lock SUZUKI SWIFT 2000 1.G SF310 Service Repair Manual

1. Cylinder block
“a”: 120 mm (4.72 in.)
6A1-58 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
Piston Rings
To measure end gap, insert piston ring (3) into cylinder bore and
then measure the gap by using thickness gauge (2).
If measured gap is out of specification, replace ring.
NOTE:
Decarbon and clean top of cylinder bore before inserting pis-
ton ring.
Item
StandardLimit
Piston
Top ring0.15 – 0.30 mm
(0.0059 – 0.0118 in.)0.7 mm
(0.0275 in.)
Piston
ring end
gap
2nd ring0.2 – 0.35 mm
(0.0079 – 0.0137 in.)0.7 mm
(0.0275 in.)
ga
Oil ring0.2 – 0.7 mm
(0.0079 – 0.0275 in.)1.7 mm
(0.0669 in.)
Connecting Rod

Big-end side clearance:
Check big-end of connecting rod for side clearance, with rod fitted
and connected to its crank pin in the normal manner. If measured
clearance is found to exceed its limit, replace connecting rod.
Item
StandardLimit
Big-end side
clearance0.10 – 0.20 mm
(0.0039 – 0.0078 in.)0.35 mm
(0.0137 in.)

Connecting rod alignment:
Mount connecting rod on aligner to check it for bow and twist and,
if limit is exceeded, replace it.
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)

1 or 2
Piston
No.1 Cylinder
No.2 Cylinder
No.3 Cylinder
No.4 Cylinder
Crank
pulley
side
Flywheel
side
6A1-60 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
5) Remove cap and using a scale (2) on gaging plastic (1) enve-
lope, measure gaging plastic width at the widest point (clear-
ance).
If clearance exceeds its limit, use a new standard size bearing
and remeasure clearance.
Item
StandardLimit
Bearing
clearance0.020 – 0.050 mm
(0.0008 – 0.0019 in.)0.080 mm
(0.0031 in.)
6) If clearance can not be brought to within its limit even by using
a new standard size bearing, regrind crankpin to undersize
and use 0.25 mm undersize bearing.
ASSEMBLY
NOTE:
Two sizes of piston are available as standard size spare part
so as to ensure proper piston-to-cylinder clearance. When
installing a standard size piston, make sure to match piston
with cylinder as follows.
a) Each piston has stamped number 1 or 2 as shown. It represents
outer diameter of piston.
b) There are also stamped numbers of 1 and 2 on the cylinder block
as shown. The first number represents inner diameter of No.1
cylinder, the second number of No.2 cylinder, the third number
of No.3 cylinder and the fourth number of No.4 cylinder.

2. Arrow mark
4. Oil hole
The oil hole should
come on intake side
1. Arrow mark
2. 1st ring end
gap
3. 2nd ring end
gap and oil ring
spacer gap
4. Oil ring upper
rail gap
5. Oil ring lower
rail gap
6. Intake side
7. Exhaust side Crankshaft
pulley side
Circlip
or
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-61
c) Stamped number on piston and that on cylinder block should
correspond. That is, install number 2 stamped piston to cylinder
which is identified with number 2 and a number 1 piston to cylin-
der with number 1.
PistonCylinder
Number
at the
top
(mark)
Outer diameterNumber
(mark)Bore diameter
Piston-to-cylinder
clearance
1
73.98 – 73.99 mm
(2.9126 –
2.9130 in.)
1
74.01 – 74.02 mm
(2.9138 –
2.9141 in.)0.02 – 0.04 mm
(0.0008 –
0.0015 in.)
2
73.97 – 73.98 mm
(2.9122 –
2.9126 in.)
2
74.00 – 74.01 mm
(2.9134 –
2.9138 in.)0.02 – 0.04 mm
(0.0008 –
0.0015 in.)
Also, a letter A, B or C is stamped on piston head but ordinarily
it is not necessary to discriminate each piston by this letter.
1) Install piston pin to piston (1) and connecting rod (3):
After applying engine oil to piston pin and piston pin holes in pis-
ton and connecting rod, fit connecting rod to piston as shown in
figure and insert piston pin to piston and connecting rod, and
install piston pin circlips.
NOTE:
Circlip should be installed with its cut part facing either up
or down as shown in figure.
2) Install piston rings to piston:

As indicated in figure, 1st and 2nd rings have “RN” or “R” mark
respectively. When installing these piston rings to piston, di-
rect marked side of each ring toward top of piston.

