oil type SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

GENERAL INFORMATION 0A-7

When removing the battery, be sure to disconnect the nega-
tive cable first and then the positive cable. When reconnect-
ing the battery, connect the positive cable first and then the
negative cable, and replace the terminal cover.

When removing parts that are to be reused, be sure to keep
them arranged in an orderly manner so that they may be rein-
stalled in the proper order and position.

Whenever you use oil seals, gaskets, packing, O-rings, lock-
ing washers, split pins, self-locking nuts, and certain other
parts as specified, be sure to use new ones. Also, before
installing new gaskets, packing, etc., be sure to remove any
residual material from the mating surfaces.

Make sure that all parts used in reassembly are perfectly
clean.

When use of a certain type of lubricant, bond or sealant is
specified, be sure to use the specified type.
“A”: Sealant 99000-31150

Be sure to use special tools when instructed.
Special Tool
(A): 09917-98221
(B): 09916-58210

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
NORMAL CONDITION SCHEDULE
Interval:
This interval should be
judged by
This table includes services as scheduled up to 90,000 km (54,000 miles)
mileage. Beyond 90,000 km (54,000 miles), carry out the same services at
the same intervals respectively.
jg y
odometer reading or months,Km(
1,000)153045607590
whichever comes first.Miles(
1,000)91827364554
Months122436486072
1. ENGINE
1-1.Drive belt (tension,V-beltIRIRIR
damage)
V-rib belt (Flat type)––I––R
1-2.Camshaft timing beltReplace every 100,000 km (60,000 miles).
1-3.Valve lash (1.3 liter engine)–I–I–I
1-4.Engine oilVehicle with O2S (SG, SH, SJ)RRRRRR
and oil filter
Vehicle with O2S (SE, SF)
Vehicle without O2SReplace every 10,000 km (6,000 miles)
or 8 months
1-5.Engine coolant–R–R–R
1-6.Exhaust system (leakage, damage, tightness)–I–I–I
2. IGNITION SYSTEM
2-1.Spark plugsWhen unleaded
fuel is usedVehicle
without
O2S
–R–R–R
Vehicle
with O2S––R––R
When leaded fuel is usedRefer to “Severe Driving Condition” schedule.
2-2.Distributor cap and rotor (if equipped)––I––I
3. FUEL SYSTEM
3-1.Air cleaner filterPaved-roadIIRIIR
Dusty conditionRefer to “Severe Driving Condition” schedule.
3-2.Fuel lines (deterioration, leakage, damage)–I–I–I
3-3.Fuel tank––I––I
NOTES:

For Item 2-1 “spark plugs”, replace every 50,000 km if the local law requires.

For Sweden, Item 2-1, 4-1 and 4-2 should be performed by odometer reading only.

For Item 1-2 Camshaft timing belt: This belt may be replaced every 90,000 km (54,000 miles) according
to customer’s maintenance convenience.

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.

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
6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
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.

Below
specified value
6-1-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
1. CKP sensor signal
2. No.1 fuel injector signal
3. No.3 fuel injector signal
4. Fuel injection time
Display of fuel injection signal using oscilloscope
Waveforms at specified idle speed5ms/Div
DTC DETECTING CONDITIONPOSSIBLE CAUSE

Engine under other than high revolution condition

Not on rough road

Engine speed changing rate

Manifold absolute
pressure changing rate

Throttle opening changing rate

Misfire rate per 200 or 1000 engine revolutions (how
much and how often crankshaft revolution speed
changes) is higher than specified value
Engine overheating

Vacuum leaks (air inhaling) from air intake system

Ignition system malfunction (spark plug(s), high-
tension cord(s), ignition coil assembly)

Fuel pressure out of specification

Fuel injector malfunction (clogged or leakage)

Engine compression out of specification

Valve lash (clearance) out of specification

Manifold absolute pressure sensor malfunction

Engine coolant temp. sensor malfunction

PCV valve malfunction

EVAP control system malfunction

EGR system malfunction
DTC CONFIRMATION PROCEDURE
NOTE:
Among different types of random misfire, if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2 simulta-
neously, it may not possible to reconfirm DTC by using the following DTC confirmation procedure. When
diagnosing the trouble of DTC P0300 (Random misfire detected) of the engine which is apparently misfir-
ing, even if DTC P0300 cannot be reconfirmed by using the following DTC confirmation procedure, pro-
ceed to the following Diag. Flow Table.
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester.
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Check vehicle and environmental condition for:
–Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Intake air temp.: between –10C and 80C (14F and 176F)
–Engine coolant temp.: –10C, 14F or higher
4) Start engine and keep it at idle for 2 min. or more.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6) If DTC is not detected at idle, consult usual driving based on information obtained in “Customer complaint analy-
sis” and “Freeze frame data check”.
Reference

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-3
ENGINE LUBRICATION
The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side.
Oil is drawn up through oil pump strainer and passed through pump to oil filter.
The filtered oil flows into two paths in cylinder block. In one path, oil reaches crankshaft journal bearings.
Oil from crankshaft journal bearings is supplied to connecting rod bearings by means of intersecting passages
drilled in crankshaft, and then injected from a small hole provided on big end of connecting rod to lubricate piston,
rings, and cylinder wall.
In another path, oil goes up to cylinder head and lubricates camshaft journals, rocker arms, camshaft, etc., passing
through oil gallery in rocker arm shaft.
An oil relief valve is provided on oil pump. This valve starts relieving oil pressure when the pressure comes over
about 400 kPa (4.0 kg / cm
2, 56.9 psi). Relieved oil drains back to oil pan.

