drain bolt SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

1A-6 HEATER AND VENTILATION
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Drain engine coolant and disconnect heater hoses (1) from
heater unit.
3) Remove heater unit mounting nut (2).
4) Remove instrument panel by referring to “INSTRUMENT
PANEL” in Section 9.
5) Disconnect blower motor and resistor couplers from heater
unit.
6) Remove bolts (1), nuts (2) and screws (3) as shown.
7) Remove cooling unit (4) and heater unit (5) from vehicle.
INSTALLATION
Reverse removal procedure to install heater unit noting the follow-
ing instructions.
When installing each part, be careful not to catch any cable
or wiring harness.
Adjust heater control cable by referring to “HEATER CON-
TROL LEVER ASSEMBLY” in this section.
Fill engine coolant to radiator.

REAR SUSPENSION 3E-21
2) Press-fit wheel bearing (1) with it’s seal side facing back
plate side using special tools and hydraulic press.
Special tool
(A) : 09913-76010
(B) : 09924-84510-004
3) Install bearing circlip (1) using special tool.
Special tool
(A) : 09900-06108
4) Install wheel sensor ring (if equipped with ABS).
Refer to “REAR WHEEL SENSOR RING” of Section 5E.
5) Install brake drum and wheel. For details, refer to “REAR
BRAKE DRUM” in Section 5.
REAR AXLE SHAFT AND WHEEL BEARING
(4WD VEHICLE)
REMOVAL
1) Hoist vehicle and remove rear wheels.
2) Remove rear brake drum. For details referring to Section 5.
3) Drain gear oil from rear axle housing by loosening drain plug
(1).
1. 8mm bolt
2. Level plug

4A-4 FRONT DRIVE SHAFT
DRIVE SHAFT ASSEMBLY
REMOVAL
1) Undo caulking (“A”) and remove drive shaft nut (1) and
washer.
2) Hoist vehicle.
3) Remove wheel.
4) Drain transmission oil or transfer oil.
5) Remove tie rod end split pin (1) and castle nut (2).
6) Disconnect tie rod end (3) from steering knuckle (4) by using
special tool.
Special tool
(A) : 09913-65210
7) (For vehicle without center shaft or 4WD model)
Using tire lever (1), pull out drive shaft joint (2) so as to
release snap ring fitting of joint spline at differential side.
(For vehicle with center shaft or 4WD model)
Using plastic hammer, drive out drive shaft joint (2) so as to
release snap ring fitting of joint spline at center shaft or inter-
mediate shaft of transfer.
8) Remove two stabilizer mount brackets from vehicle body.
9) Disconnect front suspension control arm ball stud (1) from
steering knuckle (2) by pushing down stabilizer bar (4) after
removing ball stud bolt (3).
[A] : Vehicle without center shaft or 4WD model
[B] : Vehicle with center shaft or 4WD model

FRONT DRIVE SHAFT 4A-15
Tighten each bolt and nut to the specified torque.
Tightening torque
Transfer oil filler/level and drain plugs (a) :
21 N·m (2.1 kg-m, 15.5 lb-ft)
Transmission oil filler/level and drain plugs (b) :
23 N·m (2.3 kg-m, 17.0 lb-ft)
Ball stud bolt (c) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
Tie rod end castle nut (d) :
35 - 50 N·m (3.5 - 5.0 kg-m, 25.5 - 36.0 lb-ft)
Drive shaft nut (e) : 175 N·m (17.5 kg-m, 127.0 lb-ft)
Wheel nut (f) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
Center bearing support bolts (g) :
50 N·m (5.0 kg-m, 36.0 lb-ft)
Apply sealant to drain plug (1) and filler/level plug (2) for
manual transmission.
“A” : Sealant 99000-31110
Apply sealant to drain plug (9) and filler/level plug (10) for
transfer. (For 4WD model)
“A” : Sealant 99000-31110
Fill transmission or transfer with oil as specified. (Refer to
Section 7A, 7B or 7D.)
[A] : For M/T vehicle
[B] : For A/T vehicle
[C] : For 4WD model
[D] : For vehicle equipped with center shaft
3. Drain plug (for A/T vehicle)
4. Ball stud bolt
5. Castle nut
6. Drive shaft nut
7. Wheel nut
8. Center bearing support bolt

4A-16 FRONT DRIVE SHAFT
TIGHTENING TORQUE SPECIFICATION
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
Fastening portionTightening torque
Nm kg-m lb-ft
Transfer oil filler/level and drain plugs 21 2.1 15.5
Transmission oil filler/level and drain plugs 23 2.3 17.0
Ball stud bolt 60 6.0 43.5
Tie rod end castle nut 35 - 50 3.5 - 5.0 25.5 - 36.0
Drive shaft nut 175 17.5 127.0
Wheel nut 85 8.5 61.5
Center bearing support bolts 50 5.0 36.0
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1215
(99000-31110)Oil drain and filler plug for manual
transmission or transfer
09913-65210 09900-06107 09900-06108
Tie-rod end remover Snap ring pliers (Open
type)Snap ring pliers (Closing
type)

