2007 SUZUKI SWIFT Head torque

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-2
SAS: Steering Angle Sensor
SDM: Sensing and Diagnostic Module (Air Bag Controller, Air bag Control Module)
SDT: Smart Diagnostic Tester
SFI: Sequential Multipor t Fuel Injection
SOHC: Single Over Head Camshaft
T:
TBI: Throttle Body Fuel Injection (Single-Point Fuel
Injection, SPI)
TCC: Torque Converter Clutch
TCM: Transmission Control Module (A/T Controller, A/T
Control Module)
TDC: Top Dead Center
TP Sensor: Throttle Position Sensor TVV:
Thermal Vacuum Valve (Thermal Vacuum
Switching Valve, TVSV, Bi metal Vacuum Switching
Valve, BVSV)
TWC: Three Way Catalytic Converter (Three Way
Catalyst)
2WD: 2 Wheel Drive
U:
USB: Universal Serial Bus
V:
VIN: Vehicle Identification Number
VSS: Vehicle Speed Sensor
VVT: Variable Valve Timing (Camshaft Position Control)
W:
WU-OC: Warm Up Oxidation Catalytic Converter
WU-TWC: Warm Up Three Way Catalytic Converter
SymbolsS7RS0B0101002
Wire Color SymbolsS7RS0B0101003
Symbol Definition SymbolDefinition
Tightening torque Apply SUZUKI BOND NO. 1216B
99000-31230
Apply oil (engine, transmission, transfer,
differential) Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid) Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25011
Apply SUZUKI SUPER GREASE C
99000-25030 Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050 Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25121 Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110 Do not reuse
Apply SUZUKI BO ND NO. 1207F
99000-31250 Note on reassembly
Apply SUZUKI BO ND NO. 1217G
99000-31260
Symbol Wire Color SymbolWire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue RRED Red
Br BRN Brown WWHT White
G GRN Green YYEL Yellow
Gr GRY Gray PPNK Pink
Lbl LT BLU Light blueVPPL Violet
Lg LT GRN Light green

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-5
4) Screw new filter on oil filter stand by hand until the filter O-ring contacts mounting surface.
CAUTION!
To tighten oil filter prop erly, it is important to
accurately identify the position at which filter
O-ring first contacts mounting surface.

5) Tighten the filter (1) 3/4 tu rn from the point of contact
with the mounting surface using an oil filter wrench
(2).
Tightening torque
Oil filter (b): 14 N·m (1 .4 kgf-m, 10.5 lb-ft) for
reference
6) Replenish oil until oil leve l is brought to FULL level
mark on dipstick (oil pan and oil filter capacity). The
filler inlet is at the top of the cylinder head cover. It is
recommended to use engine oil of SG, SH, SJ, SL or
SM grade. Select the appropriate oil viscosity
according to the proper engine oil viscosity chart [A].
NOTE
Engine oil capacity is specified as the
following.
However, note that the amount of oil required
when actually changing oil may somewhat
differ from the data depending on various
conditions (temperature, viscosity, etc.).

Engine oil specification
Oil pan capacity: About 3.7 liters (7.8 / 6.5 US /
lmp pt.)
Oil filter capacity: About 0.2 liter (0.4 / 0.3 US /
lmp pt.)
Others: About 0.3 liter (0 .6 / 0.5 US / lmp pt.)
Total: About 4.2 liters (8.9 / 7.4 US / lmp pt.) 7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait
another 5 minutes before checking oil level. Add oil,
as necessary, to bring oil le vel to FULL level mark (1)
on dipstick.
Engine Coolant ChangeS7RS0B0206005
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

CAUTION!
When changing engine coolant, use mixture
of 50% specified water and 50% ANTIFREEZE
/ ANTICORROSION COOLANT for the
purpose of corrosion protection and
lubrication.

