ect removal SUZUKI SWIFT 2008 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 1D-21 Engine Mechanical:
Timing Chain Cover Removal and InstallationS7RS0B1406013
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 engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1J”.
3) Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool with it
as shown in figure.
Special tool
(A): 09917–68221
4) Remove crankshaft pulley (1). If it is hard to remove, use special tools as shown in
figure.
Special tool
(A): 09944–36011
(B): 09926–58010 5) Remove cylinder head cove
r referring to “Cylinder
Head Cover Removal and Installation”.
6) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Inst allation in Section 1E”.
7) Remove water pump pulley.
8) Remove A/C bracket from cylinder block.
9) Remove oil gallery pipe s No.2 (1) and No.3 (2).
10) Remove cap (1) from timing chain cover (2). 11) Remove timing chain cover (2).
12) Remove oil control valve from timing chain cover referring to “Oil Cont rol Valve Removal and
Installation”.
10. Copper washer :30 N⋅m (3.0 kgf-m, 22.0 lb-ft)
11. Oil gallery pipe No.1 bolt : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft)
12. Oil gallery pipe No.2 : Do not reuse.
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2
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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
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1
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1
5
(b) 3
(a)
2 4
5
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Downloaded from www.Manualslib.com manuals search engine 1D-25 Engine Mechanical:
Timing Chain and Chain Tensioner Removal
and Installation
S7RS0B1406018
Removal
CAUTION!
After timing chain is removed, never turn
crankshaft and camshafts independently
more than its allowable turning range
described in “Installation”.
If turned, interferen ce may occur between
piston and valves and valves themselves,
and parts related to piston and valves may be
damaged.

1) Remove timing chain cover referring to “Timing Chain Cover Removal and Installation”.
2) By turning crankshaft, align camshafts and crankshaft at specific position as follows.
a) Align both intake and exhaust camshaft timing sprocket marks (1) with notches (2) of cylinder
head respectively.
b) Align crankshaft sprocket key (3) with notch of cylinder block (4).
Position crankshaft sprocke t key (3) at upside of
crankshaft as shown in figure.
3) Remove timing chain tensioner adjuster assembly (5).
4) Remove timing chain tensioner (6).
5) Remove timing chain No.1 guide (7).
6) Remove timing chain (8) with crankshaft timing sprocket (9). Installation
CAUTION!
After timing chain is removed, never turn
crankshaft and camshafts independently
more than such an extent (“a”, “b”) as shown
in figure.
If turned, interferen
ce may occur between
piston and valves and valves themselves,
and parts related to piston and valves may be
damaged.

1) Check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches
(2) on cylinder head as shown in figure.
2) Set key (3) and turn crankshaft to position key on upside of crankshaft.
3
4
1
1
2
5
67
8
9
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“a”: 90 °4. Camshaft (IN and EX) allowable turning range.
By marks on camshaft timing sprocket within 15 ° from notches
on cylinder head on both right and left.
“b”: 15 °5. Crankshaft allowable turning range.
By key on crankshaft, within 90 ° from top on both right and left.
“a”
“b”
“b”“b”
“b”
“a”
1
12
4
3
5
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Downloaded from www.Manualslib.com manuals search engine 1D-27 Engine Mechanical:
8) Screw in plunger (1) by turning body (2) in arrow direction and install a reta iner (3) (wire) to hold
plunger in place.
9) Install timing chain tensioner adjuster assembly (1) with a retainer (2).
Tighten adjuster bolts to specified torque and then
remove a retainer from chain tensioner adjuster
assembly.
Tightening torque
Timing chain tensioner adjuster bolt (a): 11 N·m
(1.1 kgf-m, 8.0 lb-ft)
10) Apply engine oil to timing chain, and then turn crankshaft clockwise by 2 revolutions and check that
match marks (1) are at the following specific
positions.
• Intake and exhaust camshaft timing sprockets makes (1) are in match with notches (2) on
cylinder head.
• Crankshaft sprocket key (3) is in match with notch of cylinder block (4).
• Crankshaft sprocket key (3) is on upside of crankshaft as shown in figure. 11) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
Timing Chain and Chain Tensioner InspectionS7RS0B1406019
Timing Chain No.1 Guide
Check shoe (1) for wear or damage.
Timing Chain Tensioner
Check shoe (1) for wear or damage.
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1
2
3 4
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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
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“12”“13” “20”“21”
“16”“17” “8” “9”
“2”
“5” “3”
“4”
“1”
“10”“11”“18”
“19” “14” “15” “6” “7”
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1
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-30
Installation1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to
cylinder head.
NOTE
When installing shim, make sure to direct
shim No. side toward tappet.

