oil spec SUZUKI SWIFT 2005 2.G Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine 1D-27 Engine Mechanical:
8) Screw in plunger (1) by turning body (2) in arrow direction and install a reta iner (3) (wire) to hold
plunger in place.
9) Install timing chain tensioner adjuster assembly (1) with a retainer (2).
Tighten adjuster bolts to specified torque and then
remove a retainer from chain tensioner adjuster
assembly.
Tightening torque
Timing chain tensioner adjuster bolt (a): 11 N·m
(1.1 kgf-m, 8.0 lb-ft)
10) Apply engine oil to timing chain, and then turn crankshaft clockwise by 2 revolutions and check that
match marks (1) are at the following specific
positions.
• Intake and exhaust camshaft timing sprockets makes (1) are in match with notches (2) on
cylinder head.
• Crankshaft sprocket key (3) is in match with notch of cylinder block (4).
• Crankshaft sprocket key (3) is on upside of crankshaft as shown in figure. 11) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
Timing Chain and Chain Tensioner InspectionS7RS0B1406019
Timing Chain No.1 Guide
Check shoe (1) for wear or damage.
Timing Chain Tensioner
Check shoe (1) for wear or damage.
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-28
Crankshaft Timing Sprocket
Check teeth of sprocket for wear or damage.Timing Chain
Check timing chain for wear or damage.
Timing Chain Tensioner Adjuster
Check that tooth surface (1) are free from damage.
Camshaft, Tappet and Shim ComponentsS7RS0B1406020
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1. Intake camshaft
5. Shim
: Shim No. on it faces tappet side. 9. Camshaft bearing
: Install a bearing half with some holes to upper side of intake
camshaft No.1 bearing.
2. Intake camshaft sprocket assembly 6. Tappet : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
3. Intake camshaft sprocket bolt 7. Camshaft housing : Tighten 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.
4. Exhaust camshaft 8. Camshaft housing bolt : Apply engine oil to sliding surface of each part.

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”
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2
3
(a)
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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
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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
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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”
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-34
Valves and Cylinder Head ComponentsS7RS0B1406023
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1. Valve cotters7. Exhaust valve 13. Cylinder head bolt (M8)
: Be sure to tighten cylinder head bolt (M8) after
securing the other cylinder head bolt (M10).
2. Valve spring retainer 8. Valve guide : Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft), 40 N ⋅m (4.0 kgf-
m, 29.0 lb-ft), 60 ° and 60 ° by the specified procedure.
3. Valve spring 9. Cylinder head bolt (M10)
: Never reuse cylinder head bolts once disassembled it
due to plastic deformation tightening. Be sure to use new
cylinder head bolts when installing. : 25 N
⋅m (2.5 kgf-m, 18.0 lb-ft)
4. Valve stem seal 10. Cylinder head : Do not reuse.
5. Valve spring seat 11. Cylinder head gasket
: “TOP” mark provided on gasket comes to crankshaft
pulley side, facing up. : Apply engine oil to sliding surface of each part.
6. Intake valve 12. Dowel pin

Downloaded from www.Manualslib.com manuals search engine 1D-35 Engine Mechanical:
Valves and Cylinder Head Removal and
Installation
S7RS0B1406024
Removal1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
3) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
4) Remove timing chain cover referring to Steps 2) to 11) of “Removal” in “Tim ing Chain Cover Removal
and Installation”.
5) Remove timing chain referring to Steps 2) to 6) of “Removal” in “Timing Chain and Chain Tensioner
Removal and Installation”.
6) Remove intake and exhaust camshafts referring to Steps 3) to 8) of “Removal” in “Camshaft, Tappet and
Shim Removal and Installation”.
7) Loosen cylinder head bolts in such order as indicated in the figure by using a 12 corner socket
wrenches and remove them.
NOTE
• Don’t forget to remove bolt (M8) (1) as shown in figure.
• Never reuse cylinder head bolts once disassembled it due to plastic deformation
tightening. Be sure to use new cylinder
head bolts when installing.

8) Check all around cylinder head for any other parts required to be removed or disconnected and remove
or disconnect whatever necessary.
9) Remove exhaust manifold, if necessary referring to
“Exhaust Manifold Removal and Installation in
Section 1K”.
10) Remove cylinder head wi th intake manifold and
exhaust manifold. Use lifting device, if necessary. Installation
1) Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating
surface.
2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block. “Top” or “Triangle/circle” mark provided on gasket
comes to crankshaft pulley side, facing up (toward
cylinder head side).
4) Make sure that oil jet (venturi plug) (1) is not clogged. If it is not install ed, install it as specified
torque.
Tightening torque
Venturi plug (a): 3.5 N·m (0.35 kgf-m, 3.0 lb-ft)
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-36
5) Install cylinder head to cylinder block.Apply engine oil to new cylinder head bolts and
tighten them gradually as follows.
a) Tighten cylinder head bolts (“1” – “10”) to 20 N ⋅m
(2.0 kgf-m, 14.5 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 40 N ⋅m (4.0 kgf-m, 29.0 lb-ft).
c) Turn all bolts 60 ° according to numerical order in
the figure.
d) Repeat Step c).
e) Tighten bolt “A” to specified torque.
NOTE
Be sure to tighten M8 bolt “A” after securing
the other bolts.

