2000 SUZUKI SWIFT Position

“a”: 23 mm (0.91 in.)
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-57

Piston clearance:
Measure cylinder bore diameter and piston diameter to find their
difference which is piston clearance. Piston clearance should be
within specification as given below. If it is out of specification, re-
bore cylinder and use oversize piston.
Piston clearance: 0.02 – 0.04 mm (0.0008 – 0.0015 in.)
NOTE:
Cylinder bore diameters used here are measured in thrust
direction at two positions.

Ring groove clearance:
Before checking, piston grooves must be clean, dry and free of
carbon.
Fit new piston ring (1) into piston groove, and measure clearance
between ring and ring land by using thickness gauge (2).
If clearance is out of specification, replace piston.
Ring groove clearance:
Top: 0.03 – 0.07 mm (0.0012 – 0.0027 in.)
2nd: 0.02 – 0.06 mm (0.0008 – 0.0023 in.)
Piston Pin

Check piston pin, connecting rod small end bore and piston bore
for wear or damage, paying particular attention to condition of
small end bore bush. If pin, connecting rod small end bore or pis-
ton bore is badly worn or damaged, replace pin, connecting rod
or piston.

Piston pin clearance:
Check piston pin clearance in small end. Replace connecting rod
if its small end is badly worn or damaged or if measured clearance
exceeds limit.
Item
StandardLimit
Piston clearance in
small end0.003 – 0.016 mm
(0.0001 – 0.0006 in.)0.05 mm
(0.0020 in.)
Small-end bore:
19.003 – 19.011 mm (0.7482 – 0.7486 in.)
Piston pin dia.:
18.995 – 19.000 mm (0.7478 – 0.7480 in.)

1. Paint
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-73
2) Next, check bearing cap bore diameter without bearing. On mat-
ing surface of cylinder block, four alphabets are stamped as
shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) represent the follow-
ing cap bore diameters.
Alphabet stamped
Bearing cap bore diameter
(without bearing)
A49.000 – 49.006 mm
(1.9291 – 1.9294 in.)
B49.006 – 49.012 mm
(1.9294 – 1.9296 in.)
C49.012 – 49.018 mm
(1.9296 – 1.9298 in.)
The first, second, third, fourth and fifth (left to right) stamped al-
phabets reperesent cap bore diameters of bearing caps “1”, “2”,
“3”, “4” and “5”, respectively.
For example, in figure, the first (leftmost) alphabet “B” indicates
that cap bore dia. of bearing cap “1” is within 49.006 – 49.012
mm, and the fifth (rightmost) alphabet “A” indicates that cap bore
dia. of cap “5” is within 49.000 – 49.006 mm.
3) There are five kinds of standard bearings differing in thickness.
To distinguish them, they are painted in the following colors at
the position as indicated in figure.
Each color indicates the following thickness at the center of
bearing.
Color painted
Bearing thickness
Green1.996 – 2.000 mm
(0.0786 – 0.0787 in.)
Black1.999 – 2.003 mm
(0.0787 – 0.0788 in.)
Colorless
(no paint)2.002 – 2.006 mm
(0.0788 – 0.0789 in.)
Yellow2.005 – 2.009 mm
(0.0789 – 0.0790 in.)
Blue2.008 – 2.012 mm
(0.0790 – 0.0791 in.)

