Clutch SUZUKI SWIFT 2000 1.G RG413 Service Service Manual

ENGINE MECHANICAL (M13 ENGINE) 6A1-5
9) Install special tools (compression gauge) into spark plug
hole.
Special tool
(A) : 09915-64510-001
(B) : 09915-64510-002
(C) : 09915-64530
(D) : 09915-67010
10) Disengage clutch (1) (to lighten starting load on engine) for
M/T vehicle, and depress accelerator pedal (2) all the way to
make throttle fully open.
11) Crank engine with fully charged battery, and read the highest
pressure on compression gauge.
Compression pressure
12) Carry out Steps 9) through 11) on each cylinder to obtain 4
readings.
NOTE:
For measuring compression pressure, crank engine at
least 250 rpm by using fully charged battery.
If measured compression pressure is lower than limit
value, check installation condition of special tool. If it
is properly installed, possibility is compression pres-
sure leakage from where piston ring and valve contact.
Standard 1400 kPa
(14.0 kg/cm
2, 199.0 psi)
Limit 1100 kPa
(11.0 kg/cm
2, 156.0 psi)
Max. difference between
any two cylinders100 kPa
(1.0 kg/cm
2, 14.2 psi)

6A1-22 ENGINE MECHANICAL (M13 ENGINE)
4) Remove exhaust No.1 pipe (1).
5) Drain engine oil by removing drain plug.
6) Remove clutch housing (torque converter housing for A/T
vehicle) lower plate (1).
7) For 4WD vehicle, remove transfer referring to Section 7D.
8) Remove oil pan and then oil pump strainer (1) from cylinder
block.
CLEAN
Clean oil pump strainer screen (1).

6A1-24 ENGINE MECHANICAL (M13 ENGINE)
5) Install clutch housing (torque converter housing for A/T vehi-
cle) lower plate (1).
6) For 4WD vehicle, install transfer by referring to Section 7D.
7) Install exhaust No.1 pipe (1).
Tighten bolts to specified torque.
Tightening torque
Exhaust No.1 pipe bolts (a) : 50 N·m 5.0 kg-m, 36.5 lb-ft)
8) Install oil level gauge.
9) Refill engine with engine oil referring to “ENGINE OIL
CHANGE” in Section 0B.
10) Verify that there is no engine oil leakage and exhaust gas
leakage at each connection.

ENGINE MECHANICAL (M13 ENGINE) 6A1-69
11) Disconnect the following electric lead wires:
TP sensor (1)
MAP sensor (2)
ECT sensor
CMP sensor
CKP sensor
Knock sensor
Heated oxygen sensors
EGR valve (3)
IAC valve (4)
EVAP canister purge valve (5)
Injectors (6)
Ignition coil assembly (7)
Engine oil pressure switch
Generator (8)
Starting motor
Magnet clutch switch of A/C compressor (if equipped)
Ground terminal (9) from exhaust manifold and cylinder
block
VSS
Back up light switch (For M/T vehicle)
Transmission range switch (10) (For A/T vehicle)
A/T VSS (11) (For A/T vehicle)
Dropping resistor (12) (For A/T vehicle)
A/T shift solenoid and A/T temp. sensor (13) (For A/T vehi-
cle)
Battery ground cable (14) from transmission
Each wire harness clamps
12) Remove fuse box from its bracket.
13) Disconnect the following cables :
Accelerator cable
Gear select control cable (For M/T vehicle)
Gear shift control cable (For M/T vehicle)
Clutch cable (For M/T vehicle)
Gear select cable (15) (For A/T vehicle)
14) Disconnect the following hoses :
Brake booster hose (1) from intake manifold
Canister purge hose (2) from EVAP canister purge valve
Fuel feed hose (3) from fuel delivery pipe
Heater inlet and outlet hoses from each pipe
Radiator inlet and outlet hoses from each pipe

ENGINE MECHANICAL (M13 ENGINE) 6A1-71
21) Before removing engine with transmission from body,
recheck to make sure all hoses, electric wires and cables are
disconnected from engine and transmission.
22) Lower engine with transmission from body.
23) Disconnect transmission from engine, referring to Section 7A
or 7B.
24) Remove clutch cover and clutch disk, referring to Section 7C
(M/T).
INSTALLATION
1) Install clutch cover and clutch disk referring to Section 7C.
2) Connect transmission to engine referring to Section 7A or
7B.
3) Lift engine with transmission into engine compartment, but
do not remove lifting device.
4) Install engine rear mounting bolts (1), engine left mounting
bracket nuts (2) and engine right mounting bolts (3).
Tighten these bolts and nuts to specified torque.
Tightening torque
Engine mounting bolts and nuts for M10
(a) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
Engine mounting bolt for M12
(b) : 75 N·m (7.5 kg-m, 54.5 lb-ft)
5) Remove lifting device.NOTE:
Before lowering engine, to avoid damage to A/C com-
pressor, raise it through clearance made on engine
crankshaft pulley side. At this time, use care so that no
excessive force is applied to hoses.