Tightening torque
Cylinder head bolt for M8 (a): 25 N·m (2.5
kgf-m, 18.0 lb-ft)
Cylinder head bolt for M10 (b): 20 N ⋅m (2.0
kgf-m, 14.5 lb-ft), 40 N ⋅m (4.0 kgf-m, 29.0 lb-ft)
and then retighten by turning through to 60 °
twice
NOTE
• If they are reused, check thread diameters of cylinder head bolt (1) for deformation
according to the follows and replace them
with new ones if thread diameter difference
exceeds limit.
• Measure each thread diameter of cylinder head bolt (1) at “A” on 83.5 mm (2.81 in.)
from seat side of flange bolt and “B” on
115 mm (4.53 in.) from seat side of flange
bolt by using a micrometer (2).
Then calculate difference in diameters (“A”
– “B”). If it exceeds limit, replace with new
one.

Cylinder head bolt diameter measurement
points
“a”: 83.5 mm (2.81 in.)
“b”: 115 mm (4.53 in.)
Cylinder head bolt diameter difference
(deformation)
Limit (“A” – “B”): 0.1 mm (0.004 in.)
6) Install camshafts, tappet and shim referring to “Camshaft, Tappet and Shim Removal and
Installation”.
7) Install timing chain referring to “Timing Chain and Chain Tensioner Remova l and Installation”.
8) Install timing chain cover referring to “Timing Chain Cover Removal and Installation”.
9) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
10) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Inst allation in Section 1E”.
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“A”
“a” “b” “B”

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2
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-38
Assembly1) Before installing valve guide into cylinder head, ream
guide hole with special tool (10.5 mm reamer) so as
to remove burrs and make it truly round.
Special tool
(A): 09916–34542
(B): 09916–37320
2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80
to 100 °C (176 to 212 °F) so that head will not be
distorted, and drive new valve guide into hole with
special tools.
Drive in new valve guide until special tool (Valve
guide installer) contacts cylinder head.
After installing, ma ke sure that valve guide pr otrudes
by specified dimension “a” from cylinder head.
Special tool
(A): 09916–58210
(B): 09916–56011
NOTE
• Never reuse valve guide once disassembled. Make sure to install new
valve guide (Oversize).
• Intake and exhaust valve guides are identical.

Valve guide protrusion (In and Ex)
“a”: 11.3 mm (0.44 in.) 3) Ream valve guide bore with special tool (5.5 mm
reamer). After reaming, clean bore.
Special tool
(A): 09916–34542
(B): 09916–34550
4) Install valve spring seat to cylinder head.
5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of
special tool (Valve guide installer handle), fit oil seal
to spindle, and then install seal to valve guide by
pushing special tool by hand.
After installing, check to be sure that seal is properly
fixed to valve guide.
Special tool
(A): 09917–98221
(B): 09916–58210
NOTE
• Do not reuse seal once disassembled. Be sure to install new seal.
• When installing, never tap or hit special tool with a hammer or else. Install seal to
guide only by pushing special tool by
hand. Tapping or hitting special tool may
cause damage to seal.

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Downloaded from www.Manualslib.com manuals search engine 1D-39 Engine Mechanical:
6) Install valve to valve guide.Before installing valve to valve guide, apply engine
oil to stem seal, valve guide bore and valve stem.
7) Install valve spring and spring retainer. Each valve spring has top end (large-pitch end (1))
and bottom end (small-pitch end (2)). Be sure to
position spring in place with its bottom end (small-
pitch end) facing the bottom (valve spring seat side). 8) Using special tools (Val
ve lifter), compress valve
spring and fit two valve cotters (1) into groove in
valve stem.
NOTE
When compressing the valve spring, be
carefully to free from damage in inside face
of tappet installing hole.

Special tool
(A): 09916–14510
(B): 09916–14521
(C): 09916–84511
9) Install intake manifold referring to “Engine Assembly Removal and Installation”.
10) Install fuel injectors referring to “Fuel Injector Removal and Installati on in Section 1G”.
11) Install exhaust manifold referring to “Exhaust Manifold Removal and Inst allation in Section 1K”.
A: Valve spring retainer side
B: Valve spring seat side
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-44
Pistons, Piston Rings, Connecting Rods and Cylinders ComponentsS7RS0B1406029
1. Top ring 6. Connecting rod bearing cap : See “B”: Tighten15 N
⋅m (1.5 kgf-m, 11.0 lb-ft), 45 °
and 45 ° by the specified procedure.
2. 2nd ring 7. Connecting rod bearing : Apply engine oil to sliding surface of each
part.
3. Oil ring 8. Piston pin : Do not reuse.
4. Piston 9. Piston pin circlip
5. Connecting rod : See “A” 10. Connecting rod bearing cap bolt
: See “C”
“A”: Apply engine oil to sliding surface except inner surface of big end.
“B”: Point arrow mark on cap to crankshaft pulley side.
“C”: Make sure bearing cap bolt diameter when reuse it due to plastic deformation tightening. Refer to “Piston Pins and Connecti ng Rods Inspection”.
(a)1
2
3
9
4
5
6 10
7 8
9
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
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