Change engine coolant with new one referring to
“Cooling System Flush and Refill in Section 1F”.
IYSQ01020010-01
Co
Fo-30
-22 -20
-4 -10
14 32 50 68 86 104 010203040
5W-30
20W-40
15W-40
10W-30, 10W-40
[A]
I7RS0B020001-02
2. Low level mark (hole)
IYSQ01020012-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-iii
EVAP Canister Purge Valve and Its Circuit
Inspection.......................................................... 1B-2
Vacuum Passage Inspection .............................. 1B-3
Vacuum Hose and Purge Valve Chamber Inspection.......................................................... 1B-3
EVAP Canister Purge Valve Inspection .............. 1B-3
EVAP Canister Inspection ... ................................ 1B-4
EGR Valve Removal and Installation .................. 1B-4
EGR Valve Inspection ......................................... 1B-4
PCV Hose Inspection .......................................... 1B-4
PCV Valve Inspection ......................................... 1B-5
Special Tools and Equipmen t ............................. 1B-5
Special Tool ........................................................ 1B-5
Engine Electrical Devices .. ..................... 1C-1
Repair Instructions .............................................. 1C-1
ECM Removal and Installation ............................ 1C-1
MAP Sensor Inspection ...................................... 1C-2
Electric Throttle Body Assembly On-Vehicle
Inspection.......................................................... 1C-2
Electric Throttle Body System Calibration ........... 1C-5
APP Sensor Assembly On-V ehicle Inspection .... 1C-5
APP Sensor Assembly Removal and Installation ......................................................... 1C-5
APP Sensor Assembly Inspection ...................... 1C-6
ECT Sensor Removal and In stallation ................ 1C-6
ECT Sensor Inspection ....................................... 1C-7
HO2S-1 and HO2S-2 Heater On-Vehicle Inspection.......................................................... 1C-7
HO2S-1 and HO2S-2 Removal and Installation ......................................................... 1C-7
CMP Sensor Removal and In stallation ............... 1C-8
Camshaft Position (CMP) Se nsor Inspection ...... 1C-8
CKP Sensor Removal and Installation ................ 1C-9
CKP Sensor Inspection ....................................... 1C-9
Knock Sensor Removal and Installation ........... 1C-10
Main Relay, Fuel Pump Relay and Starting
Motor Control Relay Inspection....................... 1C-10
MAF and IAT Sensor On-Vehicle Inspection .... 1C-11
MAF and IAT Sensor Removal and Installation ....................................................... 1C-11
MAF and IAT Sensor Inspection ....................... 1C-12
Electric Load Current Sensor On-Vehicle Inspection........................................................ 1C-12
Specifications ..................................................... 1C-13
Tightening Torque Specifications ...................... 1C-13
Engine Mechanical ......... ......................... 1D-1
General Description ............................................. 1D-1
Engine Construction Description ......................... 1D-1
Camshaft Position Control (VVT Variable Valve Timing) System Description .................... 1D-2
Diagnostic Information and Procedures ............ 1D-4 Compression Check ............................................ 1D-4
Engine Vacuum Check ....................................... 1D-5
Valve Lash (Clearance) Inspection ..................... 1D-6
Repair Instructions .............................................. 1D-9 Air Cleaner Components ..................................... 1D-9
Air Cleaner Element Removal and Installation .... 1D-9 Air Cleaner Element Ins
pection and Cleaning ..1D-10
Cylinder Head Co ver Removal and
Installation .......................................................1D-10
Throttle Body and Intake Manifold
Components ....................................................1D-12
Throttle Body On-Vehicle Inspection.................1D-13
Electric Throttle Body Assembly Removal and Installation .......................................................1D-13
Throttle Body Cleaning......................................1D-14
Intake Manifold Removal and Installation .........1D-14
Engine Mountings Components ........................1D-16
Engine Assembly Removal and Installation ......1D-17
Timing Chain Cover Components .....................1D-20
Timing Chain Cover Removal and Installation ..1D-21
Timing Chain Cover Inspection .........................1D-23
Oil Control Valve Removal and Installation .......1D-23
Oil Control Valve Inspection ..............................1D-24
Timing Chain and Chain Tensioner Components ....................................................1D-24
Timing Chain and Chain Tensioner Removal and Installation ................................................1D-25
Timing Chain and Chain Tensioner Inspection ..1D-27
Camshaft, Tappet and Shim Components ........1D-28
Camshaft, Tappet and Shim Removal and Installation .......................................................1D-29
Camshaft, Tappet and Shim Inspection ............1D-31
Valves and Cylinder Head Components ...........1D-34
Valves and Cylinder Head Removal and
Installation .......................................................1D-35
Valves and Cylinder Head Disassembly and Assembly.........................................................1D-37
Valves and Valve Guides Inspection.................1D-40
Cylinder Head Inspection . .................................1D-42
Valve Spring Inspection ....................................1D-43
Pistons, Piston Rings , Connecting Rods and
Cylinders Components ....................................1D-44
Pistons, Piston Rings , Connecting Rods and
Cylinders Removal and Installation .................1D-45
Pistons, Piston Rings , Connecting Rods and
Cylinders Disassembly and Assembly ............1D-46
Cylinders, Pistons and Piston Rings Inspection ........................................................1D-47
Piston Pins and Connecting Rods Inspection ...1D-49
Crank Pin and Connecting Rod Bearings Inspection ........................................................1D-50
Main Bearings, Cran kshaft and Cylinder
Block Components ..........................................1D-53
Main Bearings, Cran kshaft and Cylinder
Block Removal and Installa tion .......................1D-54
Crankshaft Inspection .......................................1D-57
Main Bearings Inspection . .................................1D-59
Sensor Plate Inspection ....................................1D-63
Rear Oil Seal Inspection ...................................1D-63
Flywheel Inspection...........................................1D-63
Cylinder Block Inspection ..................................1D-63
Specifications .................... .................................1D-64
Tightening Torque Specifications ......................1D-64
Special Tools and Equipmen t ...........................1D-66
Recommended Service Material .......................1D-66
Special Tool ......................................................1D-66

