2000 SUZUKI SWIFT Adjust

Don’t apply force
6A-16 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
6) Remove camshaft housings from cylinder head.
7) Remove camshaft from cylinder head.
8) Remove valve lash adjuster from cylinder head.
NOTE:

Never disassemble hydraulic valve lash adjuster.

Don’t apply force to body of adjuster, for oil in high pres-
sure chamber in adjuster will leak.

Immerse removed adjuster (2) in clean engine oil (1) and
keep it there till reinstalling it so as to prevent oil leakage.
If it is left in air, place it with its bucket body facing down.
Don’t place on its side or with bucket body facing up.

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.)

Indicates position from timing belt
side. Install in numerical order
starting from timing belt side.

Indicates direction of housing.
Install so that arrow is directed
toward timing belt side.
6A-18 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
1) Before installing valve lash adjuster to cylinder head, fill oil pas-
sage of cylinder head (1) with engine oil according to the follow-
ing procedure.
Pour engine oil through camshaft journal oil holes (2) and check
that oil comes out from oil holes in sliding part of valve lash ad-
juster.
2) Install lash adjuster to cylinder head.
Apply engine oil around valve lash adjuster and then install it to
cylinder head.
3) Install camshaft to cylinder head.
After applying engine oil to camshaft journal and all around cam,
set camshaft to cylinder head so that camshaft timing belt pulley
pin hole (1) in camshaft is at lower position.
4) 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.1 and No.3 housings
which will mate with cylinder head.
“A”: Sealant 99000-31110

Embossed marks are provided on each camshaft housing, in-
dicating position and direction for installation.
Install housing as indicated by these marks.

2. No.2 housing
3. No.3 housing
3. Rod
4. Shop cloth
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-19

As camshaft housing No.1 (1) retains camshaft in proper
position as to thrust direction, make sure to first fit No.1 hous-
ing to No.1 journal of camshaft securely.

After applying engine oil to housing bolts, tighten them tem-
porarily first. Then tighten them by following sequence as
shown in figure.
Tighten a little at a time and evenly among bolts and repeat
tightening sequence three to four times before they are tight-
ened to specified torque.
Special Tool
(A): 09919-16010
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
5) Install camshaft oil seal.
After applying engine oil to oil seal lip, press-fit camshaft oil
seal till oil seal surface becomes flush with housing surface.
6) Install camshaft timing belt pulley (1) to camshaft (2) after
installing dwell pin to camshaft.
With locking camshaft as shown in figure, tighten pulley bolt to
specified torque.
Tightening Torque
(b): 60 N
.m (6.0 kg-m, 43.5 lb-ft)
7) Install cylinder head cover to cylinder head as previously out-
lined.
8) Install timing belt, timing belt outside cover, crankshaft pulley,
water pump pulley and water pump belt as previously outlined.
9) Install distributor case and distributor.
Refer to Section 6F for installation.
10) Install air cleaner assembly as previously outlined.
11) Connect negative cable at battery.
12) Adjust ignition timing.
Refer to Section 6F for adjustment.

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.)

1. Rear mounting
2. Rear mounting No.2
bracket
3. Rear mounting No.1
bracket
4. Rear mounting
bracket5. Left mounting
body bracket
6. Left mounting
7. Left mounting bracket
8. Right mounting bracket
9. Right mounting
For M / T model
For A / T model
1. Rear mounting
2. Rear mounting No.2
bracket
3. Rear mounting No.1
bracket
4. Left mounting No.1
bracket
5. Stopper6. Left mounting
7. Left mounting No.2
bracket
8. Right mounting bracket
9. Right mounting
10. Torque rod bracket
11. Stiffener
12. Torque rod
6A-26 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
1) Lift engine with transmission into engine compartment, but do
not remove lifting device.
2) Install right side engine mounting to its bracket.
3) Install left side engine mounting and its bracket.
4) Install rear mounting to body.
5) Tighten bolts and nuts of all parts installed in above steps 2),
3) and 4) to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
6) Remove lifting device.
7) Reverse removal procedures for installation of remainder.

Push in each drive shaft joint fully so that snap ring engages
with differential gear or center bearing support.
Use care not to damage oil seal lip when inserting.

Clamp electric wires securely.
8) Adjust clutch pedal free travel referring to Section 7C. (For M / T
model)
Adjust gear select cable and oil pressure control cable referring
to Section 7B. (For A / T model)
9) Adjust gear shift control lever referring to Section 7A. (For M / T
model)
10) Refill transmission with gear oil. (A / T fluid for A / T model) refer-
ring to Section 0B.
11) Refill engine with engine oil referring to Section 0B.
12) Refill cooling system referring to Section 6B.
13) Adjust A / C compressor drive belt referring to Section 0B. (if
equipped)
14) Upon completion of installation, verify that there is no fuel leak-
age, coolant leakage, transmission oil leakage or exhaust gas
leakage at each connection.
15) Adjust accelerator cable play referring to Section 6E.

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.