2000 SUZUKI SWIFT fuel cap

6-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS
FUEL PRESSURE RELIEF PROCEDURE
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector
lever to “P” range for A/T model), set parking brake, and
block drive wheels.
2) Remove relay box cover.
3) Disconnect fuel pump relay (1) from relay box.
4) Remove fuel filler cap to release fuel vapor pressure in fuel
tank and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat
cranking engine 2-3 times for about 3 seconds each time to
dissipate fuel pressure in lines. Fuel connections are now
safe for servicing.
6) Upon completion of servicing, connect fuel pump relay (1) to
relay box and install relay box cover.
FUEL LEAKAGE CHECK PROCEDURE
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump)
and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pres-
sure to fuel line. (till fuel pressure is felt by hand placed on
fuel feed hose.)
2) In this state, check to see that there are no fuel leakages
from any part of fuel system.
ENGINE DIAGNOSIS
GENERAL DESCRIPTION
This vehicle is equipped with an engine and emission control system which are under control of ECM.
The engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnos-
tic system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of “On-
Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis accord-
ing to “ENGINE DIAGNOSTIC FLOW TABLE”.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust
system, etc. and the engine and emission control system in their structure and operation. In case of an engine
trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to
this flow table.CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
1

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-27
Engine noise
Note : Before
checking mechani-
cal noise, make sure
that :
Specified spark
plug is used.
Specified fuel is
used.Improper valve lash Valve lash in Section 6A1.
Worn valve stem and guide Valves inspection in Section 6A1.
Weak or broken valve spring Valve springs inspection in Section
6A1.
Warped or bent valve Valves inspection in Section 6A1.
Worn piston, ring and cylinder bore Pistons and cylinders inspection in Sec-
tion 6A1.
Worn rod bearing Crank pin and connecting rod bearing
inspection in Section 6A1.
Worn crank pin Crank pin and connecting rod bearing
inspection in Section 6A1.
Loose connecting rod nuts Connecting rod installation in Section
6A1.
Low oil pressure Previously outlined.
Low oil pressure Previously outlined.
Worn bearing Crankshaft and bearing inspection in
Section 6A1.
Worn crankshaft journal Crankshaft and bearing inspection in
Section 6A1.
Loose bearing cap bolts Crankshaft inspection in Section 6A1.
Excessive crankshaft thrust play Crankshaft thrust play inspection in
Section 6A1.
Overheating
Inoperative thermostat Thermostat in Section 6B.
Poor water pump performance Water pump in Section 6B.
Clogged or leaky radiator Radiator in Section 6B.
Improper engine oil grade Engine oil and oil filter change in Sec-
tion 0B.
Clogged oil filter or oil strainer Oil pressure check in Section 6A1.
Poor oil pump performance Oil pressure check in Section 6A1.
Faulty radiator fan control system Radiator fan control system in Section
6E1.
Dragging brakes Trouble diagnosis in Section 5.
Slipping clutch Trouble diagnosis in Section 7C.
Blown cylinder head gasket Cylinder head in Section 6A1. Condition Possible Cause Correction

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-35
RADIATOR FAN (RADIATOR FAN CONTROL RELAY, ON/OFF)
ON : Command for radiator fan control relay operation being output.
OFF : Command for relay operation not being output.
ELECTRIC LOAD (ON/OFF)
ON : Headlight, small light or rear window defogger ON signal inputted.
OFF : Above electric loads all turned OFF.
A/C SWITCH (ON/OFF)
ON : Command for A/C operation being output from ECM to A/C compressor magnet clutch.
OFF : Command for A/C operation not being output.
FUEL TANK LEVEL (%)
This parameter indicates approximate fuel level in the fuel tank. As the detectable range of the fuel level sensor
is set as 0 to 100%, however, with some models whose fuel tank capacity is smaller, the indicated fuel level may
be only 70% even when the fuel tank is full.
PNP SIGNAL (PARK/NEUTRAL POSITION SIGNAL, P/N RANGE or D RANGE)
It is detected by signal from TCM.
D range : A/T is in “R”, “D”, “2” or “L” range.
P/N range : A/T is in “P” or “N” range or the above signal is not inputted from TCM.
EGR VALVE (%)
This parameter indicates opening rate of EGR valve which controls the amount of EGR flow.