6A1-74 ENGINE MECHANICAL (M13 ENGINE)
REMOVAL
1) Remove engine assembly from vehicle as previously out-
lined.
2) Remove clutch flywheel (drive plate for A/T) by using special
tool.
Special tool
(A) : 09924-17810
3) Remove the following parts from engine as previously out-
lined.
Oil pan and oil pump strainer
Intake manifold and exhaust manifold
Cylinder head cover
Timing chain cover
Timing chain guide, chain tensioner adjuster, chain ten-
sioner, timing chain and crankshaft timing sprocket
Camshaft, tappet and shim
Cylinder head assembly
Piston and connecting rod
4) Remove rear oil seal housing (1).
[A] : Sealant application amount 4. Venturi plug 14. Main bearing cap
[B] : 1) Tighten all bolts to 50 N·m (5.0 kg-m)
2) Then, turn all bolts to 60°5. Main bearing 15. Flywheel mounting bolt
Tightening torque 6. Sensor plate 16. Rear oil seal housing mounting bolt
Do not reuse. 7. Crankshaft timing sprocket key 17. Main bearing mounting No.2 bolt
Apply engine oil to inside / sliding sur-
face.8. Crankshaft
18. Main bearing mounting No.1 bolt
Never reuse it due to plastic defor-
mation tightening bolt.
“a” : 3 mm (0.12 in.) 9. Thrust bearing 19. O-ring
“b” : 2 mm (0.08 in.) 10. Rear oil seal housing :
Apply sealant 99000-31150 to mating surface.20. Oil filter adapter case
1. CKP sensor (if equipped) 11. Rear oil seal 21. Oil filter adapter bolt
2. Knock sensor 12. Input shaft bearing
3. Cylinder block 13. Flywheel

ENGINE MECHANICAL (M13 ENGINE) 6A1-81
Rear Oil Seal
Carefully inspect oil seal (1) for wear or damage.
If its lip is worn or damaged, replace it.
For oil seal installation, press-fit rear oil seal (1) to oil seal housing
(2) by using special tool as shown in the figure.
Special tool
(A) : 09911-97820
Drive in dimension
“a” : 3 mm (0.12 in.)
Flywheel
If ring gear is damaged, cracked or worn, replace flywheel.
If the surface contacting clutch disc is damaged, or exces-
sively worn, replace flywheel.
Check flywheel for face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel on runout
Limit : 0.2 mm (0.0079 in.)
Sensor plate
Check sensor plate for crack or damage. If malcondition is
found, replace it.

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.

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 AND EMISSION CONTROL SYSTEM 6E1-5
AIR INTAKE SYSTEM
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3),
idle air control valve (4) and intake manifold (5).
The air (by the amount corresponding to the throttle valve (6) opening and engine speed) is filtered by the air
cleaner (1), passes through the throttle body (3), is distributed by the intake manifold (5) and finally drawn into
each combustion chamber.
When the idle air control valve (4) is opened according to the signal from ECM, the air (7) bypasses the throttle
valve (6) through bypass passage and is finally drawn into the intake manifold (5).
1. Air Cleaner 16. Immobilizer indicator lamp (if equipped) 31. Monitor connector (vehicle without immobi-
lizer indicator lamp)
2. EVAP canister purge valve 17. Knock sensor (if equipped) 31-1. Diagnosis switch terminal (vehicle without
immobilizer indicator lamp)
3. IAT sensor 18. ECT sensor 31-2. Test switch terminal (vehicle without immobi-
lizer indicator lamp)
4. TP sensor 19. CMP sensor 31-3. Duty output terminal (vehicle without immobi-
lizer indicator lamp)
5. IAC valve 20. CKP sensor 32. Stop lamp
6. MAP sensor 21. VSS 33. Stop lamp switch
7. EGR valve (if equipped) 22. Radiation fan 34. ECM
8. EVAP canister 23. Malfunction indicator lamp in combination meter 35. Barometric pressure sensor (if equipped)
9. Tank pressure control valve (built-in fuel pump) 24. Park/Neutral position switch (A/T) 36. Battery
10. Fuel pump (with pressure regulator) 25. Ignition switch 37. CO adjusting resistor (if equipped)
11. Fuel level sensor (vehicle with immobilizer indi-
cator lamp)26. Starter magnetic switch 38. A/C compressor clutch (if equipped)
12. Ignition coil assembly 27. TCM 39. A/C switch (if equipped)
13. Fuel injector 28. Transmission range switch (A/T) 40. A/C evaporator temp. sensor (if equipped)
14. Heated Oxygen Sensor (HO2S)-1
(if equipped)29. DLC 41. Immobilizer control module (if equipped)
15. Heated Oxygen Sensor (HO2S)-2
(if equipped)30. Electric load 42. Main relay
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