Suzuki Esteem, Swift 1994-02

Camshaft, Bearings & Lifters

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Bearing Replacement



The engines covered do not utilize camshaft bearings. If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the difference from specification is greater

Inspection



Cam Height
  1. Hold camshaft between two -V- blocks, and measure runout by using a dial gauge.
  2.  
  3. If runout exceeds the limit, replace camshaft.

    Camshaft runout limit: 0.0039 inch (0.10mm)
     

  4.  

Camshaft Journal Clearance
  1. Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
  2.  
  3. If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head without replacing housing.
  4.  
  5. Check clearance by using gauging plastic. The procedure is as follows:


    1. Clean housings and camshaft journals.
    2.  
    3. Install camshaft to cylinder head.
    4.  
    5. Place a piece of gauging plastic the full width of journal of camshaft (parallel to camshaft).
    6.  
    7. Install camshaft housing.
    8.  
    9. After applying engine oil to housing bolts, tighten them temporarily first.
    10.  
    11. Tighten camshaft housing bolts in such order as indicated in the figure a little at a time till they are tightened to 8 ft. lbs. (11 Nm).
      NOTE
      Do not rotate camshaft while gauging plastic is installed.

    12.  
    13. Remove housing and using scale (2) on gauging plastic (1) envelope, measure gauging plastic width at its widest point.
    14.  

  6.  
  7. Measure camshaft journal clearance.


    1. 1.3L and 1.6L engines:

      Standard-0.0016-0.0032 inch (0.040-0.082mm)
       
      Limit-0.0047 inch (0.12mm)
       

    2.  
    3. 1.8L engine:

      Standard-0.0008-0.0029 inch (0.020-0.074mm)
       
      Limit-0.0047 inch (0.12mm)
       

    4.  

  8.  
  9. If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal.
  10.  
  11. Measure camshaft journal bore diameter.


    1. 1.3L and 1.6L engines:

      Standard-1.1024-1.1031 inch (28.000-28.021mm)
       

    2.  
    3. 1.8L engine:

      Standard-1.0236-1.0249 inch (26.000-26.033mm)
       

    4.  

  12.  
  13. Measure camshaft journal outside diameter.


    1. 1.3L and 1.6L engines:

      Standard-1.1000-1.1008 inch (27.939-27.960mm)
       

    2.  
    3. 1.8L engine:

      Standard-1.0220-1.0228 inch (25.959-25.980mm)
       

    4.  

  14.  
  15. Replace camshaft or cylinder head assembly whichever the difference from specification is greater.
  16.  

Removal & Installation



1.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system into a re-sealable container.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Timing belt
     
    Cylinder head cover from the cylinder head
     
    Camshaft Position (CMP) sensor coupler from the CMP sensor
     
    High tension cords and couplers from the coil assemblies
     
    Ignition coil from the exhaust manifold side
     
    CMP case from the cylinder head
     

  8.  
  9. Loosen all valve adjusting screw lock nuts, turn the adjusting screws back all the way to allow the rocker arms to move freely.
  10.  
  11. Remove or disconnect the following:

    Camshaft bearing caps in the sequence illustrated in several steps
     
    Camshaft
     
    Timing belt inside cover
     
    Intake rocker arm with the clip from the rocker arm shaft. Make sure not to bend the clip when removing the intake rocker arm
     
    Rocker arm shaft bolts
     
    Exhaust rocker arms and spring by pulling out the shaft on the battery side. If necessary, remove the battery for clearance.
     

  12.  
  13. Inspect the rocker arms and shafts for wear and/or damage and replace parts as necessary.
    1. If the tip of the valve lash adjuster is badly worn, replace the adjuster.

      Click image to see an enlarged view

      Fig. Loosen the camshaft bearing caps using several steps in the sequence shown-1.3L engines

    2.  

  14.  

To install:

  1. Apply engine oil to the rocker arms and the rocker arm shafts.
  2.  
  3. Install or connect the following:

    O-ring on the shaft
     
    Rocker arm shaft with its holes facing up
     
    Rocker arm (exhaust side) and the rocker arm spring
     
    Rocker arm shaft bolts and tighten the bolts to 96 inch lbs. (11 Nm)
     

  4.  
  5. Pour a small amount of engine oil into the arm pivot holding part of the shaft.
  6.  
  7. Install or connect the following:

    Rocker arm (intake side), with the clips to the rocker arm shaft
     
    Camshaft and the bearing caps. Tighten the bearing caps in several passes to reach the final torque of 96 inch lbs. (11 Nm). Refer to the accompanying illustration for the proper camshaft bearing cap torque sequence.
     