2) Install camshaft bearing (1) to cylinder head.
CAUTION!
Do not apply engine oil to camshaft bearing
back.
Only a upper half bearing of intake camshaft
bearing No.1 has some holes. Other
bearings.

3) Install intake camshaft (1) and exhaust camshaft (2). Align knock pin (3) and match mark (4) with notches
(5) as shown in figure.
NOTE
Before installing camshafts, turn crankshaft
until key position faces upward.
Refer to “Timing Chain and Chain Tensioner
Removal and Installation”.

4) Apply engine oil to sliding surface of each camshaft and camshaft journal then install them as shown in
figure.
5) Install camshaft housing pins (1) as shown in figure.
6) Check position of camshaft housings. Embossed marks are provided on each camshaft
housing, indicating position and direction for
installation. Install housings as indicated by these
marks.I2RH0B140075-01
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“a”: Approx. 30 °
A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
1 2
3 4
5
“a”
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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”
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1
2
3
(a)
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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
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I2RH0B140080-01

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)
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-36
5) Install cylinder head to cylinder block.Apply engine oil to new cylinder head bolts and
tighten them gradually as follows.
a) Tighten cylinder head bolts (“1” – “10”) to 20 N ⋅m
(2.0 kgf-m, 14.5 lb-ft) according to numerical
order as shown by using a 12 corner socket
wrenches.
b) In the same manner as in Step a), tighten them to 40 N ⋅m (4.0 kgf-m, 29.0 lb-ft).
c) Turn all bolts 60 ° according to numerical order in
the figure.
d) Repeat Step c).
e) Tighten bolt “A” to specified torque.
NOTE
Be sure to tighten M8 bolt “A” after securing
the other bolts.

Tightening torque
Cylinder head bolt for M8 (a): 25 N·m (2.5
kgf-m, 18.0 lb-ft)
Cylinder head bolt for M10 (b): 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
NOTE
• If they are reused, check thread diameters of cylinder head bolt (1) for deformation
according to the follows and replace them
with new ones if thread diameter difference
exceeds limit.
• Measure each thread diameter of cylinder head bolt (1) at “A” on 83.5 mm (2.81 in.)
from seat side of flange bolt and “B” on
115 mm (4.53 in.) from seat side of flange
bolt by using a micrometer (2).
Then calculate difference in diameters (“A”
– “B”). If it exceeds limit, replace with new
one.

Cylinder head bolt diameter measurement
points
“a”: 83.5 mm (2.81 in.)
“b”: 115 mm (4.53 in.)
Cylinder head bolt diameter difference
(deformation)
Limit (“A” – “B”): 0.1 mm (0.004 in.)
6) Install camshafts, tappet and shim referring to “Camshaft, Tappet and Shim Removal and
Installation”.
7) Install timing chain referring to “Timing Chain and Chain Tensioner Remova l and Installation”.
8) Install timing chain cover referring to “Timing Chain Cover Removal and Installation”.
9) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
10) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Inst allation in Section 1E”.
I2RH0B140091-01

“A”
“a” “b” “B”

1
1
2
I2RH0B140092-01

Downloaded from www.Manualslib.com manuals search engine 1D-39 Engine Mechanical:
6) Install valve to valve guide.Before installing valve to valve guide, apply engine
oil to stem seal, valve guide bore and valve stem.
7) Install valve spring and spring retainer. Each valve spring has top end (large-pitch end (1))
and bottom end (small-pitch end (2)). Be sure to
position spring in place with its bottom end (small-
pitch end) facing the bottom (valve spring seat side). 8) Using special tools (Val
ve lifter), compress valve
spring and fit two valve cotters (1) into groove in
valve stem.
NOTE
When compressing the valve spring, be
carefully to free from damage in inside face
of tappet installing hole.

Special tool
(A): 09916–14510
(B): 09916–14521
(C): 09916–84511
9) Install intake manifold referring to “Engine Assembly Removal and Installation”.
10) Install fuel injectors referring to “Fuel Injector Removal and Installati on in Section 1G”.
11) Install exhaust manifold referring to “Exhaust Manifold Removal and Inst allation in Section 1K”.
A: Valve spring retainer side
B: Valve spring seat side
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