1st ring (1) difffers from 2nd ring (2) in thickness, shape and
color of surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.

When installing oil ring (3), install spacer first and then two
rails.
3) After installing three rings (1st, 2nd and oil rings), distribute their
end gaps as shown in figure.

A: Crankshaft pulley side
B: Flywheel side
6A1-62 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSTALLATION OR CONNECTION
1) Apply engine oil to pistons, rings, cylinder walls, connecting rod
bearings and crankpins.
NOTE:
Do not apply oil between connecting rod and bearing or be-
tween bearing cap and bearing.
2) Install guide hoses over connecting rod bolts.
These guide hoses protect crankpin and threads of rod bolt from
damage during installation of connecting rod and piston assem-
bly.
3) When installing piston and connecting rod assembly into cylin-
der bore, point arrow mark on piston head to crankshaft pulley
side.
4) Install piston and connecting rod assembly into cylinder bore.
Use special tool (Piston ring compressor) to compress rings.
Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until all
piston rings have entered cylinder bore.
Special Tool
(A): 09916-77310
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side (3).
Tighten cap nuts to specification.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

6A1-66 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
15) Remove exhaust No.1 pipe.
16) Remove right and left engine under covers.
17) Remove gear shift control shaft from transmission and remove
extension rod (M / T).
18) Drain engine and transmission oil.
19) Disconnect drive shaft joints from differential gears of trans-
mission or center bearing support referring to Section 4. In this
case, it is not necessary to disconnect drive shafts from steer-
ing knuckle.
20) With hoses connected, detach A / C compressor and/or P / S
pump with bracket from cylinder block, if equipped.
NOTE:
Suspend removed compressor and/or pump at a place
where no damage will be caused during removal and
installation of engine with transmission.
21) Disconnect P / S hose from P / S oil pump. (if equipped)
NOTE:
Plug pipe, hose and pump port.
22) Install support device.
23) Remove rear mounting from body. (For M / T model)
Remove rear torque rod (For A / T model).
24) Remove engine left mounting from body.
25) Remove engine right mounting from right mounting bracket
and stiffener.
26) Before removing engine with transmission from body, recheck
to make sure all hoses, electric wires and cables are discon-
nected from engine and transmission.
27) Lower engine with transmission from body.

1. Cylinder block
2. Front oil seal:
Apply engine oil to contact part
of crankshaft with oil seal lip.
3. Main bearing:
Apply engine oil to bearing
inside surfaces.
4. Bearing cap
5. Cap bolt:
Apply engine oil to bolt and
bearing surfaces.
6. Timing pulley key7. Crankshaft:
Apply engine oil to crankshaft
journals.
8. Thrust bearing:
Set oil grooves of bearing to
crank weds.
Apply engine oil.
9. Rear oil seal:
Apply engine oil to contact part
of crankshaft with oil seal lip.10. Pin
11. Oil seal housing gasket
12. Oil seal housing
13. Housing bolt
14. Input shaft bearing
15. Flywheel
16. Flywheel bolt
: Do not reuse
: Tightening Torque
15 16
78 N.m (7.8 kg-m) for flywheel
95 N.m (9.5 kg-m) for drive plate
6A1-68 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK

1. Flywheel bolt
2. Bolt
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-69
REMOVAL
1) Remove engine assembly from body as previously outlined.
2) Remove clutch cover, clutch disc and flywheel (drive plate for
A / T).
Special Tool
(A): 09924-17810
3) Remove crankshaft pulley, timing belt and crankshaft timing
pulley.
4) Remove cylinder head assembly.
5) Remove oil pan and oil pump strainer.
6) Remove oil pump (1).
7) Remove oil seal housing.
8) Remove connecting rod bearing caps.
9) Loosen crankshaft bearing cap bolts in such order as indicated
in figure a little at a time and remove bearing caps.
10) Remove crankshaft from cylinder block.