    Camshaft oil seal
     
    Timing belt inside cover
     
    Camshaft timing belt pulley, while fitting the pin on the camshaft into the slot. Tighten the pulley bolt to 43 ft. lbs. (60 Nm).
     
    Timing belt
     
    Remaining components in the reverse order of removal.
     

  8.  
  9. Check the ignition timing.

    Click image to see an enlarged view

    Fig. Tighten the camshaft bearing caps using several steps in the sequence shown-1.3L engines

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system into a re-sealable container.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Timing belt
     
    Cylinder head cover from the cylinder head
     
    Camshaft Position (CMP) sensor connector from the CMP sensor
     
    High tension cords and connectors from the coil assemblies
     
    Ignition coil from the exhaust manifold side
     
    CMP case from the cylinder head
     

  8.  
  9. Loosen all valve adjusting screw lock nuts, turn the adjusting screws back all the way to allow the rocker arms to move freely.
  10.  
  11. Remove or disconnect the following:

    Camshaft bearing caps in the sequence illustrated in several steps
     
    Camshaft
     
    Timing belt inside cover
     
    Intake rocker arm with the clip from the rocker arm shaft. Make sure not to bend the clip when removing the intake rocker arm
     
    Rocker arm shaft bolts
     
    Exhaust rocker arms and spring by pulling out the shaft on the battery side. If necessary, remove the battery for clearance.
     

  12.  
  13. Inspect the rocker arms and shafts for wear and/or damage and replace parts as necessary.
    1. If the tip of the valve lash adjuster is badly worn, replace the adjuster.

      Click image to see an enlarged view

      Fig. Loosen the camshaft bearing caps using several steps in the sequence shown-1.3L engines

    2.  

  14.  

To install:

  1. Apply engine oil to the rocker arms and the rocker arm shafts.
  2.  
  3. Install or connect the following:

    O-ring on the shaft
     
    Rocker arm shaft with its holes facing up
     
    Rocker arm (exhaust side) and the rocker arm spring
     
    Rocker arm shaft bolts and tighten the bolts to 96 inch lbs. (11 Nm)
     

  4.  
  5. Pour a small amount of engine oil into the arm pivot holding part of the shaft.
  6.  
  7. Install or connect the following:

    Rocker arm (intake side), with the clips to the rocker arm shaft
     
    Camshaft and the bearing caps. Tighten the bearing caps in several passes to reach the final torque of 96 inch lbs. (11 Nm). Refer to the accompanying illustration for the proper camshaft bearing cap torque sequence.
     
    Camshaft oil seal
     
    Timing belt inside cover
     
    Camshaft timing belt pulley, while fitting the pin on the camshaft into the slot. Tighten the pulley bolt to 43 ft. lbs. (60 Nm).
     
    Timing belt
     
    Remaining components in the reverse order of removal.
     

  8.  
  9. Check the ignition timing.

    Click image to see an enlarged view

    Fig. Tighten the camshaft bearing caps using several steps in the sequence shown-1.3L engines

  10.  

1.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:



    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-1.6L engine



    Click image to see an enlarged view

    Fig. Camshaft housing bolt tightening sequence-1.6L engine

    Water pump belt and pulley
     
    Crankshaft pulley
     
    Timing belt cover and the timing belt
     
    Camshaft sprocket
     
    Cylinder head cover
     
    Distributor and distributor case, if equipped
     
    Ignition coils and Camshaft Position (CMP) sensor case, with the CMP sensor housing coupler disconnected, if equipped
     

  6.  
  7. Loosen the valve adjusting screw locknuts and screws to allow all the valves to close.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    The camshaft housing bolts must be removed in the reverse order of installation or damage to the camshaft may occur.



    Camshaft housing bolts
     
    Housings
     
    Camshaft
     

  10.  

To install:

  1. Lubricate the lobes and journals of the camshaft with clean engine oil.
  2.  
  3. Install or connect the following:
    NOTE
    Embossed marks are provided on each camshaft housing, indicating position and direction for installation.



