6a- SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

6
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-1
GENERAL INFORMATION6- 3 . . . . . . . . . . . . . .
Statement on Cleanliness and Care 6- 3. . . . .
General Information on Engine Service 6- 3. .
Precaution on Fuel System Service 6- 4. . . . .
Fuel Pressure Relief Procedure 6- 5. . . . . . . .
Fuel Leakage Check Procedure 6- 5. . . . . . . .
ENGINE DIAGNOSIS6- 6 . . . . . . . . . . . . . . . . . . . General Description 6- 6. . . . . . . . . . . . . . . . . . .
On-Board Diagnostic System 6- 6. . . . . . . . . .
Precaution in Diagnosing Trouble 6- 9. . . . . . .
Engine Diagnostic Flow Table 6-10. . . . . . . . . .
Customer Problem Inspection From 6-12. . . . .
Malfunction Indicator Lamp Check 6-13. . . . . .
Diagnostic Trouble Code Check 6-13. . . . . . . .
SECTION 6
ENGINE GENERAL INFORMATION
AND DIAGNOSIS
(TBI FOR G10)
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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” 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).
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI for G10)6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI for G13)6-1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL (G10)6A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL (G13 1 cam 16 valves)6A1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLING6B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE FUEL6C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE AND EMISSION CONTROL SYSTEM (TBI for G10)6E1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE AND EMISSION CONTROL SYSTEM (SFI for G13)6E2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM (G10 ENGINE)6F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM (G13 ENGINE)6F1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKING SYSTEM6G-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM6H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM6K-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE:
For the descriptions for vehicle without warm up three way catalytic converter (WUTWC), refer to Section
6 and 6E1 of the Service Manual mentioned in the FOREWORD of this manual.
CONTENTS

6A
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-1
SECTION 6A
ENGINE MECHANICAL
(G10, 1-CAM 6-VALVES ENGINE)
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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
ON-VEHICLE SERVICE6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Hydraulic Valve Lash Adjuster 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash Adjuster Noise Diagnosis 6A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Piston Rings, Connecting Rods and Cylinders 6A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6A-2 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
ON-VEHICLE SERVICE
ENGINE VACUUM CHECK
The engine vacuum that develops in the intake line is a good indica-
tor of the condition of the engine. The vacuum checking procedure
is as follows:
1) Warm up engine to normal operating temperature.
2) With engine stopped, remove blind plug hose from intake man-
ifold and connect special tool (vacuum gauge and joint) to va-
cated threaded hole.
Special Tool
(A): 09915-67311
3) Run engine at specified idle speed (see Section 6E), and read
vacuum gauge. Vacuum should be within the following specifi-
cation.
Vacuum specification: 52.6 – 65.8 kPa (40 – 50 cm
.Hg,
15.7 – 19.7 in
.Hg) at specified
idling speed
4) After checking, apply sealant to thread of blind plug and install
it to intake manifold.
OIL PRESSURE CHECK
NOTE:
Prior to checking oil pressure, check the followings.

Oil level in oil pan.
If oil level is low, add oil up to Full level hole on oil level
gauge.

Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in Section 0B.

Oil leaks.
If leak is found, repair it.
1) Using special tool (Oil filter wrench), remove oil filter.
2) After removing oil filter, remove oil pressure switch (1) from cylin-
der block.

3 / 4 turn
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-3
3) Install special tool (Oil pressure gauge) to vacated threaded
hole.
Special Tool
(A): 09915-77311
(B): 09915-78211
NOTE:
At this time, be very careful not to exert force to where
heated oxygen sensor and its lead wire are connected.
4) Reinstall oil filter.
5) Start engine and warm it up to normal operating temperature.
6) After warming up, raise engine speed to 4,000 r / min and mea-
sure oil pressure.
Oil pressure specifications: 270 – 370 kPa
(2.7 – 3.7 kg / cm
2,
38.4 – 52.6 psi) at
4,000 r / min (rpm)
7) After checking oil pressure, stop engine and remove oil filter
and oil pressure gauge.
8) Before reinstalling oil pressure switch (1), be sure to wrap its
screw threads with a sealing tape and tighten switch to speci-
fied torque.
NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
9) After oiling oil filter “O” ring (rubber gasket), screw oil filter on
oil filter stand by hand until filter “O” ring contacts mounting sur-
face.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position where filter “O” ring first contacts
mounting surface.
10) Tighten filter (1) 3 / 4 (270) turn from the point of contact with
mounting surface using an oil filter wrench.
Special Tool
(C): 09915-47310
CAUTION:
To prevent oil leakage, make sure that oil filter is tight,
but do not overtighten it.
11) After installing oil filter, start engine and check oil filter for oil
leakage.

