SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

6B-12 ENGINE COOLING
COOLING WATER PIPES OR HOSES
REMOVAL
1) Drain cooling system.
2) To remove these pipes or hoses, loosen clamp on each
hose and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
Tighten each clamp securely.
Refill cooling system with proper coolant referring to “COOL-
ING SYSTEM REFILL”.
THERMOSTAT
REMOVAL
1) Drain cooling system by loosening drain plug of radiator
referring to “COOLING SYSTEM DRAINING”.
2) Remove air cleaner assembly and resonator referring to sec-
tion 6A1
3) Remove intake manifold referring to Section 6A1.
4) Remove generator referring to Section 6H.
5) Disconnect water hose (1) and heater hose (2) from each
pipe.
6) Remove thermostat case (3) with thermostat cap (4) and
water inlet pipe (5).
7) Remove water inlet pipe with thermostat cap from thermo-
stat case.
8) Remove thermostat.
INSPECTION
Make sure that air bleed valve (1) of thermostat is clean.
Should this valve be clogged, engine would tend to overheat.
Check to make sure that valve seat is free from foreign mat-
ters which would prevent valve from seating tight.
Check thermostat seal (2) for breakage, deterioration or any
other damage.

ENGINE COOLING 6B-13
Check thermostatic movement of wax pellet as follows :
a) Immerse thermostat (1) in water, and heat water gradually.
b) Check that valve starts to open at specific temperature.
Temperature at which valve begins to open
: 80 – 84°C (176 – 183°F)
Temperature at which valve become fully open
: 95 – 97°C (203°F)
Valve lift
: More than 8 mm at 95°C (203°F)
If valve starts to open at a temperature substantially below or
above specific temperature, thermostat unit should be replaced
with a new one. Such a unit, if reused, will bring about overcool-
ing or overheating tendency.
INSTALLATION
Reverse removal procedure for installation noting the following
points.
When positioning thermostat (1) on thermostat case (2), be
sure to position it so that air bleed valve (3) comes at posi-
tion as shown in figure.
Use new O-rings when installing.
Adjust water pump belt tension referring to WATER PUMP/
GENERATOR DRIVE BELT TENSION INSPECTION AND
ADJUSTMENT in this section.
Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
Refill cooling system with proper coolant referring to “COOL-
ING SYSTEM REFILL”.
Verify that there is no coolant leakage at each connection.
2. Thermometer
3. Heater

6B-14 ENGINE COOLING
RADIATOR
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system by loosening drain plug of radiator.
Refer to “COOLING SYSTEM DRAINING”.
3) Disconnect connector of cooling fan motor.
4) Remove air cleaner inlet hose (1) and suction pipe (2).
5) Remove reservoir tank (1) and then its bracket (2).
6) Disconnect radiator inlet and outlet hoses from radiator.
7) Remove cooling fan assembly (3).
8) Remove radiator.
INSPECTION
Check radiator for leakage or damage. Straighten bent fins, if
any.
CLEANING
Clean frontal area of radiator cores.
INSTALLATION
Reverse removal procedures, noting the followings.
Refill cooling system with proper coolant referring to “COOL-
ING SYSTEM REFILL”.
After installation, check each joint for leakage.

ENGINE COOLING 6B-15
RADIATOR AND CONDENSER COOLING FAN
Refer to “RADIATOR AND CONDENSER COOLING FAN” in
Section 1B for removal, inspection and installation.
RADIATOR AND CONDENSER COOLING FAN
RELAY
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove radiator and condenser cooling fan relay No.1 (1),
No.2 (2) and No.3 (3) from vehicle.
3) Check that there is no continuity between terminal “c” and
“b”. If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “b” of relay.
Connect battery negative (–) terminal “a” of relay.
Check continuity between terminal “c” and “d”.
If there is no continuity when relay is connected to the bat-
tery, replace relay.
WATER PUMP/GENERATOR DRIVE BELT
REMOVAL
1) Disconnect negative cable at battery.
2) Loosen drive belt adjusting bolt (2) and generator pivot bolt
(3).
When servicing car equipped with A/C, remove compressor
drive belt (4) before removing water pump belt (1).
Refer to “COMPRESSOR DRIVE BELT” in Section 1B.
3) Slacken belt by displacing generator and then remove it.
ba
1
c
dc
ad
b
2
3
1
c
d
2, 3b a
ac
d
b
2
3
1
4

