timing SUZUKI SWIFT 2005 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-2
Camshaft Position Control (VVT Variable Valve Timing) System DescriptionS7RS0B1401002
System Description
The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in
response to the engine operating condition.
The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation
and lower fuel consumption can be attained in the whole engine speed range from low to high. In the area of the
average engine load, low emission of nitrogen oxides (NOx) and high fuel efficiency can also be attained by making
the valve opening overlap between the intake and exhaust valves longer.
For the brief of the system operation, the intake valve timing is varied by the cam timing sprocket (1) which varies the
rotational phase between the intake camshaft (3) and sprocket . The rotor (2) in the cam timing sprocket is actuated by
switching or adjusting the hydraulic pressure applied to the chambers for the timing advancing (7) and/or retarding (6).
To switch or adjust the hydraulic pressure appropriately, ECM operates the oil control valve (12) with detecting the
engine speed, intake air value, throttle opening, engine coolant temperature and camshaft position (angle).
1
4
5
13
10
89
2
7
6
12
11
3
14
60 (variable angle)
Most retarded timing
Most advanced timing
Exhaust valve Intake valve
Crank angle
Overlap of valves
Valve lift
I3RH0B140002-01
4. Oil passage to chamber for timing retarding 8. Oil filter10. Oil pan 13. Oil return
5. Oil passage to chamber for timing advancing 9. Oil pump11. Control signal from ECM 14. Oil flow

Downloaded from www.Manualslib.com manuals search engine 1D-3 Engine Mechanical:
Oil Control Valve
The oil control valve switches and adjusts the hydraulic
pressure applied to the cam timing sprocket by moving
the spool valve (1) according to the duty pulse signals
output from the ECM. By this operation, the intake valve
timing is varied continuously. Signals output from the
ECM are the duty pulse of about 240 Hz.
Cam Timing Sprocket
The cam timing sprocket is equipped with the chambers
for timing advancing (2) and retarding (3) which are
separated by the rotor (5). The rotor rotates receiving the
hydraulic pressure applied to both the chambers. The
sprocket (1) is installed on the housing (4) and the rotor
is secured on the intake camshaft by fastening the bolts.
Therefore, the actuation of the rotor makes the phase
difference between the sprocket and intake camshaft.
Timing Advancing
When the duty ratio of the signal output from the ECM is
heavy, the spool valve (4) of the oil control valve moves
to the left (opposite direction against the coil (5)). By this
spool valve movement, the pressurized oil (1) is led into
the chambers for timing advancing and the oil in the
chambers for timing retarding is drained. This operations
actuate the rotor (3) and result in the advanced timing of
the intake valve. Timing Holding
When the duty ratio of the si
gnal output from the ECM
shows that of holding, the sp ool valve of the oil control
valve is located at hold posi tion. Because this condition
generates no oil pressure changes in both chambers,
the rotor is fixed at a target position.
Timing Retarding
When the duty ratio of the sig nal output from the ECM is
light, the spool valve of the o il control valve moves to the
right (head for the coil). By this spool valve movement,
the pressurized oil is led into the chambers for timing
retarding and the oil in the chambers for timing
advancing is drained. This operations actuate the rotor
and result in the retarded timing of the intake valve.
6. Seal
1
I3RH0B140003-01
1 2
3
4
56
I3RH0B140004-01
2. Drain
12
5
4
3
I3RH0B140005-01
I3RH0B140006-01
I3RH0B140007-01

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Targeted Timing Varying Operation
Diagnostic Information and Procedures
Compression CheckS7RS0B1404001
Check compression pressure on all 4 cylinders as
follows:
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
NOTE
After warming up engine, place transaxle
gear shift lever in “Neutral”, and set parking
brake and block drive wheels.

3) Disconnect negative cable at battery.
4) Remove engine cover.
5) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
6) Remove cylinder head upper cover.
7) Disconnect ignition coil couplers (1).
8) Remove ignition coil assemblies (2) with high- tension cord (3).
9) Remove all spark plugs.
10) Disconnect fuel injector wires (4) at the coupler. Driving condition Valve timing Target of control Effect
Engine running at idle
speed Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Stabilization of the engine
rotation at idle speed.
Average engine load
range To the advanced
sideTo lengthen the valve opening overlap
in order to enhance the internal
exhaust gas recirculation and reduce
the pumping loss. Improvement of the fuel
efficiency.
Lowering of the exhaust
emission.
Light engine load
range To the retarded sideTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Keeping of the engine stability.
Low or average
engine speed range
with heavy engine
load To the advanced
side
To advance the closing timing of the
intake valve in order to improve the
volumetric efficiency. Improvement of generating the
engine torque at low and
average engine speed.
High engine speed
range with heavy
engine load To the retarded sideTo retard the closing timing of the
intake valve in order to improve the
volumetric efficiency. Improvement of generating the
engine power.
Low engine coolant
temperature Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold and
reduce the fuel increasing.
To slow the fast idle speed of the
engine as a result of stabilizing the
engine idling. Stabilization of the fast idling of
the engine.
Improvement of the fuel
efficiency.
At engine starting and
stopping Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Improvement of start ability.I2RH0B140003-01

