2000 SUZUKI SWIFT crankshaft

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. Cylinder block
2. Front oil seal
3. Main bearing
4. Bearing cap
5. Cap washer
6. Cap bolt
7. Timing pulley key
8. Crankshaft
9. Thrust bearing:
Set oil grooves of bearing to weds.
10. Rear oil seal
11. Pin
12. Oil seal housing gasket
13. Oil seal housing
14. Housing bolt
15. Input shaft bearing
16. Flywheel
17. Flywheel bolt
: Tightening Torque
: Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
78 N.m (7.8 kg-m)
12 N
.m (1.2 kg-m)
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-27
MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK
REMOVAL
1) Remove engine with transmission from body as previously out-
lined.
2) Remove transmission from engine, and then remove clutch and
flywheel (drive plate for A / T).
3) Remove water pump belt, generator bracket, crankshaft pulley,
timing belt, and crankshaft timing belt pulley etc.
4) Remove cylinder head assembly.
5) Remove oil pan and oil pump strainer.
6) Remove pistons and connecting rods.
7) Remove oil pump and oil seal housing.
8) Remove main bearing caps and crankshaft.

2. Upper half of bearing
(a)
6A-28 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
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, pis-
ton rings and cylinder bores.

Journal bearings, bearing caps, connecting rods, rod bear-
ings, rod bearing caps, pistons and piston rings are in com-
bination sets. Do not disturb combination and try to see that
each part goes back to where it came from, when installing.
1) Fit main bearings to cylinder block (1).
Among two halves of main bearing, one halt has oil groove (3).
Install this half with oil groove to cylinder block, and another half
without oil groove to bearing cap.
Make sure that two halves are painted in the same color.
2) Fit thrust bearings (1) to cylinder block between No.2 and No.3
cylinders. Face oil groove (2) sides to crank webs.
3) Put crankshaft on cylinder block.
4) Fit bearing caps sequentially in ascending order, 1, 2, 3 and 4,
starting from pulley side. Be sure to point arrow mark (2) (on
each cap) to crankshaft pulley side (1).
Gradual and uniform tightening is important for bearing cap
bolts. Make sure that four caps become tight equally and pro-
gressively till specified torque is attained.
Tightening Torque
(a): 53 N
.m (5.3 kg-m, 38.5 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turned by hand.

ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-29
5) Install oil seal housing and its gasket.
Install new gasket. Do not reuse gasket removed in disassem-
bly. Oil lip portion of oil seal before installing. Tighten housing
bolts to specification.
After installing oil seal housing, gasket edges might bulge out;
if so, cut them off to make them flush with cylinder block and
oil seal housing.
Tightening Torque
(b): 12 N
.m (1.2 kg-m, 9.0 lb-ft)
6) Install oil pump.
Refer to item “Oil pump” for installation of oil pump.
7) Install flywheel (M / T model) or drive plate (A / T model).
Using special tool, lock flywheel and torque its bolts (1) to spec-
ification.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N
.m (7.8 kg-m, 56.5 lb-ft)
8) Install pistons and connecting rods as previously outlined.
9) Install oil pump strainer and oil pan.
10) Install cylinder head assembly to cylinder block (1).
Before installing cylinder head assembly to cylinder block,
install check valve (2) into oil gallery in cylinder block, directing
slit of valve toward top of cylinder block.
NOTE:
Tighten cylinder head bolts to specified torque as pre-
viously outlined.
Whenever installing cylinder head to new cylinder block,
use following procedure to tighten cylinder head bolts.

Tighten cylinder head bolts to specified torque as pre-
viously outlined and loosen them once till tightening
torque becomes “zero”. And then torque them to specifi-
cation again.
11) Install crankshaft timing belt pulley, timing belt, crankshaft
pulley, water pump pulley, etc., as previously outlined.
12) Install clutch to flywheel (M / T model).
For clutch installation, refer to Section 7C.
13) Install engine with transmission to body as previously outlined.

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.

6A1-2 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
GENERAL DESCRIPTION
ENGINE
The engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its S.O.H.C. (Single
Overhead Camshaft) valve mechanism arranged for “V”-type valve configuration and 16 valves (IN 2 and EX 2 / one
cylinder).
The single overhead camshaft is mounted over the cylinder head: it is driven from crankshaft through timing belt
and opens and closes its valves via the rocker arms.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-3
ENGINE LUBRICATION
The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side.
Oil is drawn up through oil pump strainer and passed through pump to oil filter.
The filtered oil flows into two paths in cylinder block. In one path, oil reaches crankshaft journal bearings.
Oil from crankshaft journal bearings is supplied to connecting rod bearings by means of intersecting passages
drilled in crankshaft, and then injected from a small hole provided on big end of connecting rod to lubricate piston,
rings, and cylinder wall.
In another path, oil goes up to cylinder head and lubricates camshaft journals, rocker arms, camshaft, etc., passing
through oil gallery in rocker arm shaft.
An oil relief valve is provided on oil pump. This valve starts relieving oil pressure when the pressure comes over
about 400 kPa (4.0 kg / cm
2, 56.9 psi). Relieved oil drains back to oil pan.

1. Rocker arm shaft
2. Rocker arm (EX)
3. Intake valve
4. Exhaust valve5. Rocker arm (IN)
6. Camshaft
7. Clip
8. PivotEx In
CYLINDER BLOCK
The cylinder block is made of cast aluminum alloy and
has 4 cylinders arranged “In-Line”. A cylindrical cast
iron sleeve is installed in each cylinder.
CRANKSHAFT AND MAIN
BEARINGS
A monoblock casting crankshaft is supported by
5 main bearings which are of precision insert type.
Four crank pins on the crankshaft are positioned 180
apart.
PISTONS, RINGS, PISTON PINS AND
CONNECTING RODS
The piston is cast aluminum alloy, and has two com-
pression rings and one oil ring.
Among two compression rings (top and 2nd rings),
the outer surface of the top ring is treated with hard
chromium for improvement in abrasion resistance.
The oil ring consists of two rails and one spacer. The
piston pin is offset 0.5 mm towards the major thrust
side.This allows a gradual change in thrust pressure
against the cylinder wall as the piston travels its path.
Pins, made of chromium steel, have a floating fit in the
pistons and in the connecting rods. The connecting
rods are made of forged steel, and the rod bearings
are of precision insert type.
CYLINDER HEAD AND VALVE TRAIN
The cylinder head is made of aluminum casting. The
supporting part of the camshaft is an independent cap
type. The combustion chamber has 4 valves and uses
the center plug type pent roof shape for higher intake
and exhaust efficiency.
As the intake side rocker arm is end pivot type, it
swings according to the camshaft movement to open
and close the intake valve.
On the other hand, the exhaust side rocker arm is see-
saw type. It swings with the rocker arm shaft as its
supporting point and according to the camshaft
movement to open and close the exhaust valve.
6A1-4 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)