6b- 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

6B
ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
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
GENERAL DESCRIPTION6B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS6B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE6B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant6B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Flush and Refill 6B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE6B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Water Pipes or Hoses6B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat6B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump6B-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Heater inlet hose
9. Heater outlet hose
10. Radiator
11. Oil cooler (A / T only)
12. Engine
13. ECT sensor1. Radiator inlet hose
2. Radiator outlet hose
3. Water intake pipe
4. Thermostat
5. Water pump
6. IAC valve (throttle body)
7. Breather pipe (air cleaner
outlet hose)
6B-2 ENGINE COOLING
GENERAL DESCRIPTION
COOLING SYSTEM CIRCULATION
During engine warm-up (thermostat closed), the water pump discharges coolant into the water jacket chamber
adjacent to No.1 cylinder. Coolant then flows through the cylinder block and the cylinder heat. Coolant then returns
to the water pump through intake manifold, heater inlet hose, heater unit, heater outlet hose, and water intake pipe.
During normal temperatures (thermostat open), coolant takes the same basic route but is now allowed to flow past
the thermostat, the inlet hose and the radiator, and then back to the water pump through the outlet hose and the
water intake pipe.

1. Cooling fan motor
2. Radiator
ENGINE COOLING 6B-3
THERMOSTAT
A wax pellet type thermostat is used in the coolant outlet passage
to control the flow of engine coolant, to provide fast engine warm
up and to regulate coolant temperatures.
A wax pellet element is hermetically contained in a metal case, and
expands when heated and contracts when cooled.
When the pellet is heated and expands, the metal case pushes
down the valve to open it.
As the pellet is cooled, the contraction allows the spring to close the
valve.
Thus, the valve remains closed while the coolant is cold, preventing
circulation of coolant through the radiator.
At this point, coolant is allowed to circulate only throughout the en-
gine to warm it quickly and evenly.
As the engine warms, the pellet expands and the thermostat valve
opens, permitting coolant to flow through the radiator.
In the top portion of the thermostat, an air bleed valve (1) is pro-
vided; this valve is for venting out the gas or air, if any, that is accu-
mulated in the circuit.
Thermostat functional spec. ± 2.8
C (5.0
F)
Temp. at which valve
begins to open88
C (190
F)
Temp. at which valve
become fully open100
C (212
F)
COOLING FAN
The cooling fan is driven by electric motor, and the motor is acti-
vated by ECM / PCM (engine coolant temp.). For its details, refer to
Section 6E.
WARNING:
Keep hands, tools, and clothing away from engine cooling
fan to help prevent personal injury. This fan is electric and
can come on whether or not the engine is running. The fan
can start automatically in response to the ECM / PCM (en-
gine coolant temp.) with the ignition switch in the “ON”
position.

6B-4 ENGINE COOLING
COOLANT (WATER) TEMP. GAUGE
The coolant temp. gauge is included in engine coolant temp. (ECT)
sensor (1). This gauge activates a temp. meter in the instrument
cluster.
DIAGNOSIS
ConditionPossible CauseCorrection
Engine overheatsLoose or broken water pump belt
Not enough coolant
Faulty thermostat
Faulty water pump
Dirty or bent radiator fins
Coolant leakage on cooling system
Defective cooling fan motor
Plugged radiator
Faulty radiator cap
Maladjusted ignition timing
Dragging brakes
Slipping clutchAdjust or replace.
Check coolant level and add as
necessary.
Replace.
Replace.
Clean or remedy.
Repair.
Check and replace as
necessary.
Check and replace radiator as
necessary.
Replace.
Adjust.
Adjust brake.
Adjust or replace.

ENGINE COOLING 6B-5
ANTI-FREEZE PROPOR-
TIONING CHART COOLANT CAPACITY
G13 engine G10 engine
MAINTENANCE
COOLANT
The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col-
lected in the reservoir tank.
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has been filled at the factory with a quality coolant that is either 50 / 50 mixture of water and
GOLDEN CRUISER 1200 (ethylene glycol antifreeze.) or 30 / 70 mixture of water and GOLDEN CRUISER 1200.
The 50 / 50 mixture coolant solution provides freezing protection to – 36
C (– 33
F), the 30 / 70 mixture coolant solu-
tion provides freezing protection to – 16
C (3
F).
When changing the engine coolant, use mixture of 50% water and 50% GOLDEN CRUISER 1200 for the market
where ambient temperature falls lower than – 16
C (3
F) in winter and mixture of 70% water and 30% GOLDEN
CRUISER 1200 for the market where ambient temperature doesn’t fall lower than – 16
C (3
F).
NOTE:
Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time
as damage to cooling system could occur.
Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ethylene
glycol antifreeze (Antifreeze / Anticorrosion coolant) should be used for the purpose of corrosion protec-
tion and lubrication.
ANTI-FREEZE PROPORTIONING TABLE
Vehicle with M / TVehicle with A / T
Freezing temperature
C–16–36–16–36Freezing temperature
F3–333–33
Anti-freeze / Anti-corrosion
coolant concentration%30503050
G10Itr.1.17 / 2.731.95 / 1.951.20 / 2.802.00 / 2.00G10
engineUS pt.2.47 / 5.774.12 / 4.122.54 / 5.924.23 / 4.23
Ratio of compound to
engineImp pt.2.06 / 4.803.43 / 3.432.11 / 3.703.52 / 3.52
cooling water
G13Itr.1.38 / 3.222.30 / 2.301.41 / 3.292.35 / 2.35G13
engineUS pt.2.92 / 6.804.86 / 4.862.98 / 6.954.96 / 4.96engineImp pt.2.43 / 5.674.05 / 4.052.48 / 5.794.13 / 4.13
Engine radiator and heater3.3 liters
(7.0 / 5.8 US / Imp pt.)3.4 liters
(7.2 / 6.0 US / Imp pt.)
Reservoir tank0.6 liters
(1.3 / 1.1 US / Imp pt.)
Total3.9 liters
(8.2 / 6.9 US / Imp pt.)4.0 liters
(8.5 / 7.0 US / Imp pt.)
Engine radiator and heater4.0 liters
(8.5 / 7.0 US / Imp pt.)4.1 liters
(8.6 / 7.2 US / Imp pt.)
Reservoir tank0.6 liters
(1.3 / 1.1 US / Imp pt.)
Total4.6 liters
(9.7 / 8.1 US / Imp pt.)4.7 liters
(9.9 / 8.3 US / Imp pt.)

