2000 SUZUKI SWIFT RG413 Service Workshop Manual

6A1-44 ENGINE MECHANICAL (M13 ENGINE)
VALVES AND CYLINDER HEAD
REMOVAL
1) Relieve fuel pressure according to procedure described in
Section 6.
2) Disconnect negative cable at battery.
3) Drain engine oil.
[A]✱1) Tighten all bolts at 40 N·m (4.0 kg-m)
2) Turn all bolts at 60°
3) Then, Turn all bolt at 60° once again6. Intake valve 12. Knock pin
1. Valve cotters 7. Exhaust valve
Tightening torque
2. Valve spring retainer 8. Valve guide
Do not reuse.
3. Valve spring 9. Cylinder head bolt
: Never reuse it due to plastic deformation
tightening bolt.Apply engine oil to sliding surface of
each part.
4. Valve stem seal 10. Cylinder head
5. Valve spring seat 11. Cylinder head gasket
: “TOP” mark provided on gasket comes to
crankshaft pulley side, facing up.

ENGINE MECHANICAL (M13 ENGINE) 6A1-45
4) Drain coolant by loosening drain plug (1).
5) Remove air cleaner assembly (1), resonator and hoses (2)
referring to “AIR CLEANER ASSEMBLY AND RESONA-
TOR”.
6) Disconnect the following electric lead wires :
EGR valve (if equipped)
IAC valve (1)
TP sensor (2)
MAP sensor (3)
CMP sensor
ECT sensor
EVAP canister purge valve (4)
Injectors (5)
Ignition coils
Heated oxygen sensors
Ground terminal from exhaust manifold
Each wire harness clamps
7) Remove heated oxygen sensor bracket from timing chain
cover and detach heated oxygen sensor couplers from its
bracket.
8) Disconnect accelerator cable from throttle body.
9) Disconnect the following hoses :
Brake booster hose (1) from intake manifold
Canister purge hose (2) from EVAP canister purge valve
Fuel feed and return hose (3) from each pipe
Water hose (4) from thermostat case
Heater inlet hose (5) from its pipe WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.

6A1-46 ENGINE MECHANICAL (M13 ENGINE)
10) Remove intake manifold stiffener (1).
11) Remove oil pan referring to “OIL PAN AND OIL PUMP
STRAINER”.
12) Remove cylinder head cover referring to “CYLINDER HEAD
COVER”.
13) Remove timing chain cover referring to “TIMING CHAIN
COVER”.
14) Remove timing chain referring to “TIMING CHAIN AND
CHAIN TENSIONER”.
15) Remove intake and exhaust camshafts referring to “CAM-
SHAFT, TAPPET AND SHIM”.
16) Loosen cylinder head bolts in such order as indicated in fig-
ure by using a 12 corner socket wrenches and remove them.
17) Check all around cylinder head for any other parts required
to be removed or disconnected and remove or disconnect
whatever necessary.
18) Remove exhaust manifold, if necessary, referring to
“EXHAUST MANIFOLD”.
19) Remove cylinder head with intake manifold and exhaust
manifold. Use lifting device, if necessary.
NOTE:
Don’t forget to remove bolt (M8) (1) as shown in figure.
Never reuse cylinder head bolts once disassembled it
due to plastic deformation tightening. Be sure to use
new cylinder head bolts when installing.

ENGINE MECHANICAL (M13 ENGINE) 6A1-47
DISASSEMBLY
1) For ease in servicing cylinder head, remove intake manifold,
injectors and exhaust manifold from cylinder head.
2) Using special tools (Valve lifter), compress valve spring and
then remove valve cotters (1) by using special tool (Forceps).
Special tool
(A) : 09916-14510
(B) : 09916-14910
(C) : 09916-84511
3) Release special tool, and remove spring retainer and valve
spring.
4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide, and then valve
spring seat (2).
6) Using special tool (valve guide remover), drive valve guide
out from combustion chamber side to valve spring side.
Special tool
(A) : 09916-46020 for engine equipped with 69G type valve
(A) : 09916-44910 for engine equipped with 54G type valve
7) Place disassembled parts except valve stem seal and valve
guide in order so that they can be installed in their original
position.
NOTE:
Do not reuse seal once disassembled. Be sure to use
new oil seal when assembling.
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.
1. Valve
2. Emboss mark 54G or 69G

