clearance SUZUKI SWIFT 2006 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 1D-19 Engine Mechanical:
24) Before removing engine with transaxle from engine compartment, recheck to make sure all hoses,
electric wires and cables are disconnected from
engine and transaxle.
25) Lower engine with transaxle from engine compartment.
CAUTION!
Before lowering engine, to avoid damage to
A/C compressor and clutch operating
cylinder, make clearance by rising them. Be
sure not to damage suspended A/C
compressor and clutch operating cylinder.

26) Disconnect transaxle from engine, referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B” or “Automatic Transaxle
Unit Dismounting and Re mounting in Section 5A”.
27) For M/T model, remove clutch cover and clutch disk referring to “Clutch Cover, Clutch Disc and Flywheel
Removal and Installa tion in Section 5C”.
Installation 1) For M/T model, install clutch cover and clutch disk referring to “Clutch Cover, Clutch Disc and Flywheel
Removal and Installa tion in Section 5C”.
2) Connect transaxle to engine referring to “Manual Transaxle Unit Dismounting and Remounting in
Section 5B” or “Automatic Transaxle Unit
Dismounting and Remounting in Section 5A”.
3) Lift engine and transaxle into engine compartment with jack.
4) Install engine left mounting bracket nuts (1) and engine right mounting nuts (2).Tighten these nuts to
specified torque.
Tightening torque
Engine left mounting bracket nut (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Engine right mounting nut (b): 65 N·m (6.5 kgf-
m, 47.0 lb-ft) 5) Support engine assemble by using chain hoist.
6) Install engine rear mounting to engine rear
mountingNo.1 bracket.
Tightening torque
Engine rear mounting bush bolt: 55 N·m (5.5
kgf-m, 40.0 lb-ft)
7) Install suspension frame referring to “Front Suspension Frame, Stabiliz er Bar and/or Bushings
Removal and Installati on in Section 2B”.
8) Remove chain hoist.
9) Install exhaust No.1, No.2 and center pipes referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
10) Connect drive shaft joints referring to “Front Drive Shaft Assembly Removal and Installation in Section
3A”.
11) Reverse disconnected hoses, cables and electric wires for connection noting the followings.
• Tighten nuts to specified torque.
Tightening torque
Starting motor terminal nut: 11 N·m (1.1 kgf-m,
8.0 lb-ft)
Generator terminal nut: 6 N·m (0.6 kgf-m, 4.5 lb-
ft)
Intake manifold ground terminal bolt: 11 N·m (
1.1 kgf-m, 18.0 lb-ft)
12) Install intake manifold rear stiffener to intake
manifold and cylinder block.
13) Install air cleaner assembly referring to “Air Cleaner Components”.
14) Install cowl top referring to “Cowl Top Components in
Section 9K”.
I4RS0A140009-01
1, (a)
2, (b)
I4RS0A140010-01

