2006 SUZUKI SWIFT ppl

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
I2RH0B140110-01
I2RH0B140111-01
I6RS0B141025-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-46
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly
S7RS0B1406031
Disassembly1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from
piston.
2) Remove piston pin from connecting rod as follows. a) Ease out piston pin circlip (1), as shown.
b) Force piston pin out.
Assembly 1) Decarbonize piston head and ring grooves using a suitable tool.
2) Install piston pin to piston (1) and connecting rod (2): a) After applying engine oil to piston pin and piston pin holes in piston and connecting rod.
b) Fit connecting rod as shown in figure.
NOTE
Be sure to position front mark or arrow mark
(4) on piston and oil hole (5) of connecting
rod at specified position as shown in figure.

c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
NOTE
Circlip should be installed with its cut part
facing as shown in figure. Install so that
circlip end gap comes within such range as
indicated by arrow.

3) Install piston rings to piston:
• As indicated in the figure, 1st and 2nd rings have discrimination mark (4) respectively. When
installing these piston rings to piston, direct
marked side of each ring toward top of piston.
• 1st ring (1) differs from 2nd ring (2) in thickness, shape and color of surface contacting cylinder
wall.
Distinguish 1st ring from 2nd ring by referring to
the figure.
• When installing oil ring (3), install spacer first and then two rails.
4) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.
I2RH0B140113-01
I2RH0B140114-01
1. 1st ring end gap 3. Oil ring upper rail gap
2. 2nd ring end gap and oil ring spacer gap 4. Oil ring lower rail gap
I6RS0C140022-01
I6RS0C140023-01
I6RS0B141018-01

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
I2RH0B140121-01
I6RS0B141026-01
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.)
I2RH0B140123-01

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”.
I2RH0B140125-01
I2RH0B140126-01
I6RS0C140026-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-56
5) Install crankshaft to cylinder block.
6) Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to
crank webs.
7) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts (a) and main bearing cap No.2 bolts (b), tighten
them 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 as
shown by using a 12 corner socket wrenches.
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 as
shown.
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)
CAUTION!
After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 N ⋅m (1.2 kgf-m, 9.0 lb-ft)
torque or below.

8) If necessary, press-fit rear oil seal (1) to oil seal housing (2) by using special tool as shown in figure.
Special tool
(A): 09911–97821
Crank rear oil seal installing position
(dimension)
“a”: 2 mm (0.08 in.) 9) Apply sealant to mating surface of rear oil seal
housing (1).
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
10) Install rear oil seal housing (1) and tighten bolts to specified torque by using special tool.
Special tool
(A): 09911–97720
Tightening torque
Rear oil seal housing bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
I6RS0C140027-01
A: Crankshaft side
I4RS0A140017-01
I4RS0A140018-01
I4RS0A140019-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-1
Engine
Engine Lubrication System
General Description
Engine Lubrication DescriptionS7RS0B1501001
The oil pump is of a trochoid type, and mounted on the
crankshaft. Oil is drawn up through the oil pump strainer
and passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
The filtered oil is passed to the passage in heat
exchanger and cylinder block to piston cooling valve of
oil gushed to the lower side of piston. In one path, oil reaches the crankshaft journal bearings.
Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting
passages drilled in the cran
kshaft, and then injected
from the big end of connecting rod to lubricate piston,
rings and cylinder wall.
In the other path oil goes up to the cylinder head and
lubricates valves and camshafts, etc., after passing
through the internal oil way of camshafts.
An oil relief valve is provided on the oil pump. This valve
starts relieving oil pressure when the pressure exceeds
about 350 kPa (3.5 kg/cm
2, 49.8 psi).
I6RS0C150001-01

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