Oil pump SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2000, Model line: SWIFT, Model: SUZUKI SWIFT 2000 1.GPages: 557, PDF Size: 14.35 MB
Page 6 of 557
1. Flywheel bolts or drive plate bolts for A / T vehicle
6) Install oil pump. Refer to “Oil pump”.
7) Install flywheel (for M / T vehicle) or drive plate
(for A / T vehicle).
Using special tool, lock flywheel or drive plate, and
tighten flywheel or drive plate bolts to specified
torque.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N
.m (7.8 kg-m, 56.0 lb-ft)
0A-2 GENERAL INFORMATION
HOW TO USE THIS MANUAL
1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL
on the third page of this manual, whereby you can easily find the
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.
2) Each section of this manual has its own pagination. It is indicated
at the top of each page along with the Section name.
3) The SPECIAL TOOL usage and TIGHTENING TORQUE
SPECIFICATION are given as shown in figure below.
4) A number of abbreviations are used in the text.
For their full explanations, refer to “ABBREVIATIONS AND
SYMBOLS MAY BE USED IN THIS MANUAL” of this section.
5) The SI, metric and foot-pound systems are used as units in this
manual.
6) DIAGNOSIS are included in each section as necessary.
7) At the end of each section, there are descriptions of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHT-
ENING TORQUE SPECIFICATIONS that should be used for the
servicing work described in that section.
Page 12 of 557
0A-8 GENERAL INFORMATION
When disconnecting vacuum hoses, attach a tag describing
the correct installation positions so that the hoses can be re-
installed correctly.
After servicing fuel, oil, coolant, vacuum, exhaust or brake
systems, check all lines related to the system for leaks.
For vehicles equipped with fuel injection systems, never dis-
connect the fuel line between the fuel pump and injector
without first releasing the fuel pressure, or fuel can be
sprayed out under pressure.
When performing a work that produces a heat exceeding
80C in the vicinity of the electrical parts, remove the heat
sensitive electrical part(s) beforehand.
Use care not to expose connectors and electrical parts to wa-
ter which will be a cause of a trouble.
Page 36 of 557
1. Thickness gauge IN
EX
0B-6 MAINTENANCE AND LUBRICATION
Water Pump Belt Replacement
Replace belt with a new one. Refer to SECTION 6B for replacement
procedure of pump belt.
NOTE:
When replacing belt with a new one, adjust belt tension to
5 – 7 mm (0.20 – 0.27 in.).
ITEM 1-2
Camshaft Timing Belt Replacement
Replace belt with new one. Refer to SECTION 6A or 6A1 for re-
placement procedure.
CAUTION:
Do not bend or twist timing belt.
Do not allow timing belt to come into contact with oil, wa-
ter, etc.
ITEM 1-3
Valve Lash Inspection (1.3 liter engine only)
1) Remove cylinder head cover.
2) Inspect intake and exhaust valve lash and adjust as necessary.
Refer to SECTION 6A1 for valve lash inspection and adjustment
procedure.
Valve
lash
(gap)
When cold
(Coolant temperature is
15 – 25C or 59 – 77F)When hot
(Coolant temperature is
60 – 68C or
140 – 154F)
(gap)
specifi-
cation
Intake0.13 – 0.17 mm
(0.005 – 0.007 in.)0.17 – 0.21 mm
(0.007 – 0.008 in.)
cation
Exhaust0.23 – 0.27 mm
(0.009 – 0.011 in.)0.28 – 0.32 mm
(0.011 – 0.013 in.)
Special Tool
(A): 09917-18211
Tightening Torque
(a): 12 N
.m (1.2 kg-m, 8.5 lb-ft)
3) Install cylinder head cover and tighten bolts to specification.
Page 54 of 557
1. No.1 cylinder
2. No.2 cylinder
3. No.3 cylinder
123
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-3
GENERAL INFORMATION
STATEMENT ON CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed,
polished and lapped surfaces with tolerances that are measured in
the thousands of an millimeter (ten thousands of an inch).
