2006 SUZUKI SWIFT oil

Downloaded from www.Manualslib.com manuals search engine 1D-55 Engine Mechanical:
Installation
NOTE
• Use new bearing cap No.1 bolts. They are deformed once they are used because they
are plastic deformation tightening bolts.
• All parts to be insta lled must be perfectly
clean.
• Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins,
connecting rod bearings, pistons, piston
rings and cylinder bores.
• Journal bearings, bearing caps, connecting rods, rod bearings, rod bearing
caps, pistons and piston rings are in
combination sets. Do not disturb such
combination and make sure that each part
goes back to where it came from, when
installing.

1) Install sensor plate (1) to crankshaft (2) and tighten bolts to spec ified torque.
NOTE
When installing sensor plate, align spring pin
(3) on crankshaft and hole of sensor plate.

Tightening torque
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft) 2) Install piston cooling valves and nozzles, if removed.
NOTE
Install piston cooling valve while matching
piston cooling nozzle (1) to positioning (3) of
cylinder block when installed piston cooling
valve (2).

Tightening torque
Piston cooling valve (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
3) Install main bearings to cylinder block. Upper half of bearing (1), has an oil groove (2).
Install it to cylinder block (3), and the other half
without oil groove to bearing cap.
Make sure that two halves are painted in the same
color.
4) Confirm that dowel pins (3 ) are installed to intake
side of each journal.
I2RH0B140128-01
I6RS0B141022-02
I2RH0B140129-01
I2RH0B140130-01

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 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 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 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 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 Engine Mechanical: 1D-66
Special Tools and Equipment
Recommended Service MaterialS7RS0B1408001
NOTE
Required service material is also described in the following.
“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”

Special ToolS7RS0B1408002
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140)
SUZUKI Bond No.1207F P/No.: 99000–31250) / ) / )
09911–97720 09911–97821
Oil seal installer Oil seal installer
))
09913–75810 09915–64512
Bearing installer Compression gauge
))
09915–64530 09915–67010
Compression gauge hose Compression gauge
attachment (C)
))
09915–67311 09916–14510
Vacuum gauge Valve lifter
)) / )
09916–14521 09916–34542
Valve spring compressor
attachment Reamer handle
) / )) / )