Downloaded from www.Manualslib.com manuals search engine 1D-7 Engine Mechanical:
Replacement of Shim1) Close the valve whose shim (2) is to be replaced by turning crankshaft, then tu rn tappet (3) till its cut
section (1) faces inside as shown in the figure.
2) Lift down the valve by turning crankshaft to 360° .
3) Hold tappet at that position using special tool as follows.
a) Remove its housing bolts.
b) Check housing No. and select special tool corresponding to housing No., referring to
“Special tool selection table”.
Special tool selection table
c) Hold down the tappet so as not to contact the shim by installing special tool on camshaft
housing with housing bolt (1) tighten housing
bolts by hand.
Special tool
(A): 09916–67020
(A): 09916–67021 4) Turn camshaft by approximately 90
° clockwise and
remove shim (3).
WARNING!
Never put in the hand between camshaft and
tappet.

5) Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement
shim by calculating the thickness of new shim with
the following formula and table.
Shim thickness specification
Intake side:
A = B + C – 0.20 mm (0.008 in.)
Exhaust side:
A = B + C – 0.30 mm (0.012 in.)
A: Thickness of new shim
B: Thickness of removed shim
C: Measured valve clearance
No. on camshaft
housing Embossed mark on
special tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345
A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
I2RH0B140006-01
I2RH0B140011-01
1. Special tool
2. Magnet
I6RS0B141028-01
I2RH0B140013-01
I2RH0B140014-01

Downloaded from www.Manualslib.com manuals search engine 1D-11 Engine Mechanical:
2) Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface area (2) as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
• Timing chain cover (1) and cylinder head (2) mating surface as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F) 3) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.

4) Tighten cylinder head cover bolts as follows.
a) Tighten cylinder head cover bolts to 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft) according to numerical order (“1”
through “7”) as shown in figure.
b) In the same manner as in Step, a) tighten them
to 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft).
c) Retighten them by turning through 8 N ⋅m (0.8
kgf-m, 6.0 lb-ft) in same manner as Step a).
Tightening torque
Cylinder head cover bolt (a): Tighten 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft), 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft) and 8
N ⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified
procedure
5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).
8) Install wire harness clamp to cylinder head cover.
9) Install ignition coil assemb lies with high-tension cord
referring to “Ignit ion Coil Assembly (Including ignitor)
Removal and Installati on in Section 1H”.
10) Connect ignition coil couplers and clamp harness securely.
11) Install cylinder head upper cover.
12) Install air cleaner case and resonator.
13) Connect negative cable at battery.
I2RH0B140036-01
I2RH0B140037-01
I3RH0B140016-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-20
15) Install A/C compressor to its bracket (if equipped) referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installa tion in Section 7B”.
16) Adjust A/C compressor belt tension (if equipped) referring to “Compressor Drive Belt Inspection and
Adjustment in Section 7B” or “Compressor Drive Belt
Inspection and Adjustment in Section 7B”.
17) Check to ensure that a ll removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
18) Refill cooling system with coolant referring to “Cooling System Flush and Refill in Section 1F”. 19) Refill engine with engine oil
referring to “Engine Oil
and Filter Change in Section 0B”.
20) Refill transaxle with transa xle oil referring to“Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A”.
21) Install battery and tray.
22) Connect positive and negative cable at battery.
23) Install engine hood and connect windshield washer hose.
24) Verify that there is no fu el leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
Timing Chain Cover ComponentsS7RS0B1406012
I6RS0C140015-02
1. Crankshaft pulley bolt 13. Oil gallery pipe No.2 bolt
2. Crankshaft pulley 14. Oil gallery pipe No.3
3. Oil seal : Apply engine oil to oil seal lip. 15. Oil gallery pipe No.3 bolt
4. Timing chain cover : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating surface of timing chain cover referring to the
figure of Step 4) of “Installation” under “Timing Chain Cover Removal and Installation”. 16. O-ring
: Apply engine oil.
5. Pin 17. Oil control valve
6. Cap bolt 18. Oil control valve mounting nut
7. Timing chain cover mounting bolts 19. Cap
8. Timing chain cover mounting nut : 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Oil gallery pipe No.1 :25 N⋅m (2.5 kgf-m, 18.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1D-21 Engine Mechanical:
Timing Chain Cover Removal and InstallationS7RS0B1406013
CAUTION!
• Keep working table, tools and hands clean while overhauling.
• Use special care to handle aluminum parts so as not to damage them.
• Do not expose removed parts to dust. Keep them always clean.

