Air SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

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.

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.

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-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”

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-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.
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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-8 ENGINE FUEL
6) Disconnect fuel pipe joint and fuel hoses from pipes.
For quick joint, disconnect it as follows :
a) Remove mud, dust and/or foreign material between pipe
and joint by blowing compressed air.
b) Unlock joint (1) lock by inserting special tool between pipe
(2) and joint (1).
Special tool
(A) : 09919-47020
c) Disconnect joint from pipe.
7) Support fuel tank (1) with jack (2) and remove its mounting
bolts.
8) Lower fuel tank a little as to disconnect wire harness at con-
nector (1), then remove fuel tank.
INSPECTION
After removing fuel tank, check hoses and pipes connected to
fuel tank for leaks, loose connections, deterioration or damage.
Also check fuel pump assembly gaskets for leaks, visually inspect
fuel tank for leaks and damage.
Replace any damaged or malconditioned parts.WARNING:
A small amount of fuel may be released after the fuel
hose is disconnected. In order to reduce the chance of
personal injury, cover the hose and pipe to be discon-
nected with a shop cloth. Be sure to put that cloth in an
approved container when disconnection is completed.
1