after removing clutch
housing (torque converter housing for A / T) lower plate.
With crankshaft locked, remove crankshaft timing belt pulley
bolt (3).
9) Remove crankshaft pulley bolts (1).
10) Remove crankshaft pulley (4).
11) Install crankshaft timing belt pulley bolt temporarily to turn
crankshaft.
12) Release harness clamps.
13) Remove timing belt outside cover.
14) For installation of timing belt, align 4 timing marks as shown in
figure by turning crankshaft.
15) Remove timing belt tensioner (3), tensioner plate (2), tensioner
spring (5) and timing belt (1).

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.
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-21
CAUTION:

After timing belt is removed, never turn camshaft and
crankshaft independently more than such an extent as
shown in figure. If turned, interference may occur among
piston and valves, and parts related to piston and valves
may be damaged.

Never bend timing belt.
INSPECTION

Inspect timing belt for wear or crack.
Replace it as necessary.

Inspect tensioner for smooth rotation.
INSTALLATION
1) Install tensioner plate to tensioner.
Insert lug (1) of tensioner plate into hole (2) in tensioner.

4. Damper
6A1-22 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
2) Install tensioner (2) and tensioner plate (3):
Do not tighten tensioner bolt (1) with 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 plate lug into ten-
sioner hole.
3) Check that timing mark (2) on camshaft timing belt pulley is
aligned with “V” mark (1) on cylinder head cover. 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 timing mark (2) on crankshaft timing belt pulley is
aligned with arrow mark (1) 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) Install timing belt and tensioner spring (2).
With two sets of marks aligned and tensioner plate pushed up,
install timing belt on two pulleys in such a way that drive side (1)
of belt is free from any slack.
And then install tensioner spring as shown in figure, and hand-
tighten tensioner stud (3).
NOTE:

When installing timing belt, match arrow mark (
) on
timing belt with rotating direction of crankshaft.

In this state, No. 4 piston is at top dead center of compres-
sion stroke.

1. Camshaft
2. Camshaft oil seal
3. Rocker arm shaft
4. O-ring
5. Rocker shaft bolt
6. Rocker arm (IN)
7. Rocker arm No.1 (EX)
8. Rocker arm No.2 (EX)
9. Valve adjusting screw
10. Valve adjusting screw
11. Clip
12. Lock nut
13. Rocker arm spring
: Tightening Torque : Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-33
ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing belt as previously outlined and remove camshaft
timing belt pulley (1) by using special tool.
Special Tool
(A): 09917-68221
3) Remove cylinder head cover as previously outlined.

1. Oil plug
6A1-34 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
4) Disconnect CMP sensor coupler from CMP sensor.
5) Remove CMP sensor case (1) from cylinder head.
Place a container or rag under CMP sensor case, for a small
amount of oil flows out during removal of case.
6) After loosening all valve adjusting screw lock nuts (2), turn ad-
justing screws (1) back all the way to allow all rocker arms (3) to
move freely.
7) Remove camshaft housing and camshaft.
NOTE:
To remove camshaft housing bolts, loosen them in such or-
der as indicated in figure, a little at a time.
8) Remove timing belt inside cover (2).
9) Remove intake rocker arm (1) with clip (2) from rocker arm shaft
(3).
NOTE:
Do not bend clip when removing intake rocker arm.

6A1-36 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
Rocker Arm-to-Rocker Arm Shaft Clearance
Using a micrometer and a bore gauge, measure rocker shaft dia.
and rocker arm l.D.
Difference between two readings is arm-to-shaft clearance on
which a limit is specified.
If limit is exceeded, replace shaft or arm, or both.
Item
StandardLimit
Rocker arm l.D.15.996 – 16.014 mm
(0.629 – 0.630 in.)———
Rocker arm shaft dia.15.969 – 15.984 mm
(0.6287 – 0.6293 in.)———
Arm-to-shaft clearance0.012 – 0.045 mm
(0.0005 – 0.0018 in.)0.09 mm
(0.0035 in.)
Cam Wear
Using a micrometer, measured height of cam. If measured height
is below limit, replace camshaft.
Cam height
StandardLimit
Intake cam36.184 – 36.344 mm
(1.4246 – 1.4309 in.)36.084 mm
(1.4206 in.)
Exhaust cam35.900 – 36.060 mm
(1.4134 – 1.4197 in.)35.800 mm
(1.4094 in.)
Camshaft Runout
Hold camshaft between two “V” blocks, and measure runout by us-
ing a dial gauge.
If runout exceeds the limit, replace camshaft.
Runout limit: 0.10 mm (0.0039 in.)
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 housing.

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.