2. Scale
1. Paint
6A1-74 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
4) From numerals stamped on crank webs (1) of No.2 and No.3 cyl-
inders and the alphabets stamped on mating surface of cylinder
block, determine new standard bearing to be installed to journal,
by referring to table given below.
For example, if numeral stamped on crank web is “1” and alpha-
bet stamped on mating surface is “B”, install a new standard
bearing painted in “Black” to its journal.
Numeral stamped on crank web
(Journal diameter)
123
Alphabet stamped
ti f
AGreenBlackColorless
on mating surface
(Bearing capboreBBlackColorlessYellow(Bearing ca bore
dia.)CColorlessYellowBlue
New standard bearing to be installed.
5) Using gaging plastic (1), check bearing clearance with newly se-
lected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and
recheck clearance.
6) When replacing crankshaft or cylinder block due to any reason,
select new standard bearings to be installed by referring to nu-
merals stamped on new crankshaft or alphabets stamped on
mating surface of new cylinder block.
UNDERSIZE BEARING (0.25 mm):

0.25 mm undersize bearing is available, in five kinds varying in
thickness.
To distinguish them, each bearing is painted in the following col-
ors at such position as indicated in figure.
Each color represents the following thicknesses at the center of
bearing.
Color painted
Bearing thickness
Green & Red2.121 – 2.125 mm
(0.0835 – 0.0836 in.)
Black & Red2.124 – 2.128 mm
(0.0836 – 0.0837 in.)
Red only2.127 – 2.131 mm
(0.0837 – 0.0838 in.)
Yellow & Red2.130 – 2.134 mm
(0.0838 – 0.0839 in.)
Blue & Red2.133 – 2.137 mm
(0.0839 – 0.0840 in.)

1. Cooling fan motor
2. Radiator
ENGINE COOLING 6B-3
THERMOSTAT
A wax pellet type thermostat is used in the coolant outlet passage
to control the flow of engine coolant, to provide fast engine warm
up and to regulate coolant temperatures.
A wax pellet element is hermetically contained in a metal case, and
expands when heated and contracts when cooled.
When the pellet is heated and expands, the metal case pushes
down the valve to open it.
As the pellet is cooled, the contraction allows the spring to close the
valve.
Thus, the valve remains closed while the coolant is cold, preventing
circulation of coolant through the radiator.
At this point, coolant is allowed to circulate only throughout the en-
gine to warm it quickly and evenly.
As the engine warms, the pellet expands and the thermostat valve
opens, permitting coolant to flow through the radiator.
In the top portion of the thermostat, an air bleed valve (1) is pro-
vided; this valve is for venting out the gas or air, if any, that is accu-
mulated in the circuit.
Thermostat functional spec. ± 2.8
C (5.0
F)
Temp. at which valve
begins to open88
C (190
F)
Temp. at which valve
become fully open100
C (212
F)
COOLING FAN
The cooling fan is driven by electric motor, and the motor is acti-
vated by ECM / PCM (engine coolant temp.). For its details, refer to
Section 6E.
WARNING:
Keep hands, tools, and clothing away from engine cooling
fan to help prevent personal injury. This fan is electric and
can come on whether or not the engine is running. The fan
can start automatically in response to the ECM / PCM (en-
gine coolant temp.) with the ignition switch in the “ON”
position.