Downloaded from www.Manualslib.com manuals search engine 1D-31 Engine Mechanical:
7) Install camshaft housing.
8) Tighten camshaft housing bolts as follows.a) Apply engine oil to camshaft housing bolts.
b) Tighten camshaft housing bolts by hand.
c) Tighten camshaft housing bolts to 5 N ⋅m (0.5 kgf-
m, 4.0 lb-ft) according to numerical order (“1”
through “21”) as shown in figure.
d) Retighten them by turning through 11 N⋅ m (1.1
kgf-m, 8.0 lb-ft) in same manner as Step c).
Tightening torque
Camshaft housing bolt (a): 5 N ⋅m (0.5 kgf-m,
4.0 lb-ft) and 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft) by
the specified procedure
9) With hexagonal section (1) of intake camshaft (2) held stationary with spanner or the like, tighten bolt
of intake cam timing sp rocket assembly (3) to
specification.
Tightening torque
Intake cam timing sprocket bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)
10) Install timing chain with cr ankshaft sprocket referring
to “Timing Chain and Chain Tensioner Removal and
Installation”.
11) Install timing chain cover referring to “Timing Chain Cover Removal and Installation”.
12) Check valve lashes referring to “Valve Lash (Clearance) Inspection”.
13) Perform Steps 9) to 14) of “Installation” of “Timing Chain Cover Removal and Installation”.Camshaft, Tappet and Shim InspectionS7RS0B1406022
Intake Cam Timing Sprocket Assembly
Fit intake cam timing sprocket assembly to camshaft (2)
and hold hexagonal section of camshaft by using
spanner or the like.
Check if sprocket (1) is not turned by hand.
If moved, replace intake ca m timing sprocket assembly.
Cam Wear
Using a micrometer, measure cam height “a”. If
measured height underruns its limit, replace camshaft.
Cam height “a”
“10”“9” “2” “1”,(a) “6” “5” “14” “13”
“20”
“17” “19”
“18”
“21”
“12”“11”
“4” “3” “8” “7” “16” “15”
I3RH0B140041-01
1
2
3
(a)
I3RH0B140042-01
Cam height Standard Limit
Intake cam 45.424 – 45.584 mm
(1.789 – 1.794 in.) 45.30 mm
(1.783 in.)
Exhaust cam 45.030 – 45.190 mm
(1.773 – 1.779 in.) 44.91 mm
(1.768 in.)
2
1
I3RH0B140043-01
I2RH0B140080-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-32
Camshaft Runout
Set camshaft between two “V” blocks, and measure its
runout by using a dial gauge.
If measured runout exceeds limit, replace camshaft.
Camshaft runout limit
0.10 mm (0.0039 in.)
Camshaft Journal Wear
Check camshaft journals and camshaft housings for
pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder
head with housing. Never re place cylinder head without
replacing housings.
Check clearance by using ga uging plastic. Checking
procedure is as follows.
1) Clean housings and camshaft journals.
2) Remove all tappets with shims.
3) Install camshafts to cylinder head.
4) Place a piece of gauging plastic to full width of
journal of camshaft (parallel to camshaft).
5) Install camshaft housing. 6) Install camshaft housing as follows.
After applying engine oil to camshaft housing bolts,
tighten them temporarily first. Then tighten them as
follows.
a) Tighten camshaft housing bolts to 5 N ⋅m (0.5 kgf-
m, 4.0 lb-ft) according to numerical order (“1”
through “21”) as shown in figure.
b) Retighten them by turning through 11 N ⋅m (1.1
kgf-m, 8.0 lb-ft) in same manner as Step a).
NOTE
Do not rotate camshaft while gauging plastic
is installed.

Tightening torque
Camshaft housing bolt (a): 5 N ⋅m (0.5 kgf-m, 4.0
lb-ft) and 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft) by the
specified procedure
1) Remove housing, and using scale (2) on gauging plastic envelop, measure gauging plastic (1) width at
its widest point.
Camshaft journal clearanceI2RH0B140081-01
I2RH0B140082-01
Standard Limit
Intake side
No.1 housing 0.020 – 0.072 mm
(0.0008 – 0.0028 in.) 0.10 mm
(0.0039 in.)
Others 0.045 – 0.087 mm
(0.0018 – 0.0034 in.) 0.12 mm
(0.0047 in.)
“10”“9” “2” “1”,(a) “6” “5” “14” “13”
“20”
“17” “19”
“18”
“21”
“12”“11”
“4” “3” “8” “7” “16” “15”
I3RH0B140041-01
I2RH0B140083-01

