2008 SUZUKI SWIFT Oil pan bolts

Downloaded from www.Manualslib.com manuals search engine 1D-23 Engine Mechanical:
8) Install new O-ring (1) to oil gallery pipes No.2 (2) and
No.3 (3).
9) Install oil gallery pipes No.2 and No.3 to cylinder
head (4) and timing chain cover (5).
Tighten bolts to specified torque.
Tightening torque
Oil gallery pipe No.2 and No.3 bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
10) Install water pump pulley. 11) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
12) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
13) Install crankshaft pulley (1). Tighten bolt (2) to specified torque. To lock crankshaft pulley, use
special tool with it as shown in figure.
Special tool
(A): 09917–68221
Tightening torque
Crankshaft pulley bolt (a): 150 N·m (15.0 kgf-m,
108.5 lb-ft)
14) Install engine assembly to vehicle referring to “Engine Assembly Removal and Installation”.
Timing Chain Cover InspectionS7RS0B1406014
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary. Timing Chain Cover
Inspect strainer (1) of oil passage for driving intake cam
timing sprocket assembly (VVT actuator).
If clog or foreign matter exists, clean strainer.
Oil Control Valve Removal and InstallationS7RS0B1406015
Removal
Remove oil gallery pipe No.1
(1) and oil control valve (2)
from timing chain cover (3).
Installation
1) Install new O-ring (4) to oil control valve.
2) Install oil control valve to timing chain cover. Tighten nuts to specification.
Tightening torque
Oil control valve mounting nut (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
3) Install oil gallery pipe No .1 with new copper washers
(5) to timing chain cover.
Tighten bolts to specification.
Tightening torque
Oil gallery pipe No.1 bolt (b): 30 N·m (3.0 kgf-m,
21.5 lb-ft)
(a)
(a) 1
2
3
4
5
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(b) 3
(a)
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Downloaded from www.Manualslib.com manuals search engine 1D-31 Engine Mechanical:
7) Install camshaft housing.
8) Tighten camshaft housing bolts as follows.a) Apply engine oil to camshaft housing bolts.
b) Tighten camshaft housing bolts by hand.
c) Tighten camshaft housing bolts to 5 N ⋅m (0.5 kgf-
m, 4.0 lb-ft) according to numerical order (“1”
through “21”) as shown in figure.
d) Retighten them by turning through 11 N⋅ m (1.1
kgf-m, 8.0 lb-ft) in same manner as Step c).
Tightening torque
Camshaft housing bolt (a): 5 N ⋅m (0.5 kgf-m,
4.0 lb-ft) and 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft) by
the specified procedure
9) With hexagonal section (1) of intake camshaft (2) held stationary with spanner or the like, tighten bolt
of intake cam timing sp rocket assembly (3) to
specification.
Tightening torque
Intake cam timing sprocket bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)
10) Install timing chain with cr ankshaft sprocket referring
to “Timing Chain and Chain Tensioner Removal and
Installation”.
11) Install timing chain cover referring to “Timing Chain Cover Removal and Installation”.
12) Check valve lashes referring to “Valve Lash (Clearance) Inspection”.
13) Perform Steps 9) to 14) of “Installation” of “Timing Chain Cover Removal and Installation”.Camshaft, Tappet and Shim InspectionS7RS0B1406022
Intake Cam Timing Sprocket Assembly
Fit intake cam timing sprocket assembly to camshaft (2)
and hold hexagonal section of camshaft by using
spanner or the like.
Check if sprocket (1) is not turned by hand.
If moved, replace intake ca m timing sprocket assembly.
Cam Wear
Using a micrometer, measure cam height “a”. If
measured height underruns its limit, replace camshaft.
Cam height “a”
“10”“9” “2” “1”,(a) “6” “5” “14” “13”
“20”
“17” “19”
“18”
“21”
“12”“11”
“4” “3” “8” “7” “16” “15”
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1
2
3
(a)
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Cam height Standard Limit
Intake cam 45.424 – 45.584 mm
(1.789 – 1.794 in.) 45.30 mm
(1.783 in.)
Exhaust cam 45.030 – 45.190 mm
(1.773 – 1.779 in.) 44.91 mm
(1.768 in.)
2
1
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Downloaded from www.Manualslib.com manuals search engine 1D-35 Engine Mechanical:
Valves and Cylinder Head Removal and
Installation
S7RS0B1406024
Removal1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
3) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
4) Remove timing chain cover referring to Steps 2) to 11) of “Removal” in “Tim ing Chain Cover Removal
and Installation”.
5) Remove timing chain referring to Steps 2) to 6) of “Removal” in “Timing Chain and Chain Tensioner
Removal and Installation”.
6) Remove intake and exhaust camshafts referring to Steps 3) to 8) of “Removal” in “Camshaft, Tappet and
Shim Removal and Installation”.
7) Loosen cylinder head bolts in such order as indicated in the figure by using a 12 corner socket
wrenches and remove them.
NOTE
• Don’t forget to remove bolt (M8) (1) as shown in figure.
• Never reuse cylinder head bolts once disassembled it due to plastic deformation
tightening. Be sure to use new cylinder
head bolts when installing.

