2000 SUZUKI SWIFT engine

ENGINE MECHANICAL (M13 ENGINE) 6A1-79
3) There are five kinds of standard bearings differing in thick-
ness. To distinguish them, they are painted in the following
colors at the position as indicated in figure.
Each color indicated the following thickness at the center of
bearing.
Standard size of crankshaft main bearing thickness
4) From number stamped on crank web No.2 and alphabets
stamped on cylinder block, determine new standard bearing
to be installed to journal, by referring to table shown below.
For example, if number stamped on crank web No.2 is “1”
and alphabet stamped on cylinder block is “B”, install a new
standard bearing painted in “Purple” to its journal.
Specification of new standard crankshaft main bearing
size
5) Using scale (1) on gaging plastic (2), check bearing clear-
ance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing
and recheck clearance.
6) When replacing crankshaft or cylinder block due to any rea-
son, select new standard bearings to be installed by referring
to number stamped on new crankshaft or alphabets stamped
on new cylinder block. Color painted Bearing thickness
Pink 1.990 – 1.994 mm (0.0783 – 0.0785 in.)
Purple 1.993 – 1.997 mm (0.0785 – 0.0786 in.)
Brown 1.996 – 2.000 mm (0.0786 – 0.0787 in.)
Green 1.999 – 2.003 mm (0.0787 – 0.0789 in.)
Black 2.002 – 2.006 mm (0.0788 – 0.0790 in.)
1. Paint
Number stamped on crank web
No.2 (Journal diameter)
123
Alphabet
stamped on cyl-
inder block
(Cap bore dia.)APink Purple Brown
B Purple Brown Green
C Brown Green Black
New standard bearing to be
installed.

6A1-80 ENGINE MECHANICAL (M13 ENGINE)
UNDERSIZE BEARING (0.25 mm) :
0.25 mm undersize bearing is available, in five kinds varying
in thickness.
To distinguish them, each bearing is painted in the following
colors at such position as indicated in figure.
Each color represents the following thickness at the center of
bearing.
Undersize of crankshaft main bearing thickness
If necessary, regrind crankshaft journal and select undersize
bearing to use with it as follows.
a) Regrind journal to the following finished diameter.
Finished diameter
: 44.732 – 44.750 mm (1.7611 – 1.7618 in.)
1) Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicu-
lar to each other in order to check for out-of-round.
2) Using journal diameter measured above and alphabets
stamped on cylinder block, select an undersize bearing by
referring to table given below.
Check bearing clearance with newly selected undersize
bearing.
Specification of new standard undersize crankshaft main bearingColor painted Bearing thickness
Red and Pink 2.115 - 2.119 mm (0.0833 - 0.0834 in.)
Red and Purple 2.118 - 2.122 mm (0.0834 - 0.0835 in.)
Red and Brown 2.121 - 2.125 mm (0.0835 - 0.0837 in.)
Red and Green 2.124 - 2.128 mm (0.0836 - 0.0838 in.)
Red and Black 2.127 - 2.131 mm (0.0837 - 0.0839 in.)
1. Paint
Measured journal diameter
44.744 – 44.750 mm
(1.7616 – 1.7618 in.)44.738 – 44.744 mm
(1.7613 – 1.7616 in.)44.732 – 44.738 mm
(1.7611 – 1.7613 in.)
Alphabets stamped
on cylinder blockA Red and Pink Red and Purple Red and Brown
B Red and Purple Red and Brown Red and Green
C Red and Brown Red and Green Red and Black
Undersize bearing to be installed

ENGINE MECHANICAL (M13 ENGINE) 6A1-81
Rear Oil Seal
Carefully inspect oil seal (1) for wear or damage.
If its lip is worn or damaged, replace it.
For oil seal installation, press-fit rear oil seal (1) to oil seal housing
(2) by using special tool as shown in the figure.
Special tool
(A) : 09911-97820
Drive in dimension
“a” : 3 mm (0.12 in.)
Flywheel
If ring gear is damaged, cracked or worn, replace flywheel.
If the surface contacting clutch disc is damaged, or exces-
sively worn, replace flywheel.
Check flywheel for face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel on runout
Limit : 0.2 mm (0.0079 in.)
Sensor plate
Check sensor plate for crack or damage. If malcondition is
found, replace it.

