check engine SUZUKI SWIFT 2005 2.G Service Workshop Manual

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5) Install crankshaft to cylinder block.
6) Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to
crank webs.
7) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts (a) and main bearing cap No.2 bolts (b), tighten
them 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 as
shown by using a 12 corner socket wrenches.
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 as
shown.
Tightening torque
Main bearing cap No.1 bolt (a): 30 N ⋅m (3.0
kgf-m, 22.0 lb-ft), 50 N ⋅m (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)
CAUTION!
After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 N ⋅m (1.2 kgf-m, 9.0 lb-ft)
torque or below.

8) If necessary, press-fit rear oil seal (1) to oil seal housing (2) by using special tool as shown in figure.
Special tool
(A): 09911–97821
Crank rear oil seal installing position
(dimension)
“a”: 2 mm (0.08 in.) 9) Apply sealant to mating surface of rear oil seal
housing (1).
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
10) Install rear oil seal housing (1) and tighten bolts to specified torque by using special tool.
Special tool
(A): 09911–97720
Tightening torque
Rear oil seal housing bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
I6RS0C140027-01
A: Crankshaft side
I4RS0A140017-01
I4RS0A140018-01
I4RS0A140019-01

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2) 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
figure.
Tightening torque
Main bearing cap No.1 bolt (a): 30 N ⋅m (3.0
kgf-m, 22.0 lb-ft), 50 N ⋅m (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) 3) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
If its limit is exceeded, replace thrust bearing with
new standard one or oversize one to obtain standard
thrust play.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0043 – 0.0122 in.)
Limit: 0.35 mm (0.0138 in.)
NOTE
After checking the thrust play, make sure that
thread deformation of each bearing cap No.1
bolt referring to “Main Bearing Cap No.1
Bolt” in “Main Bear ings Inspection”.

Out-of-Round and Taper (Uneven Wear) of Journals
An unevenly worn crankshaft journal shows up as a
difference in diameter at a cross section or along its
length (or both). This difference, if any, is determined by
taking micrometer readings. If any one of journals is
badly damaged or if amount of uneven wear in the sense
exceeds its limit, regrind or replace crankshaft.
Crankshaft out-of-round and taper
Limit: 0.01 mm (0.0004 in.)
Out-of-round
A – B
Ta p e r
a – b
I6RS0C140027-01
I2RH01140183-01
I2RH0B140138-01

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

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Selection of Main Bearings
Standard bearing
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.
1) First check journal diameter. As shown in the figure, crank web No.2 has stamped numbers.
Three kinds of numbers (“1”, “2” and “3”) represent
the following journal diameters.
Stamped numbers on crank web No.2 represent
journal diameters marked with an arrow in the figure
respectively. For example, stamped number “1”
indicates that corresponding journal diameter is
51.9940 – 52.0000 mm (2.0471 – 2.0472 in.).
Crankshaft journal diameter2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five
alphabets are stamped as shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) or
numbers (“1”, “2” and “3”) represent the following
cap bore diameters.
Stamped alphabets or numbers on cylinder block
represent bearing cap bore diameter marked with an
arrow in the figure respectively.
For example, stamped “A” or “1” indicates that
corresponding bearing cap bo re diameter is 56.0000
– 56.0060 mm (2.2048 – 2.2049 in.).
Crankshaft bearing cap bore
Stamped
numbers Journal diameter
1 51.9940 – 52.0000 mm
(2.0471 – 2.0472 in.)
2 51.9880 – 51.9939 mm
(2.0468 – 2.0470 in.)
3 51.9820 – 51.9879 mm
(2.0465 – 2.0467 in.)
I2RH0B140142-01
Stamped alphabet
(number) Bearing cap bore diameter (without
bearing)
A or 1 56.0000 – 56.0060 mm
(2.2048 – 2.2049 in.)
B or 2 56.0061 – 56.0120 mm
(2.2050 – 2.2051 in.)
C or 3 56.0121 – 56.0180 mm
(2.2052 – 2.2054 in.)
I2RH0B140143-01