8) Check all around cylinder head for any other parts required to be removed or disconnected and remove
or disconnect whatever necessary.
9) Remove exhaust manifold, if necessary referring to
“Exhaust Manifold Removal and Installation in
Section 1K”.
10) Remove cylinder head wi th intake manifold and
exhaust manifold. Use lifting device, if necessary. Installation
1) Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating
surface.
2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block. “Top” or “Triangle/circle” mark provided on gasket
comes to crankshaft pulley side, facing up (toward
cylinder head side).
4) Make sure that oil jet (venturi plug) (1) is not clogged. If it is not install ed, install it as specified
torque.
Tightening torque
Venturi plug (a): 3.5 N·m (0.35 kgf-m, 3.0 lb-ft)
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-36
5) Install cylinder head to cylinder block.Apply engine oil to new cylinder head bolts and
tighten them gradually as follows.
a) Tighten cylinder head bolts (“1” – “10”) to 20 N ⋅m
(2.0 kgf-m, 14.5 lb-ft) according to numerical
order as shown by using a 12 corner socket
wrenches.
b) In the same manner as in Step a), tighten them to 40 N ⋅m (4.0 kgf-m, 29.0 lb-ft).
c) Turn all bolts 60 ° according to numerical order in
the figure.
d) Repeat Step c).
e) Tighten bolt “A” to specified torque.
NOTE
Be sure to tighten M8 bolt “A” after securing
the other bolts.

Tightening torque
Cylinder head bolt for M8 (a): 25 N·m (2.5
kgf-m, 18.0 lb-ft)
Cylinder head bolt for M10 (b): 20 N ⋅m (2.0
kgf-m, 14.5 lb-ft), 40 N ⋅m (4.0 kgf-m, 29.0 lb-ft)
and then retighten by turning through to 60 °
twice
NOTE
• If they are reused, check thread diameters of cylinder head bolt (1) for deformation
according to the follows and replace them
with new ones if thread diameter difference
exceeds limit.
• Measure each thread diameter of cylinder head bolt (1) at “A” on 83.5 mm (2.81 in.)
from seat side of flange bolt and “B” on
115 mm (4.53 in.) from seat side of flange
bolt by using a micrometer (2).
Then calculate difference in diameters (“A”
– “B”). If it exceeds limit, replace with new
one.

Cylinder head bolt diameter measurement
points
“a”: 83.5 mm (2.81 in.)
“b”: 115 mm (4.53 in.)
Cylinder head bolt diameter difference
(deformation)
Limit (“A” – “B”): 0.1 mm (0.004 in.)
6) Install camshafts, tappet and shim referring to “Camshaft, Tappet and Shim Removal and
Installation”.
7) Install timing chain referring to “Timing Chain and Chain Tensioner Remova l and Installation”.
8) Install timing chain cover referring to “Timing Chain Cover Removal and Installation”.
9) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
10) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Inst allation in Section 1E”.
I2RH0B140091-01

“A”
“a” “b” “B”

