Crank SUZUKI SWIFT 2000 1.G SF310 Service Manual PDF

(a)
1. Oil pump
1. No. 1 bolts (short)
2. No. 2 bolts (long)
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-31
4) Install rotor plate. Tighten 5 screw securely.
After installing plate, check to be sure that gears turn smoothly
by hand.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
5) Apply engine oil to guide seal (3) and install guide seal and guide
(2).
INSTALLATION
1) Install two oil pump pins and oil pump gasket to cylinder block.
Use a new gasket.
2) To prevent oil seal lip from being damaged or upturned when
installing oil pump to crankshaft, fit special tool (Oil seal guide)
to crankshaft, and apply engine oil to special tool.
Special Tool
(A): 09926-18210
3) Install oil pump to cylinder block.
As there are 2 types of oil pump bolts, refer to figure for their cor-
rect use and tighten them to specified torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
4) Install rubber seal between oil pump and water pump.

6A1-32 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
5) Install timing pulley key (2) and crank timing belt pulley (3) and
crankshaft pulley pin (1). Refer to figure for proper installation
of these parts.
With crankshaft locked using flat end rod or the like (5), tighten
crank timing belt pulley bolt (4) to specified torque.
Tightening Torque
(a): 130 N
.m (13.0 kg-m, 94.0 lb-ft)
6) Install timing belt, tensioner, oil pump strainer, oil pan and other
parts as previously outlined.
7) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
8) Adjust water pump drive belt tension referring to Section 6B.
9) Adjust power steering pump belt tension or A / C compressor
belt tension, if equipped.
Refer to Section 0B.
10) Refill engine with engine oil referring to “ENGINE OIL
CHANGE” in Section 0B.
11) Connect negative cable at battery.
12) After completing installation, check oil pressure by running en-
gine.

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.

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. 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.)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-59
Crank Pin and Connecting Rod Bearings

Inspect crank pin for uneven wear or damage. Measure crank pin
for out-of-round or taper with a micrometer. If crank pin is dam-
aged, or out-of-round or taper is out of limit, replace crankshaft or
regrind crank pin to undersize and use undersize bearing.
Connecting rod bearing size
Crank pin diameter
Standard41.982 – 42.000 mm
(1.6528 – 1.6535 in.)
0.25 mm (0.0098 in.)41.732 – 41.750 mm
(1.6430 – 1.6437 in.)
Out-of-round and taper limit: 0.01 mm (0.0004 in.)

Rod bearing:
Inspect bearing shells for signs of fusion, pitting, burn or flaking
and observe contact pattern. Bearing shells found in defective
condition must be replaced.
Two kinds of rod bearing are available; standard size bearing and
0.25 mm undersize bearing. To distinguish them, 0. 25 mm under-
size bearing has the stamped number (US025) on its backside as
indicated in figure, but standard size one has no number.

Rod bearing clearance:
1) Before checking bearing clearance, clean bearing and crank
pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gaging plastic (1) to full width of crankpin as
contacted by bearing (parallel to crankshaft), avoiding oil hole.
4) Install rod bearing cap (1) to connecting rod.
When installing cap, be sure to point arrow mark (2) on cap to
crankshaft pulley side (3), as shown in figure. After applying
engine oil to rod bolts, tighten cap nuts to specified torque. DO
NOT turn crankshaft with gaging plastic installed.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

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)