Oil system SUZUKI SWIFT 2006 2.G Service Repair Manual

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

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-7
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

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-9
Reassembly1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case
and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Apply engine oil to relief valve (1) and spring (2), and install them with retainer (3) and new circlip (4) to
rotor plate (5).
5) Install rotor plate and tighten all bolts to specified torque. After installing plate, check to be sure that
rotors turn smoothly by hand (0.3 N ⋅m (0.03 kgf-m,
0.25 lb-ft) torque or below).
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)Oil Pump InspectionS7RS0B1506010
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Oil Pump
• Check outer (1) and inner rotors (2), rotor plate, and oil pump case for excessive wear or damage.
• Check relief valve (1) for excessive wear or damage
and operates smoothly.
I2RH0B150019-01
I3RM0A150005-01
I2RH0B150022-01
I2RH0B150023-01
I2RH0B150019-01
I2RH0B150025-01

Downloaded from www.Manualslib.com manuals search engine 1E-10 Engine Lubrication System:
Radial clearance
Check radial clearance between outer rotor (1) and case
(2) using thickness gauge (3).
If clearance exceeds its limit, replace outer rotor or case.
Radial clearance between outer rotor and case for oil
pump
Limit: 0.310 mm (0.0122 in.)
Side clearance
Using straightedge (1) and thickness gauge (2),
measure side clearance.
If side clearance exceeds its limit, replace oil pump
assembly.
Side clearance for oil pump inner rotor
Limit: 0.15 mm (0.0059 in.)Relief valve spring free length and load
Check relief valve spring free length and load as shown
in the figure. If the measured valve spring length is lower
than the specification, replace relief valve spring.
Relief valve spring free length and load
I2RH0B150026-01
I2RH0B150027-01
Standard Limit
Free length 52.4 mm
(2.06 in.) —
Load at spring length
38.5 mm (1.52 in.) 79 N
(7.9 kgf, 17.5 lb) 69 N
(6.9 kgf, 15.0 lb)
I2RH01150023-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-11
Specifications
Tightening Torque SpecificationsS7RS0B1507001
NOTE
The specified tightening torque is also described in the following.
“Heat Exchanger Components”
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B1508001
NOTE
Required service material is also described in the following.
“Heat Exchanger Components”
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Special ToolS7RS0B1508002
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Oil pressure switch 13 1.3 9.5 )
Heat exchanger stand bolt 22 2.2 16.0 )
Oil pump strainer bolt 11 1.1 8.0 )
Oil pump strainer bracket bolt 11 1.1 8.0 )
Oil pan bolt (M6) 11 1.1 8.0 )
Oil pan bolt (M10) 55 5.5 40.0 )
Oil pan nut 11 1.1 8.0 )
Oil pan drain plug 35 3.5 25.5 )
Transaxle stiffener bolt 55 5.5 40.0 )
Oil pump rotor plate bolt 11 1.1 8.0 )
MaterialSUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
09915–77310 09915–78211
Oil pressure gauge (0-10kg/
cm2) Oil pressure gauge
attachment
))

Downloaded from www.Manualslib.com manuals search engine 1F-1 Engine Cooling System:
Engine
Engine Cooling System
General Description
Cooling System DescriptionS7RS0B1601001
The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and
thermostat. The radiator is of tube-and-fin type.
Coolant DescriptionS7RS0B1601002
WARNING!
• Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir. Coolant should be added only to reservoir as necessary.
• As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal
of the radiator cap while engine is hot and pressure is high will cause the solution to boil
instantaneously and possibly with explosive force, spewing the solution over engine, fenders and
person removing cap. If the solution contains flammable anti-freeze such as alcohol (not
recommended for use at any time), there is also the possibility of causing a serious fire.
• Check to make sure that engine coolant temperature is cold before removing any part of cooling system.
• Also be sure to disconnect negative cable from battery terminal before removing any part.

The coolant recovery system is standard. The coolant in the radiator expands with heat, and the coolant is overflowed
to the reservoir.
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has be en filled with a quality coolant that is a 50/50 mixture of water and ethylene glycol
antifreeze.
This 50/50 mixture coolant solution provides freezing protection to –36 °C (–33 °F).
• Maintain cooling system freeze protection at –36 °C (–33 °F) to ensure protection against corrosion and loss of
coolant from boiling. This should be done even if freezing temperatures are not expected.
• Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added protection against freezing at temperature lower than –36 °C (–33 °F).
NOTE
• Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any
time as damage to cooling system could occur.
• Coolant must be mixed with deminerated water or distilled water.

