water pump SUZUKI SWIFT 2000 1.G RG413 Service User Guide

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.

6A1-72 ENGINE MECHANICAL (M13 ENGINE)
6) Install generator referring to Section 6H.
7) For 4WD vehicle, install propeller shaft referring to Section
4B.
8) Connect drive shaft joints referring to Section 4.
9) Install exhaust No.1 pipe and tighten pipe fasteners to speci-
fied torque.
Tightening torque
Exhaust No.1 pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
10) Reverse disconnected hoses, cables and electric wires for
connection.
11) Install air cleaner assembly, resonator and hoses referring to
“AIR CLEANER ASSEMBLY AND RESONATOR”
12) Install A/C compressor to bracket (if equipped).
13) Adjust water pump belt tension referring to Section 6B.
14) Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
15) Adjust accelerator cable play referring to Section 6E1.
16) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
17) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
18) Connect negative cable at battery.
19) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.

ENGINE MECHANICAL (M13 ENGINE) 6A1-85
9) Install flywheel (drive plate for A/T).
Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts applied with sealant to specifica-
tion.
“A” : Sealant 99000-31110
Special tool
(A) : 09924-17810
Tightening torque
Flywheel or drive plate bolts
(a) : 70 N·m (7.0 kg-m, 51.0 lb-ft)
10) Install the following parts to engine as previously outlined.
Piston and connecting rod
Cylinder head assembly
Camshaft, tappet and shim
Timing chain guide, chain tensioner adjuster, chain ten-
sioner, timing chain and crankshaft timing sprocket
Timing chain cover
Cylinder head cover
Intake manifold and exhaust manifold
Oil pan and oil pump strainer
11) Install clutch to flywheel (vehicle with M/T) referring to Sec-
tion 7C.
12) Install engine assembly to vehicle as previously outlined.
REQUIRED SERVICE MATERIAL
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant Sealant 1207C
(99000-31150)To apply to mating surfaces of cylinder block and oil
pan.
To apply to mating surfaces of cylinder block and
timing chain cover.
To apply to sealing surfaces of cylinder head cover.
To apply to mating surfaces to rear oil seal housing.
Sealant 1207B
(99000-31140)To apply to mating surface of cylinder block, cylin-
der head and timing chain cover.
Sealant 1215
(99000-31110)To apply to the thread of the bolt of water outlet
pipe.
To flywheel (M/T) or drive plate (A/T) bolts.

ENGINE COOLING 6B-1
6B
SECTION 6B
ENGINE COOLING
CONTENTS
GENERAL DESCRIPTION ...............................6B-2
COOLING SYSTEM CIRCULATION............. 6B-2
COOLANT ..................................................... 6B-3
DIAGNOSIS ......................................................6B-4
DIAGNOSIS TABLE ...................................... 6B-4
SYSTEM CIRCUIT ........................................ 6B-5
SYSTEM CIRCUIT INSPECTION ................. 6B-5
MAINTENANCE................................................6B-6
COOLANT LEVEL CHECK ........................... 6B-6
ENGINE COOLING SYSTEM
INSPECTION AND SERVICE ....................... 6B-7
COOLING SYSTEM FLUSH AND REFILL ... 6B-7
WATER PUMP/GENERATOR DRIVE
BELT TENSION INSPECTION AND
ADJUSTMENT .............................................. 6B-9
ON-VEHICLE SERVICE .................................6B-10SYSTEM COMPONENTS .......................... 6B-10
COOLING SYSTEM DRAINING ................. 6B-11
COOLING SYSTEM REFILL ...................... 6B-11
COOLING WATER PIPES OR HOSES ...... 6B-12
THERMOSTAT ........................................... 6B-12
RADIATOR ................................................. 6B-14
RADIATOR AND CONDENSER
COOLING FAN ........................................... 6B-15
RADIATOR AND CONDENSER
COOLING FAN RELAY .............................. 6B-15
WATER PUMP/GENERATOR
DRIVE BELT ............................................... 6B-15
WATER PUMP............................................ 6B-16
ECT SENSOR............................................. 6B-18
REQUIRED SERVICE MATERIAL................. 6B-18
TIGHTENING TORQUE SPECIFICATION..... 6B-18

6B-2 ENGINE COOLING
GENERAL DESCRIPTION
The cooling system consists of the radiator cap, radiator, coolant reservoir tank, hoses, water pump, cooling fan
and thermostat. The radiator is of tube-and-fin type.
COOLING SYSTEM CIRCULATION
While the engine is warmed up (thermostat closed), coolant circulates as follows.
When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radi-
ator core to be cooled as well as the above flow circuit.
1. Radiator inlet hose 5. Water pump 9. Heater outlet hose
2. Radiator outlet hose 6. Throttle body (Fast idle control plunger) 10. Radiator
3. Water inlet pipe 7. Engine
4. Thermostat 8. Heater inlet hose
Water pump Cylinder block
Thermostat closedCylinder head Water intake pipeThrottle body
Heater unit

6B-4 ENGINE COOLING
DIAGNOSIS
DIAGNOSIS TABLE
Condition Possible Cause Correction
Engine overheats
(It is in case that radia-
tor fan operates)Loose or broken water pump belt Adjust or replace.
Not enough coolant Check coolant level and add as
necessary.
Faulty thermostat Replace.
Faulty water pump Replace.
Dirty or bent radiator fins Clean or remedy.
Coolant leakage on cooling system Repair.
Clogged radiator Check and replace radiator as nec-
essary.
Faulty radiator cap Replace.
Improper ignition timing Adjust.
Dragging brakes Adjust brake.
Slipping clutch Adjust or replace.
Poor charge battery Check and replace as necessary.
Poor generation generator Check and repair.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan relay No.2 and/or No.3
faultyCheck and replace as necessary.
ECM faulty Check and replace as necessary.
Wiring or grounding faulty Repair and necessary.
Equipped with too much electric load part Dismount.
Radiator cooling fan motor faulty Check and replace as necessary.
Engine overheats
(It is in case that radia-
tor fan won’t operates)Fuse blown Check “RADTR fan” fuse and
check for short circuit to ground.
Radiator cooling fan relay No.1 Check and replace as necessary.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan motor faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary
ECM faulty Check and replace as necessary.

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 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

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