Accordingly, when any internal engine parts are serviced, care and
cleanliness are important.
Throughout this section, it should be understood that proper clean-
ing and protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard shop practice
even if not specifically stated.
A liberal coating of engine oil should be applied to friction areas
during assembly to protect and lubricate the surfaces on initial op-
eration.
Whenever valve train components, pistons, piston rings, con-
necting rods, rod bearings, and crankshaft journal bearings are
removed for service, they should be retained in order.
At the time of installation, they should be installed in the same
locations and with the same mating surfaces as when removed.
Battery cables should be disconnected before any major work is
performed on the engine.
Failure to disconnect cables may result in damage to wire har-
ness or other electrical parts.
Throughout this manual, the four cylinders of the engine are iden-
tified by numbers; No.1 (1), No.2 (2) and No.3 (3) counted from
crankshaft pulley side to flywheel side.
GENERAL INFORMATION ON ENGINE SERVICE
THE FOLLOWING INFORMATION ON ENGINE SERVICE
SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PRE-
VENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE EN-
GINE PERFORMANCE.
When raising or supporting engine for any reason, do not use a
jack under oil pan. Due to small clearance between oil pan and
oil pump strainer, jacking against oil pan may cause it to be bent
against strainer resulting in damaged oil pick-up unit.
It should be kept in mind, while working on engine, that 12-volt
electrical system is capable of violent and damaging short cir-
cuits.
When performing any work where electrical terminals can be
grounded, ground cable of the battery should be disconnected at
battery.
Any time the air cleaner, throttle body or intake manifold is re-
moved, the intake opening should be covered. This will protect
against accidental entrance of foreign material which could follow
intake passage into cylinder and cause extensive damage when
engine is started.
Page 55 of 557
HOSE CONNECTION
Clamp securely at a position 3 to
7mm (0.12–0.27 in.) from hose end. With short pipe, fit hose as far as it reaches pipe joint as
shown.
Hose
Pipe
ClampClamps securely at a position
3 to 7 mm (0.12–0.27 in.)
from hose end.
With following type pipe, fit hose as far as its peripheral
projection as shown.
Clamp securely at a position
3 to 7 mm (0.12–0.27 in.)
from hose end.
With bent pipe, fit hose as its bent part as shown or till pipe
is about 20 to 30 mm (0.79–1.18 in.) into the hose.
Clamp securely at a
position 3 to 7 mm
(0.12–0.27 in.) from hose
end.
With straight pipe, fit hose till pipe is, about 20 to 30 mm
(0.79–1.18 in.) into the hose.
Hose
20 to 30 mm
(0.79–1.18 in.)
Clamp
6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
PRECAUTION ON FUEL SYSTEM SERVICE
Work must be done with no smoking, in a well-ventilated area and
away from any open flames.
As fuel feed line (between fuel pump and fuel delivery pipe) is still
under high fuel pressure even after engine was stopped, loosen-
ing or disconnecting fuel feed line directly may cause dangerous
spout of fuel to occur where loosened or disconnected.
Before loosening or disconnecting fuel feed line, make sure to re-
lease fuel pressure according to “FUEL PRESSURE RELIEF
PROCEDURE”. A small amount of fuel may be released after the
fuel line is disconnected. In order to reduce the chance of person-
al injury, cover the fitting to be disconnected with a shop cloth. Put
that cloth in an approved container when disconnection is com-
pleted.
Never run engine with fuel pump relay disconnected when engine
and exhaust system are hot.
Fuel or fuel vapor hose connection varies with each type of pipe.
When reconnecting fuel or fuel vapor hose, be sure to connect
and clamp each hose correctly referring to left figure Hose Con-
nection.
After connecting, make sure that it has no twist or kink.
When installing injector or fuel delivery pipe, lubricate its O-ring
with spindle oil or gasoline.
When connecting fuel pipe flare nut, first tighten flare nut by hand
and then tighten it to specified torque.
Page 70 of 557
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-19
Operation
VISUAL INSPECTION
Visually check following parts and systems.