    Camshaft
     
    Camshaft housing on the camshaft and cylinder head, starting with the number 1 housing
     

  4.  
  5. Apply engine oil to the camshaft journal sliding surface of each housing. Apply sealant to the mating surface of the number 6 housing which will mate with the cylinder head.
  6.  
  7. Apply engine oil to the housing bolts, and hand-tighten the bolts into the housing. Follow the tightening sequence in 3 to 4 even stages, finishing with a final torque of 96 inch lbs. (11 Nm).
    CAUTION
    The camshaft housing bolts must be tightened in the correct order or damage to the camshaft may occur.

  8.  
  9. Apply engine oil to the camshaft oil seal lip. Install the camshaft oil seal until the surface becomes flush.
  10.  
  11. Install or connect the following:

    Camshaft sprocket
     
    Timing belt
     
    Timing belt cover
     
    Crankshaft pulley
     
    Water pump pulley
     
    Water pump belt. Be sure the pin on the camshaft fits into the slot at the E mark on the camshaft sprocket. Tighten the sprocket bolt to 41-46 ft. lbs. (56-64 Nm).
     

  12.  
  13. Prior to installation on models equipped with a distributor, apply sealant to the area of the distributor housing that covers the rear of the rocker arm shaft on the cylinder head. Install the distributor and distributor housing to the cylinder head. Be sure the distributor is facing the correct firing position.
  14.  
  15. Prior to installation on models equipped with a Distributorless Ignition System (DIS), apply sealant to the area of the housing that covers the rear of the rocker arm shaft on the cylinder head. Install the CMP sensor and housing to the cylinder head and tighten the bolts to 96 inch lbs. (11 Nm).

    Ignition coil assembly, if equipped
     

  16.  
  17. Adjust the valve lash.
  18.  
  19. Install or connect the following:

    New cylinder head cover gasket and the cover
     
    Negative battery cable
     

  20.  
  21. Start the engine and check for any water or oil leaks when finished.
  22.  
  23. Check and/or adjust the ignition timing as necessary.
  24.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:



    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-1.6L engine



    Click image to see an enlarged view

    Fig. Camshaft housing bolt tightening sequence-1.6L engine

    Water pump belt and pulley
     
    Crankshaft pulley
     
    Timing belt cover and the timing belt
     
    Camshaft sprocket
     
    Cylinder head cover
     
    Distributor and distributor case, if equipped
     
    Ignition coils and Camshaft Position (CMP) sensor case, with the CMP sensor housing connector disconnected, if equipped
     

  6.  
  7. Loosen the valve adjusting screw locknuts and screws to allow all the valves to close.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    The camshaft housing bolts must be removed in the reverse order of installation or damage to the camshaft may occur.



    Camshaft housing bolts
     
    Housings
     
    Camshaft
     

  10.  

To install:

  1. Lubricate the lobes and journals of the camshaft with clean engine oil.
  2.  
  3. Install or connect the following:
    NOTE
    Embossed marks are provided on each camshaft housing, indicating position and direction for installation.



    Camshaft
     
    Camshaft housing on the camshaft and cylinder head, starting with the number 1 housing
     

  4.  
  5. Apply engine oil to the camshaft journal sliding surface of each housing. Apply sealant to the mating surface of the number 6 housing which will mate with the cylinder head.
  6.  
  7. Apply engine oil to the housing bolts, and hand-tighten the bolts into the housing. Follow the tightening sequence in 3 to 4 even stages, finishing with a final torque of 96 inch lbs. (11 Nm).
    CAUTION
    The camshaft housing bolts must be tightened in the correct order or damage to the camshaft may occur.

  8.  
  9. Apply engine oil to the camshaft oil seal lip. Install the camshaft oil seal until the surface becomes flush.
  10.  
  11. Install or connect the following:

    Camshaft sprocket
     
    Timing belt
     
    Timing belt cover
     
    Crankshaft pulley
     
    Water pump pulley
     
    Water pump belt. Be sure the pin on the camshaft fits into the slot at the E mark on the camshaft sprocket. Tighten the sprocket bolt to 41-46 ft. lbs. (56-64 Nm).
     

  12.  
  13. Prior to installation on models equipped with a distributor, apply sealant to the area of the distributor housing that covers the rear of the rocker arm shaft on the cylinder head. Install the distributor and distributor housing to the cylinder head. Be sure the distributor is facing the correct firing position.
  14.  
  15. Prior to installation on models equipped with a Distributorless Ignition System (DIS), apply sealant to the area of the housing that covers the rear of the rocker arm shaft on the cylinder head. Install the CMP sensor and housing to the cylinder head and tighten the bolts to 96 inch lbs. (11 Nm).

