wheel torque SUZUKI SWIFT 2000 1.G RG413 Service Manual PDF

5E-40 ANTILOCK BRAKE SYSTEM (ABS)
SENSOR ROTOR INSPECTION
Check rotor serration (teeth) for being missing, damaged or
deformed.
Turn wheel and check if rotor rotation is free from eccentric-
ity and looseness.
Check that no foreign material is attached.
If any faulty is found, repair or replace.
INSTALLATION
Reverse removal procedure for installation noting the following.
Check that no foreign material is attached to sensor (1) and
ring.
Be sure to install wheel speed sensor and its bolt at the cor-
rect (upper) position as shown in figure.
Tighten sensor bolt to specified torque.
Tightening torque
Sensor bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Check that there is no clearance between sensor and rear
axle shaft.
[A] : For 2WD
[B] : For 4WD
[B] [A]
1
CAUTION:
Do not pull or twist wire harness more than necessary
when installing rear wheel speed sensor.

ANTILOCK BRAKE SYSTEM (ABS) 5E-41
REAR WHEEL SPEED SENSOR RING (FOR
2WD VEHICLE)
REMOVAL
1) Remove rear wheel sensor from rear axle housing.
2) Remove brake drum referring to Section 5.
3) Remove sensor ring (1) from brake drum (2) using special
tools.
Special tool
(A) : 09913-75520
(B) : 09913-65135
INSTALLATION
1) Install new sensor ring (1) to brake drum (2) using special
tool and hydraulic press (3).
Special tool
(A) : 09913-75840
2) Install brake drum. Refer to Section 5.
3) Install rear wheel speed sensor (1) to rear axle housing.
Tightening torque
Rear wheel speed sensor (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft) CAUTION:
Pull out sensor ring from brake drum gradually and
evenly. Attempt to pull it out partially may cause it to be
deformed.
NOTE:
Do not reuse (reinstall) removed sensor ring.
1
(a)

5E-42 ANTILOCK BRAKE SYSTEM (ABS)
REAR WHEEL SPEED SENSOR RING (FOR
4WD VEHICLE)
REMOVAL
1) Remove rear axle shaft referring to Section 3E.
2) Remove rear wheel sensor ring from axle shaft by using spe-
cial tools.
Special tool
(A) : 09927-18411
(B) : 09921-57810
INSTALLATION
1) Install new wheel sensor ring (1) by using hydraulic press
(2).
2) Install rear axle shaft referring to Section 3E.
3) Install wheel speed sensor to rear axle housing.
Tightening torque
Wheel sensor ring bolt : 10 N·m (1.0 kg-m, 7.5 lb-ft)
NOTE:
Do not reuse (reinstall) removed sensor ring.
Do not damage to retainer ring when press fitting
wheel sensor ring.
1 2

6A1-8 ENGINE MECHANICAL (M13 ENGINE)
2) Install special tools (Oil pressure gauge) to vacated threaded
hole.
Special tool
(A) : 09915-77310
(B) : 09915-78211
3) Start engine and warm it up to normal operating tempera-
ture.
4) After warming up, raise engine speed to 4,000 rpm and mea-
sure oil pressure.
Oil pressure specification
: 280 – 430 kPa (2.8 – 4.3 kg/cm
2, 39.8 – 61.1 psi)
at 4,000 rpm
5) Stop engine and remove oil pressure gauge and attachment.
6) Before reinstalling oil pressure switch (2), be sure to wrap its
screw threads with sealing tape (1) and tighten switch to
specified torque.
Tightening torque
Oil pressure switch (a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
7) Start engine and check oil pressure switch for oil leakage.
If oil leakage is found, repair it.
8) Connect oil pressure switch coupler (1).
NOTE:
Be sure to place transmission gear shift lever in “Neu-
tral” (shift selector lever to “P” range for A/T model), and
set parking brake and block drive wheels.
NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.

ENGINE MECHANICAL (M13 ENGINE) 6A1-65
INSTALLATION
1) Apply engine oil to pistons, rings, cylinder walls, connecting
rod bearings and crankpins.
2) Install guide hoses (1) over connecting rod bolts.
These guide hoses protect crank pin and threads of rod bolt
from damage during installation of connecting rod and piston
assembly.
3) When installing piston and connecting rod assembly into cyl-
inder bore, point front mark on piston head to crankshaft pul-
ley side.
4) Install piston and connecting rod assembly into cylinder
bore. Use special tool (Piston ring compressor) to compress
rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until
all piston rings have entered cylinder bore.
Special tool
(A) : 09916-77310
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side.
After applying oil to rod bolts and tighten cap nuts (3) gradu-
ally as follows.
a) Tighten all cap nuts to 15 N·m (1.5 kg-m, 11.0 lb-ft).
b) Retighten them to 45°.
c) Repeat Step b) once again.
Tightening torque
Connecting rod bearing cap nuts
(a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) and then turn to 45° twice. NOTE:
Do not apply oil between connecting rod and bearing or
between bearing cap and bearing.
A : Crankshaft pulley side
B : Flywheel side

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) 6A1-85
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.

