fuel SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-15
7) Disconnect the following electric lead wires and release clamp:

Ground wires (5) from intake manifold

TP sensor (3)

IAC valve (4)

Fuel injectors

EVAP canister purge valve (2)

MAP sensor (6)

EGR valve (1)
8) Disconnect the following hoses:

Brake booster hose (1) from intake manifold

Canister purge hose (3) from EVAP canister purge valve

Engine cooling water (coolant) hose (2) from IAC valve

PCV hose (4)

Breather hose from cylinder head
9) Disconnect fuel feed hose (2) from pipe (1), and disconnect fuel
return hose (3) from fuel pressure regulator.

1. Long bolt
2. Short bolt
6A1-16 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
10) Remove intake manifold rear stiffener (1) and generator adjust
arm reinforcement (2) from intake manifold (3).
11) Remove intake manifold with throttle body from cylinder head,
and then its gasket.
INSTALLATION
Reverse removal procedure for installation noting the followings.

Use new intake manifold gasket.

When installing intake manifold, install clamps securely.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

Adjust accelerator cable play, referring to Section 6E.

Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.

Refill cooling system referring to Section 6B.

Upon completion of installation, turn ignition switch ON but en-
gine OFF and check for fuel leaks.

Finally, start engine and check for engine coolant leaks.

: Do not reuse
1. Valve cotters
2. Valve spring retainer
3. Valve spring:
be sure to position
spring in place with its
bottom end (small-pitch
end) facing the bottom
(valve spring seat side).
4. Valve stem seal
5. Valve spring seat
6. Exhaust valve
7. Intake valve
8. Cylinder head bolt
9. Camshaft housing bolt10. Camshaft housing:
Apply sealant to mating surface of
No.1 and No.6 housings.
11. Valve guide
12. Oil venturi plug
13. Cylinder head gasket:
“TOP” mark provided on gasket comes to
crankshaft pulley side, facing up
(toward cylinder head side).
14. Dowel pin
: Tightening Torque
: Apply engine oil to sliding
: surfaces of each part.
3.5 N.m (0.35 kg-m)
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-41
VALVES AND CYLINDER HEAD
REMOVAL
1) Relieve fuel pressure according to procedure described in Sec-
tion 6.
2) Disconnect negative cable at battery.
3) Drain cooling system.
4) Remove air cleaner outlet hose as previously outlined.

6A1-42 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)

Ignition coil assembly

Ground wires from
intake manifold

EVAP canister purge
valve

ECT sensor
Injectors, TP sensor and
IAC valve wires at the
coupler

Heated oxygen sensor 1

MAP sensor
5) Remove intake manifold rear stiffener (1) and generator adjust
arm reinforcement (2) from intake manifold.
6) Disconnect the following electric wires:
and then release above wire harnesses from clamps.
7) Disconnect the following hoses:

Brake booster hose (1)

EVAP canister purge hose (3) from purge valve

Radiator inlet hose

Heater inlet hose

IAC valve outlet (2)
8) Disconnect fuel feed (2) and return hoses (3) from fuel delivery
pipe (1).

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-53
4) Reverse removal procedure for installation.
5) Adjust water pump drive belt tension by referring to “ENGINE
COOLING” section.
6) Adjust power steering pump belt tension or A / C compressor
belt tension, if equipped.
Refer to Section 0B.
7) Adjust intake and exhaust valve lashes as previously outlined.
8) Adjust accelerator cable play.
Refer to Section 6E.
9) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
10) Refill cooling system referring to Section 6B.
11) Connect negative cable at battery.
12) Confirm that ignition timing is within specification.
13) Verify that there is no fuel leakage, coolant leakage and ex-
haust gas leakage at each connection.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-63
6) Reverse removal procedure for installation, as previously out-
lined.
7) Adjust water pump drive belt tension referring to Section 6B.
8) Adjust power steering pump belt tension or A / C compressor
belt tension, if equipped.
Refer to Section 0B.
9) Adjust accelerator cable play.
Refer to Section 6E.
10) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
11) Refill engine with engine oil by referring to item “ENGINE OIL
CHANGE” in Section 0B.
12) Refill cooling system referring to Section 6B.
13) Connect negative cable at battery.
14) Check ignition timing referring to Section 6F.
15) Verify that there is no fuel leakage, coolant leakage, oil leakage
and exhaust gas leakage at each connection.