    Ignition coil assembly, if equipped
     

  16.  
  17. Adjust the valve lash.
  18.  
  19. Install or connect the following:

    New cylinder head cover gasket and the cover
     
    Negative battery cable
     

  20.  
  21. Start the engine and check for any water or oil leaks when finished.
  22.  
  23. Check and/or adjust the ignition timing as necessary.
  24.  

1.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect negative cable at battery.
  6.  
  7. Drain engine oil.
  8.  
  9. Drain coolant.
  10.  
  11. Remove oil pan.
  12.  
  13. Remove cylinder head cover.
  14.  
  15. Remove timing chain cover.
  16.  
  17. Remove 2nd timing chain.
  18.  
  19. Remove CMP sensor.
  20.  
  21. To secure work in the following steps, reinstall mounting member, engine front torque bush, rear mounting and rear mounting No.2 bracket.

    Click image to see an enlarged view

    Fig. Set key on crankshaft in position as shown by turning crankshaft in order to prevent interference between valves and piston-1.8L engine

  22.  
  23. Set key on crankshaft in position as shown by turning crankshaft. This is to prevent interference between valves and piston.

    Click image to see an enlarged view

    Fig. Camshaft housing bolt loosening sequence-1.8L engine

  24.  
  25. Loosen camshaft housing bolts in such order as indicated in the figure and remove them.
  26.  
  27. Remove camshaft housings.
  28.  
  29. Remove camshafts.
  30.  
  31. Remove valve lash adjusters.
    NOTE
    Never disassemble hydraulic valve lash adjuster. Don-t apply force to body of adjuster, oil in high pressure chamber in adjuster will leak. Immerse removed adjuster in clean engine oil and keep it there till reinstalling it so as to prevent oil leakage. If it is left in air, place it with its bucket body facing down. Don-t place on its side or with bucket body facing up.

  32.  

To install:

  1. Before installing valve lash adjuster to cylinder head, fill oil passage of cylinder head with engine oil according to the following procedure:


    1. Pour engine oil through oil holes and check that oil comes out from oil holes in sliding part of valve lash adjuster.
    2.  
    3. Perform this check on both intake and exhaust sides.
    4.  

  2.  
  3. Install valve lash adjusters to cylinder head. Apply engine oil around valve lash adjuster and then install it to cylinder head.
  4.  
  5. Match match mark on crank timing sprocket and mating surface of cylinder block and lower crankcase.

    Click image to see an enlarged view

    Fig. Intake camshaft knock pin (1), exhaust camshaft knock pin (2), intake camshaft match mark (3) and exhaust camshaft match mark (4)-1.8L engine

  6.  
  7. Install camshafts. Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match marks on cylinder head and camshafts as shown in the figure.
    NOTE
    Install camshaft in such direction that its end with groove for CMP sensor installation comes to exhaust side.

  8.  
  9. Install camshaft housing pins.

    Click image to see an enlarged view

    Fig. Intake camshaft (1), exhaust camshaft (2), camshaft housing pins (3) and sealant application (-A-)-1.8L engine

  10.  
  11. Apply sealant -A- (part No. 99000-31150) to exhaust camshaft end housing sealing surface area as shown in the figure.

    Click image to see an enlarged view

    Fig. Camshaft housing position: intake side -I- or exhaust side -E- (1), position from timing chain side (2), timing chain side (3)-1.8L engine

  12.  
  13. Check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housings as indicated by these marks.

    Click image to see an enlarged view

    Fig. Camshaft housing bolt tightening sequence-1.8L engine

  14.  
  15. After applying oil to housing bolts, tighten them temporarily first. Then tighten them by the following numerical order in the figure. Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to 8 ft. lbs. (11 Nm).
  16.  
  17. Install CMP sensor.
  18.  
  19. Install 2nd timing chain.
  20.  
  21. Install timing chain cover.
  22.  
  23. Install cylinder head cover.
  24.  
  25. Install oil pan.
  26.  
  27. Install cooling system and other parts.
  28.  
  29. Refill cooling system with coolant and engine with engine oil.
  30.  
  31. Check ignition timing and adjust as necessary.
  32.  
  33. Check to make sure that there is no coolant leakage and oil leakage at each connection.
  34.  

 
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