2000 SUZUKI SWIFT Fuel pump assembly

0A-8 GENERAL INFORMATION
 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
 When disconnecting vacuum hoses, attach a tag
describing the correct installation positions so that the
hoses can be reinstalled 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
disconnect 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
80°C (176°F) in the vicinity of the electrical parts, remove
the heat sensitive electrical part(s) beforehand.

MAINTENANCE AND LUBRICATION 0B-11
4) Install air cleaner filter fitting protrusion (1) of filter into
groove (2) of case and clamp upper case securely.
REPLACEMENT
Replace air cleaner filter with new one according to steps 1), 2)
and 4) of inspection procedure.
FUEL LINES AND CONNECTIONS
INSPECTION
Visually inspect fuel lines and connections for evidence of fuel
leakage, hose cracking and damage. Make sure all clamps are
secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.
FUEL FILTER
REPLACEMENT
Fuel filter (1) is installed in fuel pump assembly (2) in fuel tank.
Replace fuel filter with new one, referring to “FUEL PUMP
ASSEMBLY” in Section 6C for proper procedure.
WARNING:
This work must be performed in a well ventilated area
and away from any open flames (such as gas hot water
heaters).

6-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Poor gasoline mile-
age Leaks or loose connection of high-tension
cordHigh-tension cords in Section 6F1.
Faulty spark plug (improper gap, heavy
deposits and burned electrodes, etc.)Spark plugs in Section 6F1.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E1.
High idle speed Refer to item “Improper engine idle
speed” previously outlined.
Poor performance of TP sensor, ECT sensor
or MAP sensorTP sensor, ECT sensor or MAP sensor
in Section 6E1.
Faulty EGR valve (if equipped) EGR system in Section 6E1.
Faulty fuel injector(s) Diagnostic Flow Table B-1.
Faulty ECM
Poor valve seating Valves inspection in Section 6A1.
Dragging brakes Trouble diagnosis in Section 5.
Slipping clutch Trouble diagnosis in Section 7C.
Thermostat out of order Thermostat in Section 6B.
Improper tire pressure Refer to Section 3F.
Low Compression Previously outlined
Excessive engine
oil consumption Blown cylinder head gasket Cylinder head in Section 6A1.
Leaky camshaft oil seals Camshaft in Section 6A1.
Sticky piston ring Piston cleaning in Section 6A1.
Worn piston and cylinder Pistons and cylinders inspection in Sec-
tion 6A1.
Worn piston ring groove and ring Pistons inspection in Section 6A1.
Improper location of piston ring gap Pistons assembly in Section 6A1.
Worn or damaged valve stem seal Valves removal and installation in Sec-
tion 6A1.
Worn valve stem Valves inspection in Section 6A1.
Engine hesitates
(Momentary lack of
response as accel-
erator is depressed.
Can occur at all
vehicle speeds.
Usually most severe
when first trying to
make vehicle move,
as from a stop sign.)Spark plug faulty or plug gap out of adjust-
mentSpark plugs in Section 6F1.
Leaky high-tension cord High-tension cords in Section 6F1.
Fuel pressure out of specification Diagnostic Flow Table B-3.
Malfunctioning EGR valve (if equipped) EGR system in section 6E1.
Poor performance of TP sensor, ECT sensor
or MAP sensorTP sensor, ECT sensor or MAP sensor
in Section 6E1.
Faulty fuel injector Diagnostic Flow Table B-1.
Faulty ECM
Engine overheating Refer to “Overheating” section.
Low compression Previously outlined.
Surge
(Engine power vari-
ation under steady
throttle or cruise.
Feels like vehicle
speeds up and
down with no
change in accelera-
tor pedal.)Leaky or loosely connected high-tension cord High-tension cords in Section 6F1.
Faulty spark plug (excess carbon deposits,
improper gap, and burned electrodes, etc.)Spark plugs in Section 6F1.
Variable fuel pressure Diagnostic Flow Table B-3.
Kinky or damaged fuel hose and lines
Faulty fuel pump (clogged fuel filter)
Malfunctioning EGR valve EGR system in Section 6E1.
Poor performance of MAP sensor MAP sensor in Section 6E1.
Faulty fuel injector Diagnostic Flow Table B-1.
Faulty ECM Condition Possible Cause Correction