2. Outlet hose
6B-6 ENGINE COOLING
COOLING SYSTEM FLUSH AND REFILL
WARNING:
To help avoid danger of being burned, do not remove radia-
tor cap while engine and radiator cap while engine and ra-
diator are still hot. Scalding fluid and steam can be blown
out under pressure if cap is taken off too soon.
1) Remove radiator cap when engine is cool:
Turn cap counterclockwise slowly until it reaches a “stop”.
(Do not press down while turning it.)
Wait until pressure is relieved (indicated by a hissing sound)
then press down on cap and continue to turn it counterclock-
wise.
2) With radiator cap removed, run engine until upper radiator
hose is hot (this shows that thermostat is open and coolant is
flowing through system).
3) Stop engine and open radiator drain plug (1) to drain coolant.
4) Close drain plug. Add water until system is filled and run engine
until upper radiator hose is hot again.
5) Repeat Steps 3) and 4) several times until drained liquid is
nearly colorless.
6) Drain system and then close radiator drain plug tightly.
7) Disconnect reservoir tank hose from radiator. Remove reser-
voir tank and pour out any fluid. Scrub and clean inside of tank
with soap and water.
Flush it well with clean water and drain. Reinstall tank and
hose.
8) add 50 / 50 mixture of GOLDEN CRUISER 1200 (Good quality
ethylene glycol anti-freeze) and water to radiator and tank.
Fill radiator to the base of radiator filler neck and reservoir tank
to “FULL” level mark. Reinstall reservoir tank cap.
9) Run engine, with radiator cap removed, until radiator upper
hose is hot.
10) With engine idling, add coolant to radiator until level reaches
the bottom of filler neck. Install radiator cap, making sure that
the ear of cap lines up with reservoir tank hose.

1. Radiator hose
2. Clamp
ENGINE COOLING 6B-7
ON-VEHICLE SERVICE
WARNING:
Check to make sure that engine coolant temperature is
cold before removing any part of cooling system.
Also be sure to disconnect negative cord from battery ter-
minal before removing any part.
COOLING WATER PIPES OR HOSES
REMOVAL
1) Drain cooling system.
2) To remove these pipes or hoses, loosen screw on each pipe or
hose clip and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, noting
the following.
Tighten each clamp bolt securely.
Refill cooling system with proper coolant, referring to description
on COOLANT of MAINTENANCE.
THERMOSTAT
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system and tighten drain plug.
3) Disconnect thermostat cap (1) from thermostat case (2).

2. Thermostat case
2. Thermometer
3. Heater
Upside
6B-8 ENGINE COOLING
4) Remove thermostat (1).
INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clean.
Should this valve be clogged, engine would tend to overheat.
2) Check to make sure that valve seat is free from foreign matters
which would prevent valve from seating tight.
3) Check thermostatic movement of wax pellet as follows:
Immerse thermostat (1) in water, and heat water gradually.
Check that valve starts to open at specific temperature.
If valve starts to open at a temperature substantially below or
above specific temperature, thermostat unit should be re-
placed with a new one. Such a unit, if reused, will bring about
overcooling or overheating tendency.
INSTALLATION
1) When positioning thermostat on thermostat case, be sure to
position it so that air bleed valve comes uppermost and into the
recession of thermostat case.
2) Install thermostat cap to thermostat case. When installing cap,
align arrow marks on cap and case.
3) Fill cooling system.
4) Connect negative cable.
5) After installation, check each part for leakage.

ENGINE COOLING 6B-9
WATER PUMP
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Remove timing belt and tensioner according to procedure de-
scribed in “TIMING BELT AND TENSIONER” of Section 6A or
6A1.
4) Remove water pump belt adjusting arm.
5) Remove water pump assembly (1).
INSPECTION
NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes abnormal noise, replace
it.
INSTALLATION
1) Install new pump gasket to cylinder block.
2) Install water pump to cylinder block.
Tightening Torque
(a): 12 N
.m (1.2 kg-m, 9.0 lb-ft)
3) After installing water pump, install rubber seal (1) between water
pump and oil pump, and another between water pump and cylin-
der head.
4) Install timing belt tensioner, timing belt and timing belt outside
covers according to procedure described in “TIMING BELT AND
TENSIONER” of Section 6A or 6A1.
NOTE:
Special care must be used when installing belt tensioner
and timing belt.
Torque each bolt and nut to specification.
Before installing outside covers, check to make sure that
cover seal is fitted in groove of each cover properly.