2004 SUZUKI SWIFT check engine

Downloaded from www.Manualslib.com manuals search engine 1D-63 Engine Mechanical:
Main Bearing Cap No.1 Bolt
Measure each thread diameter main bearing cap No.1
bolts (1) at “A” on 60 mm (2.36 in.) from seat side of
flange bolt and “B” on 90 mm (3.54 in.) from seat side of
flange bolt by using a micrometer (2).
Calculate difference in diameters (“A” – “B”).
If it exceeds limit, replace with new one.
Main bearing cap No.1 bolt diameter measurement
points
“a”: 60 mm (2.36 in.)
“b”: 90 mm (3.54 in.)
Main bearing cap No.1 bolt diameter difference
Limit (“A” – “B”): 0.2 mm (0.008 in.)
Sensor Plate InspectionS7RS0B1406039
Check sensor plate for crack damage.
If malcondition is found, replace it.
Rear Oil Seal InspectionS7RS0B1406040
Carefully inspect oil seal (1) for wear or damage. If its lip
is worn or damaged, replace it.
Flywheel InspectionS7RS0B1406041
Visual Inspection
• If ring gear is damaged, cracked or worn, replace flywheel.
• If the surface contacting cl utch disc is damaged, or
excessively worn, replace flywheel.
Flywheel Face Runout
Check flywheel face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel face runout
Limit: 0.2 mm (0.0079 in.)
Cylinder Block InspectionS7RS0B1406042
Distortion of Gasketed Surface
Using straightedge and thickness gauge, check
gasketed surface for distortion and, if flatness exceeds
its limit, correct It.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)

“A”
“a” “b” “B”

1
1
2
I2RH0B140145-01
I2RH0B140151-01
I4RS0A140020-01
I2RH01140198-01
I2RH01140199-01

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS7RS0B1504001
WARNING!
To avoid danger of being burned, do not
touch exhaust system when it is still hot.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to Full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks If leak is found, repair it.

1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove engine front cover (1).
3) Disconnect oil pressure switch coupler (1).
4) Remove oil pressure swit ch (2) from cylinder block.
5) Install special tools (oil pressure gauge) to vacated threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
2. Low level mark (hole)
I2RH0B150002-01
1
I4RS0A150001-01
I2RH0B150003-01
I2RH0B150004-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-3
6) Start engine and warm engine up to normal operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral” (shift select lever in “P” range for
A/T vehicle), set parking brake and block
drive wheels.

7) After warming up, raise engine speed to 4,000 r/min. and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kg/cm2, 39.8 psi) at 4,000
r/min. (rpm)
8) After checking oil pressure, stop engine and remove oil pressure gauge and attachment.
9) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft) 10) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, repair it.
11) Connect oil pressure switch coupler (1).
Repair Instructions
Heat Exchanger ComponentsS7RS0B1506001
I2RH0B150005-01
I2RH0B150006-01
3
4
5
7
6
(a)
2
1
I6RS0B151001-02
1. Heat exchanger inlet No. 1 hose 4. Gasket7. O-ring
: Apply engine oil.
2. Heat exchanger outlet No. 1 hose 5. Heat exchanger stand bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft)
3. Heat exchanger 6. Oil filter adapter case : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 1E-4 Engine Lubrication System:
Heat Exchanger On-Vehicle InspectionS7RS0B1506002
• Check heat exchanger for deformation wear or damage.
• Check heat exchanger for coolant leakage and oil leakage.
If any malcondition is found, replace O-ring, stand bolt
gasket and/or heat exchanger.
Heat Exchanger Removal and InstallationS7RS0B1506003
Removal
1) Drain engine oil by removing drain plug.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
3) Remove exhaust manifold referring to “Exhaust Manifold Removal and Inst allation in Section 1K”.
4) Remove heat exchanger inlet No. 1 hose and outlet No. 1 hose.
5) Remove heat exchanger, O-ring and gasket by removing heat exchanger stand bolt. Installation
Reverse removal procedure for installation noting the
followings.
• Use new stand bolt gasket.
• Apply engine oil to new O-ring and install it to heat
exchanger.
• Install heat exchanger (1) while matching the projection of heat exchanger (2) in rib of the cylinder
block (3) as shown in figure.
• Install heat exchanger stand bolt (4) to specified torque.
Tightening torque
Heat exchanger stand bolt (a): 22 N·m (2.2 kgf-m,
16.0 lb-ft)
• Refill cooling system with co olant referring to “Cooling
System Flush and Refill in Section 1F”.
• Refill engine with engine oil referring to “Engine Oil and Filter Change in Section 0B”.
• Upon completion of installation, check for engine coolant and oil leaks.
2
3
4, (a)
1
I6RS0B151002-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-9
Reassembly1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case
and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Apply engine oil to relief valve (1) and spring (2), and install them with retainer (3) and new circlip (4) to
rotor plate (5).
5) Install rotor plate and tighten all bolts to specified torque. After installing plate, check to be sure that
rotors turn smoothly by hand (0.3 N ⋅m (0.03 kgf-m,
0.25 lb-ft) torque or below).
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)Oil Pump InspectionS7RS0B1506010
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Oil Pump
• Check outer (1) and inner rotors (2), rotor plate, and oil pump case for excessive wear or damage.
• Check relief valve (1) for excessive wear or damage
and operates smoothly.
I2RH0B150019-01
I3RM0A150005-01
I2RH0B150022-01
I2RH0B150023-01
I2RH0B150019-01
I2RH0B150025-01

