2000 SUZUKI SWIFT Cylinder head

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-27
ConditionPossible CauseReferring Item
Improper engine
idling or engine
fails to idleIgnition system out of order

Faulty spark plug

Leaky or disconnected high-tension cord

Faulty ignition coil with ignitor
Fuel system out of order

Fuel pressure out of specification

Leaky manifold, throttle body, or cylinder head
gasket
Engine and emission control system out of
order

Malfunctioning EGR valve

Faulty idle air control system

Faulty evaporative emission control system

Faulty EGR system

Faulty fuel injector(s)

Poor performance of ECT sensor, TP sensor or
MAP sensor

Faulty ECM (PCM)
Engine overheating
Low compression
Others

Loose connection or disconnection of vacuum
hoses

Malfunctioning PCV valve
Spark plugs in Section 6F
High-tension cords in Section 6F
Ignition coil in Section 6F
Diagnostic Flow Table B-3
EGR system in Section 6E2
Diagnostic Flow Table B-4
EVAP control system in Section
6E2
EGR system in Section 6E2
Diagnostic Flow Table B-1
ECT sensor, TP sensor or MAP
sensor in Section 6E2
Refer to “Overheating” section
Previously outlined
PCV system in Section 6E2

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6A-4 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
CYLINDER HEAD COVER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly.
3) Remove high-tension cord clamps (2) from cylinder head cover.
4) Disconnect breather hose from cylinder head cover.
5) Remove cylinder head cover nuts and then seal washers (1).
6) Remove cylinder head cover (3) from cylinder head.
INSTALLATION
1) Install cylinder head cover gasket to head cover.
Before installing gasket, check it for deterioration or damage,
and replace as necessary.
2) Install cylinder head cover (1).
Before installing seal washers, check each one for deterioration
or damage, and replace as necessary.
Tighten cover nuts to specified torque.
Tightening Torque
(a): 4.5 N
.m (0.45 kg-m, 3.5 lb-ft)
3) Install high-tension cord clamps (2) to cylinder head cover.
4) Connect breather hose to cylinder head cover.
5) Install air cleaner assembly.
6) Connect negative cable at battery.

1. Throttle body
1. Throttle body
2. ISC actuator
5. Clamp
6A-6 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
4) Remove air cleaner assembly.
5) Disconnect the following electric lead wires:

EGR valve

ISC actuator (2)

Ground wires from intake manifold

Fuel injector (4)

TP sensor (3)

EFE heater (5)

Engine coolant temp. gauge
6) Disconnect fuel return (4) and feed hoses (3) from fuel pipes.
7) Disconnect coolant hoses from intake manifold.
8) Disconnect the following vacuum hoses.

Canister purge hose from intake manifold.

EGR pressure transducer hoses from EGR valve.

EGR valve hose from EGR valve.

Pressure sensor hose from intake manifold.

Brake booster hose from intake manifold.
9) Disconnect breather hose from PCV valve.
10) Disconnect accelerator cable from throttle body.
11) Disconnect other connected to throttle body and intake man-
ifold, if any.
12) Remove intake manifold with throttle body from cylinder head.
13) Remove throttle body from intake manifold.

2. Ground
1. Throttle body
2. ISC actuator
coupler
3. TP sensor
coupler
4. Fuel injector
coupler
5. EFE heater
coupler
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-7
INSTALLATION
1) Install throttle body to intake manifold. (Refer to Section 6E.)
2) Install intake manifold gasket to cylinder head. Use a new gas-
ket.
3) Install intake manifold (1) with throttle body to cylinder head.

Install clamps (3) as shown in figure, and tighten bolts and
nuts to specification.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Connect breather hose to PCV valve.
5) Connect vacuum hoses.
6) Connect coolant hoses.
7) Connect fuel return and feed hoses to throttle body.
8) Connect electric lead wire.
9) Connect accelerator cable to throttle body.
10) Install air cleaner assembly to throttle body.
11) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
12) Refill cooling system.
13) Connect negative cable at battery.
14) Upon completion of installation, start engine and check for fuel
leaks and engine coolant leaks.
After warming up engine, adjust accelerator cable play to spec-
ification according to description in Section 6E.

1. Exhaust manifold
2. Gasket
3. Cover
4. Heated oxygen sensor
5. Pipe seal
6. Exhaust pipe
7. WU-TWC (if equipped)
8. Exhaust pipe bolt : Tightening Torque
: Do not reuse
6A-8 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
EXHAUST MANIFOLD
WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot.
Service should be performed after system cools down.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect heated oxygen sensor coupler.
Release its wire from clamps.
3) Disconnect exhaust pipe (1) from exhaust manifold (or WU-
TWC (2)).
4) Remove WU-TWC stiffener (3). (if equipped)
5) Remove exhaust manifold cover (2). (for vehicle with WU-TWC)
6) Remove exhaust manifold (1) with WU-TWC (if equipped) and
its gasket from cylinder head.

2. WU-TWC
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-9
INSTALLATION
1) Install manifold gasket to cylinder head.
Before installing gasket, check it for deterioration or damage,
and replace as necessary.
2) Install exhaust manifold (1).
Tighten manifold bolts and nuts to specified torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Install exhaust manifold cover (2).
4) Install pipe seal, and then connect exhaust pipe (1).
Before installing pipe seal, check it for deterioration or damage,
and replace as necessary.
Tighten pipe bolts to specified torque.
Tightening Torque
(c): 43 N
.m (4.3 kg-m, 31.5 lb-ft)
5) Install WU-TWC stiffener (3). (if equipped)
6) Connect heated oxygen sensor coupler.
7) Clamp its wire securely.
8) Connect negative cable at battery.
9) Check exhaust system for exhaust gas leakage.

1.“V” mark on cylinder head cover
2. Timing mark on camshaft timing belt pulley
3. Arrow mark on oil pump case
4. Punch mark on crankshaft timing belt pulley
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-11
8) Loosen crankshaft pulley bolts (1) and remove crankshaft
pulley (2).
9) Remove timing belt outside cover (1).
10) Align 4 timing marks as shown in figure to facilitate its installa-
tion.
11) Loosen tensioner bolt (3) and stud (4), and remove belt (1) from
crankshaft timing belt pulley and camshaft timing belt pulley af-
ter pushing up the tensioner plate (2) fully by finger as shown
figure.
CAUTION:
Never bend timing belt.