6A1-56 ENGINE MECHANICAL (M13 ENGINE)
5) Install cylinder head to cylinder block.
Apply engine oil to new cylinder head bolts and tighten them
gradually as follows.
a) Tighten cylinder head bolts (“1” – “10”) to 20 N·m (2.0 kg-m,
14.5 lb-ft) according to numerical order as shown by using
a 12 corner socket wrenches.
b) In the same manner as in Step a), tighten them to 40 N·m
(4.0 kg-m, 29.0 lb-ft).
c) Turn all bolts 60° according to numerical order in figure.
d) Repeat Step c).
e) Tighten bolt “A” to specified torque.
Tightening torque
Cylinder head bolt for M8 (a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
Cylinder head bolts for M10
(b) : 40 N·m (4.0 kg-m, 29.0 lb-ft) and then turn to 60° twice
6) Install exhaust manifold stiffener and exhaust No.1 pipe
referring to “EXHAUST MANIFOLD”.
7) Install camshafts, timing chain and chain cover as previously
outlined.
8) Install cylinder head cover and oil pan as previously outlined.
9) Install intake manifold stiffener and connect each hoses and
electric lead wires securely.
10) Install air cleaner assembly, resonator and hoses referring to
“AIR CLEANER ASSEMBLY AND RESONATOR”.
11) Adjust water pump belt tension referring to Section 6B.
12) Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
13) Adjust accelerator cable play referring to Section 6E1.
14) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
15) Refill cooling system with coolant, engine with engine oil.
16) Connect negative cable at battery.
17) Verify that there is no fuel leakage, coolant leakage, oil leak-
age and exhaust gas leakage at each connection. NOTE:
Never reuse cylinder head bolts (“1” – “10”) once dis-
assembled it due to plastic deformation tightening.
Be sure to use new cylinder head bolts.
Be sure to tighten M8 bolt (“A”) after securing the
other bolt.

6A1-68 ENGINE MECHANICAL (M13 ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL
1) Relieve fuel pressure according to procedure described in
Section 6.
2) Disconnect negative and positive cables at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove right and left side engine under covers.
5) Remove A/C compressor belt (if equipped).
6) Remove water pump belt.
7) Drain engine oil, transmission oil or A/T fluid (for A/T vehicle)
and transfer oil (for 4WD vehicle).
8) Drain coolant.
9) Remove air cleaner assembly, resonator and hoses referring
to “AIR CLEANER ASSEMBLY AND RESONATOR”.
10) With hose connected, detach A/C compressor from its
bracket (if equipped). WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed A/C compressor at a place where no
damage will be caused during removal and installation of
engine assembly.

6A1-72 ENGINE MECHANICAL (M13 ENGINE)
6) Install generator referring to Section 6H.
7) For 4WD vehicle, install propeller shaft referring to Section
4B.
8) Connect drive shaft joints referring to Section 4.
9) Install exhaust No.1 pipe and tighten pipe fasteners to speci-
fied torque.
Tightening torque
Exhaust No.1 pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
10) Reverse disconnected hoses, cables and electric wires for
connection.
11) Install air cleaner assembly, resonator and hoses referring to
“AIR CLEANER ASSEMBLY AND RESONATOR”
12) Install A/C compressor to bracket (if equipped).
13) Adjust water pump belt tension referring to Section 6B.
14) Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
15) Adjust accelerator cable play referring to Section 6E1.
16) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
17) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
18) Connect negative cable at battery.
19) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.

ENGINE FUEL 6C-1
6F1
6F2
6G
6C
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6C
ENGINE FUEL
CONTENTS
GENERAL DESCRIPTION .............................. 6C-1
ON-VEHICLE SERVICE .................................. 6C-2
COMPONENTS ........................................... 6C-2
PRECAUTIONS ........................................... 6C-3
FUEL LINES ................................................. 6C-4
FUEL PIPE ................................................... 6C-4
FUEL FILLER CAP ...................................... 6C-5FUEL TANK INLET VALVE ......................... 6C-6
FUEL TANK ................................................. 6C-7
FUEL PUMP ASSEMBLY .......................... 6C-10
DISASSEMBLY AND REASSEMBLY .... 6C-12
SPECIAL TOOL ............................................ 6C-14
TIGHTENING TORQUE SPECIFICATION.... 6C-14

GENERAL DESCRIPTION
The main components of the fuel system are fuel tank, fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator and tank pressure control valve), fuel/vapor separator fuel feed line and fuel vapor line.
For the details of fuel flow and fuel vapor flow, refer to “GENERAL DESCRIPTION” in Section 6E. 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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” 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).
CAUTION:
The engine of this vehicle requires the use of unleaded fuel only. Use of leaded and/or low lead fuel
can result in engine damage and reduce the effectiveness of the emission control system.

6C-2 ENGINE FUEL
ON-VEHICLE SERVICE
COMPONENTS
1. Fuel tank 7. Fuel vapor line 13. Fuel filler hose clamp screw 19. Fuel pressure regulator
2. Fuel pump assembly 8. EVAP canister 14. Tank cover 20. Fuel pump
3. Breather hose 9. Delivery pipe 15. Fuel filler bracket screw 21. Fuel filter assembly
4. Fuel filler cap 10. Fuel/vapor separator 16. Fuel filler bracket nut 22. Fuel level gauge (Fuel sender gauge)
5. Fuel feed line 11. Fuel pump bolt (6 pcs.) 17. Gasket Do not reuse.
6. Wire harness for fuel pump 12. Fuel tank bolt (4 pcs.) 18. O-ring Tightening torque