2000 SUZUKI SWIFT SF310 Service Workshop Manual

1. Cylinder block
“a”: 120 mm (4.72 in.)
6A1-58 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
Piston Rings
To measure end gap, insert piston ring (3) into cylinder bore and
then measure the gap by using thickness gauge (2).
If measured gap is out of specification, replace ring.
NOTE:
Decarbon and clean top of cylinder bore before inserting pis-
ton ring.
Item
StandardLimit
Piston
Top ring0.15 – 0.30 mm
(0.0059 – 0.0118 in.)0.7 mm
(0.0275 in.)
Piston
ring end
gap
2nd ring0.2 – 0.35 mm
(0.0079 – 0.0137 in.)0.7 mm
(0.0275 in.)
ga
Oil ring0.2 – 0.7 mm
(0.0079 – 0.0275 in.)1.7 mm
(0.0669 in.)
Connecting Rod

Big-end side clearance:
Check big-end of connecting rod for side clearance, with rod fitted
and connected to its crank pin in the normal manner. If measured
clearance is found to exceed its limit, replace connecting rod.
Item
StandardLimit
Big-end side
clearance0.10 – 0.20 mm
(0.0039 – 0.0078 in.)0.35 mm
(0.0137 in.)

Connecting rod alignment:
Mount connecting rod on aligner to check it for bow and twist and,
if limit is exceeded, replace it.
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-59
Crank Pin and Connecting Rod Bearings

Inspect crank pin for uneven wear or damage. Measure crank pin
for out-of-round or taper with a micrometer. If crank pin is dam-
aged, or out-of-round or taper is out of limit, replace crankshaft or
regrind crank pin to undersize and use undersize bearing.
Connecting rod bearing size
Crank pin diameter
Standard41.982 – 42.000 mm
(1.6528 – 1.6535 in.)
0.25 mm (0.0098 in.)41.732 – 41.750 mm
(1.6430 – 1.6437 in.)
Out-of-round and taper limit: 0.01 mm (0.0004 in.)

Rod bearing:
Inspect bearing shells for signs of fusion, pitting, burn or flaking
and observe contact pattern. Bearing shells found in defective
condition must be replaced.
Two kinds of rod bearing are available; standard size bearing and
0.25 mm undersize bearing. To distinguish them, 0. 25 mm under-
size bearing has the stamped number (US025) on its backside as
indicated in figure, but standard size one has no number.

Rod bearing clearance:
1) Before checking bearing clearance, clean bearing and crank
pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gaging plastic (1) to full width of crankpin as
contacted by bearing (parallel to crankshaft), avoiding oil hole.
4) Install rod bearing cap (1) to connecting rod.
When installing cap, be sure to point arrow mark (2) on cap to
crankshaft pulley side (3), as shown in figure. After applying
engine oil to rod bolts, tighten cap nuts to specified torque. DO
NOT turn crankshaft with gaging plastic installed.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

1 or 2
Piston
No.1 Cylinder
No.2 Cylinder
No.3 Cylinder
No.4 Cylinder
Crank
pulley
side
Flywheel
side
6A1-60 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
5) Remove cap and using a scale (2) on gaging plastic (1) enve-
lope, measure gaging plastic width at the widest point (clear-
ance).
If clearance exceeds its limit, use a new standard size bearing
and remeasure clearance.
Item
StandardLimit
Bearing
clearance0.020 – 0.050 mm
(0.0008 – 0.0019 in.)0.080 mm
(0.0031 in.)
6) If clearance can not be brought to within its limit even by using
a new standard size bearing, regrind crankpin to undersize
and use 0.25 mm undersize bearing.
ASSEMBLY
NOTE:
Two sizes of piston are available as standard size spare part
so as to ensure proper piston-to-cylinder clearance. When
installing a standard size piston, make sure to match piston
with cylinder as follows.
a) Each piston has stamped number 1 or 2 as shown. It represents
outer diameter of piston.
b) There are also stamped numbers of 1 and 2 on the cylinder block
as shown. The first number represents inner diameter of No.1
cylinder, the second number of No.2 cylinder, the third number
of No.3 cylinder and the fourth number of No.4 cylinder.

