2000 SUZUKI SWIFT engine

6A1-70 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSPECTION
Crankshaft
Crankshaft runout
Using a dial gauge, measure runout at center journal. Rotate crank-
shaft slowly. If runout exceeds its limit, replace crankshaft.
Limit on runout: 0.06 mm (0.0023 in.)
Crankshaft thrust play
Measure this play with crankshaft set in cylinder block in the normal
manner, that is, with thrust bearing (1) and journal bearing caps
installed.
Use a dial gauge to read displacement in axial (thrust) direction of
crankshaft.
If its limit is exceeded, replace thrust bearing with new standard one
or oversize one to obtain standard thrust play.
Item
StandardLimit
Crankshaft thrust
play0.11 – 0.31 mm
(0.0044 – 0.0122 in.)0.38 mm
(0.0149 in.)
Thickness of
crankshaft thrust
Standard2.500 mm
(0.0984 in.)
crankshaft thrust
bearingOversize:0.125 mm
(0.0049 in.)2.563 mm
(0.1009 in.)
Out-of-round and taper (uneven wear) of journals
An unevenly worn crankshaft journal shows up as a difference in
diameter at a cross section or along its length (or both). This differ-
ence, if any, is determined by taking micrometer readings.
If any one of journals is badly damaged or if amount of uneven wear
in the sense explained above exceeds its limit, regrind or replace
crankshaft.
Limit on out-of-round and taper: 0.01 mm (0.0004 in.)

1. Gaging plastic
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-71
Main Bearings
General information

Service main bearings are available in standard size and 0.25
mm (0.0098 in.) undersize, and each of them has 5 kinds of bear-
ings differing in tolerance.

Upper half of bearing (2) has oil groove (3) as shown in figure.
Install this half with oil groove to cylinder block (1).

On each main bearing cap, arrow mark and number are em-
bossed as shown in figure.
When installing each bearing cap to cylinder block, point arrow
mark toward crankshaft pulley side and install each cap from that
side to flywheel side in ascending order of numbers “1”, “2”, “3”,
“4” and “5”. Tighten cap bolts to specified torque.
Inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Never replace one half without replacing the other half.
Main bearing clearance
Check clearance by using gaging plastic (1) according to the follow-
ing procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gaging plastic to full width of bearing (parallel
to crankshaft) on journal, avoiding oil hole.
4) Install bearing cap as previously outlined and evenly toque cap
bolts to specified torque.
Bearing cap MUST be torqued to specification in order to assure
proper reading of clearance.
Tightening Torque
(a): 54 N
.m (5.4 kg-m, 39.0 lb-ft)
NOTE:
Do not rotate crankshaft while gaging plastic is installed.

6A1-72 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
5) Remove cap and using scale (2) on gaging plastic (1) envelope,
measure gaging plastic width at its widest point. If clearance ex-
ceeds its limit, replace bearing. Always replace both upper and
lower inserts as a unit.
A new standard bearing may produce proper clearance. If not,
it will be necessary to regrind crankshaft journal for use of 0.25
mm undersize bearing.
After selecting new bearing, recheck clearance.
StandardLimit
Bearing clearance0.020 – 0.040 mm
(0.0008 – 0.0016 in.)0.060 mm
(0.0023 in.)
Selection of main bearings
STANDARD BEARING:
If bearing is in malcondition, or bearing clearance is out of specifica-
tion, select a new standard bearing according to the following pro-
cedure and install it.
1) First check journal diameter by using the following procedure.
As shown in figure, crank webs (1) of No.2 and No.3 cylinders
have five stamped numerals.
Three kinds of numerals (“1”, “2” and “3”) represent the following
journal diameters.
Numeral stamped
Journal diameter
144.994 – 45.000 mm
(1.7714 – 1.7716 in.)
244.988 – 44.994 mm
(1.7712 – 1.7714 in.)
344.982 – 44.988 mm
(1.7709 – 1.7712 in.)
The first, second, third, fourth and fifth (left to right) stamped nu-
merals represent journal diameters at bearing caps “1”, “2”, “3”,
“4” and “5” respectively.
For example, in figure, the first (leftmost) numeral “3” indicates
that journal dia. at bearing cap “1” is within 44.982 – 44.988 mm,
and second one “1” indicate that journal dia. at cap “2” is within
44.994 – 45.000 mm.

1. Paint
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-73
2) Next, check bearing cap bore diameter without bearing. On mat-
ing surface of cylinder block, four alphabets are stamped as
shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) represent the follow-
ing cap bore diameters.
Alphabet stamped
Bearing cap bore diameter
(without bearing)
A49.000 – 49.006 mm
(1.9291 – 1.9294 in.)
B49.006 – 49.012 mm
(1.9294 – 1.9296 in.)
C49.012 – 49.018 mm
(1.9296 – 1.9298 in.)
The first, second, third, fourth and fifth (left to right) stamped al-
phabets reperesent cap bore diameters of bearing caps “1”, “2”,
“3”, “4” and “5”, respectively.
For example, in figure, the first (leftmost) alphabet “B” indicates
that cap bore dia. of bearing cap “1” is within 49.006 – 49.012
mm, and the fifth (rightmost) alphabet “A” indicates that cap bore
dia. of cap “5” is within 49.000 – 49.006 mm.
3) There are five kinds of standard bearings differing in thickness.
To distinguish them, they are painted in the following colors at
the position as indicated in figure.
Each color indicates the following thickness at the center of
bearing.
Color painted
Bearing thickness
Green1.996 – 2.000 mm
(0.0786 – 0.0787 in.)
Black1.999 – 2.003 mm
(0.0787 – 0.0788 in.)
Colorless
(no paint)2.002 – 2.006 mm
(0.0788 – 0.0789 in.)
Yellow2.005 – 2.009 mm
(0.0789 – 0.0790 in.)
Blue2.008 – 2.012 mm
(0.0790 – 0.0791 in.)