Downloaded from www.Manualslib.com manuals search engine 1D-33 Engine Mechanical:
If measured camshaft journal clearance exceeds
limit, measure journal (housing) bore and outside
diameter of camshaft journal. Replace camshaft or
cylinder head assembly whichever the difference
from specification is greater.
Camshaft journal diameter [A]
Camshaft journal bearing bore [B]
Wear of Tappet and Shim
Check tappet and shim for pitting, scratches, or damage.
If any malcondition is found, replace.
Measure cylinder head bore and tappet outside diameter
to determine cylinder head-to-tappet clearance. If
clearance exceeds limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 – 0.066 mm (0.0010 – 0.026 in.)
Limit: 0.15 mm (0.0059 in.)
Tappet outside diameter [A]
Standard: 30.959 – 30.975 mm (1.2189 – 1.2195 in.)
Cylinder head tappet bore [B]
Standard: 31.000 – 31.025 mm (1.2205 – 1.2215 in.)
Item Standard
Intake side No.1 housing 26.940 – 26.955 mm
(1.0606 – 1.0612 in.)
Exhaust side No.1 housing 26.934 – 26.955 mm
(1.0604 – 1.0612 in.)
Others 22.934 – 22.955 mm
(0.9029 – 0.9037 in.)
Item Standard
Intake side No.1 housing —
Exhaust side No.1 housing 27.000 – 27.021 mm
(1.0630 – 1.0638 in.)
Others 23.000 – 23.021 mm
(0.9055 – 0.9063 in.)
I2RH0B140084-01
I2RH0B140085-01
I2RH0B140086-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-40
Valves and Valve Guides InspectionS7RS0B1406026
Valve Guide
Valve stem-to-guide clearance
Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance.
Be sure to take reading at more than one place along the length of each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem and valve guide specification
Valve stem end deflection
If bore gauge is not available, check end deflection of
valve stem with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end
deflection.
If deflection exceeds its limit, replace valve stem and
valve guide.
Valve stem end deflection limit
In: 0.14 mm (0.005 in.)
Ex: 0.18 mm (0.007 in.) Va l v e
Visual inspection
• Remove all carbon from valves.
• Inspect each valve for wear, burn or distortion at its
face and stem end, as necessary, replace it.
• Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be
resurfaced, but not too much to grind off its chamber.
When it is worn out too much that its chamber is gone,
replace valve.
Item Standard Limit
Valve stem diameter [A] In 5.465 – 5.480 mm (0.2150 – 0.2157 in.) —
Ex 5.440 – 5.455 mm (0.2142 – 0.2148 in.) —
Valve guide bore [B] In & Ex 5.500 – 5.512 mm (0.2165 – 0.2170 in.) —
Stem-to-guide clearance In 0.020 – 0.047 mm (0.0008 – 0.
0018 in.) 0.070 mm (0.0028 in.)
Ex 0.045 – 0.072 mm (0.0017 – 0. 0028 in.) 0.090 mm (0.0035 in.)
I4RS0B140016-01
IYSQ01141096-01I2RH01140135-01

Downloaded from www.Manualslib.com manuals search engine 1D-43 Engine Mechanical:
Valve Spring InspectionS7RS0B1406028
Valve Spring Free Length and Preload
Referring to data, check to be sure that each spring is in
sound condition, free of any evidence of breakage or
weakening. Remember, weakened valve springs can
cause chatter, not to mention possibility of reducing
power output due to gas leakage caused by decreased
seating pressure.
Valve spring free length
Standard: 39.37 mm (1.550 in.)
Limit: 36.49 mm (1.437 in.)
Valve spring preload
Standard: 161– 185 N (16.1 – 18.5 kg)
(35.4 – 40.7 lb / 1.240 in.)
Limit: 159 N (15.9 kg) for 31.50 mm (35.1 lb / 1.240 in.) Spring Squareness
Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. Valve springs found to exhibit a
larger clearance than limit must be replaced.
Valve spring squareness
Limit: 1.7 mm (0.067 in.)
I2RH01140143-01
I2RH01140144-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-48
Piston clearance
Measure cylinder bore diameter and piston diameter to
find their difference which is piston clearance. Piston
clearance should be within spec ification as follows. If it is
out of specification, rebore cylinder and use oversize
piston.
NOTE
Cylinder bore diameters used here are
measured in thrust direction at two positions.

