Engine assembly SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1E-10 Engine Lubrication System:
Radial clearance
Check radial clearance between outer rotor (1) and case
(2) using thickness gauge (3).
If clearance exceeds its limit, replace outer rotor or case.
Radial clearance between outer rotor and case for oil
pump
Limit: 0.310 mm (0.0122 in.)
Side clearance
Using straightedge (1) and thickness gauge (2),
measure side clearance.
If side clearance exceeds its limit, replace oil pump
assembly.
Side clearance for oil pump inner rotor
Limit: 0.15 mm (0.0059 in.)Relief valve spring free length and load
Check relief valve spring free length and load as shown
in the figure. If the measured valve spring length is lower
than the specification, replace relief valve spring.
Relief valve spring free length and load
I2RH0B150026-01
I2RH0B150027-01
Standard Limit
Free length 52.4 mm
(2.06 in.) —
Load at spring length
38.5 mm (1.52 in.) 79 N
(7.9 kgf, 17.5 lb) 69 N
(6.9 kgf, 15.0 lb)
I2RH01150023-01

Downloaded from www.Manualslib.com manuals search engine 1F-5 Engine Cooling System:
Repair Instructions
Cooling System ComponentsS7RS0B1606001
I7RS0B160004-01
F: Vehicle forward10. Water outlet cap gasket 20. Heater outlet No.2 hose 30. Heat exchanger water pipe
1. Radiator 11. O-ring 21. Heater union 31. To cylinder head
2. Reservoir 12. Thermostat case water outlet pipe 22. Heater inlet No.1 hose 32. To water pump
3. Engine cooling fan assembly 13. Thermostat case 23. Heater outlet No.1 hose33. To heater core
4. Radiator cap 14. Thermostat 24. Water bypass No.2 hose 34. To throttle body
5. Drain plug 15. Thermostat cap 25. Heat exchanger 35. Heater inlet No.2 hose
6. Radiator outlet hose 16. Water bypass No.1 hose 26.Heat exchanger inlet No.1 hose 36. Heater inlet pipe
7. Radiator inlet hose 17. Water inlet No.1 pipe 27. Heat exchanger inlet No.2 hose : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
8. Water outlet cap 18. Water inlet hose 28. Heat exchanger outlet No.1 hose : Do not reuse.
9. ECT sensor 19. Water inlet No.2 pipe 29. Heat exchanger outlet No.2 hose

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.
I2RH0B160016-01
I3RM0A160016-01
I2RH0B160018-01
I2RH0B160019-01

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 Fuel System: 1G-2
Fuel Pump DescriptionS7RS0B1701003
The fuel pump (1) is an in-tank type electric pump.
Incorporated in the pump assembly are;
a fuel filter (2) and a fuel pressure regulator (3) are
included and a fuel level gauge (4) is attached.
Addition of the fuel pressure regulator to the fuel pump
makes it possible to mainta in the fuel pressure at
constant level and ECM controls compensation for
variation in the intake manifold pressure.
Schematic and Routing Diagram
Fuel Delivery System DiagramS7RS0B1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS7RS0B1704001
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
1
3
2
4
I6RS0C170001-01
4
6 7
8
12
2 3
11
10
5
1
9
I6RS0C170002-01
1. Fuel tank
5. Fuel injector9. EVAP canister
2. Fuel pump 6. Fuel feed line10. Fuel filter
3. Fuel pressure regulator 7. Fuel vapor line 11. Main fuel level sensor
4. Delivery pipe 8. Intake manifold12. EVAP canister purge valve
1
(C) (B)
(A)
I3RM0A170004-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-4
Repair Instructions
Fuel System ComponentsS7RS0B1706001
5
14
4
24
8
3
13
23
1
25
21
112
22 10
6
16
26
18
17
19
10
12
9
(b)
(a)
15
(c)
20 27
7
I6RS0C170003-01
1. Fuel tank 12. Fuel tank bolt 23. Main fuel level sensor
2. Fuel pump assembly 13. Fuel pump assembly bolt 24. To fuel vapor line
3. Breather hose 14. Fuel filler neck 25. Fuel feed hose
4. Fuel tank filler hose 15. Fuel delivery pipe 26. Grommet
5. Fuel filler cap 16. Fuel delivery pipe bolt 27. To fuel tank
6. Fuel feed line 17. Fuel injector : Do not reuse.
7. Fuel vapor line 18. Injector cushion : 45 N⋅m (4.5 kgf-m, 33.0 lb-ft)
8. Fuel tank inlet valve 19. Fuel delivery pipe insulator : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Fuel tank protector 20. O-ring : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
10. Fuel tank belt 21. To canister
11. Fuel pump gasket 22. Fuel tank cover

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-8
Installation1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn igniti on switch to ON position
and check for fuel leaks.
Fuel Injector On-Vehicle InspectionS7RS0B1706007
1) Using sound scope (1) or such, check operating sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Disconnect connector (1) from injector, connect ohmmeter between terminals of injector and check
resistance.
If resistance is out of specification, replace.
Resistance of fuel injector
11.3 – 13.8 Ω at 20 °C, 68 °F
3) Connect connector to injector securely.
Fuel Injector Removal and InstallationS7RS0B1706008
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal 1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect MAF sensor connector, and detach EVAP canister purge valve.
4) Remove air cleaner assembly with air intake pipe.
5) Disconnect fuel injector couplers.
6) Disconnect fuel feed hose from fuel delivery pipe (1).
7) Remove fuel delivery pipe bolts (2).
8) Remove fuel injector(s) (3).
I2RH0B170007-01
I2RH0B170008-01
2
1
3
3
I3RM0A170010-01

Downloaded from www.Manualslib.com manuals search engine 1G-13 Fuel System:
Installation
CAUTION!
• When connecting joint, clean outside surfaces of pipe where joint is to be
inserted, push joint into pipe till joint lock
clicks and check to ensure that pipes are
connected securely, or fuel leak may
occur.
• Never let the fuel hoses touch the ABS sensor harness (if equipped).