6A1-86 ENGINE MECHANICAL (M13 ENGINE)
TIGHTENING TORQUE SPECIFICATION
Fastening partTightening torque
Nm kg-m lb-ft
Oil pressure switch 14.0 1.4 10.5
Camshaft housing bolts
(for replacement of shim)8.0 0.8 6.0
Camshaft housing bolts 11.0 1.1 8.0
Cylinder head cover bolts 8.0 0.8 6.0
Intake manifold bolts and nuts 25.0 2.5 18.0
Exhaust manifold bolts and nuts 50.0 5.0 36.5
Exhaust No.1 pipe bolts 50.0 5.0 36.5
Exhaust manifold stiffener bolts 50.0 5.5 36.5
Oil pump strainer bolt 11.0 1.1 8.0
Oil pump strainer bracket bolt 11.0 1.1 8.0
Oil pan bolts and nuts 11.0 1.1 8.0
Oil pan drain plug bolt 50.0 5.0 36.5
Timing chain cover bolts 23.0 2.3 17.0
Engine mounting bolts 75.0 7.5 54.5
Engine mounting bracket bolts 55.0 5.5 40.0
Crank shaft pulley bolt 150.0 15.0 108.5
Oil pump rotor plate bolts 11.0 1.1 8.0
Timing chain No.1 guide bolts 9.0 0.9 6.5
Timing chain tensioner adjuster bolt 11.0 1.1 8.0
Venturi plug 5.0 0.5 3.5
Cylinder head bolts for M8 22.0 2.2 16.0
Cylinder head bolts for M10 a) Tighten 40 N·m
b) Turn 60°
c) Turn 60°a) Tighten 4.0 kg-m
b) Turn 60°
c) Turn 60°a) Tighten 29.0 lb-ft
b) Turn 60°
c) Turn 60°
Connecting rod bearing cap nuts a) Tighten 15 N·m
b) Turn 45°
c) Turn 45°a) Tighten 1.5 kg-m
b) Turn 45°
c) Turn 45°a) Tighten 11.0 lb-ft
b) Turn 45°
c) Turn 45°
Engine mounting bolts and nuts for M10 55.0 5.5 40.0
Engine mounting bolts and nuts for M12 75.0 7.5 54.5
Crankshaft bearing cap No.1 bolts
(for inspection of crankshaft thrust play)50.0 5.0 36.5
Crankshaft bearing cap No.2 bolts 22.0 2.2 16.0
Sensor plate bolts 11.0 1.1 8.0
Crankshaft bearing cap No.1 bolts a) Tighten 50 N·m
b) Turn 60°a) Tighten 5.0 kg-m
b) Turn 60°a) Tighten 36.5 lb-ft
b) Turn 60°
Rear oil seal housing bolts 11.0 1.1 8.0
Flywheel or drive plate bolts 70.0 7.0 51.0

CRANKING SYSTEM 6G-3
Condition Possible Cause Correction
Motor not running
(No operating sound of
magnetic switch)Shift lever switch is not in P or N, or not adjusted
(A/T)Shift in P or N, or adjust switch.
Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Poor contact in battery terminal connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch and mag-
netic switchReplace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and magnetic
switchRepair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Motor not running
(Operating sound of
magnetic switch
heard)Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor contacting action
of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfac-
tory, inspect starting
motor)Insufficient contact of magnetic switch main con-
tactsReplace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn commutator Repair commutator or replace
armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor run-
ning, but not cranking
engineWorn pinion tip Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of pinion gear Replace flywheel.
Noise
Abnormally worn bush Replace bush.
Worn pinion or worn teeth of pinion gear Replace pinion or flywheel.
Poor sliding of pinion (failure in return movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.
Starting motor does
not stop runningFused contact points of magnetic switch Replace magnetic switch.
Short-circuit between turns of magnetic switch coil
(layer short-circuit)Replace magnetic switch.
Failure of returning action in ignition switch Replace.