Head SUZUKI SWIFT 2000 1.G SF310 Service Repair Manual

3
2. Breather hose
3. PCV valve4. High-tension cords
5. Ignition coil assembly
6. Ignition coil coupler
A: Camshaft pulley side
B: CMP sensor case side
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-43
9) Remove cylinder head cover (1) as previously outlined.
Loosen all valve lash adjusting screws fully.
10) Remove timing belt and camshaft as previously outlined.
11) Disconnect exhaust pipe from exhaust manifold and remove
exhaust manifold stiffener (if equipped).
12) Loosen cylinder head bolts in such order as indicated in figure
and remove them.
13) Check all around cylinder head for any other parts required to
be removed or disconnected and remove or disconnect what-
ever necessary.
14) Remove cylinder head with intake manifold, exhaust manifold
CMP sensor case, using lifting device if necessary.

6A1-44 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
DISASSEMBLY
1) For ease in servicing cylinder head, remove CMP sensor case,
intake manifold with throttle body and exhaust manifold from cyl-
inder head.
2) Remove rocker arms and washers by pulling its shaft out to
transmission side.
3) Using special tools (Valve lifter), compress valve springs and
then remove valve cotters (1) by using special tool (Forceps) as
shown.
Special Tool
(A): 09916-14510
(B): 09916-14910
(C): 09916-84511
4) Release special tool, and remove spring retainer and valve
spring.
5) Remove valve from combustion chamber side.
6) Remove valve stem oil seal (1) from valve guide, and then valve
spring seat (2).
NOTE:
Do not reuse oil seal once disassembled. Be sure to use
new oil seal when assembling.
7) Using special tool (Valve guide remover), drive valve guide out
from combustion chamber side to valve spring side.
Special Tool
(A): 09916-44910
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.
8) Place disassembled parts except valve stem seal and valve
guide in order, so that they can be installed in their original posi-
tion.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-45
INSPECTION
Valve Guides
Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to check stem-to-guide clearance.
Be sure to take reading at more than one place along the length of
each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Item
StandardLimit
Valve stemIn5.465 – 5.480 mm
(0.2152 – 0.2157 in.)–
diameterEx5.440 – 5.455 mm
(0.2142 – 0.2148 in.)–
Valve guideIn5.500 – 5.512 mmg
I.D.Ex(0.2166 – 0.2170 in.)–
Stem-to-guideIn0.020 – 0.047 mm
(0.0008 – 0.0018 in.)0.07 mm
(0.0027 in.)
g
clearanceEx0.045 – 0.072 mm
(0.0018 – 0.0028 in.)0.09 mm
(0.0035 in.)
If bore gauge is not available, check end deflection of valve stem
with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end deflection.
If deflection exceeds its limit, replace valve stem and valve guide.
Valve stem end
In0.14 mm (0.005 in.)
deflection limitEx0.18 mm (0.007 in.)
Valves

Remove all carbon from valves.

Inspect each valve for wear, burn or distortion at its face and stem
and, as necessary, replace it.

Measure thickness “a” of valve head. If measured thickness ex-
ceeds limit, replace valve.
Valve head thickness
StandardLimit
In0.8 – 1.2 mm0.6 mm (0.024 in.)
Ex(0.03 – 0.047 in.)0.7 mm (0.027 in.)

6A1-46 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)

Inspect valve stem end face for pitting and wear. If pitting or wear
is found there, valve stem end may be resurfaced, but not so
much as to grind off its chamfer. When it is worn so much that its
chamfer is gone, replace valve.

Seating contact width:
Create contact pattern on each valve in the usual manner, i.e., by
giving uniform coat of marking compound to valve seat and by ro-
tatingly tapping seat with valve head. Valve lapper (tool used in
valve lapping) must be used.
Pattern produced on seating face of valve must be a continuous
ring without any break, and the width “a” of pattern must be within
specified range.
Standard seating width
revealed by contact
In1.1 – 1.3 mmrevealed by contact
pattern on valve faceEx(0.0433 – 0.0512 in.)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-47

Valve seat repair:
A valve seat (2) not producing a uniform contact with its valve or
showing width of seating contact that is out of specified range
must be repaired by regrinding or by cutting and regrinding and
finished by lapping.
1) EXHAUST VALVE SEAT: Use valve seat cutters (1) to make
two cuts as illustrated in figure. Two cutters must be used: the
first for making 15 angle, and the second for making 45
angle. The second cut must be made to produce desired seat
width.
Seat width for exhaust valve seat:
1.1 – 1.3 mm (0.0433 – 0.0512 in.)
2) INTAKE VALVE SEAT: Cutting sequence is the same as for ex-
haust valve seats.
Seat width for intake valve seat:
1.1 – 1.3 mm (0.0433 – 0.0512 in.)
3) VALVE LAPPING: Lap valve on seat in two steps, first with
coarse size lapping compound applied to face and the second
with fine-size compound, each time using valve lapper accord-
ing to usual lapping method.
Cylinder Head

Remove all carbon from combustion chambers.
NOTE:
Do not use any sharp-edged tool to scrape off carbon. Be
careful not to scuff or nick metal surfaces when decarbon-
ing. The same applies to valves and valve seats, too.

Check cylinder head for cracks in intake and exhaust ports, com-
bustion chambers, and head surface.

6A1-48 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)

Flatness of gasketed surface:
Using a straightedge and thickness gauge, check surface at a to-
tal of 6 locations. If distortion limit, given below, is exceeded, cor-
rect gasketed surface with a surface plate and abrasive paper of
about #400 (Waterproof silicon carbide abrasive paper): place
paper on and over surface plate, and rub gasketed surface
against paper to grind off high spots. Should this fail to reduce
thickness gauge readings to within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint is often
due to warped gasketed surface: such leakage results in reduced
power output.
Limit of distortion: 0.05 mm (0.002 in.)

Distortion of manifold seating faces:
Check seating faces of cylinder head for manifolds, using a
straightedge and thickness gauge, in order to determine whether
these faces should be corrected or cylinder head replaced.
Limit of distortion: 0.10 mm (0.004 in.)

“a”: Valve guide protrusion (11.5 mm)
6A1-50 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
ASSEMBLY
1) Before installing valve guide into cylinder head, ream guide hole
with special tool (11 mm reamer) to remove burrs and make it
truly round.
Special Tool
(A): 09916-34542
(B): 09916-38210
2) Install valve guide to cylinder head.
Heat cylinder head uniformly at a temperature of 80 to 100C
(176 to 212F) so that head will not be distorted, and drive new
valve guide into hole with special tools. Drive in new valve guide
until special tool (Valve guide installer) contacts cylinder head.
After installing, make sure that valve guide protrudes by 11.5
mm (0.45 in.) from cylinder head.
Special Tool
(C): 09916-56011
(D): 09916-58210
NOTE:

Do not reuse valve guide once disassembled.
Install new valve guide (Oversize).

Intake and exhaust valve guides are identical.
Valve guide oversize: 0.03 mm (0.0012 in.)
Valve guide protrusion (In and Ex): 11.5 mm (0.45 in.)
3) Ream valve guide bore with special tool (5.5 mm reamer). After
reaming, clean bore.
Special Tool
(A): 09916-34542
(B): 09916-34550
4) Install valve spring seat to cylinder head.

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.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-55
DISASSEMBLY
1) Using piston ring expander, remove two compression rings (Top
and 2nd) and oil ring from piston.
2) Remove piston pin from connecting rod.

Ease out piston pin circlips (1), as shown.

Force piston pin out.
CLEANING
Clean carbon from piston head and ring grooves, using a suitable
tool.