Rod bearings SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

1. No.1 cylinder
2. No.2 cylinder
3. No.3 cylinder
123
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-3
GENERAL INFORMATION
STATEMENT ON CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed,
polished and lapped surfaces with tolerances that are measured in
the thousands of an millimeter (ten thousands of an inch).
Accordingly, when any internal engine parts are serviced, care and
cleanliness are important.
Throughout this section, it should be understood that proper clean-
ing and protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard shop practice
even if not specifically stated.

A liberal coating of engine oil should be applied to friction areas
during assembly to protect and lubricate the surfaces on initial op-
eration.

Whenever valve train components, pistons, piston rings, con-
necting rods, rod bearings, and crankshaft journal bearings are
removed for service, they should be retained in order.
At the time of installation, they should be installed in the same
locations and with the same mating surfaces as when removed.

Battery cables should be disconnected before any major work is
performed on the engine.
Failure to disconnect cables may result in damage to wire har-
ness or other electrical parts.

Throughout this manual, the four cylinders of the engine are iden-
tified by numbers; No.1 (1), No.2 (2) and No.3 (3) counted from
crankshaft pulley side to flywheel side.
GENERAL INFORMATION ON ENGINE SERVICE
THE FOLLOWING INFORMATION ON ENGINE SERVICE
SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PRE-
VENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE EN-
GINE PERFORMANCE.

When raising or supporting engine for any reason, do not use a
jack under oil pan. Due to small clearance between oil pan and
oil pump strainer, jacking against oil pan may cause it to be bent
against strainer resulting in damaged oil pick-up unit.

It should be kept in mind, while working on engine, that 12-volt
electrical system is capable of violent and damaging short cir-
cuits.
When performing any work where electrical terminals can be
grounded, ground cable of the battery should be disconnected at
battery.

Any time the air cleaner, throttle body or intake manifold is re-
moved, the intake opening should be covered. This will protect
against accidental entrance of foreign material which could follow
intake passage into cylinder and cause extensive damage when
engine is started.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-3
GENERAL INFORMATION
STATEMENT ON CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed,
polished and lapped surfaces with tolerances that are measured in
the thousands of an millimeter (ten thousands of an inch).
Accordingly, when any internal engine parts are serviced, care and
cleanliness are important.
Throughout this section, it should be understood that proper clean-
ing and protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard shop practice
even if not specifically stated.

A liberal coating of engine oil should be applied to friction areas
during assembly to protect and lubricate the surfaces on initial op-
eration.

Whenever valve train components, pistons, piston rings, con-
necting rods, rod bearings, and crankshaft journal bearings are
removed for service, they should be retained in order.
At the time of installation, they should be installed in the same
locations and with the same mating surfaces as when removed.

Battery cables should be disconnected before any major work is
performed on the engine.
Failure to disconnect cables may result in damage to wire har-
ness or other electrical parts.

Throughout this manual, the four cylinders of the engine are iden-
tified by numbers; No.1 (1), No.2 (2), No.3 (3) and No.4 (4)
counted from crankshaft pulley side to flywheel side.
GENERAL INFORMATION ON ENGINE SERVICE
THE FOLLOWING INFORMATION ON ENGINE SERVICE
SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PRE-
VENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE EN-
GINE PERFORMANCE.

When raising or supporting engine for any reason, do not use a
jack under oil pan. Due to small clearance between oil pan and
oil pump strainer, jacking against oil pan may cause it to be bent
against strainer resulting in damaged oil pick-up unit.

It should be kept in mind, while working on engine, that 12-volt
electrical system is capable of violent and damaging short cir-
cuits.
When performing any work where electrical terminals can be
grounded, ground cable of the battery should be disconnected at
battery.

Any time the air cleaner, throttle body or intake manifold is re-
moved, the intake opening should be covered. This will protect
against accidental entrance of foreign material which could follow
intake passage into cylinder and cause extensive damage when
engine is started.

6A
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-1
SECTION 6A
ENGINE MECHANICAL
(G10, 1-CAM 6-VALVES ENGINE)
WARNING:
For vehicles equipped with Supplemental 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 of 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
ON-VEHICLE SERVICE6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Hydraulic Valve Lash Adjuster 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash Adjuster Noise Diagnosis 6A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Piston Rings, Connecting Rods and Cylinders 6A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Cylinder block
2. Front oil seal
3. Main bearing
4. Bearing cap
5. Cap washer
6. Cap bolt
7. Timing pulley key
8. Crankshaft
9. Thrust bearing:
Set oil grooves of bearing to weds.
10. Rear oil seal
11. Pin
12. Oil seal housing gasket
13. Oil seal housing
14. Housing bolt
15. Input shaft bearing
16. Flywheel
17. Flywheel bolt
: Tightening Torque
: Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
78 N.m (7.8 kg-m)
12 N
.m (1.2 kg-m)
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-27
MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK
REMOVAL
1) Remove engine with transmission from body as previously out-
lined.
2) Remove transmission from engine, and then remove clutch and
flywheel (drive plate for A / T).
3) Remove water pump belt, generator bracket, crankshaft pulley,
timing belt, and crankshaft timing belt pulley etc.
4) Remove cylinder head assembly.
5) Remove oil pan and oil pump strainer.
6) Remove pistons and connecting rods.
7) Remove oil pump and oil seal housing.
8) Remove main bearing caps and crankshaft.

2. Upper half of bearing
(a)
6A-28 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
NOTE:

All parts to be installed must be perfectly clean.

Be sure to oil crankshaft journals, journal bearings, thrust
bearings, crankpins, connecting rod bearings, pistons, pis-
ton rings and cylinder bores.

Journal bearings, bearing caps, connecting rods, rod bear-
ings, rod bearing caps, pistons and piston rings are in com-
bination sets. Do not disturb combination and try to see that
each part goes back to where it came from, when installing.
1) Fit main bearings to cylinder block (1).
Among two halves of main bearing, one halt has oil groove (3).
Install this half with oil groove to cylinder block, and another half
without oil groove to bearing cap.
Make sure that two halves are painted in the same color.
2) Fit thrust bearings (1) to cylinder block between No.2 and No.3
cylinders. Face oil groove (2) sides to crank webs.
3) Put crankshaft on cylinder block.
4) Fit bearing caps sequentially in ascending order, 1, 2, 3 and 4,
starting from pulley side. Be sure to point arrow mark (2) (on
each cap) to crankshaft pulley side (1).
Gradual and uniform tightening is important for bearing cap
bolts. Make sure that four caps become tight equally and pro-
gressively till specified torque is attained.
Tightening Torque
(a): 53 N
.m (5.3 kg-m, 38.5 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turned by hand.

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.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-3
ENGINE LUBRICATION
The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side.
Oil is drawn up through oil pump strainer and passed through pump to oil filter.
The filtered oil flows into two paths in cylinder block. In one path, oil reaches crankshaft journal bearings.
Oil from crankshaft journal bearings is supplied to connecting rod bearings by means of intersecting passages
drilled in crankshaft, and then injected from a small hole provided on big end of connecting rod to lubricate piston,
rings, and cylinder wall.
In another path, oil goes up to cylinder head and lubricates camshaft journals, rocker arms, camshaft, etc., passing
through oil gallery in rocker arm shaft.
An oil relief valve is provided on oil pump. This valve starts relieving oil pressure when the pressure comes over
about 400 kPa (4.0 kg / cm
2, 56.9 psi). Relieved oil drains back to oil pan.

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) 6A1-59
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)

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)