Downloaded from www.Manualslib.com manuals search engine 1D-61 Engine Mechanical:
3) There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in figure.
Each color indicated the following th ickness at the center of bearing.
Standard size of crankshaft main bearing thickness
4) From number stamped on crank web No.2 and alphabets stamped on cylinder block, determine new standard bearing to be installed to journal, by referring to the table shown.
For example, if number stamped on crank web No.2 is “1 ” and alphabet stamped on cylinder block is “B”, install a
new standard bearing painted in “Brown” to its journal.
New standard size crankshaft main bearing specification
5) Using scale (1) on gauging plastic (2), check be aring clearance with newly selected standard bearing.
If clearance still exceeds its limit, use ne xt thicker bearing and recheck clearance.
6) When replacing crankshaft or cylinder block due to any reason, select new standard bearings to be installed by
referring to number stamped on new crankshaft or alphabets stamped on new cylinder block.
Color
painted Bearing thickness
Purple 1.992 – 1.996 mm (0.07843 – 0.07858 in.)
Brown 1.995 – 1.999 mm (0.07855 – 0.07870 in.) Green 1.998 – 2.002 mm (0.07867 – 0.07882 in.)Black 2.001 – 2.005 mm (0.07878 – 0.07893 in.)
Colorless (no paint) 2.004 – 2.008 mm (0.07890 – 0.07906 in.)
1. Paint
Number stamped on crank web No.2 (Journal diameter)
123
Alphabet stamped on cylinder block (Cap bore dia.) A or 1 Purple Brown Green
B or 2 Brown Green Black
C or 3 Green Black Colorless
New standard bearing to be installed
I2RH01140191-01
I2RH0B140141-01

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Undersize bearing (0.25 mm (0.0098 in.))
• 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness.
To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure.
Each color represents the following thickness at the center of bearing.
Undersize of crankshaft main bearing thickness
• If necessary, regrind crankshaft journal and sele ct undersize bearing to use with it as follows.
a. Regrind journal to the following finished diameter.
Finished journal diameter
51.7320 – 51.7500 mm (2.0367 – 2.0374 in.)
b. Using micrometer, measure regrind journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
c. Using journal diameter measured above and alphabets stamped on cylinder block, select an undersize bearing
by referring to the following table.
Check bearing clearance with ne wly selected undersize bearing.
New undersize crankshaft main bearing specification
Color painted Bearing thickness
Red and Purple 2.117 – 2.121 mm (0.08335 – 0.08350 in.)
Red and Brown 2.120 – 2.124 mm (0.08347 – 0.08362 in.) Red and Green 2.123 – 2.127 mm (0.08359 – 0.08374 in.) Red and Black 2.126 – 2.130 mm (0.08371 – 0.08385 in.) Red only 2.129 – 2.133 mm (0.08382 – 0.08397 in.)
1. Paint
Measured journal diameter
51.7320 – 51.7379 mm (2.0367 – 2.0369 in.) 51.7380 – 51.7439 mm
(2.0370 – 2.0371 in.) 51.7440 – 51.7500 mm
(2.0372 – 2.0373 in.)
Alphabets stamped on cylinder block A (1) Red and Green Red and Brown Red and Purple
B (2) Red and Black Red and Green Red and Brown
C (3) Red only Red and Black Red and Green
Undersize bearing to be installed
I2RH01140192-01
I2RH0B140144-01

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Main Bearing Cap No.1 Bolt
Measure each thread diameter main bearing cap No.1
bolts (1) at “A” on 60 mm (2.36 in.) from seat side of
flange bolt and “B” on 90 mm (3.54 in.) from seat side of
flange bolt by using a micrometer (2).
Calculate difference in diameters (“A” – “B”).
If it exceeds limit, replace with new one.
Main bearing cap No.1 bolt diameter measurement
points
“a”: 60 mm (2.36 in.)
“b”: 90 mm (3.54 in.)
Main bearing cap No.1 bolt diameter difference
Limit (“A” – “B”): 0.2 mm (0.008 in.)
Sensor Plate InspectionS7RS0B1406039
Check sensor plate for crack damage.
If malcondition is found, replace it.
Rear Oil Seal InspectionS7RS0B1406040
Carefully inspect oil seal (1) for wear or damage. If its lip
is worn or damaged, replace it.
Flywheel InspectionS7RS0B1406041
Visual Inspection
• If ring gear is damaged, cracked or worn, replace flywheel.
• If the surface contacting cl utch disc is damaged, or
excessively worn, replace flywheel.
Flywheel Face Runout
Check flywheel face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel face runout
Limit: 0.2 mm (0.0079 in.)
Cylinder Block InspectionS7RS0B1406042
Distortion of Gasketed Surface
Using straightedge and thickness gauge, check
gasketed surface for distortion and, if flatness exceeds
its limit, correct It.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)

“A”
“a” “b” “B”

1
1
2
I2RH0B140145-01
I2RH0B140151-01
I4RS0A140020-01
I2RH01140198-01
I2RH01140199-01

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)
I2RH0B150002-01
1
I4RS0A150001-01
I2RH0B150003-01
I2RH0B150004-01

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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
I2RH0B150006-01
3
4
5
7
6
(a)
2
1
I6RS0B151001-02
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