1
1
2
I2RH0B140092-01

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.)
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Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-7
6) After fitting oil pan to cylinder block, run in securing bolts and start tightening at the center: move wrench
outward, tightening one bolt at a time. Tighten bolts
and nuts to specified torque.
Tightening torque
Oil pan bolt (M6) (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Oil pan bolt (M10) (c): 55 N·m (5.5 kgf-m, 40.0 lb-
ft)
Oil pan nut (e): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
7) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b): 35 N·m (3.5 kgf-m, 25.5 lb-
ft)
8) Tighten transaxle stiffener bolts to specified torque. Tightening torque
Transaxle stiffener bolt (d): 55 N·m (5.5 kgf-m,
40.0 lb-ft)
9) Install exhaust manifold stiffener (2) and exhaust No.1 pipe (1) and heated oxygen sensor No.2
(connector color: green) (3) referring to “Exhaust
System Components in Section 1K”. 10) Install clutch housing lower plate (1).
11) Install oil level gauge.
12) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
13) Verify that there is no en gine oil leakage and exhaust
gas leakage at each connection.
Oil Pan and Oil Pump Strainer CleaningS7RS0B1506006
• Clean sealing surface between oil pan and cylinder block.
Remove oil, old sealant, and dust from sealing
surface.
• Clean oil pump strainer screen (1).(a)
(b)
(c)(e)
(d)I4RS0A150008-01
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1
3
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Downloaded from www.Manualslib.com manuals search engine 5A-2 Automatic Transmission/Transaxle:
CAUTION!
• Keep component parts in group for each subassembly and avoid mixing them up.
• Clean all parts with cleaning solvent thoroughly and air dry them.
• Use kerosene or automatic transaxle fluid as cleaning solvent.
• Do not use wiping cloths or rags to clean or dry parts.
• All oil passages should be blown out and checked to make sure that they are not
obstructed.
• Keep face and eyes away from solvent spray while air blowing parts.
• Check mating surface for irregularities and remove them, if any, and clean it again.
• Soak new clutch discs and brake discs in transaxle fluid for at least 2 hours before
assembly.
• Replace all gaskets and O-ring with new ones.
• Apply automatic transaxle fluid to all O- rings.
• When installing seal ring, be careful so that it is not expanded excessively, extruded or
caught.
• Replace oil seals that are removed and apply grease to their lips.
• Before installing, be sure to apply automatic transaxle fluid to sliding, rolling
and thrusting surface of all component
part. Also after installation, make sure to
check each part for proper operation.
• Always use torque wrench when tightening bolts.

• A new discs should be soaked in ATF at least 2 hours before use.
Part Inspection and Correction Table Part Inspect for Correction
Casted part,
machined part Small flaw, burr
Remove with oil
stone.
Deep or grooved
flaw Replace part.
Clogged fluid
passage Clean with air or
wire.
Flaw on installing
surface, residual
gasket Remove with oil
stone or replace
part.
Crack Replace part.
Bearing Unsmooth rotation Replace.
Streak, pitting, flaw,
crack
Replace.
Bushing, thrust
washer Flaw, burr, wear,
burning
Replace.
Oil seal, gasket Flawed or
hardened seal ring
Replace.
Worn seal ring on
its periphery or side Replace.
Piston seal ring, oil
seal, gasket, etc. Replace.
Gear Flaw, burr Replace.
Worn gear tooth Replace.
Splined part Burr, flaw, torsion Correct with oil
stone or replace.
Snap ring Wear, flaw,
distortion
Replace.
No interference Replace.
Thread Burr Replace.
Damage Replace.
Sp rin g Settling, sign of
burning Replace.
Friction plate Wear, burning,
distortion,
damaged claw Replace.
Separator plate,
retaining plate Wear, burning,
distortion,
damaged claw
Replace.
Sealing surface
(where lip
contacts) Flaw, rough
surface, stepped
wear, foreign
material
Replace.

Downloaded from www.Manualslib.com manuals search engine 5A-98 Automatic Transmission/Transaxle:
Transmission Fluid Temperature Sensor
Inspection
S7RS0B5106021
Warm up transmission fluid temperature sensor (2).
Check resistance between terminals of valve body
harness connector (1). Thus make sure its resistance
decrease as its temperature increase.
Transmission fluid temperature sensor resistance
10 °C (50 °F): 5.8 – 7.1 k Ω
110 °C (230 °F): 231 – 263 Ω
145 °C (293 °F): 105 – 117 Ω
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation
S7RS0B5106022
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove drain plug and drain A/T fluid.
4) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N· m (1.7 kgf-m, 12.5 lb-ft)
5) Remove A/T oil pan (1) and oil pan gasket (2).
6) Remove oil strain er assembly (3). 7) Remove transmission fluid temperature sensor (1)
from sensor clamp.
8) Disconnect solenoid connectors (2).
9) Remove shift solenoid va lve-A (No.1) (1), shift
solenoid valve-B (No.2) (2) and timing solenoid valve
(3) by removing bolts.
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