warning SUZUKI SWIFT 2000 1.G RG413 Service Owners Manual

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.

6A1-68 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.

6B-6 ENGINE COOLING
MAINTENANCE
COOLANT LEVEL CHECK
To check level, lift hood and look at “see-through” coolant reser-
voir tank.
It is not necessary to remove radiator cap to check coolant level.
When engine is cool, check coolant level in reservoir tank (1).
A normal coolant level should be between FULL mark (2) and
LOW mark (3) on reservoir tank (1).
If coolant level is below LOW mark (3), remove reservoir tank cap
(4) and add proper coolant to tank to bring coolant level up to
FULL mark (2). Then, reinstall cap (4) and align match marks (5)
on tank and cap (4). WARNING:
Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through
coolant reservoir.
Coolant should be added only to reservoir as necessary.
As long as there is pressure in the cooling system, the temperature can be considerably higher
than the boiling temperature of the solution in the radiator without causing the solution to boil.
Removal of the radiator cap while engine is hot and pressure is high will cause the solution to boil
instantaneously and possibly with explosive force, spewing the solution over engine, fenders and
person removing cap. If the solution contains flammable anti-freeze such as alcohol (not recom-
mended for use at any time), there is also the possibility of causing a serious fire.
WARNING:
To help avoid danger of being burned :
do not remove reservoir tank cap while coolant is boil-
ing, and
do not remove radiator cap while engine and radiator
are still hot.
Scalding fluid and steam can be blown out under pres-
sure if either cap is taken off too soon.
NOTE:
If proper quality antifreeze is used, there is no need to
add extra inhibitors or additives that claim to improve
system.
They may be harmful to proper operation of system,
and are unnecessary expense.
When installing reservoir cap, align arrow marks on
reservoir and cap.
LOW FULL
5 41
1 32 1

ENGINE COOLING 6B-7
ENGINE COOLING SYSTEM INSPECTION
AND SERVICE
1) Check cooling system for leakage or damage.
2) Wash radiator cap and filler neck with clean water by remov-
ing radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester (1), check system and radiator cap
(2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap for this
vehicle.
Cooling system and radiator cap holding pressure (for
inspection)
: 110 kPa (1.1 kg/cm
2, 15.6 psi)
5) Tighten hose clamps and inspect all hoses. Replace hoses
whenever cracked, swollen or otherwise deteriorated.
6) Clean frontal area of radiator core.
COOLING SYSTEM FLUSH AND REFILL
1) Remove radiator cap when engine is cool.
a) Turn cap counterclockwise slowly until it reaches a “stop”.
(Do not press down while turning it).
b) Wait until pressure is relieved (indicated by a hissing
sound) then press down on cap and continue to turn it
counterclockwise.
2) With radiator cap removed, run engine until upper radiator
hose is hot (this shows that thermostat is open and coolant is
flowing through system). WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.
NOTE:
After installing radiator cap to radiator, make sure that
the ear of cap lines is parallel to radiator.
WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.

ENGINE COOLING 6B-9
WATER PUMP/GENERATOR DRIVE BELT TENSION INSPECTION AND
ADJUSTMENT
1) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If it is necessary to replace belt, refer to “WATER
PUMP/GENERATOR DRIVE BELT” in this section.
2) Check belt for tension. Belt is in proper tension when it
deflects 4.5 to 5.5 mm (0.18 – 0.22 in.) under thumb pres-
sure (about 10 kg or 22 lb.).
Water pump / generator drive belt tension “a”
4.5 – 5.5 mm (0.18 – 0.22 in.) as deflection/10 kg (22 lbs)
3) If belt is too tight or too loose, adjust it to proper tension by
displacing generator position.
4) Tighten generator adjusting bolt and pivot bolts as specified
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)
5) Connect negative cable at battery. WARNING:
Disconnect negative cable at battery before checking and adjusting belt tension.
To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still
hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.
NOTE:
When replacing belt with a new one, adjust belt tension
to 3 – 4 mm (0.12 – 0.16 in.).
“a”

6B-10 ENGINE COOLING
ON-VEHICLE SERVICE
SYSTEM COMPONENTS
WARNING:
Check to make sure that engine coolant temperature is cold before removing any part of cooling
system.
Also be sure to disconnect negative cord from battery terminal before removing any part.
1. Radiator 11. To throttle body 21. To timing chain cover
2. Reservoir tank 12. To heater unit 22. O-Ring
3. Radiator cap 13. To water pump 23. Gasket
4. Drain plug 14. Radiator and condenser cooling fan assembly 24. Water outlet cap O-ring No.1
5. Radiator outlet hose 15. Water inlet pipe No.1 25. Water outlet cap O-ring No.2
6. Radiator inlet hose 16. Water inlet pipe No.2 26. Thermostat cap bolts
7. Thermostat 17. Thermostat cap 27. Thermostat case bolts
8. ECT sensor 18. Water outlet cap Tightening torque
9. Thermostat case 19. Heater inlet hose Do not reuse.
10. To cylinder head 20. Heater outlet hose

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.

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.)

6C-4 ENGINE FUEL
FUEL LINES
INSPECTION
Visually inspect fuel lines for evidence of fuel leakage, hose crack
and deterioration, or damage.
Make sure all clamps are secure.
Replace parts as needed.
FUEL PIPE
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) Disconnect fuel pipe joint and fuel hose from fuel pipe at the
front and rear of each fuel pipe.
For quick joint (2), disconnect it as follows :
a) Remove mud, dust and/or foreign material between pipe (1)
and joint by blowing compressed air.
b) Unlock joint lock by inserting special tool between pipe and
joint.
Special tool
(A) : 09919-47020
c) Disconnect joint (2) from pipe (1). CAUTION:
Due to the fact that fuel feed line (1) is under high pres-
sure, use special care when servicing it.
1
WARNING:
A small amount of fuel may be released after fuel hose is
disconnected. In order to reduce the chance of personal
injury, cover hose and pipe to be disconnected with a
shop cloth.
Be sure to put that cloth in an approved container when
disconnection is completed.

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.