egr SUZUKI SWIFT 2000 1.G RG413 Service Owner's Guide

6A1-18 ENGINE MECHANICAL (M13 ENGINE)
11) Remove intake manifold (1) with throttle body (2) and EGR
pipe (3) from cylinder head, and then its gasket.
INSTALLATION
Reverse removal procedure for installation noting the followings.
Use new intake manifold gasket and EGR pipe gasket.
Tighten bolts (1) and nuts (2) to specified torque.
Tightening torque
Intake manifold bolts and nuts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
Adjust accelerator cable play referring in Section 6E1.
Refill cooling system referring in Section 6B.
Upon completion of installation, turn ignition switch ON but
engine OFF and check for fuel leaks.
Finally, start engine and check for engine coolant leaks.

ENGINE MECHANICAL (M13 ENGINE) 6A1-45
4) Drain coolant by loosening drain plug (1).
5) Remove air cleaner assembly (1), resonator and hoses (2)
referring to “AIR CLEANER ASSEMBLY AND RESONA-
TOR”.
6) Disconnect the following electric lead wires :
EGR valve (if equipped)
IAC valve (1)
TP sensor (2)
MAP sensor (3)
CMP sensor
ECT sensor
EVAP canister purge valve (4)
Injectors (5)
Ignition coils
Heated oxygen sensors
Ground terminal from exhaust manifold
Each wire harness clamps
7) Remove heated oxygen sensor bracket from timing chain
cover and detach heated oxygen sensor couplers from its
bracket.
8) Disconnect accelerator cable from throttle body.
9) Disconnect the following hoses :
Brake booster hose (1) from intake manifold
Canister purge hose (2) from EVAP canister purge valve
Fuel feed and return hose (3) from each pipe
Water hose (4) from thermostat case
Heater inlet hose (5) from its pipe 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.

6A1-50 ENGINE MECHANICAL (M13 ENGINE)
Valve seat repair:
A valve seat not producing a uniform contact with its valve or
showing width of seating contact that is out of specified
range must be repaired by regrinding or by cutting and
regrinding and finished by lapping.
a) EXHAUST VALVE SEAT : Use valve seat cutters (1) to
make two cuts as illustrated in figure. Two cutters must be
used: the first for making 15° angle, and the second for
making 45° angle. The second cut must be made to pro-
duce desired seat width.
Seat width for exhaust valve seat
“a” : 1.1 – 1.3 mm (0.0433 – 0.0512 in.)
b) INTAKE VALVE SEAT : Use valve seat cutters to make
three cuts as illustrated in figure. Three cutters must be
used: the 1st for making 15° angle, the 2nd for making 60°
angle, and 3rd for making 45° angle. The 3rd cut (45°) must
be made to produce desired seat width.
Seat width for intake valve seat
“b” : 1.1 – 1.3 mm (0.0433 – 0.0512 in.)
c) VALVE LAPPING : Lap valve on seat in two steps, first with
coarse size lapping compound applied to face and the sec-
ond with fine-size compound, each time using valve lapper
according to usual lapping method.
Cylinder Head
Remove all carbon deposits from combustion chambers.
NOTE:
Do not use any sharp-edged tool to scrape off carbon
deposits. Be careful not to scuff or nick metal surfaces
when decarbonizing. The same applies to valves and
valve seats, too.

6A1-62 ENGINE MECHANICAL (M13 ENGINE)
Connecting rod alignment :
Mount connecting rod on aligner to check it for bow and
twist. If limit is exceeded, replace it.
Connecting rod alignment
Limit on bow : 0.05 mm (0.0020 in.)
Limit on twist : 0.10 mm (0.0039 in.)
Connecting rod bolt deformation (Plastic deformation tight-
ening bolt)
Measure connecting rod (1) bolt (2) for diameter “A” on 32
mm (1.25 in.) from bolt mounting surface and diameter “B”
on 40 mm (1.57 in.) from bolt mounting surface by using a
micrometer (3).
Bolt diameter difference should be specification as given
below. If it is out of specification, replace connecting rod.
Connecting rod bolt diameter difference
limit (“A” – “B”) : 0.1 mm (0.004 in.)
Connecting rod bolt measurement distance
“a” : 32 mm (1.25 in.)
“b” : 40 mm (1.57 in.)
Crank Pin and Connecting Rod Bearings
Inspect crank pin for uneven wear or damage. Measure
crank pin for out-of-round or taper with a micrometer. If crank
pin is damaged or out-of round or taper is out of limit, replace
crankshaft or regrind crank pin to undersize and use under-
size bearing.
Crank pin diameter
Crank pin taper and out-of-round
Limit : 0.01 mm (0.0004 in.)
Out-of-round : A – B
Taper : a – b
Connecting rod
bearing sizeCrank pin diameter
Standard41.982 – 42.000 mm
(1.6528 – 1.6535 in.)
Undersize
0.25 mm (0.0098 in.)41.732 – 41.750 mm
(1.6430 – 1.6437 in.)

