2008 SUZUKI SWIFT Ac system

Downloaded from www.Manualslib.com manuals search engine 1D-13 Engine Mechanical:
Throttle Body On-Vehicle InspectionS7RS0B1406006
Check electric throttle body assembly referring to
“Throttle Valve Operation Check” and “Electric Throttle
Body Assembly Operation Check” under “Electric
Throttle Body Assembly On-Vehicle Inspection in
Section 1C”.
Electric Throttle Body Assembly Removal and
Installation
S7RS0B1406007
CAUTION!
Never disassemble electric throttle body.
Disassembly will spoil its original
performance. If faulty condition is found,
replace it with new one.

NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
3) Remove air cleaner assembly referring to “Air Cleaner Components”.
4) Detach EVAP canister and purge valve chamber, and remove air cleaner outlet hose.
5) Disconnect engine coolant hoses (1) and breather hose (2) from electric throttle body assembly (3).
6) Disconnect connector (4) from electric throttle body assembly.
7) Remove electric throttle body assembly from intake
manifold. Installation
1) Clean mating surfaces and install new throttle body gasket (1) to intake manifold.
2) Install electric throttle bo dy assembly (1) to intake
manifold.
3) Connect connector (2) to electric throttle body assembly securely.
4) Connect engine coolant hoses (3) and breather hose (4) to electric thrott le body assembly (1).
5) Install air cleaner assembly referring to “Air Cleaner
Components”.
6) Install EVAP canister and purge valve chamber and air cleaner outlet hose.
7) Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
8) Connect negative cable at battery.
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Downloaded from www.Manualslib.com manuals search engine 1D-15 Engine Mechanical:
Installation
Reverse removal procedure for installation noting the
followings.
• Use new intake manifold gasket (1).
• Use new EGR pipe gasket (2).
• Install intake manifold bolts (3) and nuts (4) to specified torque.
Tightening torque
Intake manifold bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Intake manifold nut (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft) • Install intake manifold rear stiffener (1) as shown in
figure.
• Connect ground terminal (2) to intake manifold to specified torque.
Tightening torque
Intake manifold ground terminal bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
• Install throttle body referrin g to “Electric Throttle Body
Assembly Removal and Installation”.
• Install cowl top plate referring to “Cowl Top Components in Section 9K”.
• Refill cooling system refe rring to “Cooling System
Flush and Refill in Section 1F”.
• Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant leaks.
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Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-20
15) Install A/C compressor to its bracket (if equipped) referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installa tion in Section 7B”.
16) Adjust A/C compressor belt tension (if equipped) referring to “Compressor Drive Belt Inspection and
Adjustment in Section 7B” or “Compressor Drive Belt
Inspection and Adjustment in Section 7B”.
17) Check to ensure that a ll removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
18) Refill cooling system with coolant referring to “Cooling System Flush and Refill in Section 1F”. 19) Refill engine with engine oil
referring to “Engine Oil
and Filter Change in Section 0B”.
20) Refill transaxle with transa xle oil referring to“Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A”.
21) Install battery and tray.
22) Connect positive and negative cable at battery.
23) Install engine hood and connect windshield washer hose.
24) Verify that there is no fu el leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
Timing Chain Cover ComponentsS7RS0B1406012
I6RS0C140015-02
1. Crankshaft pulley bolt 13. Oil gallery pipe No.2 bolt
2. Crankshaft pulley 14. Oil gallery pipe No.3
3. Oil seal : Apply engine oil to oil seal lip. 15. Oil gallery pipe No.3 bolt
4. Timing chain cover : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating surface of timing chain cover referring to the
figure of Step 4) of “Installation” under “Timing Chain Cover Removal and Installation”. 16. O-ring
: Apply engine oil.
5. Pin 17. Oil control valve
6. Cap bolt 18. Oil control valve mounting nut
7. Timing chain cover mounting bolts 19. Cap
8. Timing chain cover mounting nut : 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Oil gallery pipe No.1 :25 N⋅m (2.5 kgf-m, 18.0 lb-ft)

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 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS7RS0B1504001
WARNING!
To avoid danger of being burned, do not
touch exhaust system when it is still hot.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to Full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks If leak is found, repair it.

1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove engine front cover (1).
3) Disconnect oil pressure switch coupler (1).
4) Remove oil pressure swit ch (2) from cylinder block.
5) Install special tools (oil pressure gauge) to vacated threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
2. Low level mark (hole)
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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
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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.
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