Piston clearance
Standard (used piston): 0.032 – 0.061 mm (0.0013 –
0.0024 in.)
Standard (new piston with coating): 0.010 – 0.051
mm (0.0004 – 0.0020 in.)
Limit: 0.161 mm (0.0063 in.)
Ring groove clearance
Before checking, piston grooves must be clean, dry and
free of carbon deposits.
Fit new piston ring (1) into piston groove, and measure
clearance between ring and ring land by using thickness
gauge (2). If clearance is ou t of specification, replace
piston.
Ring groove clearance
Piston Ring
Piston ring end gap
To measure end gap, insert piston ring (2) into cylinder
bore and then measure the gap by using thickness
gauge (1).
If measured gap exceeds limit, replace ring.
NOTE
Decarbonize and clean top of cylinder bore
before inserting piston ring.

Ring groove clearance
“a”: 7.0 mm (0.28 in.)
Standard Limit
Top ring 0.04 – 0.08 mm
(0.0016 – 0.0031 in.) 0.12 mm (0.0047 in.)
2nd ring 0.03 – 0.07 mm
(0.0012 – 0.0027 in.) 0.10 mm (0.0394 in.)
Oil ring 0.04 – 0.12 mm
(0.0016 – 0.0047 in.) —
I4RS0A140022-01
Item Standard
Limit
To p r i n g 0.20 – 0.33 mm
(0.0079 – 0.0129 in.) 0.7 mm (0.0276 in.)
2nd ring 0.43 – 0.56 mm
(0.0170 – 0.0220 in.) 1.0 mm (0.0394 in.)
Oil ring 0.10 – 0.40 mm
(0.0040 – 0.0157 in.) 0.7 mm (0.0276 in.)
“a”: 120 mm (4.72 in.)
I2RH01140159-01
I2RH01140161-01

Downloaded from www.Manualslib.com manuals search engine 1D-49 Engine Mechanical:
Piston Pins and Connecting Rods InspectionS7RS0B1406033
Piston Pin
Visual inspection
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 piston bore is badly
worn or damaged, replace pin, connecting rod and/or
piston.
Piston pin clearance
Check piston pin clearance in small end and piston.
Replace connecting rod and/or piston if its small end is
badly worn or damaged or if measured clearance
exceeds limit.
Piston pin clearance in connecting rod small end
Standard: 0.003 – 0.014 mm (0.0001 – 0.0006 in.)
Piston pin clearance in piston
Standard: 0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Small-end bore
20.003 – 20.011 mm (0.7875 – 0.7878 in.)
Piston pin dia.
19.997 – 20.000 mm (0.7873 – 0.7874 in.)
Piston bore
20.006 – 20.014 mm (0.7876 – 0.7880 in.)Connecting Rod
Big-end side clearance
Check big-end of connecting rod for side clearance, with
rod fitted and connected to its crank pin in the normal
manner. If measured clearance is found to exceed its
limit, replace connecting rod.
Big-end side clearance
Standard: 0.25 – 0.40 mm (0.0098 – 0.0157 in.)
Limit: 0.55 mm (0.0217 in.)
Connecting rod alignment
Mount connecting rod on aligner to check it for bow and
twist. If measured value exceeds the limit, replace it.
Connecting rod alignment
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)
I4RS0A140023-01
I2RH0B140148-01
I4RH01140053-01

