2000 SUZUKI SWIFT Adjust

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-25
ConditionPossible CauseReferring Item
Engine hesitates
(Momentary lack of
response as
accelerator is
depressed.
Can occur at all
vehicle speeds.
Usually most severe
when first trying to
make vehicle move,
as from a stop sign.)Ignition system out of order

Spark plug faulty or plug gap out of adjustment

Leaky high-tension cord
Fuel system out of order

Fuel pressure out of specification
Engine and emission control system out of
order

Malfunctioning EGR valve

Poor performance of TP sensor, ECT sensor or
MAP sensor

Faulty fuel injector

Faulty ECM (PCM)
Engine overheating
Low compression
Spark plugs in Section 6F1
High-tension cords in Section 6F1
Diagnostic Flow Table B-3
EGR system in section 6E2
TP sensor, ECT sensor or MAP
sensor in Section 6E2
Diagnostic Flow Table B-1
Refer to “Overheating” section
Previously outlined
Surge
(Engine power
variation under
steady throttle or
cruise.
Feels like vehicle
speeds up and down
with no change in
accelerator pedal.)Ignition system out of order

Leaky or loosely connected high-tension cord

Faulty spark plug (excess carbon deposits,
improper gap, and burned electrodes, etc.)
Fuel system out of order

Variable fuel pressure
–Kinky or damaged fuel hose and lines
–Faulty fuel pump (clogged fuel filter)
Engine and emission control system out of
order

Malfunctioning EGR valve

Poor performance of MAP sensor

Faulty fuel injector

Faulty ECM (PCM)
High-tension cords in Section 6F1
Spark plugs in Section 6F1
Diagnostic Flow Table B-3
EGR system in Section 6E2
MAP sensor in Section 6E2
Diagnostic Flow Table B-1
Excessive
detonation
(Engine makes
continuously
sharp metallic
knocks that change
with throttle opening.
Sounds like pop corn
popping.)Engine overheating
Ignition system out of order

Faulty spark plug

Loose connection of high-tension cord
Fuel system out of order

Clogged fuel filter (faulty fuel pump) or fuel lines

Air inhaling from intake manifold or throttle body
gasket
Engine and emission control system out of
order

Malfunctioning EGR valve

Poor performance of ECT sensor or MAP sensor

Faulty fuel injector(s).

Faulty ECM (PCM)

Excessive combustion chamber depositsRefer to “Overheating” section
Spark plugs in Section 6F1
High-tension cords in Section 6F1
Diagnostic Flow Table B-1 or B-2
EGR system in Section 6E2
ECT sensor or MAP sensor in
Section 6E2
Diagnostic Flow Table B-1
Piston and cylinder head cleaning
in Section 6A1

6-1-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
ConditionPossible CauseReferring Item
Engine has no
powerIgnition system out of order

Faulty spark plug

Faulty ignition coil with ignitor

Leaks, loose connection or disconnection of
high-tension cord
Engine overheating
Fuel system out of order

Clogged fuel hose or pipe

Malfunctioning fuel pump

Air inhaling from intake manifold gasket or
throttle body gasket
Engine and emission control system out of
order

Malfunctioning EGR valve

Maladjusted accelerator cable play

Poor performance of TP sensor, ECT sensor or
MAP sensor

Faulty fuel injector(s)

Faulty ECM (PCM)
Low compression
Others

Dragging brakes

Slipping clutch
Spark plugs in Section 6F1
Ignition coil in Section 6F1
High-tension cords in Section 6F1
Refer to “Overheating” section
Diagnostic Flow Table B-3
Diagnostic Flow Table B-2
EGR system inspection in Section
6E2
Accelerator cable play in Section
6E2
TP sensor, ECT sensor or MAP
sensor in Section 6E2
Diagnostic Flow Table B-1
Previously outlined
Trouble diagnosis in Section 5
Trouble diagnosis in Section 7C

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-71
INSPECTION
STEPACTIONYESNO
1Was “ENGINE DIAG. FLOW TABLE” performed?Go to Step 2.Go to “ENGINE
DIAG. FLOW
TABLE“.
2Is there DTC other than Fuel system (DTC P0171 / P0172)
and misfire (DTC P0300-P0304)?Go to applicable
DTC Diag.
Flow Table.Go to Step 3.
3Check Ignition System.
1) Remove spark plugs and check them for;

Air gap: 1.0 – 1.1 mm (0.040 – 0.043 in.) See Fig. 1.