6A1-64 ENGINE MECHANICAL (M13 ENGINE)
6) If clearance can not be brought to within its limit even by
using a new standard size bearing, regrind crankpin to
undersize and use 0.25 mm undersize bearing.
ASSEMBLY
1) Install piston pin to piston (1) and connecting rod (2) :
a) After applying engine oil to piston pin and piston pin holes
in piston and connecting rod.
b) Fit connecting rod as shown in figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
2) Install piston rings to piston :
a) As indicated in figure, 1st and 2nd rings have “T” mark
respectively. When installing these piston rings to piston,
direct marked side of each ring toward top of piston.
b) 1st ring (1) differs from 2nd ring (2) in thickness, shape and
color of surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.
c) When installing oil ring (3) install spacer first and then two
rails.
3) After installing three rings (1st, 2nd and oil rings), distribute
their end gaps as shown in figure. NOTE:
After checking the rod bearing clearance, make sure that
checking for Connecting rod bolt deformation.
Refer to “INSPECTION” of “CONNECTING ROD”.
NOTE:
Circlip should be installed with its cut part facing as
shown in figure. Install so that circlip end gap comes
within such range as indicated by arrow.
1. 1st ring
2. 2nd ring
3. Oil ring
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap

ENGINE MECHANICAL (M13 ENGINE) 6A1-69
11) Disconnect the following electric lead wires:
TP sensor (1)
MAP sensor (2)
ECT sensor
CMP sensor
CKP sensor
Knock sensor
Heated oxygen sensors
EGR valve (3)
IAC valve (4)
EVAP canister purge valve (5)
Injectors (6)
Ignition coil assembly (7)
Engine oil pressure switch
Generator (8)
Starting motor
Magnet clutch switch of A/C compressor (if equipped)
Ground terminal (9) from exhaust manifold and cylinder
block
VSS
Back up light switch (For M/T vehicle)
Transmission range switch (10) (For A/T vehicle)
A/T VSS (11) (For A/T vehicle)
Dropping resistor (12) (For A/T vehicle)
A/T shift solenoid and A/T temp. sensor (13) (For A/T vehi-
cle)
Battery ground cable (14) from transmission
Each wire harness clamps
12) Remove fuse box from its bracket.
13) Disconnect the following cables :
Accelerator cable
Gear select control cable (For M/T vehicle)
Gear shift control cable (For M/T vehicle)
Clutch cable (For M/T vehicle)
Gear select cable (15) (For A/T vehicle)
14) Disconnect the following hoses :
Brake booster hose (1) from intake manifold
Canister purge hose (2) from EVAP canister purge valve
Fuel feed hose (3) from fuel delivery pipe
Heater inlet and outlet hoses from each pipe
Radiator inlet and outlet hoses from each pipe

6A1-76 ENGINE MECHANICAL (M13 ENGINE)
Use a dial gauge to read displacement in axial (thrust) direction of
crankshaft.
If its limit is exceeded, replace thrust bearing with new standard
one or oversize one to obtain standard thrust play.
Crankshaft thrust play
Standard : 0.11 – 0.31 mm (0.0043 – 0.0122 in.)
Limit : 0.35 mm (0.0138 in.)
Out-of-round and taper (uneven wear) of journals
An unevenly worn crankshaft journal shows up as a difference in
diameter at a cross section or along its length (or both). This dif-
ference, if any, is determined by taking micrometer readings. If
any one of journals is badly damaged or if amount of uneven wear
in the sense explained above exceeds its limit, regrind or replace
crankshaft.
Crankshaft out-of-round and taper
Limit : 0.01 mm (0.0004 in.)
Out-of-round : A – B
Taper : a – b
Main Bearings
General information
Service main bearings are available in standard size and
0.25 mm (0.0098 in.) undersize, and each of them has 5
kinds of bearings differing in tolerance.
Upper half of bearing (1) has an oil groove (2) as shown in
figure.
Install this half with oil groove to cylinder block.
Lower half of bearing does not have an oil groove.
Visual inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Never replace either half without replacing the other half.
Main bearing clearance
Check clearance by using gaging plastic according to the follow-
ing procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.

ENGINE MECHANICAL (M13 ENGINE) 6A1-77
3) Place a piece of gaging plastic (1) the full width of bearing
(parallel to crankshaft) on journal, avoiding oil hole.
4) Tighten bearing cap No.1 bolts (1) – (10) and No.2 bolts (11)
– (20) gradually as follows.
a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft)
according to numerical order in figure.
b) In the same manner as in Step a), tighten them to 50 N·m
(5.0 kg-m, 36.5 lb-ft).
c) In the same manner as in step a), retighten them to 60°.
d) Tighten bolts (11) – (20) to 22 N·m (2.2 kg-m, 16.0 lb-ft)
according to numerical order in figure.
Tightening torque
Crank shaft bearing No.1 bolts (1) – (10)
: 50 N·m (5.0 kg-m, 36.5 lb-ft) and extra tighten 60°
Crank shaft bearing No.2 bolts (11) – (20)
: 22 N·m (2.2 kg-m, 16.0 lb-ft)
5) Remove bearing caps and using scale (1) on gaging plastic
(2) envelop, measure gaging plastic width at its widest point.
If clearance exceeds its limit, replace bearing. Always
replace both upper and lower inserts as a unit.
A new standard bearing may produce proper clearance. If
not, it will be necessary to regrind crankshaft journal for use
of 0.25 mm undersize bearing.
After selecting new bearing, recheck clearance.
Main bearing clearance
Standard : 0.025 – 0.045 mm (0.0010 – 0.0018 in.)
Limit : 0.065 mm (0.0026 in.)
NOTE:
Do not rotate crankshaft while gaging plastic is installed.
NOTE:
After checking main bearing clearance, make sure that
replace bearing cap No.1 bolts new one.