INSPECTION ITEM
REFERRING SECTION
Engine oil ––––– level, leakage
Engine coolant ––––– level, leakage
Fuel ––––– level, leakage
A / T fluid ––––– level, leakage
Air cleaner element ––––– dirt, clogging
Battery ––––– fluid level, corrosion of terminal
Water pump belt ––––– tension, damage
Throttle cable ––––– play, installation
Vacuum hoses of air intake system ––––– disconnection,
looseness, deterioration, bend
Connectors of electric wire harness ––––– disconnection, friction
Fuses ––––– burning
Parts ––––– installation, bolt ––––– looseness
Parts ––––– deformation
Other parts that can be checked visually
Also check following items at engine start, if possible
Malfunction indicator lamp
Charge warning lamp
Engine oil pressure warning lamp
Engine coolant temp. meter
Fuel level meter
Tachometer, if equipped
Abnormal air being inhaled from air intake system
Exhaust system ––––– leakage of exhaust gas, noise
Other parts that can be checked visuallySection 0B
Section 0B
Section 0B
Section 0B
Section 0B
Section 0B
Section 6E1
Section 8
Section 6
Section 6H
Section 8 (section 6 for pressure check)
Section 8
Section 8
Page 73 of 557
6-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
ENGINE DIAGNOSIS TABLE
Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality
has been found in visual inspection and engine basic inspection previously.
Condition
Possible CauseReferring Item
Hard Starting
(Engine cranks OK)Ignition system out of order
Faulty spark plug
Leaky high-tension cord
Loose connection or disconnection of high-
tension cords or lead wires
Faulty ignition coil
Fuel system out of order
Dirty or clogged fuel hose or pipe
Malfunctioning fuel pump
Air inhaling from intake manifold gasket or
throttle body gasket
Fuel injector resistor malfunction
Engine and emission control system out of
order
Faulty idle control system
Faulty ECT sensor or MAP sensor
Faulty ECM (PCM)
Low compression
Poor spark plug tightening or faulty gasket
Compression leak from valve seat
Sticky valve stem
Weak or damaged valve springs
Compression leak at cylinder head gasket
Sticking or damaged piston ring
Worn piston, ring or cylinder
Others
Malfunctioning PCV valve
Spark plugs in Section 6F
High-tension cords in Section 6F
High-tension cords in Section 6F
Ignition coil in Section 6F
Diagnostic Flow Table B-3
Diagnostic Flow Table B-3
Fuel injector resistor in Section 6E1
Diagnostic Flow Table P0505
ECT sensor or MAP sensor in
Section 6E1
Compression check in Section
6A
Spark plugs in Section 6F
Valves inspection in Section 6A
Valves inspection in Section 6A
Valve springs inspection in
Section 6A
Cylinder head inspection in
Section 6A
Cylinders, pistons and piston rings
inspection in Section 6A
Cylinders, pistons and piston rings
inspection in Section 6A
PCV system in Section 6E1
Page 74 of 557
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-23
ConditionPossible CauseReferring Item
Low oil pressureImproper oil viscosity
Malfunctioning oil pressure switch
Clogged oil strainer
Functional deterioration of oil pump
Worn oil pump relief valve
Excessive clearance in various sliding partsEngine oil and oil filter change in
Section 0B
Oil pressure switch inspection in
Section 8
Oil pan and oil pump strainer
cleaning in Section 6A
Oil pump in Section 6A
Oil pump in Section 6A
Engine noise
Note: Before
checking mechanical
noise, make sure
that:
Specified spark
plug in used.