Downloaded from www.Manualslib.com manuals search engine 1C-8 Engine Electrical Devices:
Installation
Reverse removal procedure noting the following.
• Tighten heated oxygen sensor to specified torque.Tightening torque
Heated oxygen sensor (a): 45 N·m (4.5 kgf-m,
32.5 lb-ft)
• Install exhaust manifold referring to “Exhaust Manifold Removal and Installation in Section 1K”, if removed.
• Connect connector of heated oxygen sensor and clamp wire harness securely.
• After installing heated oxygen sensor, start engine and check that no exhaust gas leakage exists.
CMP Sensor Removal and InstallationS7RS0B1306012
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from CMP sensor.
3) Remove CMP sensor from cylinder head.
Installation 1) Install CMP sensor to cylinder head.
Tightening torque
CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect connector to CMP sensor securely.
3) Connect negative (–) cable to battery.
Camshaft Position (CMP) Sensor InspectionS7RS0B1306013
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.
Performance check 1) Remove metal particles on end face of CMP sensor, if any.
2) Arrange 12 V battery (1) and connect its positive terminal to “Vin” terminal (2) and negative terminal to
“Ground” terminal (3) of sensor. Then using
ohmmeter, measure resistance between “Vout”
terminal (4) of sensor and negative terminal of
battery by passing magnetic substance (iron) (5)
while keeping approximately 1 mm (0.03 in.) gap
with respect to end face of CMP sensor.
If resistance does not vary as specified below,
replace CMP sensor.
CMP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
1. EGR valve
(a)
(a)
I6RS0C130003-02
I6RS0C130004-01
I4RS0B130015-01
I6RS0C130005-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-4
Targeted Timing Varying Operation
Diagnostic Information and Procedures
Compression CheckS7RS0B1404001
Check compression pressure on all 4 cylinders as
follows:
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
NOTE
After warming up engine, place transaxle
gear shift lever in “Neutral”, and set parking
brake and block drive wheels.