1. Rocker arm shaft
2. Rocker arm (EX)
3. Intake valve
4. Exhaust valve5. Rocker arm (IN)
6. Camshaft
7. Clip
8. PivotEx In
CYLINDER BLOCK
The cylinder block is made of cast aluminum alloy and
has 4 cylinders arranged “In-Line”. A cylindrical cast
iron sleeve is installed in each cylinder.
CRANKSHAFT AND MAIN
BEARINGS
A monoblock casting crankshaft is supported by
5 main bearings which are of precision insert type.
Four crank pins on the crankshaft are positioned 180
apart.
PISTONS, RINGS, PISTON PINS AND
CONNECTING RODS
The piston is cast aluminum alloy, and has two com-
pression rings and one oil ring.
Among two compression rings (top and 2nd rings),
the outer surface of the top ring is treated with hard
chromium for improvement in abrasion resistance.
The oil ring consists of two rails and one spacer. The
piston pin is offset 0.5 mm towards the major thrust
side.This allows a gradual change in thrust pressure
against the cylinder wall as the piston travels its path.
Pins, made of chromium steel, have a floating fit in the
pistons and in the connecting rods. The connecting
rods are made of forged steel, and the rod bearings
are of precision insert type.
CYLINDER HEAD AND VALVE TRAIN
The cylinder head is made of aluminum casting. The
supporting part of the camshaft is an independent cap
type. The combustion chamber has 4 valves and uses
the center plug type pent roof shape for higher intake
and exhaust efficiency.
As the intake side rocker arm is end pivot type, it
swings according to the camshaft movement to open
and close the intake valve.
On the other hand, the exhaust side rocker arm is see-
saw type. It swings with the rocker arm shaft as its
supporting point and according to the camshaft
movement to open and close the exhaust valve.
6A1-4 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)

(a)
1. Oil pump
1. No. 1 bolts (short)
2. No. 2 bolts (long)
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-31
4) Install rotor plate. Tighten 5 screw securely.
After installing plate, check to be sure that gears turn smoothly
by hand.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
5) Apply engine oil to guide seal (3) and install guide seal and guide
(2).
INSTALLATION
1) Install two oil pump pins and oil pump gasket to cylinder block.
Use a new gasket.
2) To prevent oil seal lip from being damaged or upturned when
installing oil pump to crankshaft, fit special tool (Oil seal guide)
to crankshaft, and apply engine oil to special tool.
Special Tool
(A): 09926-18210
3) Install oil pump to cylinder block.
As there are 2 types of oil pump bolts, refer to figure for their cor-
rect use and tighten them to specified torque.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
4) Install rubber seal between oil pump and water pump.

1. Short bolts
2. Long bolts
6A1-78 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
3) Install crankshaft to cylinder block.
4) Install bearing cap to cylinder block, making sure to point arrow
mark (on each cap) to crankshaft pulley side. Fit them sequen-
tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side.
After installing bearing cap stiffeners, tighten bearing cap bolts
in such order as shown in figure a little at a time and repeat it till
they are tightened to specified torque.
Tightening Torque
(a): 54 N
.m (5.4 kg-m, 39.0 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turning it by 8.0 N
.m (0.8 kg-m, 5.8
lb-ft) torque or below.
5) Install new gasket and oil seal housing.
Do not reuse gasket removed in disassembly. Apply engine oil
to oil seal lip before installation. Tighten housing bolts to specifi-
cation.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
NOTE:
As there are 2 types of housing bolts, refer to figure for their
correct use.
After installing oil seal housing, gasket edges might bulge out;
if so, cut them off to make them flush with cylinder block and oil
seal housing.
6) Install oil pump.
Refer to item “Oil pump” for installation of oil pump.
7) Install flywheel (M / T model) or drive plate (A / T model).
Using special tool, lock flywheel or drive plate, and torque its
bolts to specification.
Special Tool
(A): 09924-17810
Tightening Torque
(a): 78 N
.m (7.8 kg-m, 56.5 lb-ft) (Flywheel bolts)
(a): 95 N
.m (9.5 kg-m, 69.0 lb-ft) (Drive plate bolts)

6E1-16 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1. Injector
1
3
2
1. Injector cavity
2. Lower O-ring
3. Upper O-ring
1. Positive terminal
REMOVAL
NOTE:
Use care when handling fuel injector especially not to damage
filter and its needle.
Also, because injector is an electrical component, it should
not be immersed in any type of liquid solvent or cleaner, or it
may get damaged.
1) Relieve fuel pressure, referring to Section 6.
2) Disconnect battery negative cable at battery.
3) Remove air cleaner assembly referring to Section 6A.
4) Remove air cleaner mounting stay from throttle body.
5) Remove injector wire and then remove fuel injector from throttle
body.
INSPECTION
Check fuel injector filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel lines and fuel
tank.
INSTALLATION
1) Apply thin coat of spindle oil or gasoline to new upper and lower
O-rings, install lower O-ring and upper O-ring to injector.
2) Install injector by pushing it straight into fuel injector cavity.
Never turn injector while pushing it.