2000 SUZUKI SWIFT oil

6A
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-1
SECTION 6A
ENGINE MECHANICAL
(G10, 1-CAM 6-VALVES ENGINE)
WARNING:
For vehicles equipped with Supplemental 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 of 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
ON-VEHICLE SERVICE6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Hydraulic Valve Lash Adjuster 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash Adjuster Noise Diagnosis 6A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Piston Rings, Connecting Rods and Cylinders 6A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6A-2 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
ON-VEHICLE SERVICE
ENGINE VACUUM CHECK
The engine vacuum that develops in the intake line is a good indica-
tor of the condition of the engine. The vacuum checking procedure
is as follows:
1) Warm up engine to normal operating temperature.
2) With engine stopped, remove blind plug hose from intake man-
ifold and connect special tool (vacuum gauge and joint) to va-
cated threaded hole.
Special Tool
(A): 09915-67311
3) Run engine at specified idle speed (see Section 6E), and read
vacuum gauge. Vacuum should be within the following specifi-
cation.
Vacuum specification: 52.6 – 65.8 kPa (40 – 50 cm
.Hg,
15.7 – 19.7 in
.Hg) at specified
idling speed
4) After checking, apply sealant to thread of blind plug and install
it to intake manifold.
OIL PRESSURE CHECK
NOTE:
Prior to checking oil pressure, check the followings.

Oil level in oil pan.
If oil level is low, add oil up to Full level hole on oil level
gauge.

Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in Section 0B.

Oil leaks.
If leak is found, repair it.
1) Using special tool (Oil filter wrench), remove oil filter.
2) After removing oil filter, remove oil pressure switch (1) from cylin-
der block.

3 / 4 turn
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-3
3) Install special tool (Oil pressure gauge) to vacated threaded
hole.
Special Tool
(A): 09915-77311
(B): 09915-78211
NOTE:
At this time, be very careful not to exert force to where
heated oxygen sensor and its lead wire are connected.
4) Reinstall oil filter.
5) Start engine and warm it up to normal operating temperature.
6) After warming up, raise engine speed to 4,000 r / min and mea-
sure oil pressure.
Oil pressure specifications: 270 – 370 kPa
(2.7 – 3.7 kg / cm
2,
38.4 – 52.6 psi) at
4,000 r / min (rpm)
7) After checking oil pressure, stop engine and remove oil filter
and oil pressure gauge.
8) Before reinstalling oil pressure switch (1), be sure to wrap its
screw threads with a sealing tape and tighten switch to speci-
fied torque.
NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
9) After oiling oil filter “O” ring (rubber gasket), screw oil filter on
oil filter stand by hand until filter “O” ring contacts mounting sur-
face.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position where filter “O” ring first contacts
mounting surface.
10) Tighten filter (1) 3 / 4 (270) turn from the point of contact with
mounting surface using an oil filter wrench.
Special Tool
(C): 09915-47310
CAUTION:
To prevent oil leakage, make sure that oil filter is tight,
but do not overtighten it.
11) After installing oil filter, start engine and check oil filter for oil
leakage.

1.“V” mark on cylinder head cover
2. Timing mark on camshaft timing belt pulley
3. Arrow mark on oil pump case
4. Punch mark on crankshaft timing belt pulley
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-11
8) Loosen crankshaft pulley bolts (1) and remove crankshaft
pulley (2).
9) Remove timing belt outside cover (1).
10) Align 4 timing marks as shown in figure to facilitate its installa-
tion.
11) Loosen tensioner bolt (3) and stud (4), and remove belt (1) from
crankshaft timing belt pulley and camshaft timing belt pulley af-
ter pushing up the tensioner plate (2) fully by finger as shown
figure.
CAUTION:
Never bend timing belt.

6A-12 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
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.
CAUTION:
After timing belt is removed, never turn camshaft and crank-
shaft independently more than such an extent as shown be-
low. If turned, interference may occur among piston and
valves, and parts related to piston and valves may be dam-
aged.
12) Remove tensioner, tensioner plate, tensioner spring and
spring damper.
INSPECTION

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

Check tensioner for smooth rotation and rattle.
INSTALLATION
1) Install tensioner plate (1) to tensioner (2).
Insert lug (3) of tensioner plate into hole (4) of tensioner.
2) Install tensioner (2) and tensioner plate (3).
Do not tighten the tensioner bolt (1) and stud by 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 the plate lug into
tensioner hole.

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.

1. Cylinder head cover
2. Gasket
3. Cylinder head
4. Camshaft housing No.1:
Apply sealant 99000-31110 to mating surface.
5. Camshaft housing No.2
6. Camshaft housing No.3:
Apply sealant 99000-31110 to mating surface.
7. Camshaft
8. Oil seal
9. Valve lash adjuster
10. Camshaft housing bolt
1. Crankshaft timing belt pulley: Tightening Torque
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-15
CAMSHAFT AND HYDRAULIC VALVE LASH ADJUSTER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove cylinder head cover as previously outlined.
3) Remove distributor and then its case from cylinder head.
4) Remove crankshaft pulley, timing belt outside cover and timing
belt as previously outlined.
After removing timing belt, set key (2) on crankshaft in position
as shown in figure by turning crankshaft. This is to prevent inter-
ference between valves and piston when reinstalling camshaft.
5) Remove camshaft timing belt pulley (1).
Lock camshaft (2) with a proper size rod (3) inserted into hole (10
mm, 0.39 in.) in it as shown and then loosen camshaft timing belt
pulley bolt.
NOTE:
Mating surfaces of cylinder head and cover must not be
damaged in this work. So, put clean shop cloth (4) between
rod and mating surfaces, and use care not to bump rod
against mating surfaces hard when loosening bolt.