2. Thermostat case
2. Thermometer
3. Heater
Upside
6B-8 ENGINE COOLING
4) Remove thermostat (1).
INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clean.
Should this valve be clogged, engine would tend to overheat.
2) Check to make sure that valve seat is free from foreign matters
which would prevent valve from seating tight.
3) Check thermostatic movement of wax pellet as follows:
Immerse thermostat (1) in water, and heat water gradually.
Check that valve starts to open at specific temperature.
If valve starts to open at a temperature substantially below or
above specific temperature, thermostat unit should be re-
placed with a new one. Such a unit, if reused, will bring about
overcooling or overheating tendency.
INSTALLATION
1) When positioning thermostat on thermostat case, be sure to
position it so that air bleed valve comes uppermost and into the
recession of thermostat case.
2) Install thermostat cap to thermostat case. When installing cap,
align arrow marks on cap and case.
3) Fill cooling system.
4) Connect negative cable.
5) After installation, check each part for leakage.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-1
GENERAL DESCRIPTION6E1- 2 . . . . . . . . . . . . . .
AIR AND FUEL DELIVERY SYSTEM 6E1- 4. . . . .
ELECTRONIC CONTROL SYSTEM 6E1- 5. . . . . .
ON-VEHICLE SERVICE6E1- 8 . . . . . . . . . . . . . . . .
General 6E1- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator Cable Adjustment 6E1- 8. . . . . . . . . .
Idle Speed Inspection 6E1- 8. . . . . . . . . . . . . . . . .
AIR AND FUEL DELIVERY SYSTEM 6E1- 9. . . . .
Fuel Pressure 6E1- 9. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump 6E1-11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body 6E1-12. . . . . . . . . . . . . . . . . . . . . . . .
Fuel injector 6E1-15. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E1-17. . . . . .
ECM 6E1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAP Sensor 6E1-18. . . . . . . . . . . . . . . . . . . . . . . . .
TP Sensor 6E1-19. . . . . . . . . . . . . . . . . . . . . . . . . . .
IAT Sensor 6E1-20. . . . . . . . . . . . . . . . . . . . . . . . . .
ECT Sensor 6E1-21. . . . . . . . . . . . . . . . . . . . . . . . .
Heated Oxygen Sensor -1 and -2 6E1-23. . . . . . .
Vehicle Speed Sensor 6E1-24. . . . . . . . . . . . . . . . .
Fuel Level Sensor (Gauge) 6E1-24. . . . . . . . . . . . Crankshaft Position Sensor 6E1-25. . . . . . . . . . . .
Main Relay 6E1-25. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6E1-26. . . . . . . . . . . . . . . . . . . . .
Fuel Injector Resistor 6E1-26. . . . . . . . . . . . . . . . .
Fuel Cut Operation 6E1-26. . . . . . . . . . . . . . . . . . .
ISC System 6E1-26. . . . . . . . . . . . . . . . . . . . . . . . . .
ISC Actuator 6E1-27. . . . . . . . . . . . . . . . . . . . . . . . .
CTP Switch 6E1-28. . . . . . . . . . . . . . . . . . . . . . . . . .
ISC Actuator Relay 6E1-29. . . . . . . . . . . . . . . . . . .
EFE Heater Control System 6E1-29. . . . . . . . . . . .
EFE Heater 6E1-29. . . . . . . . . . . . . . . . . . . . . . . . . .
EFE Heater Relay 6E1-30. . . . . . . . . . . . . . . . . . . .
Radiator Fan Control System 6E1-30. . . . . . . . . .
Radiator Fan Control Relay 6E1-31. . . . . . . . . . . .
Radiator Fan 6E1-31. . . . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEM 6E1-32. . . . . . . . .
EVAP Control System 6E1-32. . . . . . . . . . . . . . . . .
PCV System 6E1-34. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6E1-36 . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS6E1-36 . . . . . . . . . . . . . . . . . . . .
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM
(TBI FOR G10)
WARNING:
For vehicles equipped with a Supplemental Inflatable Restraint Air Bag System:

Service on or around Air Bag System Components or Wiring must be performed only by an authorized
Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in Section 9J under “On-
Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before
performing service on or around Air Bag System Components or Wiring. Failure to follow WARNINGS
could result in unintended air bag deployment or could render the air bag inoperative. Either of these
two conditions may result in severe injury.

SDM can maintain sufficient voltage to cause a deployment of air bags for up to 15 seconds after igni-
tion switch is turned to “LOCK” position, battery is disconnected or fuse powering SDM is removed.
Work must be started after 15 seconds from the time.
NOTE:
For the descriptions for vehicle without warm up three way catalytic converter (WU TWC), refer to the same
section of the Service Manual mentioned in the FOREWORD of this manual.
CONTENTS

