fuel pump SUZUKI SWIFT 2000 1.G RG413 Service Owner's Manual

6-120 ENGINE GENERAL INFORMATION AND DIAGNOSIS
TABLE B-3 FUEL PRESSURE CHECK
WIRING DIAGRAM
INSPECTION
1. Injector (A) : Fuel pressure gauge
2. Delivery pipe (B) : Hose
3. Fuel pump (C) : Attachment
Step Action Yes No
1 Check Fuel Pressure (Refer to Section 6E for
details).
1) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge.
3) Check fuel pressure by repeating ignition
switch ON and OFF. See Fig. 1.
Is fuel pressure then 270 – 310 kPa (2.7 – 3.1
kg/cm
2, 38.4 – 44.0 psi)?Go to Step 2. Go to Step 4.
2
Is 250 kPa (2.5 kg/cm
2, 35.6 psi) or higher fuel
pressure retained for 1 minute after fuel pump
is stopped at Step 1?Normal fuel pressure. Go to Step 3.
3 Is there fuel leakage from fuel feed line hose,
pipe or their joint?Fuel leakage from hose,
pipe or joint.Faulty fuel pressure regu-
lator.
4 Was fuel pressure higher than spec. in Step 1? Faulty fuel pressure regu-
lator.Clogged fuel filter,
Restricted fuel feed hose
or pipe, Faulty fuel pump
or Fuel leakage from hose
connection in fuel tank.

6A1-56 ENGINE MECHANICAL (M13 ENGINE)
5) Install cylinder head to cylinder block.
Apply engine oil to new cylinder head bolts and tighten them
gradually as follows.
a) Tighten cylinder head bolts (“1” – “10”) to 20 N·m (2.0 kg-m,
14.5 lb-ft) according to numerical order as shown by using
a 12 corner socket wrenches.
b) In the same manner as in Step a), tighten them to 40 N·m
(4.0 kg-m, 29.0 lb-ft).
c) Turn all bolts 60° according to numerical order in figure.
d) Repeat Step c).
e) Tighten bolt “A” to specified torque.
Tightening torque
Cylinder head bolt for M8 (a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
Cylinder head bolts for M10
(b) : 40 N·m (4.0 kg-m, 29.0 lb-ft) and then turn to 60° twice
6) Install exhaust manifold stiffener and exhaust No.1 pipe
referring to “EXHAUST MANIFOLD”.
7) Install camshafts, timing chain and chain cover as previously
outlined.
8) Install cylinder head cover and oil pan as previously outlined.
9) Install intake manifold stiffener and connect each hoses and
electric lead wires securely.
10) Install air cleaner assembly, resonator and hoses referring to
“AIR CLEANER ASSEMBLY AND RESONATOR”.
11) Adjust water pump belt tension referring to Section 6B.
12) Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
13) Adjust accelerator cable play referring to Section 6E1.
14) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
15) Refill cooling system with coolant, engine with engine oil.
16) Connect negative cable at battery.
17) Verify that there is no fuel leakage, coolant leakage, oil leak-
age and exhaust gas leakage at each connection. NOTE:
Never reuse cylinder head bolts (“1” – “10”) once dis-
assembled it due to plastic deformation tightening.
Be sure to use new cylinder head bolts.
Be sure to tighten M8 bolt (“A”) after securing the
other bolt.

6A1-66 ENGINE MECHANICAL (M13 ENGINE)
6) Reverse removal procedure for installation as previously out-
lined.
7) Adjust water pump belt tension referring to Section 6B.
8) Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
9) Adjust accelerator cable play referring to Section 6E1.
10) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
11) Refill cooling system with coolant engine with engine oil.
12) Connect negative cable at battery.
13) Verify that there is no fuel leakage, coolant leakage, oil leak-
age and exhaust gas leakage at each connection. NOTE:
Before installing bearing cap, make sure that checking
for connecting rod bolt deformation.
Refer to “INSPECTION” of “CONNECTING ROD”.

6A1-68 ENGINE MECHANICAL (M13 ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL
1) Relieve fuel pressure according to procedure described in
Section 6.
2) Disconnect negative and positive cables at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove right and left side engine under covers.
5) Remove A/C compressor belt (if equipped).
6) Remove water pump belt.
7) Drain engine oil, transmission oil or A/T fluid (for A/T vehicle)
and transfer oil (for 4WD vehicle).
8) Drain coolant.
9) Remove air cleaner assembly, resonator and hoses referring
to “AIR CLEANER ASSEMBLY AND RESONATOR”.
10) With hose connected, detach A/C compressor from its
bracket (if equipped). WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed A/C compressor at a place where no
damage will be caused during removal and installation of
engine assembly.

6A1-72 ENGINE MECHANICAL (M13 ENGINE)
6) Install generator referring to Section 6H.
7) For 4WD vehicle, install propeller shaft referring to Section
4B.
8) Connect drive shaft joints referring to Section 4.
9) Install exhaust No.1 pipe and tighten pipe fasteners to speci-
fied torque.
Tightening torque
Exhaust No.1 pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
10) Reverse disconnected hoses, cables and electric wires for
connection.
11) Install air cleaner assembly, resonator and hoses referring to
“AIR CLEANER ASSEMBLY AND RESONATOR”
12) Install A/C compressor to bracket (if equipped).
13) Adjust water pump belt tension referring to Section 6B.
14) Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
15) Adjust accelerator cable play referring to Section 6E1.
16) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
17) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
18) Connect negative cable at battery.
19) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.