Specified fuel is
used.Valve noise
Improper valve lash
Worn valve stem and guide
Weak or broken valve spring
Warped or bent valve
Piston, ring and cylinder noise
Worn piston, ring and cylinder bore
Connecting rod noise
Worn rod bearing
Worn crank pin
Loose connecting rod nuts
Low oil pressure
Crankshaft noise
Low oil pressure
Worn bearing
Worn crankshaft journal
Loose bearing cap bolts
Excessive crankshaft thrust play
Valve lash in Section 6A
Valves inspection in Section 6A
Valve springs inspection in
Section 6A
Valves inspection in Section 6A
Pistons and cylinders inspection
in Section 6A
Crank pin and connecting rod
bearing inspection in Section 6A
Crank pin and connecting rod
bearing inspection in Section 6A
Connecting rod installation in
Section 6A
Previously outlined
Previously outlined
Crankshaft and bearing
inspection in Section 6A
Crankshaft and bearing
inspection in Section 6A
Crankshaft inspection in
Section 6A
Crankshaft thrust play inspection
in Section 6A
Page 75 of 557
6-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
ConditionPossible CauseReferring Item
OverheatingInoperative thermostat
Poor water pump performance
Clogged or leaky radiator
Improper engine oil grade
Clogged oil filter or oil strainer
Poor oil pump performance
Faulty radiator fan control system
Dragging brakes
Slipping clutch
Blown cylinder head gasketThermostat in Section 6B
Water pump in Section 6B
Radiator in Section 6B
Engine oil and oil filter change in
Section 0B
Oil pressure check in Section 6A
Oil pressure check in Section 6A
Radiator fan control system in
Section 6E1
Trouble diagnosis in Section 5
Trouble diagnosis in Section 7C
Cylinder head in Section 6A
Poor gasoline
mileageIgnition system out of order
Leaks or loose connection of high-tension cord
Faulty spark plug (improper gap, heavy deposits
and burned electrodes, etc.)
Engine and emission control system out of
order
High idle speed
Poor performance of TP sensor, ECT sensor or
MAP sensor
Faulty fuel injector
Faulty fuel injector resistor
Faulty ECM (PCM)
Low compression
Others
Poor valve seating
Dragging brakes
Slipping clutch
Thermostat out of order
Improper tire pressure
High-tension cords in Section 6F
Spark plugs in Section 6F
Refer to item “Improper engine
idle speed” previously outlined
TP sensor, ECT sensor or MAP
sensor in Section 6E1
Diagnostic Flow Table B-1
Fuel injector resistor in Section 6E1
Previously outlined
Valves inspection in Section 6A
Trouble diagnosis in Section 5
Trouble diagnosis in Section 7C
Thermostat in Section 6B
Refer to Section 3F
Excessive engine
oil consumptionOil leakage
Blown cylinder head gasket
Leaky camshaft oil seals
Oil entering combustion chamber
Sticky piston ring
Worn piston and cylinder
Worn piston ring groove and ring
Improper location of piston ring gap
Worn or damaged valve stem seal
Worn valve stem
Cylinder head in Section 6A
Camshaft in Section 6A
Piston cleaning in Section 6A
Pistons and cylinders inspection
in Section 6A
Pistons inspection in Section 6A
Pistons assembly in Section 6A
Valves removal and installation in
Section 6A
Valves inspection in Section 6A
Page 77 of 557
6-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
ConditionPossible CauseReferring Item
Engine has no
powerIgnition system out of order
Faulty spark plug
Faulty ignition coil with ignitor
Leaks, loose connection or disconnection of
high-tension cord
Engine overheating
Fuel system out of order
Clogged fuel hose or pipe
Malfunctioning fuel pump
Air inhaling from intake manifold gasket or
throttle body gasket
Engine and emission control system out of
order
Maladjusted accelerator cable play
Poor performance of TP sensor, ECT sensor or
MAP sensor
Faulty fuel injector
Faulty ECM (PCM)
Low compression
Others
Dragging brakes
Slipping clutch
Spark plugs in Section 6F
Ignition coil in Section 6F
High-tension cords in Section 6F
Refer to “Overheating” section
Diagnostic Flow Table B-3 in
Section 6
Diagnostic Flow Table B-2
Accelerator cable play in Section
6E1
TP sensor, ECT sensor or MAP
sensor in Section 6E1
Diagnostic Flow Table B-1
Previously outlined
Trouble diagnosis in Section 5
Trouble diagnosis in Section 7C