2000 SUZUKI SWIFT tension

1. Crank timing belt pulley bolt
Direction of crankshaft
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-13
3) Check that timing mark (3) on camshaft timing belt pulley (1) is
aligned with “V” mark (2) on cylinder head cover (4). If not, align
two marks by turning camshaft but be careful not to turn it more
than its allowable turning range which is described on previous
page.
4) Check that punch mark (2) on crank timing belt pulley (4) is
aligned with arrow mark (3) on oil pump case. If not, align two
marks by turning crankshaft but be careful not to turn it more
than its allowable turning range which is described on previous
page.
5) With two sets of marks aligned, install timing belt (1) on two pul-
leys in such a way that the drive side of belt is free of any slack,
and with tensioner plate pushed up by finger.
And then install tensioner spring and spring damper (2) as
shown in figure, and handtighten tensioner stud.
NOTE:

When installing timing belt, match arrow mark (
) on
timing belt with rotating direction of crankshaft.

In this state, No.1 piston is at top dead center of compres-
sion stroke.
6) To take up slack of timing belt, turn crankshaft two rotations
clockwise after installing it. After making sure that belt is free
from slack, tighten tensioner stud (1) first and then tensioner bolt
(2) to each specified torque.
Then confirm again that two sets of marks are aligned respec-
tively.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 27 N
.m (2.7 kg-m, 19.5 lb-ft)

6A-14 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
7) Install timing belt outside cover.
Before installing, make sure that rubber seal (1) is between wa-
ter pump and oil pump case and another between water pump
and cylinder head.
Tightening Torque
(c): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
8) Install crankshaft pulley (2).
Tighten crankshaft pulley bolts (1).
Tightening Torque
(d): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
9) Install water pump pulley and water pump belt.
Adjust the belt tension to the specification.
Refer to Section 6B for procedure to adjust the belt tension.
10) Install air cleaner assembly.
11) Install fender apron extension of right side.
12) Connect negative cable at battery.

6A-24 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL
1) Relieve fuel pressure according to procedure described in
“FUEL PRESSURE RELIEF PROCEDURE” of Section 6.
2) Remove engine hood after disconnecting front window washer
hose.
3) Disconnect battery cables at battery and remove battery and
its tray.
4) Drain cooling system.
5) Remove air cleaner assembly.
6) Remove radiator with cooling fan. Refer to Section 6B for re-
moval.
7) Disconnect the following electric wire harness.

High-tension cord from ignition coil

Distributor

EGR valve

ECT sensor

ISC actuator

Ground wire harness from intake manifold

TP sensor

Fuel injector

Oil pressure gauge

A / C compressor pressure switch (if equipped)

Heated oxygen sensor

Generator

Starter

Back-up light switch (For M / T model)

Battery negative cable from transmission

Shift switch of A / T (For A / T model)

Direct clutch and 2nd brake solenoids of A / T (For A / T model)

Vehicle speed sensor on A / T (For A / T model)
And release above wire harness from clamps.
8) Disconnect the following vacuum hose.

Brake booster hose from intake manifold.

Canister purge hose from EVAP canister purge valve.

Pressure sensor hose from intake manifold.
9) Disconnect fuel return hose and fuel feed hose from fuel feed
and return pipes.
10) Disconnect heater inlet and outlet hoses.

1. Rear mounting
2. Left mounting
3. Left mounting bracket
4. Right mounting
5. Right mounting bracket
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
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-25
11) Disconnect the following cables.

Accelerator cable from throttle body.

Clutch cable from transmission. (For M / T model)

Gear select cable and oil pressure control cable from trans-
mission. (For A / T model)

Speedometer cable from transmission.
12) Hoist vehicle.
13) Remove fender apron extensions.
14) Remove exhaust pipe from exhaust manifold (or WU-TWC).
15) Remove gear shift control shaft from transmission and remove
extension rod. (For M / T model)
16) Drain engine oil and transmission oil.
17) Remove drive shaft joints from differential gears of transmis-
sion.
Refer to Section 4 (DRIVE SHAFT) for procedure to disconnect
drive shaft joints.
For engine and transmission removal, it is not necessary to re-
move drive shafts from steering knuckle.
18) Remove A / C compressor (if equipped) from compressor
bracket with hose still attached.
NOTE:
Suspend removed A / C compressor at a place where no
damage will be caused during removal / installation of en-
gine with transmission.
19) Remove engine rear torque rod bracket from transmission.
(For A / T model)
20) Lower vehicle.
21) Install lifting device.
22) Remove rear mounting from body.
23) Remove left side engine mounting and bracket. (For M / T mod-
el)
Remove left mounting from body. (For A / T model)
24) Remove right side engine mounting from its bracket.
25) Before removing engine with transmission, recheck to make
sure all hoses, electric wires and cables are disconnected from
engine and transmission.
26) Remove engine with transmission from body.

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.

3
3
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-13
CYLINDER HEAD COVER
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect breather hose (2) and PCV valve (3) from head cov-
er.
3) Disconnect ignition coil couplers (6).
4) Remove ignition coil assemblies (5) with high-tension cord (4).
5) Remove cylinder head cover (1) with cylinder head cover gasket
and O-rings.
INSTALLATION
1) Install O-rings (3) and cylinder head cover gasket (2) to cylinder
head cover (1).
NOTE:
Be sure to check each of these parts for deterioration or any
damage before installation and replace if found defective.
2) Install cylinder head cover to cylinder head and tighten cover
bolts to specified torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
NOTE:
When installing cylinder head cover, use care so that cylin-
der head cover gasket or O-rings will not get out of place or
fall off.
3) Install ignition coil assemblies (5) with high-tension cord (4).
4) Connect ignition coil couplers (6).
5) Connect breather hose (2) and PCV valve (3) to head cover (1).
6) Connect negative cable at battery.

1. Timing belt
2. Tensioner
3. Tensioner plate
4. Tensioner spring
5. Camshaft timing pulley
6. Tensioner bolt
7. Pulley bolt
8. Seal
9. Inside cover seal
10. Inside cover
11. Outside cover seal
12. Outside cover
13. Tensioner stud
14. Damper
1. Water pump pulley
: Tightening Torque
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-19
TIMING BELT AND BELT TENSIONER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove right side of engine under cover.
3) Remove power steering pump belt or A / C compressor belt, if
equipped.
4) Disconnect IAT sensor at coupler.
5) Remove air cleaner case with air cleaner outlet hose.
6) Remove power steering hose stay (1) (if equipped).
7) Remove water pump pulley and drive belt.

1.“V” mark on cylinder
head cover
2. Timing mark by “E” on
camshaft timing belt pulley
3. Arrow mark on oil
pump case
4. Punch mark on crankshaft
timing belt pulley
4. Tensioner stud
6. Damper
6
6A1-20 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
8) Lock crankshaft inserting flat end rod or the like (2) between fly-
wheel ring gear and transmission case, after removing clutch
housing (torque converter housing for A / T) lower plate.
With crankshaft locked, remove crankshaft timing belt pulley
bolt (3).
9) Remove crankshaft pulley bolts (1).
10) Remove crankshaft pulley (4).
11) Install crankshaft timing belt pulley bolt temporarily to turn
crankshaft.
12) Release harness clamps.
13) Remove timing belt outside cover.
14) For installation of timing belt, align 4 timing marks as shown in
figure by turning crankshaft.
15) Remove timing belt tensioner (3), tensioner plate (2), tensioner
spring (5) and timing belt (1).