6A1-80 ENGINE MECHANICAL (M13 ENGINE)
UNDERSIZE BEARING (0.25 mm) :
0.25 mm undersize bearing is available, in five kinds varying
in thickness.
To distinguish them, each bearing is painted in the following
colors at such position as indicated in figure.
Each color represents the following thickness at the center of
bearing.
Undersize of crankshaft main bearing thickness
If necessary, regrind crankshaft journal and select undersize
bearing to use with it as follows.
a) Regrind journal to the following finished diameter.
Finished diameter
: 44.732 – 44.750 mm (1.7611 – 1.7618 in.)
1) Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicu-
lar to each other in order to check for out-of-round.
2) Using journal diameter measured above and alphabets
stamped on cylinder block, select an undersize bearing by
referring to table given below.
Check bearing clearance with newly selected undersize
bearing.
Specification of new standard undersize crankshaft main bearingColor painted Bearing thickness
Red and Pink 2.115 - 2.119 mm (0.0833 - 0.0834 in.)
Red and Purple 2.118 - 2.122 mm (0.0834 - 0.0835 in.)
Red and Brown 2.121 - 2.125 mm (0.0835 - 0.0837 in.)
Red and Green 2.124 - 2.128 mm (0.0836 - 0.0838 in.)
Red and Black 2.127 - 2.131 mm (0.0837 - 0.0839 in.)
1. Paint
Measured journal diameter
44.744 – 44.750 mm
(1.7616 – 1.7618 in.)44.738 – 44.744 mm
(1.7613 – 1.7616 in.)44.732 – 44.738 mm
(1.7611 – 1.7613 in.)
Alphabets stamped
on cylinder blockA Red and Pink Red and Purple Red and Brown
B Red and Purple Red and Brown Red and Green
C Red and Brown Red and Green Red and Black
Undersize bearing to be installed

ENGINE AND EMISSION CONTROL SYSTEM 6E1-1
6F1
6F2
6G
6H
6E1
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM
CONTENTS
GENERAL DESCRIPTION ............................ 6E1-2
AIR INTAKE SYSTEM ............................... 6E1-5
FUEL DELIVERY SYSTEM ....................... 6E1-6
FUEL PUMP ........................................... 6E1-6
ELECTRONIC CONTROL SYSTEM .......... 6E1-7
ENGINE & EMISSION CONTROL
INPUT/OUTPUT TABLE ........................ 6E1-8
ECM INPUT/OUTPUT CIRCUIT
DIAGRAM............................................... 6E1-9
ECM TERMINAL ARRANGEMENT
TABLE .................................................. 6E1-13
ON-VEHICLE SERVICE .............................. 6E1-15
ACCELERATOR CABLE
ADJUSTMENT ..................................... 6E1-15
IDLE SPEED/IDLE AIR CONTROL
(IAC) DUTY INSPECTION ................... 6E1-15
IDLE MIXTURE INSPECTION /
ADJUSTMENT (VEHICLE WITHOUT
HEATED OXYGEN SENSOR) ............. 6E1-17
AIR INTAKE SYSTEM ............................. 6E1-18
THROTTLE BODY ............................... 6E1-18IDLE AIR CONTROL VALVE (IAC
VALVE) ................................................ 6E1-20
FUEL DELIVERY SYSTEM ..................... 6E1-21
FUEL PRESSURE INSPECTION ........ 6E1-21
FUEL PUMP WITH PRESSURE
REGULATOR ....................................... 6E1-22
FUEL INJECTOR ................................. 6E1-23
ELECTRONIC CONTROL SYSTEM ....... 6E1-27
ENGINE CONTROL MODULE
(ECM) ................................................... 6E1-27
MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP SENSOR)................... 6E1-27
THROTTLE POSITION SENSOR (TP
SENSOR) ............................................. 6E1-28
INTAKE AIR TEMPERATURE
SENSOR (IAT SENSOR) ..................... 6E1-29
ENGINE COOLANT TEMPERATURE
SENSOR (ECT SENSOR) ................... 6E1-30
HEATED OXYGEN SENSOR (HO2S-1
AND HO2S-2) ...................................... 6E1-31
CAMSHAFT POSITION SENSOR ....... 6E1-32 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).
NOTE:
Whether the following system (parts) are used in the particular vehicle or not depends on vehicle
specifications. Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor(s) or CO adjusting resistor
Three way catalytic converter
Immobilizer indicator lamp
Knock sensor