2008 SUZUKI SWIFT Drive

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

Downloaded from www.Manualslib.com manuals search engine 1D-37 Engine Mechanical:
Valves and Cylinder Head Disassembly and
Assembly
S7RS0B1406025
Disassembly1) For ease in servicing cylinder head, remove intake manifold, injectors, exhaust manifold from cylinder
head.
2) Using special tools (Val ve lifter), compress valve
spring and then remove valve cotters (1) also by
using special tool (Forceps).
Special tool
(A): 09916–14510
(B): 09916–14521
(C): 09916–84511 3) Release special tools (Valve lifter), and remove
spring retainer and valve spring.
4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide and valve spring seat (2).
NOTE
Do not reuse valve stem seal once
disassembled. Be sure to use new seal when
assembling.

6) Using special tool (Valve guide remover), drive valve guide out from combustion chamber side to valve
spring side.
Special tool
(A): 09916–44910
NOTE
Do not reuse valve guide once disassembled.
Be sure to use new va lve guide (oversize)
when assembling.

7) Place disassembled parts except valve stem seal
and valve guide in order so that they can be installed
in their original position.
I2RH0B140093-01
I2RH0B140094-01
I2RH0B140095-01

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.

I2RH0B140096-01
I2RH0B140097-01
I2RH0B140096-01
I2RH0B140098-01

Downloaded from www.Manualslib.com manuals search engine 1D-53 Engine Mechanical:
Main Bearings, Crankshaft and Cylinder Block ComponentsS7RS0B1406035
(a)
(c)
(d)(e)
(b)
(f)
(f)
(f)
(g)
(h)
12
3
4
5 67
8910
11 15
12 13
14 16
17
18 19
2021
22
23 24
25
26
OIL
OIL
OIL
OILOIL
I6RS0C140025-02
1. CKP sensor : See “A” 12. Input shaft bearing 23. Sensor plate bolt
2. Knock sensor 13. Flywheel or drive plate 24. Oil pressure switch 3. Cylinder block 14. Main bearing cap 25. Piston cooling nozzle
4. Venturi plug 15. Flywheel or drive plate bolt 26. Piston cooling valve
5. Main bearing : See “B” 16. Rear oil seal housing mounting bolt : 22 N
⋅m (2.2 kgf-m, 16.0 lb-ft)
6. Sensor plate 17. Main bearing cap No.2 bolt : 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Crankshaft timing sprocket key 18. Main bearing cap No.1 bolt : See “D”:70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
8. Crankshaft 19. O-ring : Tighten 25 N ⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure.
9. Thrust bearing 20. Oil filter adapter case : Tighten 30 N ⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0
kgf-m, 36.5 lb-ft) and 60 ° by the specified procedure.
10. Rear oil seal housing : See “C” 21. Oil filter adapter bolt : 11 N
⋅m (1.1 kgf-m, 8.0 lb-ft)
11. Rear oil seal 22. Spring pin : 13 N ⋅m (1.3 kgf-m, 9.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-54
Main Bearings, Crankshaft and Cylinder Block
Removal and Installation
S7RS0B1406036
Removal1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove clutch cover, clut ch disc and flywheel (drive
plate for A/T) by using special tool.
Special tool
(A): 09924–17811
3) Remove piston and connecting rod referring to “Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
4) Remove rear oil seal housing (1). 5) Loosen main bearing cap No.1 and No.2 bolts in
such order as indicated in figure and remove them.
6) Remove crankshaft from cylinder block.
7) Remove piston cooling valves and nozzles, if necessary.
“A”: When servicing CKP sensor, refer to “CMP Sensor Removal and Installation in Section 1C”. :25 N
⋅m (2.5 kgf-m, 18.0 lb-ft)
“B”: Upper half of bearing has an oil groove. : Do not reuse.
“C”: Apply sealant 99000-31250 to mating surface. : Apply engine oil to inside / sliding surface.
“D”: Make sure main bearing cap No.1 bolt deformation when reuse it due to plastic deformation tightening referring to “Main Bearings Inspection”.
I2RH0B140125-01
I2RH0B140126-01
I6RS0C140026-01

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-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 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
I2RH0B150005-01
I2RH0B150006-01
3
4
5
7
6
(a)
2
1
I6RS0B151001-02
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.