oil spec SUZUKI SWIFT 2005 2.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine 1D-45 Engine Mechanical:
Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation
S7RS0B1406030
Removal1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove cylinder head referring to “Valves and Cylinder Head Removal and Installation”.
3) Mark cylinder number on all pistons, connecting rods
and connecting rod caps using silver pencil or quick
drying paint.
4) Remove rod bearing caps.
5) Decarbonize top of cylinder bore before removing piston from cylinder.
6) Push piston and connecting rod assembly out through the top of cylinder bore.
Installation 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins.
NOTE
Do not apply oil between connecting rod and
bearing or between bearing cap and bearing.

2) When installing piston and connecting rod assembly into cylinder bore, point front mark or arrow mark (1)
on piston head to crankshaft pulley side. 3) Install piston and connecting rod assembly into
cylinder bore. Use special tool (Piston ring
compressor) to compress rings. Guide connecting
rod into place on crankshaft.
Using a hammer handle, tap piston head to install
piston into bore. Hold ring compressor firmly against
cylinder block until all piston rings have entered
cylinder bore.
Special tool
(A): 09916–77310
4) Install bearing cap (1): Point arrow mark (2) on cap to crankshaft pulley
side.
After applying engine oil to bearing cap bolts and
tighten bolts gradually as follows.
a) Tighten all bolts to 15 N ⋅m (1.5 kgf-m, 11.0 lb-ft).
b) Retighten them to 45 °.
c) Repeat Step b) once again.
NOTE
Before installing bearing cap, make sure that
checking for bearing cap bolt deformation.
Refer to “Piston Pins and Connecting Rods
Inspection”.

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) Install cylinder head referring to “Valves and Cylinder Head Removal and Installation”.
A: Crankshaft pulley side
B: Flywheel side
I2RH0B140110-01
I2RH0B140111-01
I6RS0B141025-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-46
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly
S7RS0B1406031
Disassembly1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from
piston.
2) Remove piston pin from connecting rod as follows. a) Ease out piston pin circlip (1), as shown.
b) Force piston pin out.
Assembly 1) Decarbonize piston head and ring grooves using a suitable tool.
2) Install piston pin to piston (1) and connecting rod (2): a) After applying engine oil to piston pin and piston pin holes in piston and connecting rod.
b) Fit connecting rod as shown in figure.
NOTE
Be sure to position front mark or arrow mark
(4) on piston and oil hole (5) of connecting
rod at specified position as shown in figure.

c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
NOTE
Circlip should be installed with its cut part
facing as shown in figure. Install so that
circlip end gap comes within such range as
indicated by arrow.

3) Install piston rings to piston:
• As indicated in the figure, 1st and 2nd rings have discrimination mark (4) respectively. When
installing these piston rings to piston, direct
marked side of each ring toward top of piston.
• 1st ring (1) differs from 2nd ring (2) in thickness, shape and color of surface contacting cylinder
wall.
Distinguish 1st ring from 2nd ring by referring to
the figure.
• When installing oil ring (3), install spacer first and then two rails.
4) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.
I2RH0B140113-01
I2RH0B140114-01
1. 1st ring end gap 3. Oil ring upper rail gap
2. 2nd ring end gap and oil ring spacer gap 4. Oil ring lower rail gap
I6RS0C140022-01
I6RS0C140023-01
I6RS0B141018-01