6A1-82 ENGINE MECHANICAL (M13 ENGINE)
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed
surface for distortion and, if flatness exceeds its limit, correct
it.
Cylinder block flatness
Limit : 0.05 mm (0.0020 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must
also be rebored at the same time.
2) Select oversized piston according to amount of cylinder
wear.
Oversize piston diameter
3) Using micrometer, measure piston diameter.
Measurement position for piston diameter
“a” : 19.5 mm (0.77 in.)
4) Calculate cylinder bore diameter to be rebored as follows.
D = A + B – C
D : Cylinder bore diameter to be rebored.
A : Piston diameter as measured.
B : Piston clearance = 0.02 – 0.04 mm (0.0008 – 0.0016 in.)
C : Allowance for honing = 0.02 mm (0.0008 in.)
5) Rebore and hone cylinder to calculated dimension.
6) Measure piston clearance after honing
Size Piston diameter
Oversize 0.25 78.203 - 78.218 mm (3.0789 - 3.0794 in.)
Oversize 0.50 78.453 - 78.468 mm (3.0887 - 3.0893 in.)
NOTE:
Before reboring, install all main bearing caps in place
and tighten to specification to avoid distortion of bearing
bores.

ENGINE MECHANICAL (M13 ENGINE) 6A1-83
INSTALLATION
1) Install sensor plate (1) to crankshaft (2) and tighten bolts to
specified torque.
Tightening torque
Sensor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
2) Install main bearings to cylinder block.
Upper half of bearing (1), has an oil groove (2).
Install it to cylinder block (3), and the other half without oil
groove to bearing cap.
Make sure that two halves are painted in the same color.
3) Install thrust bearings (1) to cylinder block between No.2 and
No.3 cylinders. Face oil groove (2) sides to crank webs.
4) Confirm that dowel pins (3) are installed to intake side of
each journal.
5) Install crankshaft to cylinder block.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, piston rings and cylinder bores.
Journal bearings, bearings caps, connecting rods, rod
bearings, rod bearing caps, pistons and piston rings
are in combination sets. Do not disturb such combina-
tion and make sure that each part goes back to where
it came from, when installing.
NOTE:
When installing sensor plate, align spring pin (3) on
crankshaft and hole of sensor plate.

6A1-84 ENGINE MECHANICAL (M13 ENGINE)
6) Install bearing cap to cylinder block, making sure to point
arrow mark (on each cap) to crankshaft pulley side. Fit them
sequentially in ascending order, 1, 2, 3, 4 and 5, starting
from pulley side.
After applying engine oil to new bearing cap No.1 bolts ((1) –
(10)) and bearing cap No.2 bolts ((11) – (20)), tighten them
gradually as follows.
a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft)
according to numerical order as shown by using a 12 cor-
ner socket wrenches.
b) In the same manner as in Step a), tighten them to 50 N·m
(5.0 kg-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them to 60°.
d) Tighten bolts (11) – (20) to 22 N·m (2.2 kg-m, 16.0 lb-ft)
according to numerical order as shown.
Tightening torque
Crankshaft bearing cap No.1 bolts (1) – (10)
: 50 N·m (5.0 kg-m, 36.5 lb-ft) and then turn to 60°
Crankshaft bearing cap No.2 bolts (11) – (20)
: 22 N·m (2.2 kg-m, 16.0 lb-ft)
7) Apply sealant to mating surface of rear oil seal housing (1).
“A” : Sealant 99000-31150
Sealant amount for rear oil seal housing
Width “a” : 3 mm, 0.12 in.
Height “b” : 2 mm, 0.08 in.
8) Install rear oil seal housing (1) and tighten bolts to specified
torque by using special tool.
Special tool
(A) : 09911-97720
Tightening torque
Rear oil seal housing bolts : 11 N·m (1.1 kg-m, 8.0 lb-ft) NOTE:
Never reuse bearing cap NO.1 bolts (1) - (10) once dis-
assembled it due to plastic deformation tightening.
After tightening cap bolts, check to be sure that crank-
shaft rotates smoothly when turning it by 12 N·m (1.2
kg-m, 9.0 lb-ft) torque or below.
A : Crankshaft side