6A1-48 ENGINE MECHANICAL (M13 ENGINE)
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.
Valve stem-to-guide clearance
Valve stem diameter [A]
Valve guide bore [B] standard
In and Ex : 6.000 – 6.012 mm (0.2362 – 0.2367 in.) for 69G
type valve
In and Ex : 5.485 – 5.510 mm (0.2159 – 0.2169 in.) for 54G
type valve
If bore gauge is not available, check end deflection of valve stem
with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end deflec-
tion.
If deflection exceeds its limit, replace valve stem and valve guide.
Valve stem end deflection limit
In : 0.14 mm (0.005 in.)
Ex : 0.18 mm (0.007 in.)Valve type Standard Limit
69GIn0.020 – 0.047 mm
(0.0008 – 0.0019 in.)0.07 mm
(0.0028 in.)
Ex0.045 – 0.072 mm
(0.0018 – 0.0028 in.)0.09 mm
(0.0035 in.)
54GIn0.020 – 0.030 mm
(0.0008 – 0.0012 in.)0.05 mm
(0.0017 in.)
Ex0.045 – 0.055 mm
(0.0018 – 0.0022 in.)0.07 mm
(0.0028 in.)
Valve type Standard
69GIn5.965 – 5.980 mm
(0.2348 – 0.2354 in.)
Ex5.940 – 5.955 mm
(0.2339 – 0.2344 in.)
54GIn5.465 – 5.480 mm
(0.2152 – 0.2157 in.)
Ex5.440 – 5.455 mm
(0.2142 – 0.2148 in.)
1. Emboss mark 54G or 69G

ENGINE MECHANICAL (M13 ENGINE) 6A1-49
Valves
Remove all carbon from valves.
Inspect each valve for wear, burn or distortion at its face and
stem end, as necessary, replace it.
Measure thickness “a” of valve head. If measured thickness
exceeds limit, replace valve.
Valve head thickness (In and Ex)
Standard : 1.22 – 1.55 mm (0.048 – 0.061 in.)
Limit : 0.9 mm (0.035 in.)
Inspect valve stem end face for pitting and wear. If pitting or
wear is found there, valve stem end may be resurfaced, but
not too much to grind off its chamber. When it is worn out too
much that its chamber is gone, replace valve.
Check each valve for radial runout with a dial gauge and “V”
block. To check runout, rotate valve slowly. If runout exceeds
its limit, replace valve.
Limit on valve head radial runout
: 0.08 mm (0.003 in.)
Seating contact width:
Create contact pattern on each valve in the usual manner,
i.e. by giving uniform coat of marking compound to valve
seat and by rotatingly tapping seat with valve head. Valve
lapper (tool used in valve lapping) must be used.
Pattern produced on seating face of valve must be a continu-
ous ring without any break, and the width of pattern must be
within specified range.
Standard seating width “a” revealed by contact pattern on
valve face
In and Ex : 1.1 - 1.3 mm (0.0433 - 0.0512 in.)

6A1-50 ENGINE MECHANICAL (M13 ENGINE)
Valve seat repair:
A valve seat not producing a uniform contact with its valve or
showing width of seating contact that is out of specified
range must be repaired by regrinding or by cutting and
regrinding and finished by lapping.
a) EXHAUST VALVE SEAT : Use valve seat cutters (1) to
make two cuts as illustrated in figure. Two cutters must be
used: the first for making 15° angle, and the second for
making 45° angle. The second cut must be made to pro-
duce desired seat width.
Seat width for exhaust valve seat
“a” : 1.1 – 1.3 mm (0.0433 – 0.0512 in.)
b) INTAKE VALVE SEAT : Use valve seat cutters to make
three cuts as illustrated in figure. Three cutters must be
used: the 1st for making 15° angle, the 2nd for making 60°
angle, and 3rd for making 45° angle. The 3rd cut (45°) must
be made to produce desired seat width.
Seat width for intake valve seat
“b” : 1.1 – 1.3 mm (0.0433 – 0.0512 in.)
c) VALVE LAPPING : Lap valve on seat in two steps, first with
coarse size lapping compound applied to face and the sec-
ond with fine-size compound, each time using valve lapper
according to usual lapping method.
Cylinder Head
Remove all carbon deposits from combustion chambers.
NOTE:
Do not use any sharp-edged tool to scrape off carbon
deposits. Be careful not to scuff or nick metal surfaces
when decarbonizing. The same applies to valves and
valve seats, too.

ENGINE MECHANICAL (M13 ENGINE) 6A1-51
Check cylinder head for cracks on intake and exhaust ports,
combustion chambers, and head surface.
Using a straightedge and thickness gauge, check flatness of
gasketed surface at a total of 2 locations. If distortion limit,
given below, is exceeded, correct gasketed surface with a
surface plate and abrasive paper of about #400 (Waterproof
silicon carbide abrasive paper): place abrasive paper on and
over surface plate, and rub gasketed surface against paper
to grind off high spots. Should this fail to reduce thickness
gauge readings to within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint is
often due to warped gasketed surface: such leakage results
in reduced power output.
Limit of distortion for cylinder head surface on piston side
: 0.03 mm (0.001 in.)
Distortion of manifold seating faces:
Check seating faces of cylinder head for manifolds, using a
straightedge and thickness gauge, in order to determine
whether these faces should be corrected or cylinder head
replaced.
Limit of distortion for cylinder head surface on intake and
exhaust manifold
: 0.05 mm (0.002 in.)