G13 SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-79
8) Install pistons and connecting rods as previously outlined.
9) Install oil pump strainer and oil pan as previously outlined.
10) Install cylinder head assembly to cylinder block as previously
outlined.
11) Install camshaft, crankshaft timing belt pulley, timing belt,
crankshaft pulley, water pump pulley, etc., as previously out-
lined.
12) Install clutch to flywheel (for M / T vehicle). For clutch installa-
tion, refer to “CLUTCH” section.
13) Install engine mountings and brackets.
Refer to tightening torque for INSTALLATION of “ENGINE AS-
SEMBLY” in this section.
14) Install engine with transmission to vehicle as previously out-
lined.

1. 09915-64510-001
Compression gauge
2. 09915-64510-002
Connector
3. 09915-64530
Hose
4. 09915-67010
Attachment
09915-67311
Vacuum gauge09918-08210
Vacuum gauge hose joint09915-77311
Oil pressure gauge
09917-18211
Tappet adjuster wrench09919-16020
17 mm socket09926-18210
Oil seal guide (Vinyl resin)09917-68221
Camshaft pulley holder
1. 09916-14510
Valve lifter
2. 09916-14910
Valve lifter attachment
09916-84511
Forceps09916-44910
Valve guide remover09916-34542
Reamer handle
09916-38210
Reamer (11 mm)09916-58210
Valve guide installer handle09916-56011
Valve guide installer
attachment09916-34550
Reamer (5.5 mm)
6A1-80 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
SPECIAL TOOLS

09917-98221
Valve stem seal installer09916-77310
Piston ring compressor09924-17810
Flywheel holder09915-47330
Oil filter wrench
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-81
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
SealantSUZUKI BOND NO.1207C
(99000-31150)
Mating surfaces of cylinder block and oil pan.
SealantSUZUKI BOND NO.1215
(99000-31110)
Mating surfaces of camshaft housings (No.6).

Mating surfaces of CMP sensor case and cylinder
block.

6A1-82 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
TIGHTENING TORQUE SPECIFICATIONS
FASTENING PARTSTIGHTENING TORQUEFASTENING PA R T SN.mkg-mlb-ft
Oil pressure switch131.39.5
Valve adjusting screw lock nuts121.29.0
Cylinder head cover bolts111.18.0
Intake manifold bolts and nuts232.317.0
Timing belt tensioner stud111.18.0
Timing belt tensioner bolt252.518.0
Timing belt cover bolts and nut111.18.0
Exhaust manifold bolts and nuts323.223.5
Crankshaft pulley bolt161.611.5
Crankshaft timing belt pulley bolt13013.094.0
Exhaust pipe nuts and bolts505036 5Exhaust manifold stiffener nut505.036.5
Oil pump strainer bolt and stay bolt111180Oil pan bolts and nuts111.18.0
CKP sensor bolt101.07.5
Oil pan drain plug505.036.0
Oil pump rotor plate screws111180Oil pump case bolts111.18.0
Camshaft housing bolts111180Rocker arm shaft bolts111.18.0
Camshaft timing belt pulley bolt606.043.5
Cylinder head venturi plug3.50.352.5
Cylinder head bolts686.849.0
Connecting rod bearing cap nuts353.525.5
Crankshaft main bearing cap bolts545.439.0
Flywheel bolts787.856.5
Drive plate bolts959.569.0
Engine mounting & bracket bolts and nutsRefer to INSTALLATION of
ENGINE ASSEMBLY in this section.

ENGINE COOLING 6B-5
ANTI-FREEZE PROPOR-
TIONING CHART COOLANT CAPACITY
G13 engine G10 engine
MAINTENANCE
COOLANT
The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col-
lected in the reservoir tank.
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has been filled at the factory with a quality coolant that is either 50 / 50 mixture of water and
GOLDEN CRUISER 1200 (ethylene glycol antifreeze.) or 30 / 70 mixture of water and GOLDEN CRUISER 1200.
The 50 / 50 mixture coolant solution provides freezing protection to – 36
C (– 33
F), the 30 / 70 mixture coolant solu-
tion provides freezing protection to – 16
C (3
F).
When changing the engine coolant, use mixture of 50% water and 50% GOLDEN CRUISER 1200 for the market
where ambient temperature falls lower than – 16
C (3
F) in winter and mixture of 70% water and 30% GOLDEN
CRUISER 1200 for the market where ambient temperature doesn’t fall lower than – 16
C (3
F).
NOTE:
Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time
as damage to cooling system could occur.
Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ethylene
glycol antifreeze (Antifreeze / Anticorrosion coolant) should be used for the purpose of corrosion protec-
tion and lubrication.
ANTI-FREEZE PROPORTIONING TABLE
Vehicle with M / TVehicle with A / T
Freezing temperature
C–16–36–16–36Freezing temperature
F3–333–33
Anti-freeze / Anti-corrosion
coolant concentration%30503050
G10Itr.1.17 / 2.731.95 / 1.951.20 / 2.802.00 / 2.00G10
engineUS pt.2.47 / 5.774.12 / 4.122.54 / 5.924.23 / 4.23
Ratio of compound to
engineImp pt.2.06 / 4.803.43 / 3.432.11 / 3.703.52 / 3.52
cooling water
G13Itr.1.38 / 3.222.30 / 2.301.41 / 3.292.35 / 2.35G13
engineUS pt.2.92 / 6.804.86 / 4.862.98 / 6.954.96 / 4.96engineImp pt.2.43 / 5.674.05 / 4.052.48 / 5.794.13 / 4.13
Engine radiator and heater3.3 liters
(7.0 / 5.8 US / Imp pt.)3.4 liters
(7.2 / 6.0 US / Imp pt.)
Reservoir tank0.6 liters
(1.3 / 1.1 US / Imp pt.)
Total3.9 liters
(8.2 / 6.9 US / Imp pt.)4.0 liters
(8.5 / 7.0 US / Imp pt.)
Engine radiator and heater4.0 liters
(8.5 / 7.0 US / Imp pt.)4.1 liters
(8.6 / 7.2 US / Imp pt.)
Reservoir tank0.6 liters
(1.3 / 1.1 US / Imp pt.)
Total4.6 liters
(9.7 / 8.1 US / Imp pt.)4.7 liters
(9.9 / 8.3 US / Imp pt.)