Downloaded from www.Manualslib.com manuals search engine 1E-10 Engine Lubrication System:
Radial clearance
Check radial clearance between outer rotor (1) and case
(2) using thickness gauge (3).
If clearance exceeds its limit, replace outer rotor or case.
Radial clearance between outer rotor and case for oil
pump
Limit: 0.310 mm (0.0122 in.)
Side clearance
Using straightedge (1) and thickness gauge (2),
measure side clearance.
If side clearance exceeds its limit, replace oil pump
assembly.
Side clearance for oil pump inner rotor
Limit: 0.15 mm (0.0059 in.)Relief valve spring free length and load
Check relief valve spring free length and load as shown
in the figure. If the measured valve spring length is lower
than the specification, replace relief valve spring.
Relief valve spring free length and load
I2RH0B150026-01
I2RH0B150027-01
Standard Limit
Free length 52.4 mm
(2.06 in.) —
Load at spring length
38.5 mm (1.52 in.) 79 N
(7.9 kgf, 17.5 lb) 69 N
(6.9 kgf, 15.0 lb)
I2RH01150023-01

Downloaded from www.Manualslib.com manuals search engine 1F-1 Engine Cooling System:
Engine
Engine Cooling System
General Description
Cooling System DescriptionS7RS0B1601001
The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and
thermostat. The radiator is of tube-and-fin type.
Coolant DescriptionS7RS0B1601002
WARNING!
• Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir. Coolant should be added only to reservoir as necessary.
• As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal
of the radiator cap while engine is hot and pressure is high will cause the solution to boil
instantaneously and possibly with explosive force, spewing the solution over engine, fenders and
person removing cap. If the solution contains flammable anti-freeze such as alcohol (not
recommended for use at any time), there is also the possibility of causing a serious fire.
• Check to make sure that engine coolant temperature is cold before removing any part of cooling system.
• Also be sure to disconnect negative cable from battery terminal before removing any part.

The coolant recovery system is standard. The coolant in the radiator expands with heat, and the coolant is overflowed
to the reservoir.
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has be en filled with a quality coolant that is a 50/50 mixture of water and ethylene glycol
antifreeze.
This 50/50 mixture coolant solution provides freezing protection to –36 °C (–33 °F).
• Maintain cooling system freeze protection at –36 °C (–33 °F) to ensure protection against corrosion and loss of
coolant from boiling. This should be done even if freezing temperatures are not expected.
• Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added protection against freezing at temperature lower than –36 °C (–33 °F).
NOTE
• Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any
time as damage to cooling system could occur.
• Coolant must be mixed with deminerated water or distilled water.

Anti-freeze proportioning table
For M/T model For A/T model
Freezing temperature °
C –36 –36
° F –33 –33
Anti-freeze / Anti-corrosion coolant concentration % 50 50
Ratio of compound to cooling water ltr. 3.10/3.10 3.05/3.05
US pt. 6.55/6.55 6.44/6.44
Imp pt. 5.46/5.46 5.37/5.37

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-4
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS7RS0B1604001
ConditionPossible cause Correction / Reference Item
Engine overheats
(Radiator fan operates) Loose or broken water pump belt
Adjust or replace.
Not enough coolant Check coolant level and add as necessary.
Faulty thermostat Replace.
Faulty water pump Replace.
Dirty or bent radiator fins Clean or remedy.
Coolant leakage on cooling system Repair.
Clogged radiator Check and replace radiator as necessary.
Faulty radiator cap Replace.
Improper ignition timing Adjust.
Dragging brakes Adjust brake.
Slipping clutch Adjust or replace.
Poor charge battery Check and replace as necessary.
Poor generation generator Check and repair.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan relay No.2 and/or
No.3 faulty Check and replace as necessary.
Radiator fan motor faulty Check and replace as necessary.
ECM faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary.
Equipped with too much electric load
part(s) Dismount.
Engine overheats
(Radiator fan does not
operate) Fuse blown
Check 30 A fuse of relay/fuse box and check
for short circuit to ground.
Radiator cooling fan relay No.1 faulty Check and replace as necessary.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan motor faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary.
ECM faulty Check and replace as necessary.