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Engine Mechanical: Other Suzuki Verona I

Mechanical 36 illustrations ~1430 words

Definition for Knock

Engine knock refers to various types of engine noise. Heavy knock is usually very loud and the result of broken or excessively worn internal engine components. Light knock is a noticeable noise, but not as loud. Light knock can be caused by worn internal engine components. Loose or broken external engine components can also cause heavy or light knock.

Light Knock Hot

StepActionValue(s)YesNo
1Is there a light knock when the engine is hot?Go to Step 2System OK
2Is detonation or spark knock evident?Go to Step 3Go to Step 4
3Check the engine timing and the fuel quality. Was the problem found?Go to Step 1
4Inspect the torque converter bolts. Are the bolts loose?Go to Step 5Go to Step 6
5Tighten the torque converter bolts. Is the repair complete?Go to Step 1
6Inspect the manifold. Is there an exhaust leak at the manifold?Go to Step 7Go to Step 8
7Tighten the bolts or replace the gasket. Is the repair complete?Go to Step 1
8Check the rod bearing clearance. Is the clearance within the value specified?0.031 - 0.065 mm (0.00122 - 0.00256 in.)Go to Step 9System OK
9Replace the rod bearings, as necessary. Is the repair complete?Go to Step 1

LIGHT KNOCK HOT

Knocks during Initial Start-Up But Lasts Only a Few Seconds

StepActionValue(s)YesNo
1Does the engine knock during initial start-up but last only a few seconds?Go to Step 2System OK
2Check the engine oil. Is the proper viscosity oil used in the crankcase?Go to Step 4Go to Step 3
3Install oil of the proper viscosity for the expected seasonal temperatures. Is the repair complete?Go to Step 1
4Inspect the hydraulic lifters. Is there evidence of hydraulic lifter bleed-down?Go to Step 5Go to Step 6
5Clean, test and replace the lifters as necessary. Is the repair complete? (1)Go to Step 1
6Inspect the crankshaft end clearance. Is the clearance more than specified value?0.055 - 0.265 mm (0.002 - 0.010 in.)Go to Step 7Go to Step 8
7Replace the crankshaft thrust bearing. Is the repair complete?Go to Step 1
8Inspect the front main bearing clearance. Is the clearance more than the value specified?0.019 - 0.049 mm (0.00075 - 0.00193 in.)Go to Step 9System OK
9Replace the worn parts of the front main bearing. Is the repair complete?Go to Step 1
(1) When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed the lifter down. Attempts to repair this should be made only if the problem is consistent.
(1)When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed the lifter down. Attempts to repair this should be made only if the problem is consistent.

KNOCKS DURING INITIAL START-UP BUT LASTS ONLY FEW SECONDS

An engine that is operated for only short periods between start-ups may have lifter noise that lasts for a few minutes. This is a normal condition.

Knocks at Idle Hot

StepActionValue(s)YesNo
1Does the engine knock at idle when hot?Go to Step 2System OK
2Inspect the drive belts. Are the belts loose or worn?Go to Step 3Go to Step 4
3Tension or replace the belts, as necessary. Is the repair complete?Go to Step 1
4Inspect the A/C compressor and the generator. Is either the compressor or the generator faulty?Go to Step 5Go to Step 6
5Replace the faulty A/C compressor or the generator. Is the repair complete?Go to Step 1
6Inspect the valve train. Are valve train components faulty?Go to Step 7Go to Step 8
7Replace faulty valve train components. Is the repair complete?Go to Step 1
8Check the engine oil. Is the proper viscosity oil used in the crankcase?Go to Step 10Go to Step 9
9Install oil of the proper viscosity for the expected seasonal temperatures. Is the repair complete?Go to Step 1
10Inspect the piston pin clearance. Is the clearance more than the specified value?0.009 - 0.019 mm (0.00035 - 0.00075 in.)Go to Step 11Go to Step 12
11Replace the piston and the pin. Is the repair complete?Go to Step 1
12Check the connecting rod alignment. Is the alignment faulty?Go to Step 13Go to Step 14
13Check and replace rods as necessary. Is the repair complete?Go to Step 1
14Inspect the piston-to-bore clearance. Is the clearance more than the value specified?0.015 - 0.027 mm (-0.00059 - 0.001063 in.)Go to Step 15Go to Step 16
15Measure the diameter of the piston. Is the diameter greater than the specification?76.973 - 77.015 mm (3.0304 - 3.0320 in.)Go to Step 16Go to Step 17
16Replace the piston and piston rings. Is the piston-to-bore clearance still more than the value specified?Go to Step 18Go to Step 19
17Measure the diameter of the cylinder bore. Is the diameter greater than the specification?76.994 - 77.006 mm (3.0313 - 3.0317 in.)Go to Step 18Go to Step 19
18Replace the cylinder block. Is the repair complete?Go to Step 1
19Inspect the crankshaft balancer. Is the balancer loose?Go to Step 20Go to Step 21
20Torque or replace worn parts. Is the repair complete?Go to Step 1

