2007 SUZUKI SWIFT Assembly head

Downloaded from www.Manualslib.com manuals search engine 1B-5 Aux. Emission Control Devices:
PCV Valve InspectionS7RS0B1206010
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC duty, for obstructed PCV valve or hose
hampers its accurate adjustment.

1) Detach air cleaner assembly.
2) Disconnect PCV valve from cylinder head cover and install plug to head cover hole.
3) Install air cleaner assembly temporarily.
4) Run engine at idle.
5) Place your finger over end of PCV valve (1) to check for vacuum.
If there is no vacuum, ch eck for clogged valve.
Replace as necessary. 6) After checking vacuum, stop engine and remove
PCV valve (1).
Shake valve and listen for rattle of check needle
inside the valve. If valve does not rattle, replace PCV
valve.
7) After checking, remove plug and install PCV valve.
8) Install air cleaner assembly securely.
Special Tools and Equipment
Special ToolS7RS0B1208001
I2RH0B120007-01
I2RH0B120008-01
09917–47011 SUZUKI scan tool
Vacuum pump gauge —
) / ) This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. )

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 1D-5 Engine Mechanical:
11) Connect negative cable at battery.
12) Install special tools (Compression gauge) into spark plug hole.
Special tool
(A): 09915–64512
(B): 09915–64530
(C): 09915–67010
13) Disengage clutch (1) (to lighten starting load on engine) for M/T vehicle, and depress accelerator
pedal (2) all the way to make throttle fully open.
14) Crank engine with fully charged battery, and read the highest pressure on compression gauge.
NOTE
• For measuring compression pressure, crank engine at least 250 r/min. by using
fully charged battery.
• If measured compression pressure is lower than limit value, check installation
condition of special tool. If it is properly
installed, possibility is compression
pressure leakage from where piston ring
and valve contact.

Compression pressure
Standard: 1400 kPa (14.0 kg/cm2, 199.0 psi)
Limit: 1100 kPa (11.0 kg/cm2, 156.0 psi)
Max. difference between any two cylinders: 100
kPa (1.0 kg/cm
2, 14.2 psi) 15) Carry out Steps 12) through 14) on each cylinder to
obtain 4 readings.
16) Disconnect negative cable at battery.
17) After checking, install spark plugs and ignition coil assemblies (2) with high-tension cord (3).
18) Connect ignition coil couplers (1).
19) Connect fuel injector wires (4) at the coupler.
20) Install cylinder head upper cover.
21) Install air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
22) Install engine cover.
23) Connect negative cable at battery.
Engine Vacuum CheckS7RS0B1404002
The engine vacuum that develops in the intake line is a
good indicator of the condition of the engine. The
vacuum checking procedure is as follows:
1) Warm up engine to normal operating temperature.
NOTE
After warming up engine, be sure to place
transaxle gear shift lever in “Neutral”, and set
parking brake and block drive wheels.

2) Stop engine and turn off the all electric switches.
3) Remove engine cover.
4) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
5) Remove PCV hose (1) from PCV valve (2).
(A)
(C)
(B)
I3RH0B140009-01
I2RH0B140005-01
I2RH0B140003-01
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-6
6) Connect special tool (Vacuum gauge) to PCV hose (1).
Special tool
(A): 09915–67311
7) Blind PCV valve (2) using tape (3) or the like.
8) Install air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
9) Run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification.
Vacuum specification (at sea level)
59 – 73 kPa (45 – 55 cmHg, 17.7 – 21.6 in.Hg) at
specified idle speed
10) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
11) Disconnect special tool (vacuum gage) from PCV valve.
12) Detach blind cap from PCV valve, and connect PCV hose to PCV valve.
13) Install air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
14) Install engine cover.
Valve Lash (Clearance) InspectionS7RS0B1404003
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
3) Remove right side engine under cover, if necessary.
4) Using 17 mm wrench, turn crankshaft pulley (1) clockwise until cam lobes (2) become perpendicular
to shim faces (3) at valves “1” and “7” as shown in
the figure. 5) Check valve lashes with thickness gauge (4)
according to the following procedure.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90 ° (by turning crankshaft
with wrench).
c) Make sure that cam lobes are perpendicular to shim faces at valves to be checked (in this case,
“3” and “8”), if not, adjust it by turning crankshaft.
Check valve lashes.
d) In the same manner as b) – c), check valve
lashes at valves “4” and “6”.
e) In the same manner as b) – c) again, check valve lashes at valves “2” and “5”.
If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.
Valve clearance specification
When cold (Coolant te mperature is 15 – 25 °C (59 –
77 °F)):
• Intake: 0.18 – 0.22 mm (0.007 – 0.009 in.)
• Exhaust: 0.28 – 0.32 mm (0.011 – 0.013 in.)
When hot (Coolant temperature is 60 – 68 °C (140 –
154 °F)):
• Intake: 0.21 – 0.27 mm (0.008 – 0.011 in.)
• Exhaust: 0.30 – 0.36 mm (0.012 – 0.014 in.)
(A)
13 2
I3RM0A140003-01
I3RM0A140004-01

