Home ReviewsRefund
Home/Suzuki/Aerio/Suzuki Aerio I (2001-2007)/Repair manual/Mechanical/Engine Mechanical: Diagnosis
Contents Wiring diagrams Section: Mechanical All sections

Engine Mechanical: Diagnosis Suzuki Aerio I

Mechanical 16 illustrations ~1782 words

Valve Lash Adjuster Noise Diagnosis

In case of the following, valve lash adjuster noise may be caused by air trapped into valve lash adjusters.

  1. Vehicle is left for 24 hours or more.
  2. Engine oil is changed.
  3. Hydraulic lash adjuster is replaced or reinstalled.
  4. Engine is overhauled.

If noise from valve lash adjusters is suspected, perform the following checks.

  1. Check engine oil for the following. Oil level in oil pan If oil level is low, add oil up to Full level hole on oil level gauge. Oil quality If oil is discolored, or deteriorated, change it. For particular oil to be used, refer to «ENGINE OIL AND FILTER CHANGE»(ref-251055-S17352766582007032000000) . Oil leaks If leak is found, repair it. Oil pressure (refer to «OIL PRESSURE CHECK»(ref-251062-S36608618952007032000000) .) If defective pressure is found, repair it.
  2. Run engine for about half an hour at about 2,000 to 3,000 RPM, and then air will be purge and tapping sound will cease.
  3. Should tapping sound not cease, it is possible that hydraulic valve lash adjuster is defective. Replace it if defective. If defective adjuster can't be located by hearing among 16 of them, check as follows. Stop engine and remove cylinder head cover referring to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) . Push adjuster downward by hand (with less than 20 kg or 44 lbs. force) when cam crest is not on adjuster to check if clearance exists between cam and adjuster. If it does, adjuster is defective and needs replacement.

Scheme 5

Scheme 5: Removal
Scheme 5: Removal
  1. Disconnect MAF sensor coupler (3) and air cleaner outlet hose (4) from air cleaner upper case (1).
  2. Remove air cleaner upper case (1) from lower case after hooking clamps (2) from upper case.
  3. Remove air cleaner element.

Air Cleaner Element Inspection and Cleaning

Reference: AIR CLEANER ELEMENT REMOVAL AND INSTALLATION

Inspection

Check air cleaner element for dirt.

Throttle Body On-Vehicle Inspection

Check that throttle valve lever (2) and accelerator cable (1) moves smoothly.

Scheme 6

Scheme 6: Throttle Body On-Vehicle Inspection
Scheme 6: Throttle Body On-Vehicle Inspection

Cylinder Block Heater (If Equipped) Inspection

Reference: CYLINDER BLOCK HEATER (IF EQUIPPED) REMOVAL AND INSTALLATION

Scheme 7

Scheme 7: Cylinder Block Heater (If Equipped) Inspection
Scheme 7: Cylinder Block Heater (If Equipped) Inspection
  1. Check continuity between terminal "a" and "c" by using ohmmeter. If there is no continuity, replace cylinder block heater.
  2. Check that there is no continuity between terminal "a" and "b" or "c" and "b". If there is continuity, replace cylinder block heater.
  3. Check no continuity between "c" and block heater body. If there is continuity, replace cylinder block heater.