2. Scale
1. Paint
6A1-74 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
4) From numerals stamped on crank webs (1) of No.2 and No.3 cyl-
inders and the alphabets stamped on mating surface of cylinder
block, determine new standard bearing to be installed to journal,
by referring to table given below.
For example, if numeral stamped on crank web is “1” and alpha-
bet stamped on mating surface is “B”, install a new standard
bearing painted in “Black” to its journal.
Numeral stamped on crank web
(Journal diameter)
123
Alphabet stamped
ti f
AGreenBlackColorless
on mating surface
(Bearing capboreBBlackColorlessYellow(Bearing ca bore
dia.)CColorlessYellowBlue
New standard bearing to be installed.
5) Using gaging plastic (1), check bearing clearance with newly se-
lected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and
recheck clearance.
6) When replacing crankshaft or cylinder block due to any reason,
select new standard bearings to be installed by referring to nu-
merals stamped on new crankshaft or alphabets stamped on
mating surface of new cylinder block.
UNDERSIZE BEARING (0.25 mm):

0.25 mm undersize bearing is available, in five kinds varying in
thickness.
To distinguish them, each bearing is painted in the following col-
ors at such position as indicated in figure.
Each color represents the following thicknesses at the center of
bearing.
Color painted
Bearing thickness
Green & Red2.121 – 2.125 mm
(0.0835 – 0.0836 in.)
Black & Red2.124 – 2.128 mm
(0.0836 – 0.0837 in.)
Red only2.127 – 2.131 mm
(0.0837 – 0.0838 in.)
Yellow & Red2.130 – 2.134 mm
(0.0838 – 0.0839 in.)
Blue & Red2.133 – 2.137 mm
(0.0839 – 0.0840 in.)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-75

If necessary, regrind crankshaft journal and select under-size
bearing to use with it as follows.
1) Regrind journal to the following finished diameter.
Finished diameter: 44.732 – 44.750 mm
(1.7611 – 1.7618 in.)
2) Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicular
to each other in order to check for out-of-round.
3) Using journal diameter measured above and alphabets
stamped on mating surface of cylinder block, select an under-
size bearing by referring to table given below.
Check bearing clearance with newly selected undersize bear-
ing.
Measured journal diameter
44.744 – 44.750 mm
(1.7616 – 1.7618 in.)44.738 – 44.744 mm
(1.7613 – 1.7616 in.)44.732 – 44.738 mm
(1.7611 – 1.7613 in.)
Alphabets stampedAGreen & RedBlack & RedRed only
on mating surfaceBBlack & RedRed onlyYellow & Red
of cylinder block
CRed onlyYellow & RedBlue & Red
Undersize bearing to be installed
Rear Oil Seal
Carefully inspect oil seal (1) for wear or damage. If its lip is worn or
damaged, replace it.
For oil seal installation, press-fit rear oil seal (1) so that oil seal
housing (2) end face is flush with oil seal end face.

“a”: 23 mm (0.91 in.)
6A1-76 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
Flywheel

If ring gear is damaged, cracked or worn, replace flywheel.

If the surface contacting clutch disc is damaged, or excessively
worn, replace flywheel.

Check flywheel for face runout with dial gauge.
If runout exceeds its limit, replace flywheel.
Limit on runout: 0.2 mm (0.0078 in.)
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed surface
for distortion and, if flatness exceeds its limit, correct it.
Item
StandardLimit
Flatness0.03 mm
(0.0012 in.)0.06 mm
(0.0024 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must also
be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Size
Piston diameter
O / S 0.2574.220 – 74.230 mm
(2.9220 – 2.9224 in.)
O / S 0.5074.470 – 74.480 mm
(2.9319 – 2.9323 in.)
3) Using micrometer, measure piston diameter.
4) Calculate cylinder bore diameter to be rebored.
D = A + B – C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.02 – 0.04 mm
(0.0008 – 0.0015 in.)
C: Allowance for honing = 0.02 mm (0.0008 in.)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-77
5) Rebore and hone cylinder to calculated dimension.
NOTE:
Before reboring, install all main bearing caps in place and
tighten to specification to avoid distortion of bearing bores.
6) Measure piston clearance after honing.
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 such combination and make
sure that each part goes back to where it came from, when
installing.
1) Install main bearings to cylinder block.
One of two halves of main bearing (2), has an oil groove (3).
Install it to cylinder block (1), and the other half without oil groove
to bearing cap.
Make sure that two halves are painted in the same color.
2) Install thrust bearings (1) to cylinder block between No.2 and
No.3 cylinders. Face oil groove (2) sides to crank webs.