wheel bolts SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

1. Flywheel bolts or drive plate bolts for A / T vehicle
6) Install oil pump. Refer to “Oil pump”.
7) Install flywheel (for M / T vehicle) or drive plate
(for A / T vehicle).
Using special tool, lock flywheel or drive plate, and
tighten flywheel or drive plate bolts to specified
torque.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N
.m (7.8 kg-m, 56.0 lb-ft)
0A-2 GENERAL INFORMATION
HOW TO USE THIS MANUAL
1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL
on the third page of this manual, whereby you can easily find the
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.
2) Each section of this manual has its own pagination. It is indicated
at the top of each page along with the Section name.
3) The SPECIAL TOOL usage and TIGHTENING TORQUE
SPECIFICATION are given as shown in figure below.
4) A number of abbreviations are used in the text.
For their full explanations, refer to “ABBREVIATIONS AND
SYMBOLS MAY BE USED IN THIS MANUAL” of this section.
5) The SI, metric and foot-pound systems are used as units in this
manual.
6) DIAGNOSIS are included in each section as necessary.
7) At the end of each section, there are descriptions of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHT-
ENING TORQUE SPECIFICATIONS that should be used for the
servicing work described in that section.

1. Drive shaft
2. Boot
MAINTENANCE AND LUBRICATION 0B-15
[Wheel disc inspection]
Inspect each wheel disc for dents, distortion and cracks. A disc in
badly damaged condition must be replaced.
[Tire rotation]
Rotate tires referring to SECTION 3F.
Wheel Bearing Inspection
1) Check front wheel bearing for wear, damage, abnormal noise or
rattles. For details, refer to SECTION 3D.
2) Check rear wheel bearing for wear, damage abnormal noise or
rattle. For details, refer to SECTION 3E.
ITEM 6-3
Propeller Shaft Inspection (4WD vehicle only)
1) Check propeller shaft connecting bolts for looseness. If loose-
ness is found, tighten to specified torque.
2) Check propeller shaft joints for wear, play and damage.
If any defect is found, replace.
3) Check propeller shaft center support (1) for biting of foreign mat-
ter, crack, abnormal noise and damage. If any defect is found,
replace.
Drive Shaft Boot Inspction
Check drive shaft boots (wheel side and differential side) for leak-
age, detachment, tear or any other damage.
Replace boot as necessary.
ITEM 6-4
Suspension System Inspection

Inspect front & rear struts for evidence of oil leakage, dents or any
other damage on sleeves; and inspect anchor ends for deteriora-
tion.
Replace defective parts, if any.

ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-29
5) Install oil seal housing and its gasket.
Install new gasket. Do not reuse gasket removed in disassem-
bly. Oil lip portion of oil seal before installing. Tighten housing
bolts to specification.
After installing oil seal housing, gasket edges might bulge out;
if so, cut them off to make them flush with cylinder block and
oil seal housing.
Tightening Torque
(b): 12 N
.m (1.2 kg-m, 9.0 lb-ft)
6) Install oil pump.
Refer to item “Oil pump” for installation of oil pump.
7) Install flywheel (M / T model) or drive plate (A / T model).
Using special tool, lock flywheel and torque its bolts (1) to spec-
ification.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N
.m (7.8 kg-m, 56.5 lb-ft)
8) Install pistons and connecting rods as previously outlined.
9) Install oil pump strainer and oil pan.
10) Install cylinder head assembly to cylinder block (1).
Before installing cylinder head assembly to cylinder block,
install check valve (2) into oil gallery in cylinder block, directing
slit of valve toward top of cylinder block.
NOTE:
Tighten cylinder head bolts to specified torque as pre-
viously outlined.
Whenever installing cylinder head to new cylinder block,
use following procedure to tighten cylinder head bolts.

Tighten cylinder head bolts to specified torque as pre-
viously outlined and loosen them once till tightening
torque becomes “zero”. And then torque them to specifi-
cation again.
11) Install crankshaft timing belt pulley, timing belt, crankshaft
pulley, water pump pulley, etc., as previously outlined.
12) Install clutch to flywheel (M / T model).
For clutch installation, refer to Section 7C.
13) Install engine with transmission to body as previously outlined.

1.“V” mark on cylinder
head cover
2. Timing mark by “E” on
camshaft timing belt pulley
3. Arrow mark on oil
pump case
4. Punch mark on crankshaft
timing belt pulley
4. Tensioner stud
6. Damper
6
6A1-20 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
8) Lock crankshaft inserting flat end rod or the like (2) between fly-
wheel ring gear and transmission case, after removing clutch
housing (torque converter housing for A / T) lower plate.
With crankshaft locked, remove crankshaft timing belt pulley
bolt (3).
9) Remove crankshaft pulley bolts (1).
10) Remove crankshaft pulley (4).
11) Install crankshaft timing belt pulley bolt temporarily to turn
crankshaft.
12) Release harness clamps.
13) Remove timing belt outside cover.
14) For installation of timing belt, align 4 timing marks as shown in
figure by turning crankshaft.
15) Remove timing belt tensioner (3), tensioner plate (2), tensioner
spring (5) and timing belt (1).

A: Timing belt side
B: Flywheel side
6A1-38 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSTALLATION
1) Apply engine oil to rocker arm shaft and rocker arms.
2) Check O-ring for damage or deterioration. Install O-ring to rock-
er arm shaft.
3) Install rocker arm shaft (3) with shaft bolt holes (4) facing up,
rocker arm (exhaust side) (2) and rocker arm spring (1).
4) Install rocker arm shaft bolts and tighten them to specified
torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
5) Fill small amount of engine oil into arm pivot holding part (3) of
rocker arm shaft. Install rocker arm (intake side) (1) with clips (2)
to rocker arm shaft.
6) Apply engine oil to cams and journals on camshaft and put cam-
shaft on cylinder head. 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.6 housing which will
mate with cylinder head.
“A” Sealant: 99000-31110

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)

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)

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.

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. Short bolts
2. Long bolts
6A1-78 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
3) Install crankshaft to cylinder block.
4) Install bearing cap to cylinder block, making sure to point arrow
mark (on each cap) to crankshaft pulley side. Fit them sequen-
tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side.
After installing bearing cap stiffeners, tighten bearing cap bolts
in such order as shown in figure a little at a time and repeat it till
they are tightened to specified torque.
Tightening Torque
(a): 54 N
.m (5.4 kg-m, 39.0 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turning it by 8.0 N
.m (0.8 kg-m, 5.8
lb-ft) torque or below.
5) Install new gasket and oil seal housing.
Do not reuse gasket removed in disassembly. Apply engine oil
to oil seal lip before installation. Tighten housing bolts to specifi-
cation.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
NOTE:
As there are 2 types of housing bolts, refer to figure for their
correct use.
After installing oil seal housing, gasket edges might bulge out;
if so, cut them off to make them flush with cylinder block and oil
seal housing.
6) Install oil pump.
Refer to item “Oil pump” for installation of oil pump.
7) Install flywheel (M / T model) or drive plate (A / T model).
Using special tool, lock flywheel or drive plate, and torque its
bolts to specification.
Special Tool
(A): 09924-17810
Tightening Torque
(a): 78 N
.m (7.8 kg-m, 56.5 lb-ft) (Flywheel bolts)
(a): 95 N
.m (9.5 kg-m, 69.0 lb-ft) (Drive plate bolts)