crankshaft bolt SUZUKI SWIFT 2008 2.G Service Owner's Manual

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 Engine Mechanical: 1D-58
2) 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
figure.
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) 3) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
If its limit is exceeded, replace thrust bearing with
new standard one or oversize one to obtain standard
thrust play.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0043 – 0.0122 in.)
Limit: 0.35 mm (0.0138 in.)
NOTE
After checking the thrust play, make sure that
thread deformation of each bearing cap No.1
bolt referring to “Main Bearing Cap No.1
Bolt” in “Main Bear ings Inspection”.

Out-of-Round and Taper (Uneven Wear) of Journals
An unevenly worn crankshaft journal shows up as a
difference in diameter at a cross section or along its
length (or both). This difference, if any, is determined by
taking micrometer readings. If any one of journals is
badly damaged or if amount of uneven wear in the sense
exceeds its limit, regrind or replace crankshaft.
Crankshaft out-of-round and taper
Limit: 0.01 mm (0.0004 in.)
Out-of-round
A – B
Ta p e r
a – b
I6RS0C140027-01
I2RH01140183-01
I2RH0B140138-01

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

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-64
Honing or Reboring Cylinders1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Oversize piston specification
Oversize 0.50: 78.453 – 78.468 mm (3.0887 –
3.0893 in.)
3) Using micrometer, measure piston diameter. Measurement position for piston diameter
“a”: 7.0 mm (0.28 in.) 4) Rebore and hone cylinder to the following
dimension.
NOTE
Before reboring, install all main bearing caps
in place and tighten to specification to avoid
distortion of bearing bores.

Cylinder bore diameter to be rebored
Oversize 0.50: 78.500 – 78.514 mm (3.0906 –
3.0911 in.)
5) Measure piston clearance after honing. Piston clearance
0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Specifications
Tightening Torque SpecificationsS7RS0B1407001
I2RH01140157-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Camshaft housing bolt 11 1.1 8.0 )
Cylinder head cover bolt 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 )
Intake manifold bolt 23 2.3 17.0 )
Intake manifold nut 23 2.3 17.0 )
Intake manifold ground terminal bolt 11 1.1 8.0 )
Engine left mounting bracket nut 55 5.5 40.0 )
Engine right mounting nut 65 6.5 47.0 )
Engine rear mounting bush bolt 55 5.5 40.0 )
Starting motor terminal nut 11 1.1 8.0 )
Generator terminal nut 6 0.6 4.5 )
Intake manifold ground terminal bolt 11 1.1 18.0 )
Timing chain cover bolt 25 2.5 18.0 )
Timing chain cover nut 25 2.5 18.0 )
Cap bolt 25 2.5 18.0 )
Oil gallery pipe No.2 and No.3 bolt 11 1.1 8.0 )
Crankshaft pulley bolt 150 15.0 108.5 )
Oil control valve mounting nut 11 1.1 8.0 )
Oil gallery pipe No.1 bolt 30 3.0 21.5 )
Timing chain No.1 guide bolt 9 0.9 6.5 )
Timing chain tensioner bolt 25 2.5 18.0 )
Timing chain tensioner adjuster bolt 11 1.1 8.0 )
Camshaft housing bolt 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 )
/ )
Intake cam timing sprocket bolt 60 6.0 43.5 )
Venturi plug 3.5 0.35 3.0 )
Cylinder head bolt for M8 25 2.5 18.0 )
Cylinder head bolt for M10 20 N ⋅m (2.0 kgf-m, 14.5 lb-ft), 40 N ⋅m (4.0
kgf-m, 29.0 lb-ft) and then retighten by
turning through to 60 ° twice )

Downloaded from www.Manualslib.com manuals search engine 1D-65 Engine Mechanical:
NOTE
The specified tightening torque is also described in the following.
“Air Cleaner Components”
“Throttle Body and Intake Manifold Components”
“Engine Mountings Components”
“Timing Chain Cover Components”
“Timing Chain and Chain Tensioner Components”
“Camshaft, Tappet and Shim Components”
“Valves and Cylinder Head Components”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components”
“Main Bearings, Crankshaft and Cylinder Block Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Connecting rod bearing cap bolt
15 N⋅m (1.5 kgf-m, 11.0 lb-ft) and then
retighten by turning through 45 ° twice )
/ )
Sensor plate bolt 111.1 8.0 )
Piston cooling valve 111.1 8.0 )
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) 252.5 18.0 )
Rear oil seal housing bolt 111.1 8.0 )
Flywheel or drive plate bolt 707.0 51.0 )
Main bearing cap No.1 bolt 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 252.5 18.0 ) / )
Main bearing cap No.1 bolt 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 ° )
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft

Downloaded from www.Manualslib.com manuals search engine 1J-8 Charging System:
3) After loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tensio n to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified torque.
Tightening torque
Generator adjusting bolt (c): 7 N·m (0.7 kgf-m,
5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.Water Pump / Generator Drive Belt Removal and
Installation
S7RS0B1A06004
Removal 1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor drive belt before removing water pump belt (1). Refer
to “Compressor Drive Belt Removal and Installation
in Section 7B” or “Compr essor Drive Belt Removal
and Installation in Section 7B”.
3) Loosen drive belt adjusting bolt (2) and generator pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then remove water pump belt.
Installation
Reverse removal procedure for installation noting the
following.
• Adjust belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment” and “Compressor Drive Belt Inspection
and Adjustment in Section 7B” or “Compressor Drive
Belt Inspection and Adjustment in Section 7B”.
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I6RS0C1A0002-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-9
3) Pull out input shaft bearing (1) from flywheel (2), use the following special tool if necessary.
Special tool
(A): 09921–26020
(B): 09930–30104
4) Remove flywheel (1) from crank shaft using special tool.
Special tool
(A): 09924–17811 Installation
CAUTION!
Do not reuse flywheel bolts. Otherwise, bolts
may loosen. Be sure to use new bolts with
pre-coated adhesive.