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-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-53 Engine Mechanical:
Main Bearings, Crankshaft and Cylinder Block ComponentsS7RS0B1406035
(a)
(c)
(d)(e)
(b)
(f)
(f)
(f)
(g)
(h)
12
3
4
5 67
8910
11 15
12 13
14 16
17
18 19
2021
22
23 24
25
26
OIL
OIL
OIL
OILOIL
I6RS0C140025-02
1. CKP sensor : See “A” 12. Input shaft bearing 23. Sensor plate bolt
2. Knock sensor 13. Flywheel or drive plate 24. Oil pressure switch 3. Cylinder block 14. Main bearing cap 25. Piston cooling nozzle
4. Venturi plug 15. Flywheel or drive plate bolt 26. Piston cooling valve
5. Main bearing : See “B” 16. Rear oil seal housing mounting bolt : 22 N
⋅m (2.2 kgf-m, 16.0 lb-ft)
6. Sensor plate 17. Main bearing cap No.2 bolt : 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Crankshaft timing sprocket key 18. Main bearing cap No.1 bolt : See “D”:70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
8. Crankshaft 19. O-ring : Tighten 25 N ⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure.
9. Thrust bearing 20. Oil filter adapter case : Tighten 30 N ⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0
kgf-m, 36.5 lb-ft) and 60 ° by the specified procedure.
10. Rear oil seal housing : See “C” 21. Oil filter adapter bolt : 11 N
⋅m (1.1 kgf-m, 8.0 lb-ft)
11. Rear oil seal 22. Spring pin : 13 N ⋅m (1.3 kgf-m, 9.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-54
Main Bearings, Crankshaft and Cylinder Block
Removal and Installation
S7RS0B1406036
Removal1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove clutch cover, clut ch disc and flywheel (drive
plate for A/T) by using special tool.
Special tool
(A): 09924–17811
3) Remove piston and connecting rod referring to “Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
4) Remove rear oil seal housing (1). 5) Loosen main bearing cap No.1 and No.2 bolts in
such order as indicated in figure and remove them.
6) Remove crankshaft from cylinder block.
7) Remove piston cooling valves and nozzles, if necessary.
“A”: When servicing CKP sensor, refer to “CMP Sensor Removal and Installation in Section 1C”. :25 N
⋅m (2.5 kgf-m, 18.0 lb-ft)
“B”: Upper half of bearing has an oil groove. : Do not reuse.
“C”: Apply sealant 99000-31250 to mating surface. : Apply engine oil to inside / sliding surface.
“D”: Make sure main bearing cap No.1 bolt deformation when reuse it due to plastic deformation tightening referring to “Main Bearings Inspection”.
I2RH0B140125-01
I2RH0B140126-01
I6RS0C140026-01

Downloaded from www.Manualslib.com manuals search engine 1D-55 Engine Mechanical:
Installation
NOTE
• Use new bearing cap No.1 bolts. They are deformed once they are used because they
are plastic deformation tightening bolts.
• All parts to be insta lled must be perfectly
clean.
• Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins,
connecting rod bearings, pistons, piston
rings and cylinder bores.
• Journal bearings, bearing caps, connecting rods, rod bearings, rod bearing
caps, pistons and piston rings are in
combination sets. Do not disturb such
combination and make sure that each part
goes back to where it came from, when
installing.

1) Install sensor plate (1) to crankshaft (2) and tighten bolts to spec ified torque.
NOTE
When installing sensor plate, align spring pin
(3) on crankshaft and hole of sensor plate.

Tightening torque
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft) 2) Install piston cooling valves and nozzles, if removed.
NOTE
Install piston cooling valve while matching
piston cooling nozzle (1) to positioning (3) of
cylinder block when installed piston cooling
valve (2).

Tightening torque
Piston cooling valve (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
3) Install main bearings to cylinder block. Upper half of bearing (1), has an oil groove (2).
Install it to cylinder block (3), and the other half
without oil groove to bearing cap.
Make sure that two halves are painted in the same
color.
4) Confirm that dowel pins (3 ) are installed to intake
side of each journal.
I2RH0B140128-01
I6RS0B141022-02
I2RH0B140129-01
I2RH0B140130-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-56
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

Downloaded from www.Manualslib.com manuals search engine 1D-57 Engine Mechanical:
11) Install flywheel (drive plate for A/T).Using special tool, lock flyw heel or drive plate, and
tighten flywheel or drive plate bolts to specified
torque.
NOTE
Use new flywheel or drive plate bolts.

Special tool
(A): 09924–17811
Tightening torque
Flywheel or drive plate bolt (a): 70 N·m (7.0 kgf-
m, 51.0 lb-ft)
12) Install piston and connecting rod referring to “Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
13) Install cylinder head referring to “Valves and Cylinder Head Removal and Installation”.
14) Install camshafts, tappet and shim referring to “Camshaft, Tappet and Shim Removal and
Installation”.
15) Install timing chain referring to “Timing Chain and Chain Tensioner Removal and Installation”.
16) Install timing chain cover referring to “Timing Chain Cover Removal and Installation”.
17) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
18) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”
19) Install engine assembly to vehicle referring to “Engine Assembly Removal and Installation”.
Crankshaft InspectionS7RS0B1406037
Crankshaft Runout
Using a dial gauge, measure runout at center journal.
Rotate crankshaft slowly. If runout exceeds its limit,
replace crankshaft.
Crankshaft runout
Limit: 0.02 mm (0.0008 in.)
Crankshaft Thrust Play
1) Measure this play with crankshaft set in cylinder block in the normal manner, that is with thrust
bearing (1) and journal bearing caps installed.
Thickness of crankshaft thrust bearing
Standard: 2.500 mm (0.0984 in.)
Oversize (0.125 mm (0.0049 in.)): 2.563 mm
(0.1009 in.)
I6RS0B141029-01
I2RH0B140135-01
I2RH0B140136-01

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