2000 SUZUKI SWIFT Valve clearance

Below
specified value
6-1-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
1. CKP sensor signal
2. No.1 fuel injector signal
3. No.3 fuel injector signal
4. Fuel injection time
Display of fuel injection signal using oscilloscope
Waveforms at specified idle speed5ms/Div
DTC DETECTING CONDITIONPOSSIBLE CAUSE

Engine under other than high revolution condition

Not on rough road

Engine speed changing rate

Manifold absolute
pressure changing rate

Throttle opening changing rate

Misfire rate per 200 or 1000 engine revolutions (how
much and how often crankshaft revolution speed
changes) is higher than specified value
Engine overheating

Vacuum leaks (air inhaling) from air intake system

Ignition system malfunction (spark plug(s), high-
tension cord(s), ignition coil assembly)

Fuel pressure out of specification

Fuel injector malfunction (clogged or leakage)

Engine compression out of specification

Valve lash (clearance) out of specification

Manifold absolute pressure sensor malfunction

Engine coolant temp. sensor malfunction

PCV valve malfunction

EVAP control system malfunction

EGR system malfunction
DTC CONFIRMATION PROCEDURE
NOTE:
Among different types of random misfire, if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2 simulta-
neously, it may not possible to reconfirm DTC by using the following DTC confirmation procedure. When
diagnosing the trouble of DTC P0300 (Random misfire detected) of the engine which is apparently misfir-
ing, even if DTC P0300 cannot be reconfirmed by using the following DTC confirmation procedure, pro-
ceed to the following Diag. Flow Table.
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester.
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Check vehicle and environmental condition for:
–Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Intake air temp.: between –10C and 80C (14F and 176F)
–Engine coolant temp.: –10C, 14F or higher
4) Start engine and keep it at idle for 2 min. or more.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6) If DTC is not detected at idle, consult usual driving based on information obtained in “Customer complaint analy-
sis” and “Freeze frame data check”.
Reference

ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-17
INSPECTION
Camshaft journal wear:

Check camshaft journals and camshaft housings for pitting,
scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head
with housing. Never replace cylinder head without replacing
housings.
Check clearance by using gaging plastic (1). The procedure is as
follows.
1) Clean housings and camshaft journals.
2) Make sure that all valve lash adjusters are removed and install
camshaft to cylinder head.
3) Place a piece of gaging plastic the full width of journal of cam-
shaft (parallel to camshaft).
4) Install housings as outlined on the following page and evenly
torque housing bolts to specified torque. Housings MUST be
torqued to specification in order to assure proper reading of
camshaft journal clearance.
NOTE:
Do not rotate camshaft while gaging plastic is installed.
5) Remove housing, and using scale (2) on gaging plastic envel-
op, measure gaging plastic width at its widest point.
JournalStandardLimitJournal
clearance0.040 – 0.082 mm
(0.0016 – 0.0032 in.)0.12 mm
(0.0047 in.)
If measured camshaft journal clearance exceeds limit, mea-
sure journal (housing) bore and outside diameter of camshaft
journal. Replace camshaft or cylinder head assembly which-
ever the difference from specification is greater.
Item
Standard
Camshaft journalNo.126.000 – 26.021 mm
(1.0236 – 1.0244 in.)
j
bore dia.No.2 &
No.330.000 – 30.021 mm
(1.1811 – 1.1819 in.)
Camshaft journalNo.125.939 – 25.960 mm
(1.0212 – 1.0220 in.)
j
O.D.No.2 &
No.329.939 – 29.960 mm
(1.1787 – 1.1795 in.)

6A-20 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
CAUTION:

Don’t turn camshaft or start engine (i.e., valves should not be operated) for about half an hour after
reinstalling hydraulic valve lash adjusters and camshaft. As it takes time for valves to settle in place,
operating engine within half an hour after their installation may cause interference to occur between
valves and piston.

If air is trapped in valve lash adjuster, valve may make tapping sound when engine is operated after
valve lash adjuster is installed. In such a case, run engine for about half an hour at about 2,000 – 3,000
r / min., and then air will be purged and tapping sound will cease. Should tapping should not cease,
it is possible that valve lash adjuster is defective. Replace it if defective.
If defective adjuster can’t be located by hearing among 6 of them, check as follows.
1) Stop engine and remove cylinder head cover.
2) Push adjuster downward by hand (with less than 15 kg or 33 lbs force) when cam crest is not on
adjuster to be checked and check if clearance exists between cam and adjuster. If it does, adjuster
is defective and needs replacement.
VALVE LASH ADJUSTER NOISE DIAGNOSIS
In case of the followings, valve lash adjuster noise may be caused by air trapped into valve lash adjusters.

Vehicle is left for 24 hours or more.

Engine oil is changed.

Hydraulic lash adjuster is replaced or reinstalled.

Engine is overhauled.
If noise from valve lash adjusters is suspected, perform the following checks.
1) Check engine oil for the followings.

Oil level in oil pan
If oil level is low, add oil up to Full level hole on oil level gauge.

Oil quality
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to Section 0B.

Oil leaks
If leak is found, repair it.