NOTE
Before assembling, make
sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Install flywheel (2) to crankshaft and tighten new bolts (1) to specification.
Special tool
(A): 09924–17811
Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)
2) Using special tool, install input shaft bearing to flywheel (1).
Special tool
(B): 09925–98210
I2RH01530023-01
I4RS0A530015-02
I2RH01530024-01
I4RS0A530016-01

Downloaded from www.Manualslib.com manuals search engine 5C-10 Clutch:
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts, compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
4) Slightly apply grease to input shaft (1), then join manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft li ttle by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S7RS0B5306015
Input Shaft Bearing
Check bearing (1) for smooth ro tation and replace it if
abnormality is found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to hav e reached service limit at
any of rivet holes (2), repl ace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)
I4RS0A530017-01
I4RS0A530018-01
I3RM0A530014-01
I4RS0A530019-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-9
Abnormal Noise Symptom Diagnosis of A/C SystemS7RS0B7214002
Abnormal Noise from Compressor
Abnormal Noise from Magnetic Clutch
Abnormal Noise from Tubing
Abnormal Noise from Condenser Assembly
Abnormal Noise from Crankshaft PulleyInsufficient airflow of
cooled air
A/C evaporator clogged or frosted
Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Air leaking from HVAC unit or air duct Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Wiring or grounding faulty Repair as necessary.
Condition Possible cause Correction / Reference Item
Condition
Possible cause Correction / Reference Item
During compressor
operation, a rumbling
noise is heard
proportional to engine
revolutions Inadequate clearance in scroll area
Replace compressor.
A loud noise is heard at a
certain rpm,
disproportionately to
engine revolution Loose or faulty compressor drive belt
Adjust drive belt tension or replace drive belt.
Loose compressor mounting bolts Retighten mounting bolts.
A loud rattle is heard at
low engine rpm Loose compressor clutch plate bolt
Retighten clutch plate bolt.
Replace compressor if it was operated in this
condition for a long time.
Condition Possible cause Correction / Reference Item
A rumbling noise is heard
when compressor is not
in operation Worn or damaged bearings
Replace magnet clutch assembly.
A chattering noise is
heard when compressor
is in operation Faulty magnet clutch clearance
(excessive clearance)
Adjust magnet clutch clearance.
Worn magnet clutch friction surface Replace magnet clutch assembly.
Compressor oil leaked from shaft seal,
contaminating the friction surface Replace compressor body assembly.
Condition
Possible cause Correction / Reference Item
A droning noise is heard
from inside of the vehicle,
but not particularly
noticeable in engine
compartment Faulty tubing clamps
Reposition clamps or increase the number of
clamps.
Resonance caused by pulsation from
variations in re frigerant pressure Attach a silencer to tubing, or modify its
position and length.
Condition
Possible cause Correction / Reference Item
Considerable vibration in
condenser assembly Resonance from condenser assembly
bracket and body Firmly insert a silenc
er between condenser
assembly bracket and body.
Condition Possible cause Correction / Reference Item
A large rattling noise is
heard at idle or sudden
acceleration Loosen crankshaft pulley bolt
Retighten bolt.

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A/C Switch InspectionS7RS0B7216014
• Check that there is continuity between terminal (1) and terminal (2) when A/C s witch is at ON position.
• Check that there is no continuity between terminal (1) and terminal (2) when A/C s witch is at OFF position.
If check result does not meet the above conditions,
replace HVAC control unit.
Compressor Relay InspectionS7RS0B7216015
1) Disconnect negative (–) cable from battery.
2) Remove compressor relay (1) from main fuse box.
3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.
4) Connect battery positive (+ ) terminal to terminal “b”
of relay and battery negative (–) terminal to terminal
“a” of relay, and then check continuity between
terminal “c” and “d”. If there is no continuity, replace
relay.
Compressor Drive Belt Inspection and
Adjustment
S7RS0B7216016
Inspection
• Check compressor drive belt (1) for wear, crack, deformation and cleanliness. If any defect is found,
replace the belt with new one referring to
“Compressor Drive Belt Re moval and Installation”.
• Check compressor drive belt tension by measuring how much it deflects when pushed intermediate point
between magnet clutch pulley (6) and crankshaft
pulley (3) with about 100 N (10 kg) force after rotating
crankshaft pulley 360 °. If belt tension is out of
specification, adjust belt tension referring to
“Adjustment”.
Compressor drive belt tension
“a”
: 7 – 8mm (0.28 – 0.31 in.)
NOTE
When replacing drive belt, adjust drive belt
tension to the following specification.

New compressor dr ive belt tension “a”
: 6 – 7mm (0.24 – 0.28 in.)
Adjustment 1) Loosen tension pulley nut (4).
2) Adjust belt tension by ti ghten or loosen tension
pulley adjusting bolt (5).
3) Tighten tension pulley nut.
4) Rotate the crankshaft pulley 360 °, and then recheck
belt tension.
1 2
I4RS0B720013-01
"d"
"b" "a"
"c"
1
I4RS0B720014-01
2. Tension pulley
I4RS0A720033-01