Gas SUZUKI SWIFT 2007 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-10
Air Cleaner Element Inspection and CleaningS7RS0B1406003
Inspection
Check air cleaner element for dirt. Replace excessive
dirty element.
Cleaning
Blow off dust by compressed air from air outlet side of
element.
Cylinder Head Cover Removal and InstallationS7RS0B1406004
Removal1) Disconnect negative cable at battery.
2) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
3) Remove cylinder head upper cover.
4) Disconnect ignition coil couplers (1).
5) Remove ignition coil assemblies (2) with high- tension cord (3).
6) Remove wire harness clamp from cylinder head cover.
7) Remove oil level gauge (1).
8) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head
cover.
9) Remove cylinder head cove r mounting bolts in such
order as indicated in the figure. 10) Remove cylinder head cover (1) with cylinder head
cover gasket (2).
Installation 1) Install new cylinder head cover gasket (2) to cylinder
head cover (1) as shown in figure.
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2) Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface area (2) as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
• Timing chain cover (1) and cylinder head (2) mating surface as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F) 3) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.

4) Tighten cylinder head cover bolts as follows.
a) Tighten cylinder head cover bolts to 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft) according to numerical order (“1”
through “7”) as shown in figure.
b) In the same manner as in Step, a) tighten them
to 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft).
c) Retighten them by turning through 8 N ⋅m (0.8
kgf-m, 6.0 lb-ft) in same manner as Step a).
Tightening torque
Cylinder head cover bolt (a): Tighten 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft), 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft) and 8
N ⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified
procedure
5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).
8) Install wire harness clamp to cylinder head cover.
9) Install ignition coil assemb lies with high-tension cord
referring to “Ignit ion Coil Assembly (Including ignitor)
Removal and Installati on in Section 1H”.
10) Connect ignition coil couplers and clamp harness securely.
11) Install cylinder head upper cover.
12) Install air cleaner case and resonator.
13) Connect negative cable at battery.
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Throttle Body and Intake Manifold ComponentsS7RS0B1406005
45
2
15
12 11
13
14 8 10
15
6
3 9
1
(c)
(b)
(a)
(c)
(c)(d)
7
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1. Intake manifold 6. Breather hose11. PCV valve : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
2. Intake manifold gasket 7. EGR pipe 12. PCV valve seal : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
3. EVAP canister purge valve hose 8. Gasket 13. PCV hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Throttle body 9. EVAP canister purge valve 14. To EGR valve : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
5. Throttle body gasket 10. MAP sensor15. To cylinder head cover : Do not reuse.

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Throttle Body On-Vehicle InspectionS7RS0B1406006
Check electric throttle body assembly referring to
“Throttle Valve Operation Check” and “Electric Throttle
Body Assembly Operation Check” under “Electric
Throttle Body Assembly On-Vehicle Inspection in
Section 1C”.
Electric Throttle Body Assembly Removal and
Installation
S7RS0B1406007
CAUTION!
Never disassemble electric throttle body.
Disassembly will spoil its original
performance. If faulty condition is found,
replace it with new one.

NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
3) Remove air cleaner assembly referring to “Air Cleaner Components”.
4) Detach EVAP canister and purge valve chamber, and remove air cleaner outlet hose.
5) Disconnect engine coolant hoses (1) and breather hose (2) from electric throttle body assembly (3).
6) Disconnect connector (4) from electric throttle body assembly.
7) Remove electric throttle body assembly from intake
manifold. Installation
1) Clean mating surfaces and install new throttle body gasket (1) to intake manifold.
2) Install electric throttle bo dy assembly (1) to intake
manifold.
3) Connect connector (2) to electric throttle body assembly securely.
4) Connect engine coolant hoses (3) and breather hose (4) to electric thrott le body assembly (1).
5) Install air cleaner assembly referring to “Air Cleaner
Components”.
6) Install EVAP canister and purge valve chamber and air cleaner outlet hose.
7) Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
8) Connect negative cable at battery.
2
4
3
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1
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4
2
1
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Throttle Body CleaningS7RS0B1406008
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection in Section 1C”.
Intake Manifold Removal and InstallationS7RS0B1406009
Removal1) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
2) Remove throttle body referring to “Electric Throttle Body Assembly Removal and Installation”.
3) Disconnect MAP sensor coupler (1).
4) Disconnect the following hoses: • Brake booster hose (2) from cylinder head cover
• Breather hose (3) from cylinder head cover
• PCV hose (4) from intake manifold
• EVAP canister purge valve hose (5) from intake manifold
5) Remove hose clamp (6) from intake manifold.
6) Remove EGR pipe bolt (7) from EGR valve. 7) Remove stiffener (1) and ground terminal (2) from
intake manifold.
8) Remove intake manifold (1) with EGR pipe (2) from
cylinder head, and then remove their gaskets (3).
9) Remove EGR pipe from intake manifold, if necessary.
6
2 1
3
54
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1
2
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2
1
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Installation
Reverse removal procedure for installation noting the
followings.
• Use new intake manifold gasket (1).
• Use new EGR pipe gasket (2).
• Install intake manifold bolts (3) and nuts (4) to specified torque.
Tightening torque
Intake manifold bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Intake manifold nut (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft) • Install intake manifold rear stiffener (1) as shown in
figure.
• Connect ground terminal (2) to intake manifold to specified torque.
Tightening torque
Intake manifold ground terminal bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
• Install throttle body referrin g to “Electric Throttle Body
Assembly Removal and Installation”.
• Install cowl top plate referring to “Cowl Top Components in Section 9K”.
• Refill cooling system refe rring to “Cooling System
Flush and Refill in Section 1F”.
• Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant leaks.
1
2
3,(a)
4,(b)
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(a)
12
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-20
15) Install A/C compressor to its bracket (if equipped) referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installa tion in Section 7B”.
16) Adjust A/C compressor belt tension (if equipped) referring to “Compressor Drive Belt Inspection and
Adjustment in Section 7B” or “Compressor Drive Belt
Inspection and Adjustment in Section 7B”.
17) Check to ensure that a ll removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
18) Refill cooling system with coolant referring to “Cooling System Flush and Refill in Section 1F”. 19) Refill engine with engine oil
referring to “Engine Oil
and Filter Change in Section 0B”.
20) Refill transaxle with transa xle oil referring to“Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A”.
21) Install battery and tray.
22) Connect positive and negative cable at battery.
23) Install engine hood and connect windshield washer hose.
24) Verify that there is no fu el leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
Timing Chain Cover ComponentsS7RS0B1406012
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1. Crankshaft pulley bolt 13. Oil gallery pipe No.2 bolt
2. Crankshaft pulley 14. Oil gallery pipe No.3
3. Oil seal : Apply engine oil to oil seal lip. 15. Oil gallery pipe No.3 bolt
4. Timing chain cover : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating surface of timing chain cover referring to the
figure of Step 4) of “Installation” under “Timing Chain Cover Removal and Installation”. 16. O-ring
: Apply engine oil.
5. Pin 17. Oil control valve
6. Cap bolt 18. Oil control valve mounting nut
7. Timing chain cover mounting bolts 19. Cap
8. Timing chain cover mounting nut : 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Oil gallery pipe No.1 :25 N⋅m (2.5 kgf-m, 18.0 lb-ft)

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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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Cylinder Head InspectionS7RS0B1406027
• Remove all carbon deposits from combustion chambers.
NOTE
Do not use any sharp-edged tool to scrape
off carbon deposits. Be careful not to scuff or
nick metal surfaces when decarbonizing. The
same applies to valves and valve seats, too.

• Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using
a straightedge and thickness gauge, check flatness of
gasketed surface at a total of 6 locations. If distortion
limit is exceeded, correct gasketed surface with a
surface plate and abrasive paper of about #400
(Waterproof silicon carbide abrasive paper): place
abrasive paper on and over surface plate, and rub
gasketed surface against paper to grind off high spots.
Should this fail to reduce thickness gauge readings to
within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint
is often due to warped gasketed surface: such
leakage results in reduced power output.
Distortion for cylinder head surface on piston side
Limit: 0.03 mm (0.001 in.) • Distortion of manifold seating faces:
Check seating faces of cylinder head for manifolds,
using a straightedge and thickness gauge, in order to
determine whether these faces should be corrected or
cylinder head replaced.
Distortion for cylinder head surface on intake and
exhaust manifold
Limit: 0.05 mm (0.002 in.)
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