ENGINE MECHANICAL (M13 ENGINE) 6A1-85
9) Install flywheel (drive plate for A/T).
Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts applied with sealant to specifica-
tion.
“A” : Sealant 99000-31110
Special tool
(A) : 09924-17810
Tightening torque
Flywheel or drive plate bolts
(a) : 70 N·m (7.0 kg-m, 51.0 lb-ft)
10) Install the following parts to engine as previously outlined.
Piston and connecting rod
Cylinder head assembly
Camshaft, tappet and shim
Timing chain guide, chain tensioner adjuster, chain ten-
sioner, timing chain and crankshaft timing sprocket
Timing chain cover
Cylinder head cover
Intake manifold and exhaust manifold
Oil pan and oil pump strainer
11) Install clutch to flywheel (vehicle with M/T) referring to Sec-
tion 7C.
12) Install engine assembly to vehicle as previously outlined.
REQUIRED SERVICE MATERIAL
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant Sealant 1207C
(99000-31150)To apply to mating surfaces of cylinder block and oil
pan.
To apply to mating surfaces of cylinder block and
timing chain cover.
To apply to sealing surfaces of cylinder head cover.
To apply to mating surfaces to rear oil seal housing.
Sealant 1207B
(99000-31140)To apply to mating surface of cylinder block, cylin-
der head and timing chain cover.
Sealant 1215
(99000-31110)To apply to the thread of the bolt of water outlet
pipe.
To flywheel (M/T) or drive plate (A/T) bolts.

6A1-86 ENGINE MECHANICAL (M13 ENGINE)
TIGHTENING TORQUE SPECIFICATION
Fastening partTightening torque
Nm kg-m lb-ft
Oil pressure switch 14.0 1.4 10.5
Camshaft housing bolts
(for replacement of shim)8.0 0.8 6.0
Camshaft housing bolts 11.0 1.1 8.0
Cylinder head cover bolts 8.0 0.8 6.0
Intake manifold bolts and nuts 25.0 2.5 18.0
Exhaust manifold bolts and nuts 50.0 5.0 36.5
Exhaust No.1 pipe bolts 50.0 5.0 36.5
Exhaust manifold stiffener bolts 50.0 5.5 36.5
Oil pump strainer bolt 11.0 1.1 8.0
Oil pump strainer bracket bolt 11.0 1.1 8.0
Oil pan bolts and nuts 11.0 1.1 8.0
Oil pan drain plug bolt 50.0 5.0 36.5
Timing chain cover bolts 23.0 2.3 17.0
Engine mounting bolts 75.0 7.5 54.5
Engine mounting bracket bolts 55.0 5.5 40.0
Crank shaft pulley bolt 150.0 15.0 108.5
Oil pump rotor plate bolts 11.0 1.1 8.0
Timing chain No.1 guide bolts 9.0 0.9 6.5
Timing chain tensioner adjuster bolt 11.0 1.1 8.0
Venturi plug 5.0 0.5 3.5
Cylinder head bolts for M8 22.0 2.2 16.0
Cylinder head bolts for M10 a) Tighten 40 N·m
b) Turn 60°
c) Turn 60°a) Tighten 4.0 kg-m
b) Turn 60°
c) Turn 60°a) Tighten 29.0 lb-ft
b) Turn 60°
c) Turn 60°
Connecting rod bearing cap nuts a) Tighten 15 N·m
b) Turn 45°
c) Turn 45°a) Tighten 1.5 kg-m
b) Turn 45°
c) Turn 45°a) Tighten 11.0 lb-ft
b) Turn 45°
c) Turn 45°
Engine mounting bolts and nuts for M10 55.0 5.5 40.0
Engine mounting bolts and nuts for M12 75.0 7.5 54.5
Crankshaft bearing cap No.1 bolts
(for inspection of crankshaft thrust play)50.0 5.0 36.5
Crankshaft bearing cap No.2 bolts 22.0 2.2 16.0
Sensor plate bolts 11.0 1.1 8.0
Crankshaft bearing cap No.1 bolts a) Tighten 50 N·m
b) Turn 60°a) Tighten 5.0 kg-m
b) Turn 60°a) Tighten 36.5 lb-ft
b) Turn 60°
Rear oil seal housing bolts 11.0 1.1 8.0
Flywheel or drive plate bolts 70.0 7.0 51.0