ENGINE FUEL 6C-1
6F1
6F2
6G
6C
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6C
ENGINE FUEL
CONTENTS
GENERAL DESCRIPTION .............................. 6C-1
ON-VEHICLE SERVICE .................................. 6C-2
COMPONENTS ........................................... 6C-2
PRECAUTIONS ........................................... 6C-3
FUEL LINES ................................................. 6C-4
FUEL PIPE ................................................... 6C-4
FUEL FILLER CAP ...................................... 6C-5FUEL TANK INLET VALVE ......................... 6C-6
FUEL TANK ................................................. 6C-7
FUEL PUMP ASSEMBLY .......................... 6C-10
DISASSEMBLY AND REASSEMBLY .... 6C-12
SPECIAL TOOL ............................................ 6C-14
TIGHTENING TORQUE SPECIFICATION.... 6C-14

GENERAL DESCRIPTION
The main components of the fuel system are fuel tank, fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator and tank pressure control valve), fuel/vapor separator fuel feed line and fuel vapor line.
For the details of fuel flow and fuel vapor flow, refer to “GENERAL DESCRIPTION” in Section 6E. 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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” 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).
CAUTION:
The engine of this vehicle requires the use of unleaded fuel only. Use of leaded and/or low lead fuel
can result in engine damage and reduce the effectiveness of the emission control system.

6C-2 ENGINE FUEL
ON-VEHICLE SERVICE
COMPONENTS
1. Fuel tank 7. Fuel vapor line 13. Fuel filler hose clamp screw 19. Fuel pressure regulator
2. Fuel pump assembly 8. EVAP canister 14. Tank cover 20. Fuel pump
3. Breather hose 9. Delivery pipe 15. Fuel filler bracket screw 21. Fuel filter assembly
4. Fuel filler cap 10. Fuel/vapor separator 16. Fuel filler bracket nut 22. Fuel level gauge (Fuel sender gauge)
5. Fuel feed line 11. Fuel pump bolt (6 pcs.) 17. Gasket Do not reuse.
6. Wire harness for fuel pump 12. Fuel tank bolt (4 pcs.) 18. O-ring Tightening torque

6C-6 ENGINE FUEL
FUEL TANK INLET VALVE
REMOVAL
1) Remove fuel filler cap.
2) Insert hose of a hand operated pump into fuel filler hose (1)
and drain fuel in space “A” in the figure.
3) Hoist vehicle and remove clamp (2) and fuel filler hose (1)
from fuel tank.
4) Remove fuel tank inlet valve (1) using flat-bladed screw-
driver.
INSPECTION
Check fuel tank inlet valve for the followings.
Damage
Smooth opening and closing
If any damage or malfunction is found, replace.WARNING:
Refer to the WARNING at the beginning of ON-VEHICLE
SERVICE in this section.
CAUTION:
Do not force pump hose into fuel tank, or pump hose
may damage fuel tank inlet valve (2).
1
2
CAUTION:
Be careful not to damage fuel tank inlet valve (1) with flat-
bladed screwdriver.

ENGINE FUEL 6C-7
INSTALLATION
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel filler hose (1) to fuel tank and secure it with clamp
(2).
For proper installation, refer to “COMPONENTS” under “ON-
VEHICLE SERVICE”.
3) Lower vehicle and install fuel filler cap.
FUEL TANK
REMOVAL
1) Relieve fuel pressure in fuel feed line according to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6.
2) Disconnect negative cable at battery.
3) Hoist vehicle.
4) Disconnect fuel filler hose (1) and breather hose (2) from
filler neck (3).
5) Due to absence of fuel tank drain plug, drain fuel tank by
pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
1
2
WARNING:
Before starting the following procedure, be sure to
observe “PRECAUTIONS”.
CAUTION:
Never disconnect fuel filler hose (1) from fuel tank inlet. If
half or more of fuel is remaining to fuel tank, fuel over
flows in this case and come out.
CAUTION:
Do not force pump hose into fuel tank, or pump hose
may damage fuel tank inlet valve.
Never drain or store fuel in an open container due to
possibility of fire or explosion.
2
1
3

6C-8 ENGINE FUEL
6) Disconnect fuel pipe joint and fuel hoses from pipes.
For quick joint, disconnect it as follows :
a) Remove mud, dust and/or foreign material between pipe
and joint by blowing compressed air.
b) Unlock joint (1) lock by inserting special tool between pipe
(2) and joint (1).
Special tool
(A) : 09919-47020
c) Disconnect joint from pipe.
7) Support fuel tank (1) with jack (2) and remove its mounting
bolts.
8) Lower fuel tank a little as to disconnect wire harness at con-
nector (1), then remove fuel tank.
INSPECTION
After removing fuel tank, check hoses and pipes connected to
fuel tank for leaks, loose connections, deterioration or damage.
Also check fuel pump assembly gaskets for leaks, visually inspect
fuel tank for leaks and damage.
Replace any damaged or malconditioned parts.WARNING:
A small amount of fuel may be released after the fuel
hose is disconnected. In order to reduce the chance of
personal injury, cover the hose and pipe to be discon-
nected with a shop cloth. Be sure to put that cloth in an
approved container when disconnection is completed.
1