2. Arrow mark
4. Oil hole
The oil hole should
come on intake side
1. Arrow mark
2. 1st ring end
gap
3. 2nd ring end
gap and oil ring
spacer gap
4. Oil ring upper
rail gap
5. Oil ring lower
rail gap
6. Intake side
7. Exhaust side Crankshaft
pulley side
Circlip
or
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-61
c) Stamped number on piston and that on cylinder block should
correspond. That is, install number 2 stamped piston to cylinder
which is identified with number 2 and a number 1 piston to cylin-
der with number 1.
PistonCylinder
Number
at the
top
(mark)
Outer diameterNumber
(mark)Bore diameter
Piston-to-cylinder
clearance
1
73.98 – 73.99 mm
(2.9126 –
2.9130 in.)
1
74.01 – 74.02 mm
(2.9138 –
2.9141 in.)0.02 – 0.04 mm
(0.0008 –
0.0015 in.)
2
73.97 – 73.98 mm
(2.9122 –
2.9126 in.)
2
74.00 – 74.01 mm
(2.9134 –
2.9138 in.)0.02 – 0.04 mm
(0.0008 –
0.0015 in.)
Also, a letter A, B or C is stamped on piston head but ordinarily
it is not necessary to discriminate each piston by this letter.
1) Install piston pin to piston (1) and connecting rod (3):
After applying engine oil to piston pin and piston pin holes in pis-
ton and connecting rod, fit connecting rod to piston as shown in
figure and insert piston pin to piston and connecting rod, and
install piston pin circlips.
NOTE:
Circlip should be installed with its cut part facing either up
or down as shown in figure.
2) Install piston rings to piston:

As indicated in figure, 1st and 2nd rings have “RN” or “R” mark
respectively. When installing these piston rings to piston, di-
rect marked side of each ring toward top of piston.

1st ring (1) difffers from 2nd ring (2) in thickness, shape and
color of surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.

When installing oil ring (3), install spacer first and then two
rails.
3) After installing three rings (1st, 2nd and oil rings), distribute their
end gaps as shown in figure.

A: Crankshaft pulley side
B: Flywheel side
6A1-62 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSTALLATION OR CONNECTION
1) Apply engine oil to pistons, rings, cylinder walls, connecting rod
bearings and crankpins.
NOTE:
Do not apply oil between connecting rod and bearing or be-
tween bearing cap and bearing.
2) Install guide hoses over connecting rod bolts.
These guide hoses protect crankpin and threads of rod bolt from
damage during installation of connecting rod and piston assem-
bly.
3) When installing piston and connecting rod assembly into cylin-
der bore, point arrow mark on piston head to crankshaft pulley
side.
4) Install piston and connecting rod assembly into cylinder bore.
Use special tool (Piston ring compressor) to compress rings.
Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until all
piston rings have entered cylinder bore.
Special Tool
(A): 09916-77310
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side (3).
Tighten cap nuts to specification.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-63
6) Reverse removal procedure for installation, as previously out-
lined.
7) Adjust water pump drive belt tension referring to Section 6B.
8) Adjust power steering pump belt tension or A / C compressor
belt tension, if equipped.
Refer to Section 0B.
9) Adjust accelerator cable play.
Refer to Section 6E.
10) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
11) Refill engine with engine oil by referring to item “ENGINE OIL
CHANGE” in Section 0B.
12) Refill cooling system referring to Section 6B.
13) Connect negative cable at battery.
14) Check ignition timing referring to Section 6F.
15) Verify that there is no fuel leakage, coolant leakage, oil leakage
and exhaust gas leakage at each connection.

1
2
6A1-64 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL
1) Release fuel pressure in fuel feed line by referring to Section
6.
2) Remove battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Drain cooling system.
WARNING:
To help avoid danger of being burned, do not remove
drain plug (2) and radiator cap while engine and radiator
(1) are still hot. Scalding fluid and steam can be blown
out under pressure if plug and cap are taken off too
soon.
5) Disconnect coupler of cooling fan motor.
6) Disconnect radiator inlet hose from thermostat case.
7) Disconnect A / T fluid hoses from A / T fluid pipes (for A / T mod-
el)
8) Remove outlet hose from water inlet pipe and radiator.
9) Remove radiator referring to Section 6B.
10) Remove air cleaner case and air cleaner outlet hose as pre-
viously outlined.
11) Disconnect the following cables.

Accelerator cable (1) from throttle body.

A / T throttle pressure control cable from A / T.

Clutch cable from transmission (M / T).

Gear select cable from transmission (A / T).

Speedometer cable

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-65
12) Disconnect the following electric wires:

Ignition coil assembly

Ground wires from intake manifold

Engine oil pressure switch

EVAP canister purge valve (if equipped)

Engine coolant temp. sensor

Fuel injectors

Power steering pressure switch (if equipped)

Oxygen sensor-1

Back-up light switch (M / T)

Transmission range switch (A / T)

A/T vehicle speed sensor (A / T)

Solenoid coupler (A / T)

Generator

Starter

Battery negative cable from transmission

TP sensor

IAC valve

CMP sensor

MAP sensor
and then release wire harnesses from clamps.
13) Disconnect the following hoses:

Canister purge hose (2) from EVAP canister purge valve

Brake booster hose (1) from intake manifold

Radiator outlet hose from inlet pipe

Heater inlet and outlet hose from heater unit
14) Disconnect fuel feed (2) and return hoses (3) from fuel delivery
pipe (1).