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G13) 6E1-1
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM
(TBI FOR G13)
NOTE:
For the details of this section, refer to the same section of the Service Manual mentioned in the FORE-
WORD of this manual.

6E2
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-1
GENERAL DESCRIPTION6E2- 2 . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E2- 6. . . . . . . . . . . . . . . . . .
FUEL DELIVERY SYSTEM 6E2- 7. . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E2- 8. . . . . .
Engine and Emission Control Input /
Output Table 6E2- 9. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSISSee Section 6. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE6E2-13 . . . . . . . . . . . . . . . .
Accelerator Cable Adjustment 6E2-13. . . . . . . . . .
Idle Speed/Idle Air Control (IAC)
Duty Inspection 6E2-14. . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E2-15. . . . . . . . . . . . . . . . . .
Throttle Body 6E2-15. . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control Valve 6E2-17. . . . . . . . . . . . . . . . .
FUEL DELIVERY SYSTEM 6E2-18. . . . . . . . . . . . . .
Fuel Pressure Inspection 6E2-18. . . . . . . . . . . . . .
Fuel Pump 6E2-21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 6E2-22. . . . . . . . . . . . . . .
Fuel Injector 6E2-23. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E2-27. . . . . .
ECM / PCM 6E2-27. . . . . . . . . . . . . . . . . . . . . . . . . .
MAP Sensor 6E2-27. . . . . . . . . . . . . . . . . . . . . . . . .
TP Sensor 6E2-28. . . . . . . . . . . . . . . . . . . . . . . . . . .
IAT Sensor 6E2-29. . . . . . . . . . . . . . . . . . . . . . . . . .
ECT Sensor 6E2-30. . . . . . . . . . . . . . . . . . . . . . . . . Heated Oxygen Sensor -1 and -2 6E2-31. . . . . . .
Camshaft Position Sensor 6E2-32. . . . . . . . . . . . .
Crankshaft Position Sensor 6E2-32. . . . . . . . . . . .
Vehicle Speed Sensor 6E2-33. . . . . . . . . . . . . . . . .
Fuel Level Sensor (gauge) 6E2-33. . . . . . . . . . . . .
Main Relay, Fuel Pump Relay and
Radiator Fan Control Relay 6E2-33. . . . . . . . . . .
Fuel Cut Operation (Inspection) 6E2-34. . . . . . . .
Radiator Fan Control System 6E2-34. . . . . . . . . .
System Inspection 6E2-34. . . . . . . . . . . . . . . . . .
Radiator Fan 6E2-34. . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEM 6E2-35. . . . . . . . .
EGR System 6E2-35. . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Control System 6E2-36. . . . . . . . . . . . . . . . .
EVAP Canister Purge Inspection 6E2-36. . . . . .
Vacuum Passage Inspection 6E2-37. . . . . . . . .
Vacuum Hose Inspection 6E2-37. . . . . . . . . . . .
EVAP Canister Purge Valve
Inspection 6E2-37. . . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Inspection 6E2-38. . . . . . . . . . .
PCV System 6E2-38. . . . . . . . . . . . . . . . . . . . . . . . .
PCV Hose Inspection 6E2-38. . . . . . . . . . . . . . .
PCV Valve Inspection 6E2-38. . . . . . . . . . . . . . .
SPECIAL TOOLS6E2-39 . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS6E2-39 . . . . . . . . . . . . . . . . . . . . .
SECTION 6E2
ENGINE AND EMISSION CONTROL SYSTEM
(SFI FOR G13)
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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” 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).
CONTENTS

6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
The engine and emission control system is divided
into 4 major sub-systems: air intake system, fuel de-
livery system, electronic control system and emission
control system.
Air intake system includes air cleaner, throttle body,
IAC valve and intake manifold.Fuel delivery system includes fuel pump, delivery
pipe, fuel pressure regulator, etc. Electronic control
system includes ECM (PCM), various sensors and
controlled devices.
Emission control system includes EGR, EVAP and
PCV system.
GENERAL DESCRIPTION

ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-3

6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)