Position SUZUKI SWIFT 2000 1.G SF310 Service Manual PDF

1. Cylinder head cover
2. Gasket
3. Cylinder head
4. Camshaft housing No.1:
Apply sealant 99000-31110 to mating surface.
5. Camshaft housing No.2
6. Camshaft housing No.3:
Apply sealant 99000-31110 to mating surface.
7. Camshaft
8. Oil seal
9. Valve lash adjuster
10. Camshaft housing bolt
1. Crankshaft timing belt pulley: Tightening Torque
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-15
CAMSHAFT AND HYDRAULIC VALVE LASH ADJUSTER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove cylinder head cover as previously outlined.
3) Remove distributor and then its case from cylinder head.
4) Remove crankshaft pulley, timing belt outside cover and timing
belt as previously outlined.
After removing timing belt, set key (2) on crankshaft in position
as shown in figure by turning crankshaft. This is to prevent inter-
ference between valves and piston when reinstalling camshaft.
5) Remove camshaft timing belt pulley (1).
Lock camshaft (2) with a proper size rod (3) inserted into hole (10
mm, 0.39 in.) in it as shown and then loosen camshaft timing belt
pulley bolt.
NOTE:
Mating surfaces of cylinder head and cover must not be
damaged in this work. So, put clean shop cloth (4) between
rod and mating surfaces, and use care not to bump rod
against mating surfaces hard when loosening bolt.

Indicates position from timing belt
side. Install in numerical order
starting from timing belt side.

Indicates direction of housing.
Install so that arrow is directed
toward timing belt side.
6A-18 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
1) Before installing valve lash adjuster to cylinder head, fill oil pas-
sage of cylinder head (1) with engine oil according to the follow-
ing procedure.
Pour engine oil through camshaft journal oil holes (2) and check
that oil comes out from oil holes in sliding part of valve lash ad-
juster.
2) Install lash adjuster to cylinder head.
Apply engine oil around valve lash adjuster and then install it to
cylinder head.
3) Install camshaft to cylinder head.
After applying engine oil to camshaft journal and all around cam,
set camshaft to cylinder head so that camshaft timing belt pulley
pin hole (1) in camshaft is at lower position.
4) 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.1 and No.3 housings
which will mate with cylinder head.
“A”: Sealant 99000-31110

Embossed marks are provided on each camshaft housing, in-
dicating position and direction for installation.
Install housing as indicated by these marks.

2. No.2 housing
3. No.3 housing
3. Rod
4. Shop cloth
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-19

As camshaft housing No.1 (1) retains camshaft in proper
position as to thrust direction, make sure to first fit No.1 hous-
ing to No.1 journal of camshaft securely.

After applying engine oil to housing bolts, tighten them tem-
porarily first. Then tighten them by following sequence as
shown in figure.
Tighten a little at a time and evenly among bolts and repeat
tightening sequence three to four times before they are tight-
ened to specified torque.
Special Tool
(A): 09919-16010
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
5) Install camshaft oil seal.
After applying engine oil to oil seal lip, press-fit camshaft oil
seal till oil seal surface becomes flush with housing surface.
6) Install camshaft timing belt pulley (1) to camshaft (2) after
installing dwell pin to camshaft.
With locking camshaft as shown in figure, tighten pulley bolt to
specified torque.
Tightening Torque
(b): 60 N
.m (6.0 kg-m, 43.5 lb-ft)
7) Install cylinder head cover to cylinder head as previously out-
lined.
8) Install timing belt, timing belt outside cover, crankshaft pulley,
water pump pulley and water pump belt as previously outlined.
9) Install distributor case and distributor.
Refer to Section 6F for installation.
10) Install air cleaner assembly as previously outlined.
11) Connect negative cable at battery.
12) Adjust ignition timing.
Refer to Section 6F for adjustment.

1. Cylinder head
2. Cylinder head bolt
3. Valve guide
4. Cylinder head gasket:
“TOP” mark provided on
gasket comes to crankshaft
pulley side, facing up
(toward cylinder head side).
5. Pin
6. Camshaft
7. Valve lash adjuster
8. Valve cotters
9. Valve spring retainer
10. Valve spring:
Be sure to position spring in place with
its bottom end (small-pitched) facing the
bottom (valve spring seat side).11. Valve stem seal
12. Valve spring seat
13. Exhaust valve
14. Intake valve
15. Oil seal
16. Gasket
17. Camshaft housing bolt: Tightening Torque
: Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-21
VALVES AND CYLINDER HEAD
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 stemIn5.457 – 5.480 mm
(0.2148 – 0.2157 in.)———
diameterEx5.440 – 5.455 mm
(0.2142 – 0.2148 in.)———
Valve guide
I.D.In &
Ex5.500 – 5.512 mm
(0.2165 – 0.2170 in.)———
Stem-to-
guide
In0.020 – 0.055 mm
(0.0008 – 0.0021 in.)0.07 mm
(0.0027 in.)
guide
clearanceEx0.045 – 0.072 mm
(0.0018 – 0.0028 in.)0.09 mm
(0.0035 in.)

6A1
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-1
SECTION 6A1
ENGINE MECHANICAL
(G13B, 1-CAM 16-VALVES ENGINE)
WARNING:
For vehicles equipped with Supplement Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either or these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
GENERAL DESCRIPTION6A1- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine6A1- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication6A1- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block6A1- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings 6A1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Rings, Piston Pins and Connecting Rods 6A1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Value Train 6A1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON VEHICLE SERVICE6A1- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Check6A1- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A1- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A1- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash (Clearance)6A1- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Element6A1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Outlet Hose6A1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A1-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A1-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Oil Pump Strainer 6A1-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump6A1-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arms, Rocker Arm Shaft and Camshaft 6A1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A1-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Rings, Connecting Rods and Cylinders 6A1-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A1-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A1-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A1-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A1-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A1-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS6A1-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE:
For what each abbreviation stands for (i.e., full term), refer to SECTION 0A.

