app SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1D-67 Engine Mechanical:
09916–3455009916–37320
Reamer handle Valve guide outer reamer
(10.5 mm)
))
09916–44910 09916–56011
Valve guide installer &
remover Valve guide installer
attachment (protrusion: 11.5
mm)
))
09916–58210 09916–67020
Valve guide installer handle Tappet holder (Overseas)
) / )) / )
09916–67021 09916–77310
Tappet holder Piston ring compressor (50-
125 mm)
) / ))
09916–84511 09917–68221
Forceps Camshaft pulley holder
) / )) / )
09917–98221 09924–17811
Valve guide stem
attachment Flywheel holder
)) / )
09926–58010 09944–36011
Bearing remover attachment Steering wheel remover
))

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-3
6) Start engine and warm engine up to normal operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral” (shift select lever in “P” range for
A/T vehicle), set parking brake and block
drive wheels.

7) After warming up, raise engine speed to 4,000 r/min. and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kg/cm2, 39.8 psi) at 4,000
r/min. (rpm)
8) After checking oil pressure, stop engine and remove oil pressure gauge and attachment.
9) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft) 10) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, repair it.
11) Connect oil pressure switch coupler (1).
Repair Instructions
Heat Exchanger ComponentsS7RS0B1506001
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3
4
5
7
6
(a)
2
1
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1. Heat exchanger inlet No. 1 hose 4. Gasket7. O-ring
: Apply engine oil.
2. Heat exchanger outlet No. 1 hose 5. Heat exchanger stand bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft)
3. Heat exchanger 6. Oil filter adapter case : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 1E-4 Engine Lubrication System:
Heat Exchanger On-Vehicle InspectionS7RS0B1506002
• Check heat exchanger for deformation wear or damage.
• Check heat exchanger for coolant leakage and oil leakage.
If any malcondition is found, replace O-ring, stand bolt
gasket and/or heat exchanger.
Heat Exchanger Removal and InstallationS7RS0B1506003
Removal
1) Drain engine oil by removing drain plug.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
3) Remove exhaust manifold referring to “Exhaust Manifold Removal and Inst allation in Section 1K”.
4) Remove heat exchanger inlet No. 1 hose and outlet No. 1 hose.
5) Remove heat exchanger, O-ring and gasket by removing heat exchanger stand bolt. Installation
Reverse removal procedure for installation noting the
followings.
• Use new stand bolt gasket.
• Apply engine oil to new O-ring and install it to heat
exchanger.
• Install heat exchanger (1) while matching the projection of heat exchanger (2) in rib of the cylinder
block (3) as shown in figure.
• Install heat exchanger stand bolt (4) to specified torque.
Tightening torque
Heat exchanger stand bolt (a): 22 N·m (2.2 kgf-m,
16.0 lb-ft)
• Refill cooling system with co olant referring to “Cooling
System Flush and Refill in Section 1F”.
• Refill engine with engine oil referring to “Engine Oil and Filter Change in Section 0B”.
• Upon completion of installation, check for engine coolant and oil leaks.
2
3
4, (a)
1
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Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-5
Oil Pan and Oil Pump Strainer ComponentsS7RS0B1506004
Oil Pan and Oil Pump Strainer Removal and
Installation
S7RS0B1506005
Removal1) Remove oil level gauge.
2) Drain engine oil by removing drain plug.
3) Remove exhaust No.1 pipe (1), exhaust manifold stiffener (2) and heated oxygen sensor No.2
(connector color: green) (3) referring to “Exhaust
System Components in Section 1K”. 4) Remove clutch housing lower plate (1).
5) Remove oil pan and then oil pump strainer (1) from
cylinder block.
I4RS0A150002-01
1. Oil pan : Apply sealant 99000-31260 to mating surface. 6. Strainer bolt 11. Transaxle stiffener bolt
2. Strainer 7. Bracket bolt : 35 N ⋅m (3.5 kgf-m, 25.5 lb-ft)
3. O-ring 8. Oil pan nut : Tighten 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft) by the specified
procedure.
4. Gasket 9. Oil pan bolt (M6) : 55 N ⋅m (5.5 kgf-m, 40.0 lb-ft)
5. Drain plug 10. Oil pan bolt (M10) : Do not reuse.
2
1
3
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Downloaded from www.Manualslib.com manuals search engine 1E-6 Engine Lubrication System:
Installation1) Install new O-rings (2) in the position as shown in figure and install o il pump strainer (1).
Tighten strainer bolt (3) first and then bracket bolt (4)
to specified torque.
Tightening torque
Oil pump strainer bolt (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
Oil pump strainer bracket bolt (b): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
2) Install dowel pin (1) to oil pan. 3) Apply sealant continuously to oil pan mating surface
as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for oil pan
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
4) Install oil pan to cy linder block temporarily.
5) Insert dowel pin (1) in hole (2) of oil pan in order to
locate oil pan precisely.
NOTE
Dowel pin is available as a spare part (part
number: 04211–13189).

