2000 SUZUKI SWIFT Head

: Tightening Torque
: Do not reuse
1. Exhaust manifold
2. Gasket
3. Cover
4. Heated oxygen sensor
7. Gasket
8. Exhaust No.1 pipe.
21
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-17
EXHAUST MANIFOLD
WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot.
Service should be performed after system cools down.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect heated oxygen sensor coupler.
Release its wire from clamps.
3) Disconnect exhaust No.1 pipe (1) from WU-TWC.
4) Remove WU-TWC stiffener (2) (if equipped).
5) Remove exhaust manifold (1) and its gasket from cylinder head.

(b)
(a)
6A1-18 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
INSTALLATION
1) Install new gaskets to cylinder head.
2) Install exhaust manifold.
Tighten bolts and nuts to specified torque.
Tightening Torque
(a): 32 N
.m (3.2 kg-m, 23.5 lb-ft)
3) Install exhaust manifold cover(s) (1).
4) Connect oxygen sensor coupler (3) and clamp (2) its wire se-
curely.
5) Tighten exhaust No.1 pipe to manifold nuts and exhaust man-
ifold stiffener bolt.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
6) Connect negative cable at battery.
7) Check exhaust system for exhaust gas leakage.

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).

1. Camshaft allowable turning range - - - By timing mark,
within 90 from “V” mark on head cover on both right
and left.
2. Crankshaft allowable turning range - - - By punch mark,
within 90 from arrow mark on oil pump case on both
right and left.
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-21
CAUTION:

After timing belt is removed, never turn camshaft and
crankshaft independently more than such an extent as
shown in figure. If turned, interference may occur among
piston and valves, and parts related to piston and valves
may be damaged.

Never bend timing belt.
INSPECTION

Inspect timing belt for wear or crack.
Replace it as necessary.

Inspect tensioner for smooth rotation.
INSTALLATION
1) Install tensioner plate to tensioner.
Insert lug (1) of tensioner plate into hole (2) in tensioner.

4. Damper
6A1-22 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
2) Install tensioner (2) and tensioner plate (3):
Do not tighten tensioner bolt (1) with wrench yet. Hand tighten
only at this time.
Check to ensure that plate movement in arrow direction as
shown in figure causes tensioner to move in the same direction.
If no associated movement between plate and tensioner occurs,
remove tensioner and plate again and reinsert plate lug into ten-
sioner hole.
3) Check that timing mark (2) on camshaft timing belt pulley is
aligned with “V” mark (1) on cylinder head cover. 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 timing mark (2) on crankshaft timing belt pulley is
aligned with arrow mark (1) 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) Install timing belt and tensioner spring (2).
With two sets of marks aligned and tensioner plate pushed up,
install timing belt on two pulleys in such a way that drive side (1)
of belt is free from any slack.
And then install tensioner spring as shown in figure, and hand-
tighten tensioner stud (3).
NOTE:

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

In this state, No. 4 piston is at top dead center of compres-
sion stroke.

1. Camshaft
2. Camshaft oil seal
3. Rocker arm shaft
4. O-ring
5. Rocker shaft bolt
6. Rocker arm (IN)
7. Rocker arm No.1 (EX)
8. Rocker arm No.2 (EX)
9. Valve adjusting screw
10. Valve adjusting screw
11. Clip
12. Lock nut
13. Rocker arm spring
: Tightening Torque : Do not reuse
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-33
ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing belt as previously outlined and remove camshaft
timing belt pulley (1) by using special tool.
Special Tool
(A): 09917-68221
3) Remove cylinder head cover as previously outlined.

1. Oil plug
6A1-34 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
4) Disconnect CMP sensor coupler from CMP sensor.
5) Remove CMP sensor case (1) from cylinder head.
Place a container or rag under CMP sensor case, for a small
amount of oil flows out during removal of case.
6) After loosening all valve adjusting screw lock nuts (2), turn ad-
justing screws (1) back all the way to allow all rocker arms (3) to
move freely.
7) Remove camshaft housing and camshaft.
NOTE:
To remove camshaft housing bolts, loosen them in such or-
der as indicated in figure, a little at a time.
8) Remove timing belt inside cover (2).
9) Remove intake rocker arm (1) with clip (2) from rocker arm shaft
(3).
NOTE:
Do not bend clip when removing intake rocker arm.

6A1-36 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
Rocker Arm-to-Rocker Arm Shaft Clearance
Using a micrometer and a bore gauge, measure rocker shaft dia.
and rocker arm l.D.
Difference between two readings is arm-to-shaft clearance on
which a limit is specified.
If limit is exceeded, replace shaft or arm, or both.
Item
StandardLimit
Rocker arm l.D.15.996 – 16.014 mm
(0.629 – 0.630 in.)———
Rocker arm shaft dia.15.969 – 15.984 mm
(0.6287 – 0.6293 in.)———
Arm-to-shaft clearance0.012 – 0.045 mm
(0.0005 – 0.0018 in.)0.09 mm
(0.0035 in.)
Cam Wear
Using a micrometer, measured height of cam. If measured height
is below limit, replace camshaft.
Cam height
StandardLimit
Intake cam36.184 – 36.344 mm
(1.4246 – 1.4309 in.)36.084 mm
(1.4206 in.)
Exhaust cam35.900 – 36.060 mm
(1.4134 – 1.4197 in.)35.800 mm
(1.4094 in.)
Camshaft Runout
Hold camshaft between two “V” blocks, and measure runout by us-
ing a dial gauge.
If runout exceeds the limit, replace camshaft.
Runout limit: 0.10 mm (0.0039 in.)
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 housing.