Carbon deposits

Insulator damage

Plug type
If abnormality is found, adjust, clean or replace.
2) Disconnect all injector connectors. See Fig. 2.
3) Connect spark plugs to high tension cords and then ground
spark plugs.
4) Crank engine and check that each spark plug sparks.
Are above check results satisfactory?Go to Step 4.Check ignition
system parts
(Refer to Section
6F1).
4Check Fuel Pressure (Refer to Section 6E2 for details).
1) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge. See Fig. 3.
3) Check fuel pressure.
With fuel pump operating
and engine at stop : 270 – 310 kPa, 2.7 – 3.1 kg / cm
2,
38.4 – 44.0 psi.
At specified idle speed : 200 – 240 kPa, 2.0 – 2.4 kg / cm
2,
28.4 – 34.1 psi.
Is measured value as specified?
Go to Step 5.Go to Diag. Flow
Table B-3 fuel
pressure check.
5Check Fuel Injectors and Circuit.
1) Using sound scope (1) or such, check operating sound of
each injector (2) when engine is running. Cycle of
operating sound should very according to engine speed.
See Fig 4.
If no sound or an unusual sound is heard, check injector
circuit (wire or coupler) or injector.
2) Turn ignition switch OFF and disconnect a fuel injector
connector.
3) Check for proper connection to fuel injector at each
terminal. See Fig. 5.
4) If OK, then check injector resistance.
Injector Resistance: 12 – 13 ohm at 20C (68F)
5) Carry out steps 1) and 3) on each injector.
6) Check each injector for injected fuel volume referring to
Section 6E2. See Fig. 6.
Injected Fuel Volume: 38 – 48 cc / 15 sec (1.28 / 1.34 –
1.62 / 1.69 US / Imp. oz / 15 sec)
7) Check each injector for fuel leakage after injector closed.
Fuel Leakage: Less than 1 drop / min.
Is check result in step 1) and 3) to 7) satisfactory?Go to Step 6.Check injector
circuit or replace
fuel injector(s).

6A
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-1
SECTION 6A
ENGINE MECHANICAL
(G10, 1-CAM 6-VALVES ENGINE)
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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
ON-VEHICLE SERVICE6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Hydraulic Valve Lash Adjuster 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash Adjuster Noise Diagnosis 6A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Piston Rings, Connecting Rods and Cylinders 6A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Ground
1. Throttle body
2. ISC actuator
coupler
3. TP sensor
coupler
4. Fuel injector
coupler
5. EFE heater
coupler
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-7
INSTALLATION
1) Install throttle body to intake manifold. (Refer to Section 6E.)
2) Install intake manifold gasket to cylinder head. Use a new gas-
ket.
3) Install intake manifold (1) with throttle body to cylinder head.

Install clamps (3) as shown in figure, and tighten bolts and
nuts to specification.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Connect breather hose to PCV valve.
5) Connect vacuum hoses.
6) Connect coolant hoses.
7) Connect fuel return and feed hoses to throttle body.
8) Connect electric lead wire.
9) Connect accelerator cable to throttle body.
10) Install air cleaner assembly to throttle body.
11) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
12) Refill cooling system.
13) Connect negative cable at battery.
14) Upon completion of installation, start engine and check for fuel
leaks and engine coolant leaks.
After warming up engine, adjust accelerator cable play to spec-
ification according to description in Section 6E.

1. Timing belt
2. Tensioner
3. Tensioner plate
4. Tensioner spring
5. Spring damper
6. Camshaft timing pulley
7. Pin
8. Pulley bolt
9. Seal
10. Inside cover seal
11. Inside cover
12. Outside cover seal
13. Outside cover
14. Tensioner stud
15. Tensioner bolt
16. Tensioner spring screw
: Tightening Torque
6A-10 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
TIMING BELT AND BELT TENSIONER
REMOVAL
1) Disconnect negative cable at battery.
2) Hoist vehicle.
3) Remove clip (2) after pushing center pin, and then remove fend-
er apron extension (1) on right side.
NOTE:
Do not push center pin (3) too far in, or it will fall off into
fender.
4) Remove air cleaner assembly as previously outlined.
5) Remove A / C compressor drive belt, if equipped.
6) Loosen water pump pulley bolts (1).
7) Loosen generator pivot bolts (3) and its adjusting bolt (2) and re-
move water pump belt (4) and its pulley (5).

6A-14 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
7) Install timing belt outside cover.
Before installing, make sure that rubber seal (1) is between wa-
ter pump and oil pump case and another between water pump
and cylinder head.
Tightening Torque
(c): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
8) Install crankshaft pulley (2).
Tighten crankshaft pulley bolts (1).
Tightening Torque
(d): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
9) Install water pump pulley and water pump belt.
Adjust the belt tension to the specification.
Refer to Section 6B for procedure to adjust the belt tension.
10) Install air cleaner assembly.
11) Install fender apron extension of right side.
12) Connect negative cable at battery.

1. Cylinder head cover
2. Gasket
3. Cylinder head
4. Camshaft housing No.1:
Apply sealant 99000-31110 to mating surface.
5. Camshaft housing No.2
6. Camshaft housing No.3:
Apply sealant 99000-31110 to mating surface.
7. Camshaft
8. Oil seal
9. Valve lash adjuster
10. Camshaft housing bolt
1. Crankshaft timing belt pulley: Tightening Torque
: Apply engine oil to sliding
: surfaces of each part.
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-15
CAMSHAFT AND HYDRAULIC VALVE LASH ADJUSTER
REMOVAL
1) Disconnect negative cable at battery.
2) Remove cylinder head cover as previously outlined.
3) Remove distributor and then its case from cylinder head.
4) Remove crankshaft pulley, timing belt outside cover and timing
belt as previously outlined.
After removing timing belt, set key (2) on crankshaft in position
as shown in figure by turning crankshaft. This is to prevent inter-
ference between valves and piston when reinstalling camshaft.
5) Remove camshaft timing belt pulley (1).
Lock camshaft (2) with a proper size rod (3) inserted into hole (10
mm, 0.39 in.) in it as shown and then loosen camshaft timing belt
pulley bolt.
NOTE:
Mating surfaces of cylinder head and cover must not be
damaged in this work. So, put clean shop cloth (4) between
rod and mating surfaces, and use care not to bump rod
against mating surfaces hard when loosening bolt.