6B-16 ENGINE COOLING
INSTALLATION
1) Install belt (1) to water pump pulley (2), crankshaft pulley (3)
and generator pulley (4).
When servicing car equipped with A/C, install compressor
drive belt, too.
2) Adjust belt tension by referring to “WATER PUMP/GENERA-
TOR DRIVE BELT TENSION INSPECTION AND ADJUST-
MENT” in this section.
For adjustment of compressor drive belt tension, refer to
COMPRESSOR DRIVE BELT in Section 1B.
3) Tighten water pump belt adjusting bolt and pivot bolt to spec-
ified torque.
Tightening torque
Generator adjusting bolt (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Generator pivot bolt (b) : 50 N·m (5.0 kg-m, 36.0 lb-ft)
4) Connect negative cable at battery.
WATER PUMP BELT TENSION INSPECTION AND
ADJUSTMENT
For this inspection or adjustment, refer to “WATER PUMP GEN-
ERATOR DRIVE BELT TENSION INSPECTION AND ADJUST-
MENT”.
WATER PUMP
REMOVAL
1) Disconnect negative cable at battery.
2) Drain coolant. Refer to “COOLING SYSTEM DRAINING”.
3) Remove A/C compressor belt (4) by referring to “COM-
PRESSOR DRIVE BELT” in Section 1B. (if equipped).
4) Loosen water pump/generator drive belt adjusting bolt (1)
and generator pivot bolt (2). Then remove water pump/gen-
erator drive belt (3) and water pump pulley.
Refer to “WATER PUMP BELT” in this section.
2
1
3
4
1
2
43

ENGINE COOLING 6B-17
5) Remove water pump assembly (1).
INSPECTION
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes abnormal noise,
replace it.
INSTALLATION
1) Apply sealant to mating surface of water pump as shown in
figure.
“A” : Sealant 99000-31150
Sealant quantity (to mating surface of water pump)
Width “a” : 3mm (0.12 in.)
Height “b” : 2mm (0.08 in.)
2) Install water pump assembly (1) to cylinder block and tighten
bolts and nut to specified torque.
Tightening torque
Water pump bolts and nut (a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
3) Install water pump pulley.
4) Install water pump/generator drive belt. Refer to “WATER
PUMP/GENERATOR DRIVE BELT” in this Section.
5) Install A/C compressor belt (if equipped). Refer to “COM-
PRESSOR DRIVE BELT” in Section 1B.
6) Fill coolant. Refer to “COOLING SYSTEM REFILL”.
7) Connect negative cable at battery.
8) Check each part for leakage.
CAUTION:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.
“a”
“b”

6B-18 ENGINE COOLING
ECT SENSOR
Refer to “ECT SENSOR” in Section 6E1.
REQUIRED SERVICE MATERIAL
TIGHTENING TORQUE SPECIFICATION
MaterialRecommended SUZUKI product
(Part Number)Use
Ethylene glycol base
coolant (Anti-freeze/
Anti-corrosion coolant)—Additive to engine cooling system for improving
cooling efficiency and for protection against
rusting.
SealantSUZUKI BOND NO. 1207C
(99000-31150)To apply to mating surface of water pump
Fastening partTightening torque
Nm kg-m lb-ft
Generator adjusting bolt 23 2.3 17
Generator pivot bolt 50 5 36
Water pump bolt and Nuts 22 2.2 16

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

ENGINE FUEL 6C-3
PRECAUTIONS
WARNING:
Before attempting service of any type on fuel system, the
followings should be always observed in order to reduce
the risk or fire and personal injury.
Disconnect negative cable at battery.
Do not smoke, and place no smoking signs near work
area.
Be sure to have CO
2 fire extinguisher handy.
Be sure to perform work in a well-ventilated area and
away from any open flames (such as gas hot heater).
Wear safety glasses.
To relieve fuel vapor pressure in fuel tank, remove fuel
filler cap from fuel filler neck and then reinstall it.
As fuel feed line is still under high fuel pressure even
after engine was stopped, loosening or disconnecting
fuel feed line directly may cause dangerous spout of
fuel to occur where loosened or disconnected.
Before loosening or disconnecting fuel feed line, make
sure to relieve fuel pressure “FUEL PRESSURE
RELIEF PROCEDURE” in Section 6.
A small amount of fuel may be released after the fuel
line is disconnected. In order to reduce the chance of
personal injury, cover the fitting to be disconnected
with a shop cloth. Be sure to put that cloth in an
approved container when disconnection is completed.
Note that fuel hose connection varies with each type of
pipe. Be sure to connect and clamp each hose cor-
rectly referring to the figure.
[A] : With short pipe, fit hose as far as it reaches pipe joint as shown.
[B] : With the following type pipe, fit hose as far as its peripheral projection as shown.
[C] : With bent pipe, fit hose as far as its bent part as shown or till depth “b”.
[D] : With straight pipe, fit hose till depth “b”.
[E] : With red marked pipe, fit hose end reaches red mark on pipe.
1. Pipe
2. Hose
3. Clamp
4. Ped mark
“a” : Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.
“b” : 20 to 30 mm (0.79 – 1.18 in.)
“c” : 0 to 5 mm (0 – 0.19 in.)