6A-4 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
CYLINDER HEAD COVER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly.
3) Remove high-tension cord clamps (2) from cylinder head cover.
4) Disconnect breather hose from cylinder head cover.
5) Remove cylinder head cover nuts and then seal washers (1).
6) Remove cylinder head cover (3) from cylinder head.
INSTALLATION
1) Install cylinder head cover gasket to head cover.
Before installing gasket, check it for deterioration or damage,
and replace as necessary.
2) Install cylinder head cover (1).
Before installing seal washers, check each one for deterioration
or damage, and replace as necessary.
Tighten cover nuts to specified torque.
Tightening Torque
(a): 4.5 N
.m (0.45 kg-m, 3.5 lb-ft)
3) Install high-tension cord clamps (2) to cylinder head cover.
4) Connect breather hose to cylinder head cover.
5) Install air cleaner assembly.
6) Connect negative cable at battery.

1. Stay
2. Throttle body
3. Gasket
4. EFE heater
5. Intake manifold
6. Gasket : Tightening Torque
: Do not reuse
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-5
THROTTLE BODY AND INTAKE MANIFOLD
REMOVAL
1) Relieve fuel pressure according to procedure described in
“FUEL PRESSURE RELIEF PROCEDURE” of Section 6.
2) Disconnect negative cable at battery.
3) Drain cooling system.
WARNING:
To help avoid danger of being burned, do not remove
drain plug (2) and radiator cap while engine and radiator
(1) are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.

1. Throttle body
1. Throttle body
2. ISC actuator
5. Clamp
6A-6 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
4) Remove air cleaner assembly.
5) Disconnect the following electric lead wires:

EGR valve

ISC actuator (2)

Ground wires from intake manifold

Fuel injector (4)

TP sensor (3)

EFE heater (5)

Engine coolant temp. gauge
6) Disconnect fuel return (4) and feed hoses (3) from fuel pipes.
7) Disconnect coolant hoses from intake manifold.
8) Disconnect the following vacuum hoses.

Canister purge hose from intake manifold.

EGR pressure transducer hoses from EGR valve.

EGR valve hose from EGR valve.

Pressure sensor hose from intake manifold.

Brake booster hose from intake manifold.
9) Disconnect breather hose from PCV valve.
10) Disconnect accelerator cable from throttle body.
11) Disconnect other connected to throttle body and intake man-
ifold, if any.
12) Remove intake manifold with throttle body from cylinder head.
13) Remove throttle body from intake manifold.

2. Ground
1. Throttle body
2. ISC actuator
coupler
3. TP sensor
coupler
4. Fuel injector
coupler
5. EFE heater
coupler
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-7
INSTALLATION
1) Install throttle body to intake manifold. (Refer to Section 6E.)
2) Install intake manifold gasket to cylinder head. Use a new gas-
ket.
3) Install intake manifold (1) with throttle body to cylinder head.

Install clamps (3) as shown in figure, and tighten bolts and
nuts to specification.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Connect breather hose to PCV valve.
5) Connect vacuum hoses.
6) Connect coolant hoses.
7) Connect fuel return and feed hoses to throttle body.
8) Connect electric lead wire.
9) Connect accelerator cable to throttle body.
10) Install air cleaner assembly to throttle body.
11) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
12) Refill cooling system.
13) Connect negative cable at battery.
14) Upon completion of installation, start engine and check for fuel
leaks and engine coolant leaks.
After warming up engine, adjust accelerator cable play to spec-
ification according to description in Section 6E.

1. Exhaust manifold
2. Gasket
3. Cover
4. Heated oxygen sensor
5. Pipe seal
6. Exhaust pipe
7. WU-TWC (if equipped)
8. Exhaust pipe bolt : Tightening Torque
: Do not reuse
6A-8 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
EXHAUST MANIFOLD
WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot.
Service should be performed after system cools down.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect heated oxygen sensor coupler.
Release its wire from clamps.
3) Disconnect exhaust pipe (1) from exhaust manifold (or WU-
TWC (2)).
4) Remove WU-TWC stiffener (3). (if equipped)
5) Remove exhaust manifold cover (2). (for vehicle with WU-TWC)
6) Remove exhaust manifold (1) with WU-TWC (if equipped) and
its gasket from cylinder head.

2. WU-TWC
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-9
INSTALLATION
1) Install manifold gasket to cylinder head.
Before installing gasket, check it for deterioration or damage,
and replace as necessary.
2) Install exhaust manifold (1).
Tighten manifold bolts and nuts to specified torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Install exhaust manifold cover (2).
4) Install pipe seal, and then connect exhaust pipe (1).
Before installing pipe seal, check it for deterioration or damage,
and replace as necessary.
Tighten pipe bolts to specified torque.
Tightening Torque
(c): 43 N
.m (4.3 kg-m, 31.5 lb-ft)
5) Install WU-TWC stiffener (3). (if equipped)
6) Connect heated oxygen sensor coupler.
7) Clamp its wire securely.
8) Connect negative cable at battery.
9) Check exhaust system for exhaust gas leakage.