1) If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
2) Raise fuel tank (1) with jack (2) and connect fuel pump connector (3), ground wire (4) and clamp wire
harness.
Tightening torque
Ground wire bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install fuel tank to vehicle. Tightening torque
Fuel tank bolt (b): 45 N·m (4.5 kgf-m, 33.0 lb-ft) 4) Connect fuel filler hose (1
) and breather hose (2) to
filler neck (3) as shown in figure, and clamp them
securely.
Tightening torque
Fuel filler hose clamp (a): 2 N·m (0.2 kgf-m, 1.5
lb-ft)
5) Connect fuel feed hose (1) and vapor hose (2) to each pipe as shown in figure, and clamp them
securely.
6) Install exhaust center pipe referring to “Exhaust Pipe and Muffler Removal and Installation in Section 1K”.
7) Connect negative cable at battery.
8) With engine OFF, turn ignition switch to ON position and check for fuel leaks.
Fuel Tank InspectionS7RS0B1706014
After removing fuel tank, check hoses and pipes
connected to fuel tank for leaks, loose connections,
deterioration or damage. Also check fuel pump
assembly gaskets for leaks, visually inspect fuel tank for
leaks and damage.
Replace any damaged or malconditioned parts.
(b)(b)
1
2
3
4
(a)
I6RS0C170006-02
1
2
(a)
3
I4RS0A170012-01
1
2
I4RS0A170013-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-14
Fuel Tank Purging ProcedureS7RS0B1706015
WARNING!
• Before starting the following procedure, be sure to observe “Precautions on Fuel
System Service” in order to reduce the risk
or fire and personal injury.
• This purging procedure will not remove all fuel vapor.
Do not attempt any repair on tank using
heat of flame as an explosion resulting in
personal injury could occur.

CAUTION!
Never remain water in fu el tank after washing,
or fuel tank inside will get corrosion.

The following procedure are used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain. Repeat this washing until
inside of tank is clean. Replace tank if its inside is
rusty.
5) Completely flush out rema ining water after washing.
Fuel Pump On-Vehicle InspectionS7RS0B1706016
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

NOTE
The fuel pressure regulator is incorporated
with the fuel pump assembly so individual
inspection of it is impossible.

1) Remove filler cap and turn ON ignition switch (2).
Then fuel pump operating sound should be heard
from fuel filler (1) for about 2 seconds and stop. Be
sure to reinstall fuel filler cap after checking.
If the check result is not satisfactory, go to “Fuel
Pump and Its Circuit Check in Section 1A”. 2) Turn OFF ignition switch and leave over 10 minutes
as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for about 2 seconds after ignition switch ON.
If fuel pressure is not felt, go to “Fuel Pressure
Check in Section 1A”.
Fuel Pump Assembly Removal and InstallationS7RS0B1706017
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Remove fuel tank from vehicle. Refer to “Fuel Tank Removal and Installation”.
2) Disconnect fuel feed pipe (1) from fuel pump assembly (2) referring to “Fuel Hose Disconnecting
and Reconnecting”.
IVSY01170013-01
1I3RM0A170019-01
1
2
I6RS0C170008-02

Downloaded from www.Manualslib.com manuals search engine 1G-15 Fuel System:
3) Remove fuel pump assembly (1) from fuel tank (2).
Installation
CAUTION!
When connecting joint, clean outside surface
of pipe where joint is to be inserted, push
joint into pipe till jo int lock clicks and check
to ensure that pipes are connected securely,
or fuel leak may occur.

1) Clean mating surfaces of fuel pump assembly (1) and fuel tank.
2) Put plate (2) on fuel pump assembly (1) by matching the protrusion of fuel pump assembly (3) to plate
hole (4) as shown.
3) Install new gasket (2) and fuel pump assembly (1) earth bracket (5) with plate (3) to fuel tank (4).
Tightening torque
Fuel pump assembly bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft) 4) Connect fuel feed line (1) (pipe joint) to fuel pump
assembly (2).
5) Install fuel tank to vehi cle. Refer to “Fuel Tank
Removal and Installation”.
Main Fuel Level Sensor Removal and
Installation
S7RS0B1706018
CAUTION!
• Do not touch resister plate (1) and deform arm (2). It may cause main fuel level sensor
to fail.
• Be very careful not to cause damage to fuel tube installed section (sealed section
in bore). If it be damaged, replace it with
new one, or fuel will leak from the part.

1
2
I3RM0A170021-01
3
1
3
2
44
I4RS0A170015-01
3
1 2
(a)
4
5
I6RS0C170009-01
2
1
I4RS0A170014-01
1
2I4RS0A170016-01