6A1-70 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSPECTION
Crankshaft
Crankshaft runout
Using a dial gauge, measure runout at center journal. Rotate crank-
shaft slowly. If runout exceeds its limit, replace crankshaft.
Limit on runout: 0.06 mm (0.0023 in.)
Crankshaft thrust play
Measure this play with crankshaft set in cylinder block in the normal
manner, that is, with thrust bearing (1) and journal bearing caps
installed.
Use a dial gauge to read displacement in axial (thrust) direction of
crankshaft.
If its limit is exceeded, replace thrust bearing with new standard one
or oversize one to obtain standard thrust play.
Item
StandardLimit
Crankshaft thrust
play0.11 – 0.31 mm
(0.0044 – 0.0122 in.)0.38 mm
(0.0149 in.)
Thickness of
crankshaft thrust
Standard2.500 mm
(0.0984 in.)
crankshaft thrust
bearingOversize:0.125 mm
(0.0049 in.)2.563 mm
(0.1009 in.)
Out-of-round and taper (uneven wear) of journals
An unevenly worn crankshaft journal shows up as a difference in
diameter at a cross section or along its length (or both). This differ-
ence, if any, is determined by taking micrometer readings.
If any one of journals is badly damaged or if amount of uneven wear
in the sense explained above exceeds its limit, regrind or replace
crankshaft.
Limit on out-of-round and taper: 0.01 mm (0.0004 in.)

1. Gaging plastic
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-71
Main Bearings
General information

Service main bearings are available in standard size and 0.25
mm (0.0098 in.) undersize, and each of them has 5 kinds of bear-
ings differing in tolerance.

Upper half of bearing (2) has oil groove (3) as shown in figure.
Install this half with oil groove to cylinder block (1).

On each main bearing cap, arrow mark and number are em-
bossed as shown in figure.
When installing each bearing cap to cylinder block, point arrow
mark toward crankshaft pulley side and install each cap from that
side to flywheel side in ascending order of numbers “1”, “2”, “3”,
“4” and “5”. Tighten cap bolts to specified torque.
Inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Never replace one half without replacing the other half.
Main bearing clearance
Check clearance by using gaging plastic (1) according to the follow-
ing procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gaging plastic to full width of bearing (parallel
to crankshaft) on journal, avoiding oil hole.
4) Install bearing cap as previously outlined and evenly toque cap
bolts to specified torque.
Bearing cap MUST be torqued to specification in order to assure
proper reading of clearance.
Tightening Torque
(a): 54 N
.m (5.4 kg-m, 39.0 lb-ft)
NOTE:
Do not rotate crankshaft while gaging plastic is installed.

1. Paint
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-73
2) Next, check bearing cap bore diameter without bearing. On mat-
ing surface of cylinder block, four alphabets are stamped as
shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) represent the follow-
ing cap bore diameters.
Alphabet stamped
Bearing cap bore diameter
(without bearing)
A49.000 – 49.006 mm
(1.9291 – 1.9294 in.)
B49.006 – 49.012 mm
(1.9294 – 1.9296 in.)
C49.012 – 49.018 mm
(1.9296 – 1.9298 in.)
The first, second, third, fourth and fifth (left to right) stamped al-
phabets reperesent cap bore diameters of bearing caps “1”, “2”,
“3”, “4” and “5”, respectively.
For example, in figure, the first (leftmost) alphabet “B” indicates
that cap bore dia. of bearing cap “1” is within 49.006 – 49.012
mm, and the fifth (rightmost) alphabet “A” indicates that cap bore
dia. of cap “5” is within 49.000 – 49.006 mm.
3) There are five kinds of standard bearings differing in thickness.
To distinguish them, they are painted in the following colors at
the position as indicated in figure.
Each color indicates the following thickness at the center of
bearing.
Color painted
Bearing thickness
Green1.996 – 2.000 mm
(0.0786 – 0.0787 in.)
Black1.999 – 2.003 mm
(0.0787 – 0.0788 in.)
Colorless
(no paint)2.002 – 2.006 mm
(0.0788 – 0.0789 in.)
Yellow2.005 – 2.009 mm
(0.0789 – 0.0790 in.)
Blue2.008 – 2.012 mm
(0.0790 – 0.0791 in.)