Anti-freeze proportioning table
For M/T model For A/T model
Freezing temperature °
C –36 –36
° F –33 –33
Anti-freeze / Anti-corrosion coolant concentration % 50 50
Ratio of compound to cooling water ltr. 3.10/3.10 3.05/3.05
US pt. 6.55/6.55 6.44/6.44
Imp pt. 5.46/5.46 5.37/5.37

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-1
Engine
Ignition System
General Description
Ignition System ConstructionS7RS0B1801001
The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below.
• ECM
It detects the engine and vehicle conditions through the si gnals from the sensors, determines the most suitable
ignition timing and time for electricity to flow to the primar y coil and sends a signal to the ignitor (power unit) in the
ignition coil assembly.
• Ignition coil assembly (including an ignitor)
The ignition coil assembly has a built -in ignitor which turns ON and OFF the current flow to the primary coil
according to the signal from ECM. When the current flow to the primary coil is turned OFF, a high voltage is induced
in the secondary coil.
• High-tension cords and spark plugs
• CMP sensor (Camshaft position sensor) and CKP sensor (Crankshaft position sensor)
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts in itial ignition timing automatically.
• TP sensor, ECT sensor, MAP sensor, MAF sensor, IAT sensor, knock sensor and other sensors / switches
Although this ignition system does not have a distributor, it has two ignition coil assemblies (one is for No.1 and No.4
spark plugs and the other is for No.2 and No.3 spark plugs). W hen an ignition signal is sent from ECM to the ignitor in
the ignition coil assembly for No.1 and No.4 spark plugs, a high voltage is induced in the secondary coil and that
passes through the high-tension cords and causes No.1 and No.4 spark plugs to spark simultaneously. Likewise,
when an ignition signal is sent to the ignitor in the ot her ignition coil assembly, No.2 and No.3 spark plugs spark
simultaneously.

Downloaded from www.Manualslib.com manuals search engine 1H-2 Ignition System:
Schematic and Routing Diagram
Ignition System Wiring Circuit DiagramS7RS0B1802001
E23-60
E23-29 12V 5V
5V
E23-1
E23-16
BLK/WHT
BLK/RED
BLK/RED BLK/RED
BLK/YELBLK/YEL
BLK/YEL
GRN
BLKWHT
WHT
BRN/WHT
BLK/ORN
BLK
BLK
C37-20
BLK/RED
PNK
5V
C37-21
BLK/WHT
7
3 4
1
12 5
6
2
11
8
9
10
GRN/YEL
GRN/WHT
C37-6
C37-5 5V
5V
RED/YEL
C37-58
C37-15
C37-30
E23
C37
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
13
14
15
16
17
50A50A80A
BLK/ORN
E23-31 BLK
I4RS0B180001-01
1. Ignition switch 7. No.1 spark plug 13. Individual circuit fuse box
No.1
2. Main relay 8. No.2 spark plug 14. “IG ACC” fuse
3. Ignition coil assembly for No.1 and No.4 spark plugs 9. No.3 spark plug 15. “FI” fuse
4. Ignition coil assembly for No.2 and No.3 spark plugs 10. No.4 spark plug 16. Junction block assembly
5. CMP sensor 11. Sensed information (MAP sensor, ECT sensor, MAF and IAT
sensor, TP sensor, Knock sensor, VSS, Electric load signal,
Engine start signal) 17. “IG COIL” fuse
6. CKP sensor 12. Battery fuse box

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-3
Component Location
Ignition System Components LocationS7RS0B1803001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

16*
1
2
14
7
5 12 11
410
6
89
3 13*
15
17
I6RS0C180001-01
1. ECM 7. ECT sensor13. Data link connector
2. Ignition coil assembly for No.1 and No.4 spark plugs 8. MAF and IAT sensor 14. Battery fuse box
3. Ignition coil assembly for No.2 and No.3 spark plugs 9. Electric throttle body 15. Relay box
4. CMP sensor 10. Wheel speed sensor (VSS) 16. Junction block assembly
5. CKP sensor 11. High-tension cords
6. MAP sensor 12. Knock sensor