3) Disconnect negative cable at battery.
4) Remove engine cover.
5) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
6) Remove cylinder head upper cover.
7) Disconnect ignition coil couplers (1).
8) Remove ignition coil assemblies (2) with high- tension cord (3).
9) Remove all spark plugs.
10) Disconnect fuel injector wires (4) at the coupler. Driving condition Valve timing Target of control Effect
Engine running at idle
speed Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Stabilization of the engine
rotation at idle speed.
Average engine load
range To the advanced
sideTo lengthen the valve opening overlap
in order to enhance the internal
exhaust gas recirculation and reduce
the pumping loss. Improvement of the fuel
efficiency.
Lowering of the exhaust
emission.
Light engine load
range To the retarded sideTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Keeping of the engine stability.
Low or average
engine speed range
with heavy engine
load To the advanced
side
To advance the closing timing of the
intake valve in order to improve the
volumetric efficiency. Improvement of generating the
engine torque at low and
average engine speed.
High engine speed
range with heavy
engine load To the retarded sideTo retard the closing timing of the
intake valve in order to improve the
volumetric efficiency. Improvement of generating the
engine power.
Low engine coolant
temperature Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold and
reduce the fuel increasing.
To slow the fast idle speed of the
engine as a result of stabilizing the
engine idling. Stabilization of the fast idling of
the engine.
Improvement of the fuel
efficiency.
At engine starting and
stopping Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Improvement of start ability.I2RH0B140003-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-8
For example of intake side:
When thickness of removed shim is 2.40 mm (0.094
in.), and measured valve clearance is 0.45 mm
(0.018 in.).
A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20
mm (0.008 in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104
in.)
6) Select new shim No. (1) with a thickness as close as possible to calculated value.
Available new shims No.
7) Install new shim facing shim No. side with tappet. 8) Lift valve by turning crankshaft counterclockwise (in
opposite direction against above Step 4)) and
remove special tool.
Special tool
(A): 09916–67020
(A): 09916–67021
9) Install camshaft housing (1) and tighten bolts to specified torque.
Tightening torque
Camshaft housing bolt (a ): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
10) Check valve clearance again after adjusting it. 11) After checking and adjusting all valves.
12) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
Thickness
mm (in.) Shim No.Thickness
mm (in.) Shim No.
2.175 (0.0856) 218 2.600 (0.1024) 260
2.200 (0.0866) 220 2.625 (0.1033) 263
2.225 (0.0876) 223 2.650 (0.1043) 265
2.250 (0.0886) 225 2.675 (0.1053) 268
2.275 (0.0896) 228 2.700 (0.1063) 270
2.300 (0.0906) 230 2.725 (0.1073) 273
2.325 (0.0915) 233 2.750 (0.1083) 275
2.350 (0.0925) 235 2.775 (0.1093) 278
2.375 (0.0935) 238 2.800 (0.1102) 280
2.400 (0.0945) 240 2.825 (0.1112) 283
2.425 (0.0955) 243 2.850 (0.1122) 285
2.450 (0.0965) 245 2.875 (0.1132) 288
2.475 (0.0974) 248 2.900 (0.1142) 290
2.500 (0.0984) 250 2.925 (0.1152) 293
2.525 (0.0994) 253 2.950 (0.1161) 295
2.550 (0.1004) 255 2.975 (0.1171) 298
2.575 (0.1014) 258 3.000 (0.1181) 300
I2RH0B140015-01
1. Tappet
2. Camshaft
(A)2
1
I3RM0A140006-01
I2RH0B140149-01

Downloaded from www.Manualslib.com manuals search engine 1D-11 Engine Mechanical:
2) Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface area (2) as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
• Timing chain cover (1) and cylinder head (2) mating surface as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F) 3) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.

4) Tighten cylinder head cover bolts as follows.
a) Tighten cylinder head cover bolts to 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft) according to numerical order (“1”
through “7”) as shown in figure.
b) In the same manner as in Step, a) tighten them
to 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft).
c) Retighten them by turning through 8 N ⋅m (0.8
kgf-m, 6.0 lb-ft) in same manner as Step a).
Tightening torque
Cylinder head cover bolt (a): 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
5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).
8) Install wire harness clamp to cylinder head cover.
9) Install ignition coil assemb lies with high-tension cord
referring to “Ignit ion Coil Assembly (Including ignitor)
Removal and Installati on in Section 1H”.
10) Connect ignition coil couplers and clamp harness securely.
11) Install cylinder head upper cover.
12) Install air cleaner case and resonator.
13) Connect negative cable at battery.
I2RH0B140036-01
I2RH0B140037-01
I3RH0B140016-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-22
Installation1) Clean sealing surface on timing chain cover, cylinder block and cylinder head.
Remove oil, old sealant and dust from sealing
surface.
2) Install oil seal (1) to timi ng chain cover, if removed.
NOTE
When installing new oil seal, press fit to
timing chain cover (2) by using special tool
(bearing installer) as shown in figure.

Drive in dimension
“a”: 1.5 mm (0.06 in.)
Special tool
(A): 09913–75810
3) Install oil control valve to timing chain cover referring to “Oil Control Valve Removal and Installation”.
4) Apply sealant “A” to mating surface of cylinder and cylinder head and “B” to mating surface of timing
chain cover as shown in figure.
“A”: Water tight sealant 99000–31140 (SUZUKI
Bond No.1207B)
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for timing chain cover
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 5) Apply engine oil to oil seal lip, then install timing
chain cover (1). Tighten bolts and nut to specified
torque.
NOTE
Before installing timing chain cover, check
that pin is securely fitted.

Tightening torque
Timing chain cover bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Timing chain cover nut (b): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
6) Apply engine oil to new O-rings (2) and install them to cap (3).
7) Install cap (3) to ti ming chain cover (1).
Tighten bolts to specified torque.
Tightening torque
Cap bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
I2RH0B140058-01
I3RH0B140025-01
(a)
(b)
(c)
1
2
3
I4RS0B140011-02