Oil pressure (refer to Oil Pressure Check in this section)
If defective pressure is found, repair it.
2) Run engine for about half an hour at about 2,000 to 3,000 r / min., and then air will be purge and tapping sound
will cease.
3) Should tapping sound not cease, it is possible that hydraulic valve lash adjuster is defective.
Replace it if defective.
If defective adjuster can’t be located by hearing among 16 of them, check as follows.
a) Stop engine and remove cylinder head cover.
b) Push adjuster downward by hand (with less than 20 kg or 44 lbs. Force) when cam crest is not on adjuster
to be check if clearance exists between cam and adjuster.
If it does, adjuster is defective and needs replacement.

1. Cylinder head
2. Cylinder head bolt
3. Valve guide
4. Cylinder head gasket:
“TOP” mark provided on
gasket comes to crankshaft
pulley side, facing up
(toward cylinder head side).
5. Pin
6. Camshaft
7. Valve lash adjuster
8. Valve cotters
9. Valve spring retainer
10. Valve spring:
Be sure to position spring in place with
its bottom end (small-pitched) facing the
bottom (valve spring seat side).11. Valve stem seal
12. Valve spring seat
13. Exhaust valve
14. Intake valve
15. Oil seal
16. Gasket
17. Camshaft housing bolt: Tightening Torque
: Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-21
VALVES AND CYLINDER HEAD
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.
Item
StandardLimit
Valve stemIn5.457 – 5.480 mm
(0.2148 – 0.2157 in.)———
diameterEx5.440 – 5.455 mm
(0.2142 – 0.2148 in.)———
Valve guide
I.D.In &
Ex5.500 – 5.512 mm
(0.2165 – 0.2170 in.)———
Stem-to-
guide
In0.020 – 0.055 mm
(0.0008 – 0.0021 in.)0.07 mm
(0.0027 in.)
guide
clearanceEx0.045 – 0.072 mm
(0.0018 – 0.0028 in.)0.09 mm
(0.0035 in.)

6A-22 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
Valve Springs

Referring to data given below, check to be sure that each spring
is in sound condition, free of any evidence of breakage or weak-
ening. Remember, weakened valve springs can cause chatter,
not to mention possibility of reducing power output due to gas
leakage caused by decreased seating pressure.
Item
StandardLimit
Valve spring
free length42.29 mm
(1.6649 in.)41.0 mm
1.6142 in.)
Valve spring
preload
209 – 235 N
(20.9 – 23.5 kg) at
32.6 mm (46.1 –
51.8 lb at 1.28 in.)187 N (18.7 kg)
at 32.6 mm
(41.2 lb at 1.28 in.)

Spring squareness:
Use a square and surface plate to check each spring for square-
ness in terms of clearance between end of valve spring and
square. Valve spring found to exhibit a larger clearance than limit
must be replaced.
Valve spring
2 0 mm (0 079 in )g
squareness limit.2.0 mm (0.079 in.)

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.

2
IN
EX (A)
1
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-9
VALVE LASH (CLEARANCE)
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to item “Cylinder Head
cover”.
3) Remove engine under cover of right side from body.
4) Using special tool and wrench (1), turn crankshaft pulley clock-
wise until “V” mark (2) (in white paint) on pulley aligns with “0”
(zero) calibrated on timing belt cover.
Special Tool
(A): 09919-16020
5) See if the rocker arms of No.1 cylinder are off the respective cam
lobes (of camshaft); if so, valves (1), (2), (5) and (7) in figure are
ready for clearance checking and adjustment. Check valve
lashes at valves (1), (2), (5) and (7).
If the rocker arms of No.4 cylinder are off the respective cam
lobes, check valve lashes at valves (3), (4), (6) and (8).
NOTE:
When checking valve clearance, insert thickness gauge be-
tween camshaft and cam-riding face of rocker arm.

1. Thickness gauge IN
EX
360
IN
EX
6A1-10 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
6) If valve lash is out of specification, adjust it to specification by
turning adjusting screw after loosening lock nut.
After adjustment, tighten lock nut to specified torque while hold-
ing adjusting screw stationary, and then make sure again that
valve lash is within specification.
Valve
clearance
When cold
(Coolant tempera-
ture is 15 – 25C
or 59 – 77F)When hot
(Coolant tempera-
ture is 60 – 68C
or 140 – 154F)
specifica-
tionIntake0.13 – 0.17 mm
(0.005 – 0.007 in.)0.18 – 0.22 mm
(0.007 – 0.009 in.)
Exhaust0.23 – 0.27 mm
(0.009 – 0.011 in.)0.28 – 0.32 mm
(0.011 – 0.013 in.)
Special Tool
(A): 09917-18211
Tightening Torque
(a): 12 N
.m (1.2 kg-m, 9.0 lb-ft)
7) After checking and adjusting valve lashes at valves (1), (2), (5)
and (7), (or (3), (4), (6) and (8)) rotate crankshaft exactly one full
turn (360) and check the same at valves (3), (4), (6) and (8) (or
(1), (2), (5) and (7)). Adjust them as necessary.
8) After checking and adjusting all valves, reverse removal proce-
dure for installation.