clock SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

1. Crank timing belt pulley bolt
Direction of crankshaft
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-13
3) Check that timing mark (3) on camshaft timing belt pulley (1) is
aligned with “V” mark (2) on cylinder head cover (4). If not, align
two marks by turning camshaft but be careful not to turn it more
than its allowable turning range which is described on previous
page.
4) Check that punch mark (2) on crank timing belt pulley (4) is
aligned with arrow mark (3) on oil pump case. If not, align two
marks by turning crankshaft but be careful not to turn it more
than its allowable turning range which is described on previous
page.
5) With two sets of marks aligned, install timing belt (1) on two pul-
leys in such a way that the drive side of belt is free of any slack,
and with tensioner plate pushed up by finger.
And then install tensioner spring and spring damper (2) as
shown in figure, and handtighten tensioner stud.
NOTE:

When installing timing belt, match arrow mark (
) on
timing belt with rotating direction of crankshaft.

In this state, No.1 piston is at top dead center of compres-
sion stroke.
6) To take up slack of timing belt, turn crankshaft two rotations
clockwise after installing it. After making sure that belt is free
from slack, tighten tensioner stud (1) first and then tensioner bolt
(2) to each specified torque.
Then confirm again that two sets of marks are aligned respec-
tively.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 27 N
.m (2.7 kg-m, 19.5 lb-ft)

2
IN
EX (A)
1
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-9
VALVE LASH (CLEARANCE)
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to item “Cylinder Head
cover”.
3) Remove engine under cover of right side from body.
4) Using special tool and wrench (1), turn crankshaft pulley clock-
wise until “V” mark (2) (in white paint) on pulley aligns with “0”
(zero) calibrated on timing belt cover.
Special Tool
(A): 09919-16020
5) See if the rocker arms of No.1 cylinder are off the respective cam
lobes (of camshaft); if so, valves (1), (2), (5) and (7) in figure are
ready for clearance checking and adjustment. Check valve
lashes at valves (1), (2), (5) and (7).
If the rocker arms of No.4 cylinder are off the respective cam
lobes, check valve lashes at valves (3), (4), (6) and (8).
NOTE:
When checking valve clearance, insert thickness gauge be-
tween camshaft and cam-riding face of rocker arm.

1. Clamp
1. Long bolt
2. Short bolt
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-23
6) To take up slack of timing belt, turn crankshaft two rotations
clockwise after installing it. After making sure that belt is free
from slack, tighten tensioner stud first and then tensioner bolt
to each specified torque.
Then confirm again that two sets of marks are aligned respec-
tively.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
7) Install timing belt outside cover.
Before installing, make sure that seal is between water pump
and oil pump case.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
8) With crankshaft locked, remove crankshaft timing belt pulley
bolt (4).
9) Install crankshaft pulley (2).
Fit hole of pulley to pin (1) on crankshaft timing belt pulley, and
tighten pulley bolts (3) to specified torque.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
10) With crankshaft locked using flat end rod or the like, tighten
crankshaft timing belt pulley bolt (4).
Tightening Torque
(b): 130 N
.m (13.0 kg-m, 94.0 lb-ft)
11) Clamp harness securely.

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.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-19
1. TP sensor
2. TP sensor
adjusting holes
3. TP sensor
screw holes4. Turn TP sensor after
fitting and align holes.
1. Throttle stop screw
2. Throttle lever
3. Thickness gauge
THROTTLE POSITION SENSOR (TP SENSOR)
INSPECTION
Check TP sensor referring to step 2 of DTC P0121 Flow Table. If
malfunction is found, replace.
REMOVAL
1) Disconnect battery negative cable at battery.
2) Remove air cleaner assembly referring to Section 6A.
3) Disconnect coupler from TP sensor.
4) Remove TP sensor from throttle body.
INSTALLATION
1) Install TP sensor to throttle body.
Fit TP sensor to throttle body in such way that its adjusting holes
are a little away from TP sensor screw holes as shown in left fig-
ure and turn TP sensor clockwise so that those holes align.
Then hand-tighten TP sensor screws.
2) Connect coupler to TP sensor securely.
3) Install air cleaner assembly referring to Section 6A.
4) Connect battery negative cable battery.
5) Adjust installation angle of TP sensor according to procedure
described in item “ADJUSTMENT”.
ADJUSTMENT
1) Insert 3.5 mm (0.14 in.) thickness gauge between throttle stop
screw and throttle lever.
CAUTION:
As throttle stop screw is factory adjusted precisely, don’t
remove or adjust it.

6E1-20 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1. Plunger
2. Throttle lever screw
2) Check to make sure that plunger of ISC actuator and throttle le-
ver screw are not in contact with each other. If they are, warm
up engine.
3) Loosen TP sensor screws.
a) Connect SUZUKI scan tool to DLC with ignition switch OFF.
b) Select “Data List” mode on SUZUKI scan tool.
c) Observe TP sensor voltage.
4) Turn TP sensor clockwise or counterclockwise and tighten TP
sensor screw at a position where voltage as specified below is
obtained.
TP sensor voltage when lever-to-stop
screw clearance is 3.5 mm (0.14 in.) : 0.98 – 1.02 V
Tightening Torque
(a): 2.0 N
.m (0.20 kg-m, 1.5 lb-ft)
5) Install ECM and connect couplers securely.
INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from IAT sensor.
3) Remove IAT sensor and gasket from air cleaner case.

1
2
3
1. Ground terminal
2. Reference voltage terminal
3. Output voltage terminal
(a)
1
23
4
6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
THROTTLE POSITION SENSOR (TP SENSOR)
Inspection
1) Disconnect negative cable at battery and coupler from TP sen-
sor.
2) Using ohmmeter, check resistance between terminals under
each condition given in table below.
TERMINALS
RESISTANCE
Between 1 and
2 terminals2.5 – 6.0 kΩ
Between 1 and
Throttle valve is
at idle position0.17 – 11.4 kΩ
3 terminalsThrottle valve is
fully opened1.72 – 15.50 kΩ
NOTE:
There should be more than 1.5 kΩ resistance difference
between when throttle valve is at idle position and when
it is fully open.
If check result is not satisfactory, replace TP sensor.
3) Connect TP sensor coupler securely.
4) Connect negative cable to battery.
Removal
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from TP sensor.
3) Remove TP sensor from throttle body.
Installation
1) Install TP sensor (1) to throttle body.
Fit TP sensor to throttle body in such way that its holes (3) are
a little away from TP sensor screw holes (2) as shown in left fig-
ure and turn TP sensor clockwise so that those holes align (4).
Tightening Torque
(a): 2.0 N
.m (0.20 kg-m, 1.5 lb-ft)
2) Connect coupler to TP sensor securely.
3) Connect battery negative cable to battery.