Clé SUZUKI SWIFT 2007 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1D-43 Engine Mechanical:
Valve Spring InspectionS7RS0B1406028
Valve Spring Free Length and Preload
Referring to data, check to be sure that each spring is in
sound condition, free of any evidence of breakage or
weakening. Remember, weakened valve springs can
cause chatter, not to mention possibility of reducing
power output due to gas leakage caused by decreased
seating pressure.
Valve spring free length
Standard: 39.37 mm (1.550 in.)
Limit: 36.49 mm (1.437 in.)
Valve spring preload
Standard: 161– 185 N (16.1 – 18.5 kg)
(35.4 – 40.7 lb / 1.240 in.)
Limit: 159 N (15.9 kg) for 31.50 mm (35.1 lb / 1.240 in.) Spring Squareness
Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. Valve springs found to exhibit a
larger clearance than limit must be replaced.
Valve spring squareness
Limit: 1.7 mm (0.067 in.)
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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
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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.) —
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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.)
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Downloaded from www.Manualslib.com manuals search engine 1D-49 Engine Mechanical:
Piston Pins and Connecting Rods InspectionS7RS0B1406033
Piston Pin
Visual inspection
Check piston pin, connecting rod small end bore and
piston bore for wear or damage, paying particular
attention to condition of small end bore bush. If pin,
connecting rod small end bore or piston bore is badly
worn or damaged, replace pin, connecting rod and/or
piston.
Piston pin clearance
Check piston pin clearance in small end and piston.
Replace connecting rod and/or piston if its small end is
badly worn or damaged or if measured clearance
exceeds limit.
Piston pin clearance in connecting rod small end
Standard: 0.003 – 0.014 mm (0.0001 – 0.0006 in.)
Piston pin clearance in piston
Standard: 0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Small-end bore
20.003 – 20.011 mm (0.7875 – 0.7878 in.)
Piston pin dia.
19.997 – 20.000 mm (0.7873 – 0.7874 in.)
Piston bore
20.006 – 20.014 mm (0.7876 – 0.7880 in.)Connecting Rod
Big-end side clearance
Check big-end of connecting rod for side clearance, with
rod fitted and connected to its crank pin in the normal
manner. If measured clearance is found to exceed its
limit, replace connecting rod.
Big-end side clearance
Standard: 0.25 – 0.40 mm (0.0098 – 0.0157 in.)
Limit: 0.55 mm (0.0217 in.)
Connecting rod alignment
Mount connecting rod on aligner to check it for bow and
twist. If measured value exceeds the limit, replace it.
Connecting rod alignment
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)
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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
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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.)
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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”.
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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.
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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.)
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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.)
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-60
Selection of Main Bearings
Standard bearing
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.
1) First check journal diameter. As shown in the figure, crank web No.2 has stamped numbers.
Three kinds of numbers (“1”, “2” and “3”) represent
the following journal diameters.
Stamped numbers on crank web No.2 represent
journal diameters marked with an arrow in the figure
respectively. For example, stamped number “1”
indicates that corresponding journal diameter is
51.9940 – 52.0000 mm (2.0471 – 2.0472 in.).
Crankshaft journal diameter2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five
alphabets are stamped as shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) or
numbers (“1”, “2” and “3”) represent the following
cap bore diameters.
Stamped alphabets or numbers on cylinder block
represent bearing cap bore diameter marked with an
arrow in the figure respectively.
For example, stamped “A” or “1” indicates that
corresponding bearing cap bo re diameter is 56.0000
– 56.0060 mm (2.2048 – 2.2049 in.).
Crankshaft bearing cap bore
Stamped
numbers Journal diameter
1 51.9940 – 52.0000 mm
(2.0471 – 2.0472 in.)
2 51.9880 – 51.9939 mm
(2.0468 – 2.0470 in.)
3 51.9820 – 51.9879 mm
(2.0465 – 2.0467 in.)
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Stamped alphabet
(number) Bearing cap bore diameter (without
bearing)
A or 1 56.0000 – 56.0060 mm
(2.2048 – 2.2049 in.)
B or 2 56.0061 – 56.0120 mm
(2.2050 – 2.2051 in.)
C or 3 56.0121 – 56.0180 mm
(2.2052 – 2.2054 in.)
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