1. Rocker arm shaft
2. Rocker arm (EX)
3. Intake valve
4. Exhaust valve5. Rocker arm (IN)
6. Camshaft
7. Clip
8. PivotEx In
CYLINDER BLOCK
The cylinder block is made of cast aluminum alloy and
has 4 cylinders arranged “In-Line”. A cylindrical cast
iron sleeve is installed in each cylinder.
CRANKSHAFT AND MAIN
BEARINGS
A monoblock casting crankshaft is supported by
5 main bearings which are of precision insert type.
Four crank pins on the crankshaft are positioned 180
apart.
PISTONS, RINGS, PISTON PINS AND
CONNECTING RODS
The piston is cast aluminum alloy, and has two com-
pression rings and one oil ring.
Among two compression rings (top and 2nd rings),
the outer surface of the top ring is treated with hard
chromium for improvement in abrasion resistance.
The oil ring consists of two rails and one spacer. The
piston pin is offset 0.5 mm towards the major thrust
side.This allows a gradual change in thrust pressure
against the cylinder wall as the piston travels its path.
Pins, made of chromium steel, have a floating fit in the
pistons and in the connecting rods. The connecting
rods are made of forged steel, and the rod bearings
are of precision insert type.
CYLINDER HEAD AND VALVE TRAIN
The cylinder head is made of aluminum casting. The
supporting part of the camshaft is an independent cap
type. The combustion chamber has 4 valves and uses
the center plug type pent roof shape for higher intake
and exhaust efficiency.
As the intake side rocker arm is end pivot type, it
swings according to the camshaft movement to open
and close the intake valve.
On the other hand, the exhaust side rocker arm is see-
saw type. It swings with the rocker arm shaft as its
supporting point and according to the camshaft
movement to open and close the exhaust valve.
6A1-4 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-39

Indicates position from timing
belt side. Install in numerical
order starting from timing belt
side.

Indicates direction of housing.
Install so that arrow is directed
toward timing belt side.

Embossed marks are provided on each camshaft housing, in-
dicating position and direction for installation.
Install housing as indicated by these marks.

As camshaft housing No. 1 retains camshaft in proper position
as to thrust direction, make sure to first fit No. 1 housing to No.
1 journal of camshaft securely.

After applying engine oil to housing bolts, tighten them tempo-
rarily first. Then tighten them by the following sequence as in-
dicated in figure.
Tighten a little at a time and evenly among bolts and repeat
tightening sequence three to four times before they are tight-
ened to specified torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
7) Install camshaft oil seal (1).
After applying engine oil to oil seal lip, press-fit camshaft oil seal
till oil seal surface becomes flush with housing surface.
8) Install timing belt inside cover.
9) Install camshaft timing belt pulley (1) to camshaft while fitting pin
(2) on camshaft into slot at “E” mark.

: 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: Valve spring retainer side
B: Valve spring seat side
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-51
5) Install new valve stem seal (1) to valve guide.
After applying engine oil to seal and spindle of special tool (Valve
guide installer handle), fit oil seal to spindle, and then install seal
to valve guide by pushing special tool by hand.
After installing, check to be sure that seal is properly fixed to
valve guide.
Special Tool
(A): 09917-98221
(B): 09916-58210
NOTE:

Do not reuse seal once disassembled. Be sure to install
new seal.

When installing, never tap or hit special tool with a ham-
mer or else. Install seal to guide only by pushing special
tool by hand. Tapping or hitting special tool may cause
damage to seal.
6) Install valve to valve guide.
Before installing valve to valve guide, apply engine oil to stem
seal, valve guide bore, and valve stem.
7) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch (1) end) and bottom
end (small-pitch (2) end). Be sure to position spring in place with
its bottom end (small-pitch end) facing the bottom (valve spring
seat side).
8) Using special tools (Valve lifter), compress valve spring and fit
two valve cotters (1) into groove in valve stem.
Special Tool
(A): 09916-14510
(B): 09916-14910
(C): 09916-84511

“a”: 50 mm (1.96 in.)
“b”: 95 mm (3.74 in.)
“a”: 23 mm (0.91 in.)
6A1-56 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSPECTION
Cylinders

Inspect cylinder walls for scratches, roughness, or ridges which
indicate excessive wear. If cylinder bore is very rough or deeply
scratched, or ridged, rebore cylinder and use oversize piston.

Using a cylinder gauge, measure cylinder bore in thrust and axial
directions at two positions as shown in figure.
If any of the following conditions is noted, rebore cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions exceeds taper lim-
it.
3) Difference between thrust and axial measurements exceeds
out-of-round limit.
Cylinder bore dia. limit: 74.15 mm (2.9196 in.)
Tapper and out-of-round limit: 0.10 mm (0.0039 in.)
NOTE:
If any one of four cylinders has to be rebored, rebore all four
to the same next oversize. This is necessary for the sake of
uniformity and balance.
Pistons

Inspect piston for faults, cracks or other damaged.
Damaged or faulty piston should be replaced.

Piston diameter:
As indicated in figure, piston diameter should be measured at a
position 23 mm (0.91 in.) from piston skirt end in the direction per-
pendicular to piston pin.
Standard73.970 – 73.990 mm
(2.9122 – 2.9130 in.)
Piston
diameterOversize:
0.25 mm
(0.0098 in.)74.220 – 74.230 mm
(2.9220 – 2.9224 in.)
0.50 mm
(0.0196 in.)74.470 –74.480 mm
(2.9319 – 2.9323 in.)