2007 SUZUKI SWIFT Assembly head

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-38
Assembly1) Before installing valve guide into cylinder head, ream
guide hole with special tool (10.5 mm reamer) so as
to remove burrs and make it truly round.
Special tool
(A): 09916–34542
(B): 09916–37320
2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80
to 100 °C (176 to 212 °F) so that head will not be
distorted, and drive new valve guide into hole with
special tools.
Drive in new valve guide until special tool (Valve
guide installer) contacts cylinder head.
After installing, ma ke sure that valve guide pr otrudes
by specified dimension “a” from cylinder head.
Special tool
(A): 09916–58210
(B): 09916–56011
NOTE
• Never reuse valve guide once disassembled. Make sure to install new
valve guide (Oversize).
• Intake and exhaust valve guides are identical.

Valve guide protrusion (In and Ex)
“a”: 11.3 mm (0.44 in.) 3) Ream valve guide bore with special tool (5.5 mm
reamer). After reaming, clean bore.
Special tool
(A): 09916–34542
(B): 09916–34550
4) Install valve spring seat to cylinder head.
5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of
special tool (Valve guide installer handle), fit oil seal
to spindle, and then install seal to valve guide by
pushing special tool by hand.
After installing, check to be sure that seal is properly
fixed to valve guide.
Special tool
(A): 09917–98221
(B): 09916–58210
NOTE
• Do not reuse seal once disassembled. Be sure to install new seal.
• When installing, never tap or hit special tool with a hammer or else. Install seal to
guide only by pushing special tool by
hand. Tapping or hitting special tool may
cause damage to seal.

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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
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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.
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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
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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.)
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Downloaded from www.Manualslib.com manuals search engine 1F-5 Engine Cooling System:
Repair Instructions
Cooling System ComponentsS7RS0B1606001
I7RS0B160004-01
F: Vehicle forward10. Water outlet cap gasket 20. Heater outlet No.2 hose 30. Heat exchanger water pipe
1. Radiator 11. O-ring 21. Heater union 31. To cylinder head
2. Reservoir 12. Thermostat case water outlet pipe 22. Heater inlet No.1 hose 32. To water pump
3. Engine cooling fan assembly 13. Thermostat case 23. Heater outlet No.1 hose33. To heater core
4. Radiator cap 14. Thermostat 24. Water bypass No.2 hose 34. To throttle body
5. Drain plug 15. Thermostat cap 25. Heat exchanger 35. Heater inlet No.2 hose
6. Radiator outlet hose 16. Water bypass No.1 hose 26.Heat exchanger inlet No.1 hose 36. Heater inlet pipe
7. Radiator inlet hose 17. Water inlet No.1 pipe 27. Heat exchanger inlet No.2 hose : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
8. Water outlet cap 18. Water inlet hose 28. Heat exchanger outlet No.1 hose : Do not reuse.
9. ECT sensor 19. Water inlet No.2 pipe 29. Heat exchanger outlet No.2 hose

Downloaded from www.Manualslib.com manuals search engine 1H-6 Ignition System:
Ignition Spark TestS7RS0B1804004
1) Remove air cleaner assembly with air intake pipe.
2) Disconnect all injector couplers from injectors.
WARNING!
Without disconnection of injector couplers,
combustible gas may come out from spark
plug holes during this test and may get
ignited in engine room.

3) Remove spark plug and check it for condition and
type referring to “Spark Plug Inspection”.
4) If OK, connect ignition coil coupler to ignition coil assembly and connect spark plug to ignition coil
assembly or high-tension cord. Ground spark plug. 5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as
described in “Ignition System Symptom Diagnosis”.
Repair Instructions
High-Tension Cord Removal and InstallationS7RS0B1806001
Removal
1) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
2) Disconnect No.1 cylinder (2) and No.3 cylinder (3)
high-tension cords from ignition coil assemblies (1)
while gripping each cap.
3) Pull out high-tension cords from spark plugs while gripping each cap.
CAUTION!
• Removal of high-tension cords together with clamps will be recommended so as
not to damage their inside wire (resistive
conductor).
• For the same reason, pull out each connection by gripping cap portion.

Installation
1) Install No.1 cylinder (2) and No.3 cylinder (3) high-
tension cords to spark plugs and ignition coil
assemblies (1) while gripping each cap.
CAUTION!
• Never attempt to use metal conductor high-tension cords as replacing parts.
• Insert each cap portion fully when installing high-tension cords.

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Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-7
High-Tension Cord InspectionS7RS0B1806002
Measure resistance of high-tension cord (1) by using
ohmmeter.
If resistance exceeds specification, replace high-tension
cord(s).
High-tension cord resistance
No.1 cylinder high-tension cord resistance: 1.4 – 4.0
k Ω
No.3 cylinder high-tension cord resistance: 0.6 – 2.0
k Ω
Spark Plug Removal and InstallationS7RS0B1806003
Removal
1) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
2) Pull out high-tension cords by gripping their caps and then remove ignition coil assemblies referring to
“Ignition Coil Assembly (Inc luding ignitor) Removal
and Installation”.
3) Remove spark plugs.
Installation 1) Install spark plugs and tighten them to specified torque.
Tightening torque
Spark plug: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Install ignition coil assemblies referring to “Ignition Coil Assembly (Including ignitor) Removal and
Installation”.
3) Install high-tension cords securely by gripping their caps.
4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
Spark Plug InspectionS7RS0B1806004
CAUTION!
• When servicing the iridium / platinum
spark plugs (slender center electrode type
plugs), do not touch the center electrode
to avoid damage to it. The electrode is not
strong enough against mechanical force
as it is slender and its material is not
mechanically tough.
• Do not clean or adjust gap for the iridium / platinum spark plugs.

Inspect spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
If any abnormality is found for nickel spark plugs, adjust
air gap, clean with spark plug cleaner or replace them
with specified new plugs.
For iridium / platinum spark plugs, replace them with
new plugs.
Spark plug air gap
“a”
: 1.0 – 1.1 mm (0.040 – 0.043 in.)
Spark plug type
NGK: IFR6J11 (Iridium)
NOTE
NGK IFR6J11 is highly recommended for
better engine starting performance under –25
°C (–13 °F).

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Downloaded from www.Manualslib.com manuals search engine 1H-8 Ignition System:
Ignition Coil Assembly (Including ignitor)
Removal and Installation
S7RS0B1806005
Removal1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil assembly (2).
5) Remove ignition coil bolts (1) and then pull out ignition coil assembly.
Installation 1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and then connect igni tion coil coupler.
Tightening torque
Ignition coil bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly while gripping its cap.
4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
5) Connect negative (–) cable to battery.
Ignition Coil Assembly (Including ignitor)
Inspection
S7RS0B1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.5 – 10.3 k Ω at 20 °C, 68 ° F
Ignition Timing InspectionS7RS0B1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
2) Start engine and warm it up to normal operating temperature.
3) Make sure that all of electrical loads except ignition are switched off.
4) Check to be sure that idle speed is within specification referring to “Idle Speed and IAC
Throttle Valve Opening Inspection in Section 1A”
5) Fix ignition timing by using “Fixed Spark” of “Misc Test” mode on scan tool.
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1
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