6A1-6 ENGINE MECHANICAL (M13 ENGINE)
13) After checking, install spark plugs and ignition coil assem-
blies (1) with high-tension cord (2).
14) Connect ignition coil couplers (3).
15) Connect fuel injector wires(4) at the coupler.
16) Check cylinder head upper cover gasket for deterioration
and then install it into groove of cylinder head upper cover
(1) securely.
17) Install cylinder head upper cover with gasket on to cylinder
head cover.
18) Install air cleaner assembly, resonator and hoses referring to
“AIR CLEANER ASSEMBLY AND RESONATOR”.
ENGINE VACUUM CHECK
The engine vacuum that develops in the intake line is a good indi-
cator of the condition of the engine. The vacuum checking proce-
dure is as follows :
1) Warm up engine to normal operating temperature.
2) Stop engine and turn off the all electric switches.
3) Remove cap (1) from intake manifold.
NOTE:
After warming up engine, be sure to place transmission
gear shift lever in “Neutral” (shift selector lever to “P”
range for A/T model), and set parking brake and block
drive wheels.

6A1-16 ENGINE MECHANICAL (M13 ENGINE)
THROTTLE BODY AND INTAKE MANIFOLD
REMOVAL
1) Relieve fuel pressure according to fuel pressure relief proce-
dure described in Section 6.
2) Disconnect negative cable at battery.
3) Drain coolant by loosening drain plug (1).
1. Intake manifold 7. EVAP canister purge valve 13. Intake manifold mounting bolt (short) 19. Cushion
2. Intake manifold gasket 8. TP sensor 14. Intake manifold mounting bolt (long) 20. Fuel delivery pipe mounting bolt
3. Throttle body 9. IAC valve 15. EGR pipe gasket Tightening torque
4. Gasket 10. Fuel delivery pipe 16. O-Ring Do not reuse.
5. EGR pipe 11. Intake manifold stiffener 17. Grommet
6. MAP sensor 12. Intake manifold mounting nut 18. Injector assembly
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.

ENGINE MECHANICAL (M13 ENGINE) 6A1-45
4) Drain coolant by loosening drain plug (1).
5) Remove air cleaner assembly (1), resonator and hoses (2)
referring to “AIR CLEANER ASSEMBLY AND RESONA-
TOR”.
6) Disconnect the following electric lead wires :
EGR valve (if equipped)
IAC valve (1)
TP sensor (2)
MAP sensor (3)
CMP sensor
ECT sensor
EVAP canister purge valve (4)
Injectors (5)
Ignition coils
Heated oxygen sensors
Ground terminal from exhaust manifold
Each wire harness clamps
7) Remove heated oxygen sensor bracket from timing chain
cover and detach heated oxygen sensor couplers from its
bracket.
8) Disconnect accelerator cable from throttle body.
9) Disconnect the following hoses :
Brake booster hose (1) from intake manifold
Canister purge hose (2) from EVAP canister purge valve
Fuel feed and return hose (3) from each pipe
Water hose (4) from thermostat case
Heater inlet hose (5) from its pipe 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.

ENGINE MECHANICAL (M13 ENGINE) 6A1-57
PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS
REMOVAL
1) Relieve fuel pressure according to procedure described in
Section 6.
2) Disconnect negative cable at battery.
3) Drain engine oil.
4) Drain coolant.
5) Remove cylinder head referring to “VALVES AND CYLIN-
DER HEAD”.
6) Mark cylinder number on all pistons, connecting rods and
connecting rod caps using silver pencil or quick drying paint.
7) Remove rod bearing caps.
[A] : 1) Tighten all nuts to 15 N·m (1.5 kg-m)
2) Turn all nuts to 45°
3) Then, Turn all nuts to 45° one again7. Connecting rod bearing
1. Top ring8. Piston pin
2. 2nd ring9. Piston pin circlip
3. Oil ring10. Bearing cap nut
4. PistonTightening torque
5. Connecting rod
: Apply engine oil to sliding surface except inner surface of big end, and rod bolts.
Make sure rod bolt diameter when reuse it due to plastic deformation tightening.
Refer to “INSPECTION” of “CONNECTING ROD”.Apply engine oil to sliding surface of each parts.
6. Connecting rod bearing cap
: Point arrow mark on cap to crankshaft pulley side.Do not reuse.

6A1-66 ENGINE MECHANICAL (M13 ENGINE)
6) Reverse removal procedure for installation as previously out-
lined.
7) Adjust water pump belt tension referring to Section 6B.
8) Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
9) Adjust accelerator cable play referring to Section 6E1.
10) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
11) Refill cooling system with coolant engine with engine oil.
12) Connect negative cable at battery.
13) Verify that there is no fuel leakage, coolant leakage, oil leak-
age and exhaust gas leakage at each connection. NOTE:
Before installing bearing cap, make sure that checking
for connecting rod bolt deformation.
Refer to “INSPECTION” of “CONNECTING ROD”.