Cylinder Block Heater Harness (If Equipped) Inspection

Reference: CYLINDER BLOCK HEATER HARNESS (IF EQUIPPED) REMOVAL AND INSTALLATION

  1. Check cylinder block heater harness for damage.

Scheme 8

Scheme 8: Engine Mountings Components
Scheme 8: Engine Mountings Components

Scheme 9

Scheme 9: Removal
Scheme 9: Removal

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16
  1. Release fuel pressure in fuel feed line by referring to «FUEL PRESSURE RELIEF PROCEDURE»(ref-251064-S02352031162007032000000).
  2. Disconnect negative cable at battery.
  3. Remove engine hood after disconnecting windshield washer hose.
  4. Drain cooling system. WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
  5. Remove radiator referring to «RADIATOR REMOVAL AND INSTALLATION»(ref-251063-S07115297932007032000000).
  6. Remove engine cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000).
  7. Remove air cleaner outlet hose referring to «AIR CLEANER OUTLET HOSE REMOVAL AND INSTALLATION»(ref-251061-S24859413062007032000000).
  8. Disconnect MAF sensor coupler (1).
  9. Remove air cleaner case assembly (2).
  10. Disconnect the following cables. Accelerator cable (1) from throttle valve lever (2). Shift and select cable from transaxle (for M/T model) Gear select cable from transaxle (for A/T model)
  11. Remove accelerator cable with its bracket from intake manifold.
  12. Disconnect the following hoses: See «HOSES»(ref-251061-S02179821492007032100000). (Scheme 12)HOSES Brake booster hose (1) from intake manifold Heater outlet hose (5) from heater outlet pipe Fuel feed hose (2) from delivery pipe Vacuum hose (6) from EVAP canister purge valve Fuel return hose (3) from return pipe P/S suction hose (7) and high pressure pipe (8) from P/S pump Heater inlet hose (4) from water outlet cap
  13. Disconnect the following connectors and wires: See «CONNECTOR & WIRE IDENTIFICATION»(ref-251061-S40827915232007032100000) table. (Scheme 13) CONNECTOR & WIRE IDENTIFICATION Injector wire (1) Cylinder block heater connector (15) (if equipped) CMP sensor coupler (2) Heated oxygen sensor wire (16) Ignition coil wire (3) Starter wires (17) TP sensor coupler (4) Generator wires (18) IAC valve coupler (5) A/C magnetic switch wire (19) (if equipped) IAC valve coupler (6) Power steering pressure switch coupler (20) MAP sensor coupler (6) Vehicle speed sensor (21) CKP sensor coupler (7) Battery negative cable from transmission (22) Ground terminals from cylinder head (8) and throttle body (9) Input shaft speed sensor (23) (A/T) EVAP canister purge valve coupler (10) Output shaft speed sensor (24) (A/T) EGR valve coupler (11) Transmission range switch (25) (for A/T model) ECT sensor coupler (12) Valve body and transmission fluid temperature sensor connector (26) (for A/T model) Knock sensor coupler (13) Back-up light switch (for M/T model) Oil pressure switch wire (14)
  14. Release the wire harness from clamps.
  15. Remove clutch operating cylinder (1) from transmission with hose still attached (for M/T model). NOTE: Suspend removed clutch operating cylinder at a place free from any possible damage during removal and installation of engine assembly.
  16. Remove right and left engine under covers.
  17. Remove generator belt (Power steering pump drive belt) for equipped with A/C referring to «GENERATOR DRIVE BELT REMOVAL AND INSTALLATION»(ref-251067-S00664805372007032000000).
  18. Remove exhaust No.1 pipe and No. 2 pipe referring to «EXHAUST PIPE REMOVAL AND INSTALLATION»(ref-251068-S05980668122007032000000).
  19. Drain engine oil, transaxle oil for M/T vehicle or A/T fluid for A/T vehicle and transfer oil for 4WD vehicle.
  20. Remove drive shafts referring to «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-251075-S13290362612007032000000).
  21. Separate propeller shaft front end from transfer output flange for 4WD vehicle.
  22. Remove A/C compressor from compressor bracket with hoses still attached, if equipped with A/C. NOTE: Suspend removed compressor at a place free from any possible damage during removal and installation of engine assembly.
  23. Remove intake manifold rear stiffener.
  24. Install lifting device.
  25. Remove mounting member (1) from front member and suspension frame (7).
  26. Remove suspension frame (7) with stabilizer bar and suspension control arms referring to «FRONT SUSPENSION FRAME REMOVAL AND INSTALLATION»(ref-251071-S19517275642007032000000) for 4WD vehicle.
  27. Remove engine left mounting bolts (9).
  28. Remove engine right mounting No. 1 bracket (8).
  29. Before removing engine with transaxle and transfer (for 4WD model) from vehicle body, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transaxle.
  30. Lower engine with transaxle and transfer (for 4WD model) from vehicle body. NOTE: Before lowering engine, to avoid damage to A/C compressor, raise it through clearance made on engine crankshaft pulley side. At this time, use care so that no excessive force is applied to hoses.
  31. Disconnect transfer from transaxle referring to «TRANSFER DISMOUNTING AND REMOUNTING»(ref-251077-S24392748132007032000000) for 4WD model.
  32. Disconnect transaxle from engine referring to «MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-251086-S18912192892007032000000) or «AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-251085-S12999855152007032000000).
  33. Remove clutch cover and clutch disk referring to «CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION»(ref-251087-S31535220782007032000000) (for M/T model).