Removal
1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1J”.
3) Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool with it
as shown in figure.
Special tool
(A): 09917–68221
4) Remove crankshaft pulley (1). If it is hard to remove, use special tools as shown in
figure.
Special tool
(A): 09944–36011
(B): 09926–58010 5) Remove cylinder head cove
r referring to “Cylinder
Head Cover Removal and Installation”.
6) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Inst allation in Section 1E”.
7) Remove water pump pulley.
8) Remove A/C bracket from cylinder block.
9) Remove oil gallery pipe s No.2 (1) and No.3 (2).
10) Remove cap (1) from timing chain cover (2). 11) Remove timing chain cover (2).
12) Remove oil control valve from timing chain cover referring to “Oil Cont rol Valve Removal and
Installation”.
10. Copper washer :30 N⋅m (3.0 kgf-m, 22.0 lb-ft)
11. Oil gallery pipe No.1 bolt : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft)
12. Oil gallery pipe No.2 : Do not reuse.
I2RH0B140051-01
I2RH0B140052-01
1
2
I3RH0B140021-01
1 2
I3RH0B140022-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-22
Installation1) Clean sealing surface on timing chain cover, cylinder block and cylinder head.
Remove oil, old sealant and dust from sealing
surface.
2) Install oil seal (1) to timi ng chain cover, if removed.
NOTE
When installing new oil seal, press fit to
timing chain cover (2) by using special tool
(bearing installer) as shown in figure.

Drive in dimension
“a”: 1.5 mm (0.06 in.)
Special tool
(A): 09913–75810
3) Install oil control valve to timing chain cover referring to “Oil Control Valve Removal and Installation”.
4) Apply sealant “A” to mating surface of cylinder and cylinder head and “B” to mating surface of timing
chain cover as shown in figure.
“A”: Water tight sealant 99000–31140 (SUZUKI
Bond No.1207B)
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for timing chain cover
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 5) Apply engine oil to oil seal lip, then install timing
chain cover (1). Tighten bolts and nut to specified
torque.
NOTE
Before installing timing chain cover, check
that pin is securely fitted.

Tightening torque
Timing chain cover bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Timing chain cover nut (b): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
6) Apply engine oil to new O-rings (2) and install them to cap (3).
7) Install cap (3) to ti ming chain cover (1).
Tighten bolts to specified torque.
Tightening torque
Cap bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
I2RH0B140058-01
I3RH0B140025-01
(a)
(b)
(c)
1
2
3
I4RS0B140011-02

Downloaded from www.Manualslib.com manuals search engine 1D-23 Engine Mechanical:
8) Install new O-ring (1) to oil gallery pipes No.2 (2) and
No.3 (3).
9) Install oil gallery pipes No.2 and No.3 to cylinder
head (4) and timing chain cover (5).
Tighten bolts to specified torque.
Tightening torque
Oil gallery pipe No.2 and No.3 bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
10) Install water pump pulley. 11) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
12) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
13) Install crankshaft pulley (1). Tighten bolt (2) to specified torque. To lock crankshaft pulley, use
special tool with it as shown in figure.
Special tool
(A): 09917–68221
Tightening torque
Crankshaft pulley bolt (a): 150 N·m (15.0 kgf-m,
108.5 lb-ft)
14) Install engine assembly to vehicle referring to “Engine Assembly Removal and Installation”.
Timing Chain Cover InspectionS7RS0B1406014
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary. Timing Chain Cover
Inspect strainer (1) of oil passage for driving intake cam
timing sprocket assembly (VVT actuator).
If clog or foreign matter exists, clean strainer.
Oil Control Valve Removal and InstallationS7RS0B1406015
Removal
Remove oil gallery pipe No.1
(1) and oil control valve (2)
from timing chain cover (3).
Installation
1) Install new O-ring (4) to oil control valve.
2) Install oil control valve to timing chain cover. Tighten nuts to specification.
Tightening torque
Oil control valve mounting nut (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
3) Install oil gallery pipe No .1 with new copper washers
(5) to timing chain cover.
Tighten bolts to specification.
Tightening torque
Oil gallery pipe No.1 bolt (b): 30 N·m (3.0 kgf-m,
21.5 lb-ft)
(a)
(a) 1
2
3
4
5
I3RH0B140027-01
I2RH0B140056-01
1
I3RH0B140028-01
1
5
(b) 3
(a)
2 4
5
I3RM0A140027-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-24
Oil Control Valve InspectionS7RS0B1406016
Oil Control Valve1) Inspect strainer (1) and mating surface (2) of oil control valve for clog or damage. Clean oil control
valve if clog or foreign matter is present on strainer
or mating surface of oil control valve.
Replace oil control valve if its mating surface is
damaged.
2) Check resistance between terminals of oil control
valve.
Oil control valve resistance
6.7 – 7.7 Ω (at 20 °C (68 °F)) Oil Gallery Pipe
Inspect oil gallery pipes No
.1, No.2 (2) and No.3 (3).
Replace if crack, deformation or clog exists.
Timing Chain and Chain Tensioner ComponentsS7RS0B1406017
1
2
I3RM0A140028-01
1
3
2
I3RH0B140030-01
I4RS0A140012-04
1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly 9. Spacer
2. Timing chain : Apply engine oil. 6. Chain tensioner adjuster mounting bolt
: 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
3. Timing chain No.1 guide : Apply engine oil to sliding surface. 7. Timing chain tensioner bolt
: 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
4. Timing chain tensioner : Apply engine oil to sliding surface. 8. Timing chain No.1 guide bolt
: 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)