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Downloaded from www.Manualslib.com manuals search engine 1E-8 Engine Lubrication System:
Oil Pump ComponentsS7RS0B1506007
Oil Pump Removal and InstallationS7RS0B1506008
Oil pump is incorporated with timing chain cover.
For removal and installation, refer to “Timing Chain
Cover Removal and Installation in Section 1D”.
Oil Pump Disassembly and ReassemblyS7RS0B1506009
Disassembly1) Remove rotor plate (1) by removing its mounting bolts. 2) Remove outer rotor (1) and inner rotor (2).
3) Remove relief valve (1), spring (2) and retainer (3) by
removing circlip (4).
I4RS0A150010-01
1. Rotor plate 6. Rotor plate bolt10. Circlip
2. O-ring 7. Relief valve : 11 N⋅m (1.1 kgf-mm 8.0 lb-ft)
3. Outer rotor 8. Spring : Do not reuse.
4. Inner rotor 9. Retainer : Apply thin coat of engine oil to sliding surface.
5. Timing chain cover 10. Circlip
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Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-9
Reassembly1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case
and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Apply engine oil to relief valve (1) and spring (2), and install them with retainer (3) and new circlip (4) to
rotor plate (5).
5) Install rotor plate and tighten all bolts to specified torque. After installing plate, check to be sure that
rotors turn smoothly by hand (0.3 N ⋅m (0.03 kgf-m,
0.25 lb-ft) torque or below).
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)Oil Pump InspectionS7RS0B1506010
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Oil Pump
• Check outer (1) and inner rotors (2), rotor plate, and oil pump case for excessive wear or damage.
• Check relief valve (1) for excessive wear or damage
and operates smoothly.
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Downloaded from www.Manualslib.com manuals search engine 1F-11 Engine Cooling System:
Water Pump Removal and InstallationS7RS0B1606014
Removal1) Disconnect negative cable at battery.
2) Drain coolant.
3) Remove water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1J”.
4) Remove water pump assembly (1).
Installation 1) Apply sealant to mating surface of water pump (1) as shown in the figure.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant quantity (to mating surface of water
pump)
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 2) Install water pump assemb
ly (1) to cylinder block
and tighten bolts and nut to specified torque.
Tightening torque
Water pump bolt and nut (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
3) Install water pump pulley.
4) Install water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
5) Install A/C compressor belt (if equipped) referring to “Compressor Drive Belt Inspection and Adjustment
in Section 7B” or “Compressor Drive Belt Inspection
and Adjustment in Section 7B”.
6) Refill cooling system referri ng to Step 7) to 22) of
“Cooling System Flush and Refill”.
7) Connect negative cable at battery.
8) Check each part for leakage.
Water Pump InspectionS7RS0B1606015
CAUTION!
Do not disassemble water pump.
If any repair is requir ed on pump, replace it
as assembly.

Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
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Downloaded from www.Manualslib.com manuals search engine 1G-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS7RS0B1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pr essure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing inje ctor or fuel feed pipe, lubr icate its O-ring with gasoline.

General Description
Fuel System DescriptionS7RS0B1701001
CAUTION!
This engine requires the unleaded fuel only.
The leaded and/or low lead fuel can result in
engine damage and reduce the effectiveness
of the emission control system.

The main components of the fuel system are fuel tank,
fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator, fuel feed line and fuel vapor line.
For the details of fuel flow, refer to “Fuel Delivery System
Diagram”.
Fuel Delivery System DescriptionS7RS0B1701002
The fuel delivery system consists of the fuel tank, fuel
pump assembly (with built-in f uel filter and fuel pressure
regulator), delivery pipe, injectors and fuel feed line.
The fuel in the fuel tank is pumped up by the fuel pump,
sent into delivery pipe and injected by the injectors.
As the fuel pump assembly is equipped with built-in fuel
filter and fuel pressure regulator, the fuel is filtered and
its pressure is regulated before being sent to the feed
pipe.
The excess fuel at fuel pressure regulation process is
returned back into the fuel tank.
Also, fuel vapor generated in fuel tank is led through the
fuel vapor line into the EVAP canister.
For system diagram, refer to “Fuel Delivery System
Diagram”.

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine
stopped: 270 – 310 kPa (2.7 – 3.1 kg/cm2, 38.4
– 44.0 psi)
b) Start engine and warm it up to normal operating temperature, and measure fuel pressure at
idling.
Fuel pressure specification
At specified idle speed: 270 – 310 kPa (2.7 –
3.1 kg/cm2, 38.4 – 44.0 psi)
c) Stop engine, and measure fuel pressure at one minute after stopping.
Fuel pressure specification
With 1 min. after engine (fuel pump) stop
(Pressure reduces as time passes): Over 300
kPa (3.0 kg/cm
2, 42.7 psi)
6) After checking fuel pressure, remove fuel pressure gauge.
WARNING!
As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag and loosen joint nut slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel feed hose.
8) Connect fuel feed hose to fuel delivery pipe and clamp it securely.
9) With engine OFF and ignition switch ON, check for fuel leaks.
Fuel Cut Operation InspectionS7RS0B1704002
NOTE
Before inspection, make sure that gear shift
lever is in neutral positi on (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.
3) Check to make sure that injector operation sound is stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.
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