6A1-16 ENGINE MECHANICAL (M13 ENGINE)
THROTTLE BODY AND INTAKE MANIFOLD
REMOVAL
1) Relieve fuel pressure according to fuel pressure relief proce-
dure described in Section 6.
2) Disconnect negative cable at battery.
3) Drain coolant by loosening drain plug (1).
1. Intake manifold 7. EVAP canister purge valve 13. Intake manifold mounting bolt (short) 19. Cushion
2. Intake manifold gasket 8. TP sensor 14. Intake manifold mounting bolt (long) 20. Fuel delivery pipe mounting bolt
3. Throttle body 9. IAC valve 15. EGR pipe gasket Tightening torque
4. Gasket 10. Fuel delivery pipe 16. O-Ring Do not reuse.
5. EGR pipe 11. Intake manifold stiffener 17. Grommet
6. MAP sensor 12. Intake manifold mounting nut 18. Injector assembly
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.

ENGINE MECHANICAL (M13 ENGINE) 6A1-21
4) Install exhaust manifold cover (1) .
5) Connect heated oxygen sensor coupler (2) and fit coupler to
bracket securely (if equipped).
6) Install heat insulator panel and front bumper with front grille
by referring to Section 9.
7) Connect negative cable at battery.
8) Check exhaust system for exhaust gas leakage.
OIL PAN AND OIL PUMP STRAINER
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect heated oxygen sensor coupler and detach it from
its stay.
3) Remove oil level gauge.
[A] : Sealant application amount 3. O-ring 8. Oil pan nut
“a” : 3 mm (0.12 in.) 4. Gasket 9. Oil pan bolt
“b” : 2 mm (0.08 in.) 5. Drain plug Tightening torque
1. Oil pan
: Apply sealant 99000-31150 to mating surface.6. Strainer bolt Do not reuse.
2. Strainer 7. Bracket bolt

ENGINE MECHANICAL (M13 ENGINE) 6A1-23
Clean sealing surface on oil pan and cylinder block.
Remove oil, old sealant and dust from sealing surface.
INSTALLATION
1) Apply sealant continuously to oil pan mating surface as
shown in figure.
“A” : sealant 99000-31150
Sealant amount for oil pan
Width “a” : 3 mm (0.12 in.)
Height “b” : 2 mm (0.08 in.)
2) Install new O-rings (2) in the position as shown in figure and
install oil pump strainer (1).
Tighten strainer bolt (3) first and then bracket bolt (4) to
specified torque.
Tightening torque
Oil pump strainer bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Oil pump strainer bracket bolt
(b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
3) After fitting oil pan to cylinder block, run in securing bolts and
start tightening at the center :
move wrench outward, tightening one bolt at a time. Tighten
bolts and nuts to specified torque.
Tightening torque
Oil pan bolts and nuts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
4) Install new gasket and drain plug to oil pan.
Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug bolt (b) : 50 N·m 5.0 kg-m, 36.5 lb-ft)

6A1-26 ENGINE MECHANICAL (M13 ENGINE)
3) Remove right side engine under cover (1).
4) Remove A/C compressor belt (3) (if equipped).
5) Remove water pump belt (1).
6) Remove water pump pulley (2).
7) Drain engine oil.
8) Remove crankshaft pulley bolt (2).
To lock crankshaft pulley (1), use special tool with it as
shown in figure.
Special tool
(A) : 09917-68221
9) Remove oil pan (1) referring to “OIL PAN AND OIL PUMP
STRAINER”.
10) Remove cylinder head cover referring to “CYLINDER HEAD
COVER”.

6A1-34 ENGINE MECHANICAL (M13 ENGINE)
TIMING CHAIN AND CHAIN TENSIONER
REMOVAL
1) Disconnect negative cable at battery.
2) Drain engine oil.
3) Remove oil pan referring to “OIL PAN AND OIL PUMP
STRAINER”.
4) Remove cylinder head cover referring to “CYLINDER HEAD
COVER”.
5) Remove timing chain cover referring to “TIMING CHAIN
COVER”.
6) Align both intake and exhaust camshaft timing sprocket
marks (1) with notches (2) of cylinder head respectively by
turning crankshaft.
7) Remove timing chain tensioner adjuster assembly (3).
8) Remove timing chain tensioner (4).
9) Remove timing chain No.1 guide (5).
10) Remove timing chain (6) with crankshaft timing sprocket (7).
1. Crankshaft timing sprocket 4. Timing chain tensioner
: Apply engine oil to sliding surface.7. Chain tensioner mounting bolt
2. Timing chain
: Apply engine oil.5. Timing chain tensioner adjuster assembly 8. Chain guide mounting bolt
3. Timing chain No.1 guide
: Apply engine oil to sliding surface.6. Chain tensioner adjuster mounting bolt Tightening torque
CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than its allowable turning
range described in “INSTALLATION” section.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.