Scheme 17

Scheme 17: Installation
Scheme 17: Installation
  1. Install clutch cover and clutch disk referring to «CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION»(ref-251087-S31535220782007032000000) (for M/T model).
  2. Connect transaxle to engine referring to «MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-251086-S18912192892007032000000) or «AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-251085-S12999855152007032000000) .
  3. Connect transfer to transaxle referring to «TRANSFER DISMOUNTING AND REMOUNTING»(ref-251077-S24392748132007032000000) for 4WD model.
  4. Lift engine with transaxle and transfer (for 4WD model) into engine compartment, but do not remove lifting device.
  5. Install engine right mounting No. 1 bracket (8) to right mounting bracket (4), generator & P/S bracket and engine right mounting (3) with temporal tightening its bolts.
  6. Install engine left mounting bolts (9) with temporal tightening its nut.
  7. Install mounting member (1) to front member and suspension frame (7).
  8. Install suspension frame (7) with stabilizer bar and suspension control arms referring to «FRONT SUSPENSION FRAME REMOVAL AND INSTALLATION»(ref-251071-S19517275642007032000000) for 4WD model.
  9. Tighten bolts and nuts of all parts installed in steps 5 ), 6 ) and 7 ) to specified torque. NOTE: Be sure to tighten engine right mounting No.1 bracket bolt (10) previously, and tighten engine left mounting bolts (9). Be sure to tighten mounting member to suspension frame bolts (12) or nuts (12) previously, and tighten mounting member to body bolts (11). Tightening torque Engine mounting bolts and nut a: 55 N.m (5.5 kg-m, 40.0 lb-ft) Engine front and rear mounting nut b: 45 N.m (4.5 kg-m, 32.5 lb-ft)
  10. Remove lifting device.
  11. Reverse removal procedures for installation of reminder. Push in each drive shaft joint fully so that snap ring engages with differential gear or center bearing support. Use care not to damage oil seal lip when inserting. Clamp electric wire securely.
  12. For 4WD model, connect propeller shaft referring to «PROPELLER SHAFT REMOVAL AND INSTALLATION»(ref-251078-S27693340762007032000000) .
  13. Adjust gear shift control cable, referring to «GEAR SHIFT LEVER AND CABLE REMOVAL AND INSTALLATION»(ref-251086-S31636697912007032000000) .
  14. Install generator belt (Power steering pump drive belt) referring to «GENERATOR DRIVE BELT REMOVAL AND INSTALLATION»(ref-251067-S00664805372007032000000) .
  15. Refill transaxle with A/T fluid or gear oil, referring to «AUTOMATIC TRANSAXLE FLUID REPLACEMENT»(ref-251055-S37420471212007032000000) or «MANUAL TRANSAXLE OIL CHANGE»(ref-251086-S15712712282007032000000) .
  16. For 4WD model, refill transfer with transfer oil referring to «TRANSFER OIL CHANGE»(ref-251077-S24406507472007032000000) .
  17. Refill engine with engine oil, referring to «ENGINE OIL AND FILTER CHANGE»(ref-251055-S17352766582007032000000) .
  18. Refill cooling system, referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-251063-S04981760882007032000000) .
  19. Upon completion of installation, check to make sure that there is no fuel leakage, coolant leakage, transaxle oil leakage, transfer oil leakage or exhaust gas leakage at each connection.
  20. Adjust accelerator cable play, referring to «ACCELERATOR CABLE ADJUSTMENT»(ref-251061-S37871809172007032000000) .

Scheme 18

Scheme 18: Timing Chain Cover Components
Scheme 18: Timing Chain Cover Components

Timing Chain Cover Cleaning and Inspection

Reference: TIMING CHAIN COVER REMOVAL AND INSTALLATION

Check oil seal lip for fault or other damage. Replace as necessary.

Note. When installing new oil seal (2), drive it in until its surface is flash with edge of timing chain cover (1). To install oil seal, use special tool (bearing installer).

Special Tool

(A): 09913-75510

Scheme 19

Scheme 19: Inspection
Scheme 19: Inspection

Scheme 20

Scheme 20: 2nd Timing Chain and Chain Tensioner Components
Scheme 20: 2nd Timing Chain and Chain Tensioner Components

2nd Timing Chain and Chain Tensioner Inspection

Reference: 2nd Timing Chain and Chain Tensioner Removal and Installation

1st Timing Chain and Chain Tensioner Inspection

Reference: 1st Timing Chain and Chain Tensioner Removal and Installation

Camshaft and Valve Lash Adjuster Inspection

Reference: CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION

Valves and Cylinder Head Inspection

Reference: VALVES AND CYLINDER HEAD DISASSEMBLY AND ASSEMBLY

Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY AND ASSEMBLY

Main Bearings, Crankshaft and Cylinder Block Inspection

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

Main bearings inspection

Check bearings for pitting, scratches, wear or damage.

If any malcondition is found, replace both upper and lower halves. Never replace either half without replacing the other half.

More articles — Engine Mechanical