Downloaded from www.Manualslib.com manuals search engine 1D-9 Engine Mechanical:
Repair Instructions
Air Cleaner ComponentsS7RS0B1406001
Air Cleaner Element Removal and InstallationS7RS0B1406002
Removal1) Remove engine cover.
2) Open air cleaner case (1) by unhooking its clamps (2).
3) Remove air cleaner element from case.
Installation
Reverse removal procedure for installation.
(c)
1
2
3
4
5
6
7
8
11
910
8
(a)(a)
(b)
(c)
(e)
(d)
(b)
(b)
I7RS0B140001-01
1. Engine Cover 7. Air cleaner outlet hose : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
2. Cylinder head upper cover 8. Hose clamp : 3 N⋅m (0.3 kgf-m, 2.5 lb-ft)
3. Air cleaner assembly 9. MAF sensor : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft)
4. Air intake pipe 10. EVAP canister purge valve : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
5. Air suction hose 11. To throttle body
6. Air cleaner suction pipe : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
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I3RM0A140007-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-10
Air Cleaner Element Inspection and CleaningS7RS0B1406003
Inspection
Check air cleaner element for dirt. Replace excessive
dirty element.
Cleaning
Blow off dust by compressed air from air outlet side of
element.
Cylinder Head Cover Removal and InstallationS7RS0B1406004
Removal1) Disconnect negative cable at battery.
2) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
3) Remove cylinder head upper cover.
4) Disconnect ignition coil couplers (1).
5) Remove ignition coil assemblies (2) with high- tension cord (3).
6) Remove wire harness clamp from cylinder head cover.
7) Remove oil level gauge (1).
8) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head
cover.
9) Remove cylinder head cove r mounting bolts in such
order as indicated in the figure. 10) Remove cylinder head cover (1) with cylinder head
cover gasket (2).
Installation 1) Install new cylinder head cover gasket (2) to cylinder
head cover (1) as shown in figure.
I2RH0B140150-01
I2RH0B140032-01
I2RH0B140033-01
I6RS0B141004-01
I6RS0B141005-01

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-14
Throttle Body CleaningS7RS0B1406008
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection in Section 1C”.
Intake Manifold Removal and InstallationS7RS0B1406009
Removal1) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
2) Remove throttle body referring to “Electric Throttle Body Assembly Removal and Installation”.
3) Disconnect MAP sensor coupler (1).
4) Disconnect the following hoses: • Brake booster hose (2) from cylinder head cover
• Breather hose (3) from cylinder head cover
• PCV hose (4) from intake manifold
• EVAP canister purge valve hose (5) from intake manifold
5) Remove hose clamp (6) from intake manifold.
6) Remove EGR pipe bolt (7) from EGR valve. 7) Remove stiffener (1) and ground terminal (2) from
intake manifold.
8) Remove intake manifold (1) with EGR pipe (2) from
cylinder head, and then remove their gaskets (3).
9) Remove EGR pipe from intake manifold, if necessary.
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3
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