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-3
1. Tank pressure control valve
2. Fuel liquid separator
3. Fuel tank
4. Fuel pump
5. Fuel level sensor (gauge)
6. Fuel filter
7. Fuel pressure regulator
8. Throttle body
9. Fuel injector
10. MAP sensor
11. TP sensor
12. ISC actuator
(including CTP switch)
13. PCV valve
14. Exhaust manifold
15. Intake manifold
16. Heated oxygen sensor-117. Warm up three way catalytic
convertor (WU-TWC)
(if equipped)
18. Three way catalytic convertor
19. IAT sensor
20. ECT sensor
21. EFE heater
22. EVAP canister purge valve
23. EVAP canister
24. Heated oxygen sensor-2
25. Radiator fan motor
26. Ignition coil
27. Ignitor
28. Electric load
29. A / C amplifier (if equipped)
30. Camshaft position sensor
31. Crankshaft position sensor32. VSS (on A / T)
33. Transmission range sensor
(switch) (A / T)
34. Shift solenoid-A (A / T)
35. Shift solenoid-B (A / T)
36. Data link connector
37. VSS (in combination meter of
M / T vehicle)
38. PSP switch (if equipped)
39. Malfunction indicator lamp
40. Transmission range sensor
(switch) (A / T)
41. Main (Ignition) switch
42. Main fuse
43. Battery
44. Immobilizer indicator lamp

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-7
CON-
NECTOR
C02TERMI-
NAL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26ECM ground
Power source (from main relay)
Blank
Blank
Blank
Blank
EVAP canister purge valve
Shift solenoid-B (A / T)
Shift solenoid-A (A / T)
Igniter
Idle speed control actuator
Fuel injector
Injector ground
Power source (from battery)
Power source (from main relay)
Idle speed control actuator relay
Malfunction indicator lamp
Immobilizer indicator lamp
Heater of HO2S-2
Radiator fan relay
Fuel pump relay
Main relay
Blank
Idle speed control actuator
EFE heater relay
Injector groundC031
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22Data link connector
Vehicle speed sensor (+) (A / T)
Vehicle speed sensor (M / T)
Transmission range sensor (switch)“2”
Transmission range sensor (switch)“N”
Transmission range sensor (switch)“P”
Blank
Blank
Heated oxygen sensor-2
Blank
Fuel level sensor (gauge)
Blank
Data link connector
Vehicle speed sensor (–) (A / T)
Transmission range sensor (switch)“L”
Transmission range sensor (switch)“D”
Transmission range sensor (switch)“R”
A / C ON (output) signal for A / C control module
(if equipped)
Electric load signal
A / C (input) signal from A / C control module
(if equipped)
Ignition switch
Blank
Blank CIRCUITCON-
NECTORTERMI-
NALCIRCUIT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16Power source for sensors
Camshaft position sensor (+)
Crankshaft position sensor (+)
Closed throttle position switch
Manifold absolute pressure sensor
Throttle position sensor
Engine coolant temp. sensor
Heater of HO2S-1
Sensor ground
Camshaft position sensor (–)
Crankshaft position sensor (–)
EFE heater (monitor)
Heated oxygen sensor-1
Intake air temp sensor
Power steering pressure switch (if equipped)
Engine start signal circuit
C01
1. CMP sensor (in Distributor)
2. CKP sensor
3. TP sensor
4. MAP sensor
5. ECT sensor
6. IAT sensor
7. HO2S-1
8. HO2S-2
9. Transmission range switch (A / T)
10. VSS (A / T)
11. A / C control module (if equipped)
12. Heater blower switch
13. Fuel level sensor
14. Speedometer
15. P.SP switch
16. Rear defogger switch
17. Light switch
18. DLC
19. Fuel injector20. Injector resistor
21. Conister purge valve
22. Fuel pump relay
23. Rediator fan relay
24. EFE heater relay
25. ISC actuator relay
26. ISC actuator
27. Ignition coil
28. Igniter
29. Immobilizer indicator lamp
30. MIL
31. Main relay
32. Shift solenoid A (A / T)
33. Shift solenoid B (A / T)
34. Starter motor
35. Ignition switch