1h 8 SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-66
Special Tools and Equipment
Recommended Service MaterialS7RS0B1408001
NOTE
Required service material is also described in the following.
“Timing Chain Cover Components”
“Timing Chain and Chain Tensioner Components”
“Camshaft, Tappet and Shim Components”
“Valves and Cylinder Head Components”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components”
“Main Bearings, Crankshaft and Cylinder Block Components”

Special ToolS7RS0B1408002
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140)
SUZUKI Bond No.1207F P/No.: 99000–31250) / ) / )
09911–97720 09911–97821
Oil seal installer Oil seal installer
))
09913–75810 09915–64512
Bearing installer Compression gauge
))
09915–64530 09915–67010
Compression gauge hose Compression gauge
attachment (C)
))
09915–67311 09916–14510
Vacuum gauge Valve lifter
)) / )
09916–14521 09916–34542
Valve spring compressor
attachment Reamer handle
) / )) / )

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-1
Engine
Engine Lubrication System
General Description
Engine Lubrication DescriptionS7RS0B1501001
The oil pump is of a trochoid type, and mounted on the
crankshaft. Oil is drawn up through the oil pump strainer
and passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
The filtered oil is passed to the passage in heat
exchanger and cylinder block to piston cooling valve of
oil gushed to the lower side of piston. In one path, oil reaches the crankshaft journal bearings.
Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting
passages drilled in the cran
kshaft, and then injected
from the big end of connecting rod to lubricate piston,
rings and cylinder wall.
In the other path oil goes up to the cylinder head and
lubricates valves and camshafts, etc., after passing
through the internal oil way of camshafts.
An oil relief valve is provided on the oil pump. This valve
starts relieving oil pressure when the pressure exceeds
about 350 kPa (3.5 kg/cm
2, 49.8 psi).
I6RS0C150001-01

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS7RS0B1504001
WARNING!
To avoid danger of being burned, do not
touch exhaust system when it is still hot.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to Full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks If leak is found, repair it.

1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove engine front cover (1).
3) Disconnect oil pressure switch coupler (1).
4) Remove oil pressure swit ch (2) from cylinder block.
5) Install special tools (oil pressure gauge) to vacated threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
2. Low level mark (hole)
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1
I4RS0A150001-01
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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
I2RH0B150005-01
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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.

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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
I6RS0B151002-01

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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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1I4RS0A150004-01
I2RH0B150010-01

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).

I2RH0B150012-01
I4RS0A150005-01
I4RS0A150006-01
21I4RS0A150007-01

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6) After fitting oil pan to cylinder block, run in securing bolts and start tightening at the center: move wrench
outward, tightening one bolt at a time. Tighten bolts
and nuts to specified torque.
Tightening torque
Oil pan bolt (M6) (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Oil pan bolt (M10) (c): 55 N·m (5.5 kgf-m, 40.0 lb-
ft)
Oil pan nut (e): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
7) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b): 35 N·m (3.5 kgf-m, 25.5 lb-
ft)
8) Tighten transaxle stiffener bolts to specified torque. Tightening torque
Transaxle stiffener bolt (d): 55 N·m (5.5 kgf-m,
40.0 lb-ft)
9) Install exhaust manifold stiffener (2) and exhaust No.1 pipe (1) and heated oxygen sensor No.2
(connector color: green) (3) referring to “Exhaust
System Components in Section 1K”. 10) Install clutch housing lower plate (1).
11) Install oil level gauge.
12) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
13) Verify that there is no en gine oil leakage and exhaust
gas leakage at each connection.
Oil Pan and Oil Pump Strainer CleaningS7RS0B1506006
• Clean sealing surface between oil pan and cylinder block.
Remove oil, old sealant, and dust from sealing
surface.
• Clean oil pump strainer screen (1).(a)
(b)
(c)(e)
(d)I4RS0A150008-01
2
1
3
I4RS0A150003-01
1I4RS0A150004-01
I2RH0B150016-01

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
I2RH0B150018-01
I2RH0B150019-01
I2RH0B150020-01