Downloaded from www.Manualslib.com manuals search engine 1D-51 Engine Mechanical:
Connecting Rod Bearing Clearance1) Before checking bearing clearance, clean bearing and crank pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gauging plastic (1) to full width of crank pin as contacted by bearing (parallel to
crankshaft), avoiding oil hole.
4) Install rod bearing cap (1) to connecting rod. When installing cap, be sure to point arrow mark (2)
on cap to crankshaft pulley side, as shown in figure.
After applying engine oil to bearing cap bolts (3),
tighten bearing cap bolts (3) gradually as follows.
a) Tighten all bearing cap bolts to 15 N ⋅m (1.5 kgf-
m, 11.0 lb-ft)
b) Retighten them to 45°
c) Repeat Step b) once again.
Tightening torque
Connecting rod bearing cap bolt: 15 N ⋅m (1.5
kgf-m, 11.0 lb-ft) and then retighten by
turning through 45 ° twice 5) Remove cap and using a scale (1) on gauging
plastic envelope (2), measure gauging plastic (2)
width at the widest point (clearance).
If clearance exceed its limit, use a new standard size
bearing referring to “Selection of Connecting Rod
Bearings: ”.
After selecting new bearing, recheck clearance.
Connecting rod bearing clearance
Standard: 0.029 – 0.047 mm (0.0011 – 0.0018 in.)
Limit: 0.065 mm (0.0026 in.)
6) If clearance can not be brought to its limit even by using a new standard size bearing, use next thicker
bearing and recheck clearance or regrind crank pin
to undersize and use 0.25 mm undersize bearing.
Selection of Connecting Rod Bearings
NOTE
• If bearing is in malcondition, or bearing clearance is out of specification, select a
new standard bearing according to the
following procedure and install it.
• When replacing crankshaft or connecting rod and its bearing due to any reason,
select new standard bearings to be
installed by referring to numbers stamped
on connecting rod and its cap and/or
alphabets stamped on crank web of No.3
cylinder.

1) Check stamped numbers on connecting rod and its cap as shown.
Three kinds of numbers (“1”, “2” and “3”) represent
the following connecting rod big end inside
diameters.
For example, stamped number “1” indicates that
corresponding connecting rod big end inside
diameter is 45.000 – 45.006 mm (1.7717 – 1.7718
in.).
Connecting rod big end inside diameter
I2RH0B140121-01
I6RS0B141026-01
Stamped
numbers Connecting rod big end inside diameter
1 45.0000 – 45.0060 mm (1.7717 – 1.7718 in.)
2 45.0061 – 45.0120 mm (1.7719 – 1.7721 in.)
3 45.0121 – 45.0180 mm (1.7722 – 1.7723 in.)
I2RH0B140123-01

Downloaded from www.Manualslib.com manuals search engine 1D-59 Engine Mechanical:
Main Bearings InspectionS7RS0B1406038
General Information
• Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them
has 5 kinds of bearings differing in tolerance.
• Upper half of bearing (1) has oil groove (2) as shown in figure.
Install this half with o il groove to cylinder block.
• Lower half of bearing does not have an oil groove.
Visual Inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is foun d, replace both upper and
lower halves. Never replace either half without replacing
the other half.
Main Bearing Clearance
NOTE
Do not rotate crankshaft while gauging
plastic is installed.

Check clearance by using ga uging plastic according to
the following procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) the full width of bearing (parallel to crankshaft) on journal, avoiding
oil hole. 4) Tighten main bearing cap No.1 bolts (a) and main
bearing cap No.2 bolts (b) gradually as follows.
a) Tighten bolts (“1” through “10”) to 30 N ⋅m (3.0
kgf-m, 22.0 lb-ft) according to numerical order in
the figure.
b) In the same manner as in Step a), tighten them to 50 N ⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them to 60 °.
d) Tighten bolts (“11” through “18”) to 25 N ⋅m (2.5
kgf-m, 18.0 lb-ft) according to numerical order in
the figure.
Tightening torque
Main bearing cap No.1 bolt (a): 30 Nm (3.0
kgf-m, 22.0 lb-ft), 50 Nm (5.0 kgf-m, 36.5 lb-ft)
and then retighten by turning through 60°
Main bearing cap No.2 bolt (b): 25 N·m (2.5
kgf-m, 18.0 lb-ft)
5) Remove bearing caps and using scale (1) on gauging plastic envelop (2), measure gauging plastic
width at its widest point. If clearance exceeds its
limit, replace bearing. Always replace both upper
and lower inserts as a unit.
A new standard bearing may produce proper
clearance. If not, it will be necessary to regrind
crankshaft journal for use of 0.25 mm undersize
bearing.
After selecting new bearing, recheck clearance.
Main bearing clearance
Standard: 0.021 – 0.041 mm (0.0008 – 0.0016 in.)
Limit: 0.054 mm (0.0021 in.)
I2RH0B140139-01
I2RH0B140140-01
I6RS0C140027-01
I2RH0B140141-01