Clé SUZUKI SWIFT 2007 2.G Service Workshop Manual

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)

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-26
3) Install timing chain by aligning dark blue plate (1) of timing chain and triangle mark (2) on camshaft
timing sprocket as shown in figure.
4) Fit crankshaft timing sprocket to timing chain by aligning gold plate (3) of timing chain and circle mark
(4) on crankshaft timing sprocket. Then install
crankshaft timing sprocket fitted with chain to
crankshaft.
5) Apply engine oil to sliding surface of timing chain No.1 guide (1) and install it as shown in figure.
Tighten guide bolts to specified torque.
Tightening torque
Timing chain No.1 guide bolt (a): 9 N·m (0.9 kgf-
m, 6.5 lb-ft) 6) Apply engine oil to sliding surface of chain tensioner
(1) and install chain tensioner and spacer.
Tighten tensioner bolt to specified torque.
Tightening torque
Timing chain tensioner bolt (a): 25 N·m (2.5 kgf-
m, 18.0 lb-ft)
7) Check that match marks (2) on intake and exhaust camshaft timing sprockets are in match with dark
blue plates (1) of timing chain and match mark (4) on
crankshaft timing sprocket is in match with gold plate
(3) of timing chain.
[A]: View C
34
1
1
2
2
Approx. Approx.
C[A]
I6RS0C140016-02
I2RH0B140062-01
[A]: View C
I2RH0B140063-01
34
1
1
2
2
Approx. Approx.
C[A]
I6RS0C140016-02

Downloaded from www.Manualslib.com manuals search engine 1D-29 Engine Mechanical:
Camshaft, Tappet and Shim Removal and
Installation
S7RS0B1406021
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 timing chain cover referring to “Timing Chain Cover Removal and Installation”.
2) Remove timing chain referring to “Timing Chain and Chain Tensioner Removal and Installation”.
3) With hexagonal section (1) of intake camshaft (2) held stationary with spanner or the like, loosen
mounting bolt of intake cam timing sprocket
assembly (3) and remove it.
CAUTION!
Never attempt to loosen mounting bolt with
intake cam timing sprocket assembly held
stationary. Failure to fo llow this could result
in damage to lock pin.
Do not loosen bolt “a” because intake cam
timing sprocket assembly is not serviceable.

4) Loosen camshaft housing bolts in such order as indicated in the figure and remove them.
5) Remove camshaft housings.
6) Remove intake and exhaust camshafts.
7) Remove camshaft bearing (1).
8) Remove tappets (2) with shims (1).
3“a”
1
2
I3RM0A140030-01
“12”“13” “20”“21”
“16”“17” “8” “9”
“2”
“5” “3”
“4”
“1”
“10”“11”“18”
“19” “14” “15” “6” “7”
I3RM0A140031-01
1
I3RH0B140039-01
I2RH0B140074-01

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”
I3RH0B140041-01
1
2
3
(a)
I3RH0B140042-01
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
I3RH0B140043-01
I2RH0B140080-01

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
I2RH0B140082-01
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”
I3RH0B140041-01
I2RH0B140083-01

Downloaded from www.Manualslib.com manuals search engine 1D-33 Engine Mechanical:
If measured camshaft journal clearance exceeds
limit, measure journal (housing) bore and outside
diameter of camshaft journal. Replace camshaft or
cylinder head assembly whichever the difference
from specification is greater.
Camshaft journal diameter [A]
Camshaft journal bearing bore [B]
Wear of Tappet and Shim
Check tappet and shim for pitting, scratches, or damage.
If any malcondition is found, replace.
Measure cylinder head bore and tappet outside diameter
to determine cylinder head-to-tappet clearance. If
clearance exceeds limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 – 0.066 mm (0.0010 – 0.026 in.)
Limit: 0.15 mm (0.0059 in.)
Tappet outside diameter [A]
Standard: 30.959 – 30.975 mm (1.2189 – 1.2195 in.)
Cylinder head tappet bore [B]
Standard: 31.000 – 31.025 mm (1.2205 – 1.2215 in.)
Item Standard
Intake side No.1 housing 26.940 – 26.955 mm
(1.0606 – 1.0612 in.)
Exhaust side No.1 housing 26.934 – 26.955 mm
(1.0604 – 1.0612 in.)
Others 22.934 – 22.955 mm
(0.9029 – 0.9037 in.)
Item Standard
Intake side No.1 housing —
Exhaust side No.1 housing 27.000 – 27.021 mm
(1.0630 – 1.0638 in.)
Others 23.000 – 23.021 mm
(0.9055 – 0.9063 in.)
I2RH0B140084-01
I2RH0B140085-01
I2RH0B140086-01

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)
I2RH0B140088-01
I4RS0B140018-01
I2RH0B140089-01

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.

I2RH0B140096-01
I2RH0B140097-01
I2RH0B140096-01
I2RH0B140098-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-40
Valves and Valve Guides InspectionS7RS0B1406026
Valve Guide
Valve stem-to-guide clearance
Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance.
Be sure to take reading at more than one place along the length of each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem and valve guide specification
Valve stem end deflection
If bore gauge is not available, check end deflection of
valve stem with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end
deflection.
If deflection exceeds its limit, replace valve stem and
valve guide.
Valve stem end deflection limit
In: 0.14 mm (0.005 in.)
Ex: 0.18 mm (0.007 in.) Va l v e
Visual inspection
• Remove all carbon from valves.
• Inspect each valve for wear, burn or distortion at its
face and stem end, as necessary, replace it.
• Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be
resurfaced, but not too much to grind off its chamber.
When it is worn out too much that its chamber is gone,
replace valve.
Item Standard Limit
Valve stem diameter [A] In 5.465 – 5.480 mm (0.2150 – 0.2157 in.) —
Ex 5.440 – 5.455 mm (0.2142 – 0.2148 in.) —
Valve guide bore [B] In & Ex 5.500 – 5.512 mm (0.2165 – 0.2170 in.) —
Stem-to-guide clearance In 0.020 – 0.047 mm (0.0008 – 0.
0018 in.) 0.070 mm (0.0028 in.)
Ex 0.045 – 0.072 mm (0.0017 – 0. 0028 in.) 0.090 mm (0.0035 in.)
I4RS0B140016-01
IYSQ01141096-01I2RH01140135-01