1
2
6A1-64 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL
1) Release fuel pressure in fuel feed line by referring to Section
6.
2) Remove battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Drain cooling system.
WARNING:
To help avoid danger of being burned, do not remove
drain plug (2) and radiator cap while engine and radiator
(1) are still hot. Scalding fluid and steam can be blown
out under pressure if plug and cap are taken off too
soon.
5) Disconnect coupler of cooling fan motor.
6) Disconnect radiator inlet hose from thermostat case.
7) Disconnect A / T fluid hoses from A / T fluid pipes (for A / T mod-
el)
8) Remove outlet hose from water inlet pipe and radiator.
9) Remove radiator referring to Section 6B.
10) Remove air cleaner case and air cleaner outlet hose as pre-
viously outlined.
11) Disconnect the following cables.

Accelerator cable (1) from throttle body.

A / T throttle pressure control cable from A / T.

Clutch cable from transmission (M / T).

Gear select cable from transmission (A / T).

Speedometer cable

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-65
12) Disconnect the following electric wires:

Ignition coil assembly

Ground wires from intake manifold

Engine oil pressure switch

EVAP canister purge valve (if equipped)

Engine coolant temp. sensor

Fuel injectors

Power steering pressure switch (if equipped)

Oxygen sensor-1

Back-up light switch (M / T)

Transmission range switch (A / T)

A/T vehicle speed sensor (A / T)

Solenoid coupler (A / T)

Generator

Starter

Battery negative cable from transmission

TP sensor

IAC valve

CMP sensor

MAP sensor
and then release wire harnesses from clamps.
13) Disconnect the following hoses:

Canister purge hose (2) from EVAP canister purge valve

Brake booster hose (1) from intake manifold

Radiator outlet hose from inlet pipe

Heater inlet and outlet hose from heater unit
14) Disconnect fuel feed (2) and return hoses (3) from fuel delivery
pipe (1).

(a)
1
2
3
(a)
(a)
6
74
5
(a)
M/TM/T
9
(a)
4
7
(a)
8
1. Right mounting
2. Right mounting
bracket
3. Left mounting
4. Left mounting bracket
5. Left mounting bracket
stiffener6. Rear mounting
7. Rear mounting
bracket
8. Rear torque rod
9. Rear torque rod
bracket
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-67
INSTALLATION
1) Lift engine with transmission into engine compartment, but do
not remove support device.
2) Install engine right mounting to right mounting bracket and stiff-
ener.
3) Install engine left mounting to body.
4) Install rear mounting to body (For M/T model)
Install torque rod (For A/T model)
5) Tighten bolts and nuts of all parts installed in above steps 2),
3) and 4) or 5) to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
6) Remove support device.
7) Reverse removal procedures for installation of remainder.

Push in each drive shaft joint fully so that snap ring engages
with differential gear or center bearing support.
Use care not to damage oil seal lip when inserting.

Clamp electric wire securely.
8) Adjust clutch pedal free travel by referring to Section 7C. (M / T)
Adjust gear select cable and A / T throttle pressure control
cable, referring to Section 7B. (A / T)
9) Adjust gear shift control lever by referring to Section 7A. (M / T)
10) Adjust accelerator cable play by referring to Section 6E.
11) Refill transmission with gear oil. (A / T fluid for A / T model) by
referring to Section 0B.
12) Refill engine with engine oil by referring to Section 0B.
13) Refill cooling system by referring to Section 6B.
14) Adjust A / C compressor and / or P / S pump drive belt referring
to Section 0B. (if equipped)
15) Check P / S fluid level by referring to Section 3B1. (if equipped)
16) Upon completion of installation, verify that there is no fuel leak-
age, coolant leakage, transmission oil leakage or exhaust gas
leakage at each connection.

6C
ENGINE FUEL 6C-1
GENERAL DESCRIPTION6C-1 . . . . . . . . . . . . . .
Fuel System 6C-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Assembly 6C-1. . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE6C-2 . . . . . . . . . . . . . . . .
Fuel Lines 6C-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 6C-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Assembly 6C-4. . . . . . . . . . . . . . . . .
SECTION 6C
ENGINE FUEL
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
CAUTION:
BE SURE TO USE 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.
GENERAL DESCRIPTION
FUEL SYSTEM
The main components of the fuel system are fuel tank, fuel pump, fuel filter and fuel level gauge and it includes
three lines; fuel feed line, fuel return line and fuel vapor line.
For the details of fuel vapor flow, refer to Section 6E “ENGINE AND EMISSION CONTROL SYSTEM”.
FUEL PUMP ASSEMBLY (WITH FUEL LEVEL
GAUGE)
The fuel pump assembly consists of fuel pump and fuel level gauge.
For structure and operation of the fuel pump, refer to Section 6E.