2000 SUZUKI SWIFT cooling

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.

6A-24 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL
1) Relieve fuel pressure according to procedure described in
“FUEL PRESSURE RELIEF PROCEDURE” of Section 6.
2) Remove engine hood after disconnecting front window washer
hose.
3) Disconnect battery cables at battery and remove battery and
its tray.
4) Drain cooling system.
5) Remove air cleaner assembly.
6) Remove radiator with cooling fan. Refer to Section 6B for re-
moval.
7) Disconnect the following electric wire harness.

High-tension cord from ignition coil

Distributor

EGR valve

ECT sensor

ISC actuator

Ground wire harness from intake manifold

TP sensor

Fuel injector

Oil pressure gauge

A / C compressor pressure switch (if equipped)

Heated oxygen sensor

Generator

Starter

Back-up light switch (For M / T model)

Battery negative cable from transmission

Shift switch of A / T (For A / T model)

Direct clutch and 2nd brake solenoids of A / T (For A / T model)

Vehicle speed sensor on A / T (For A / T model)
And release above wire harness from clamps.
8) Disconnect the following vacuum hose.

Brake booster hose from intake manifold.

Canister purge hose from EVAP canister purge valve.

Pressure sensor hose from intake manifold.
9) Disconnect fuel return hose and fuel feed hose from fuel feed
and return pipes.
10) Disconnect heater inlet and outlet hoses.

1. Rear mounting
2. Rear mounting No.2
bracket
3. Rear mounting No.1
bracket
4. Rear mounting
bracket5. Left mounting
body bracket
6. Left mounting
7. Left mounting bracket
8. Right mounting bracket
9. Right mounting
For M / T model
For A / T model
1. Rear mounting
2. Rear mounting No.2
bracket
3. Rear mounting No.1
bracket
4. Left mounting No.1
bracket
5. Stopper6. Left mounting
7. Left mounting No.2
bracket
8. Right mounting bracket
9. Right mounting
10. Torque rod bracket
11. Stiffener
12. Torque rod
6A-26 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
1) Lift engine with transmission into engine compartment, but do
not remove lifting device.
2) Install right side engine mounting to its bracket.
3) Install left side engine mounting and its bracket.
4) Install rear mounting to body.
5) Tighten bolts and nuts of all parts installed in above steps 2),
3) and 4) to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
6) Remove lifting device.
7) Reverse removal procedures for installation of remainder.

Push in each drive shaft joint fully so that snap ring engages
with differential gear or center bearing support.
Use care not to damage oil seal lip when inserting.

Clamp electric wires securely.
8) Adjust clutch pedal free travel referring to Section 7C. (For M / T
model)
Adjust gear select cable and oil pressure control cable referring
to Section 7B. (For A / T model)
9) Adjust gear shift control lever referring to Section 7A. (For M / T
model)
10) Refill transmission with gear oil. (A / T fluid for A / T model) refer-
ring to Section 0B.
11) Refill engine with engine oil referring to Section 0B.
12) Refill cooling system referring to Section 6B.
13) Adjust A / C compressor drive belt referring to Section 0B. (if
equipped)
14) Upon completion of installation, verify that there is no fuel leak-
age, coolant leakage, transmission oil leakage or exhaust gas
leakage at each connection.
15) Adjust accelerator cable play referring to Section 6E.

1. Intake manifold
2. Throttle body
3. Gasket
4. EGR valve
5. Fuel delivery pipe
6. Fuel injector7. Fuel pressure regulator
8. EVAP canister purge valve
9. MAP sensor
10. O-ring
11. Gasket
12. Cushion : Tightening Torque
: Do not reuse
1
2
6A1-14 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
THROTTLE BODY AND INTAKE MANIFOLD
REMOVAL
1) Relieve fuel pressure according to procedure described in Sec-
tion 6.
2) Disconnect negative cable at battery.
3) Drain cooling system.
WARNING:
To help avoid danger of being burned, do not remove
drain plug (2) and radiator cap while engine and radiator
(1) are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
4) Disconnect IAT sensor at coupler.
5) Remove air cleaner outlet hose (2) with resonator.
6) Disconnect accelerator cable (1) from throttle body.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-15
7) Disconnect the following electric lead wires and release clamp:

Ground wires (5) from intake manifold

TP sensor (3)

IAC valve (4)

Fuel injectors

EVAP canister purge valve (2)

MAP sensor (6)

EGR valve (1)
8) Disconnect the following hoses:

Brake booster hose (1) from intake manifold

Canister purge hose (3) from EVAP canister purge valve

Engine cooling water (coolant) hose (2) from IAC valve

PCV hose (4)

Breather hose from cylinder head
9) Disconnect fuel feed hose (2) from pipe (1), and disconnect fuel
return hose (3) from fuel pressure regulator.

1. Long bolt
2. Short bolt
6A1-16 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
10) Remove intake manifold rear stiffener (1) and generator adjust
arm reinforcement (2) from intake manifold (3).
11) Remove intake manifold with throttle body from cylinder head,
and then its gasket.
INSTALLATION
Reverse removal procedure for installation noting the followings.

Use new intake manifold gasket.

When installing intake manifold, install clamps securely.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

Adjust accelerator cable play, referring to Section 6E.

Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.

Refill cooling system referring to Section 6B.

Upon completion of installation, turn ignition switch ON but en-
gine OFF and check for fuel leaks.

Finally, start engine and check for engine coolant leaks.

: Do not reuse
1. Valve cotters
2. Valve spring retainer
3. Valve spring:
be sure to position
spring in place with its
bottom end (small-pitch
end) facing the bottom
(valve spring seat side).
4. Valve stem seal
5. Valve spring seat
6. Exhaust valve
7. Intake valve
8. Cylinder head bolt
9. Camshaft housing bolt10. Camshaft housing:
Apply sealant to mating surface of
No.1 and No.6 housings.
11. Valve guide
12. Oil venturi plug
13. Cylinder head gasket:
“TOP” mark provided on gasket comes to
crankshaft pulley side, facing up
(toward cylinder head side).
14. Dowel pin
: Tightening Torque
: Apply engine oil to sliding
: surfaces of each part.
3.5 N.m (0.35 kg-m)
ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-41
VALVES AND CYLINDER HEAD
REMOVAL
1) Relieve fuel pressure according to procedure described in Sec-
tion 6.
2) Disconnect negative cable at battery.
3) Drain cooling system.
4) Remove air cleaner outlet hose as previously outlined.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-53
4) Reverse removal procedure for installation.
5) Adjust water pump drive belt tension by referring to “ENGINE
COOLING” section.
6) Adjust power steering pump belt tension or A / C compressor
belt tension, if equipped.
Refer to Section 0B.
7) Adjust intake and exhaust valve lashes as previously outlined.
8) Adjust accelerator cable play.
Refer to Section 6E.
9) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
10) Refill cooling system referring to Section 6B.
11) Connect negative cable at battery.
12) Confirm that ignition timing is within specification.
13) Verify that there is no fuel leakage, coolant leakage and ex-
haust gas leakage at each connection.