KNOCKS AT IDLE HOT

Piston Noises

StepActionYesNo
1Are any of the following noises heard: a sharp double knock when the engine is idling, a light ticking with no load on the engine, or a "slapping" noise when the engine is cold?Go to Step 2System OK
2Inspect the piston pin and the bushing. Is the piston pin or the bushing worn or loose?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 3
3Inspect the piston. Is the piston broken or cracked?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 4
4Inspect the connecting rods. Is there a misaligned connecting rod?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 5
5Inspect the piston position. Is the piston 180° out of position?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .System OK

PISTON NOISES

Valve Mechanism or Valve Train Noises

StepActionYesNo
1Is a light tapping sound heard from the engine?Go to Step 2System OK
2Inspect the valve springs. Are the springs weak or broken?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 3
3Inspect the valves. Are the valves sticking or warped?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 4
4Inspect the valve lifters. Are the valve lifters dirty, stuck or worn?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 5
5Inspect the camshaft lobes. Are the camshaft lobes damaged or improperly machined?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 6
6Check the oil supply to the valve train. Is the oil supply insufficient or poor?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 7
7Inspect the valve guides. Are the valve guides worn?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .Go to Step 8
8Inspect the valve spring seat. Is the valve spring seat incorrect?Go to Cylinder Head and Valve Train Components Removal and Cylinder Head and Valve Train Components Installation .System OK

VALVE MECHANISM OR VALVE TRAIN NOISES

Scheme 132

Scheme 132: Throttle Body Assembly Removal
Scheme 132: Throttle Body Assembly Removal

Scheme 133

Scheme 133
Scheme 133
  1. Disconnect the negative battery cable.
  2. Remove the air filter outlet hose.
  3. Remove the coolant inlet and outlet hoses from the throttle body assembly.
  4. Disconnect the main Electronic Throttle Control (ETC) connector.
  5. Remove the throttle body assembly.
  6. Remove the throttle body gasket. NOTE: Inspect the throttle body gasket for a distortion or damage.

Scheme 134

Scheme 134: Throttle Body Assembly Installation
Scheme 134: Throttle Body Assembly Installation
  1. Installation should follow the removal procedure in the reverse order.
  2. Install the throttle body assembly. Tighten: Tighten the throttle body assembly retaining bolts to 8 - 18 N.m (71 - 159 lb-in.).

Scheme 135

Scheme 135: Accelerator Pedal Module (APM) Removal
Scheme 135: Accelerator Pedal Module (APM) Removal

Scheme 136

Scheme 136
Scheme 136
  1. Turn the ignition switch OFF.
  2. Disconnect the Electronic Throttle Control (ECT) connector from the APM.
  3. Remove the bolts, three places, attaching the APM to the APM support bracket.

Scheme 137

Scheme 137: Accelerator Pedal Module (APM) Installation
Scheme 137: Accelerator Pedal Module (APM) Installation
  1. Installation should follow the removal procedure in the reverse order.
  2. Tighten the APM retaining bolts to the APM support bracket. Tighten: Tighten the APM upper retaining bolts (a) to 8 - 12 N.m (17 - 106 lb-in.) and the lower retaining bolt (b) to 18 - 28 N.m (13 - 21 lb-in.).

Scheme 138

Scheme 138: Intake Manifold Removal
Scheme 138: Intake Manifold Removal

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Scheme 147
  1. Remove the fuel pump fuse.
  2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257290-S30388178292007070900000) .
  5. Remove the engine beautification cover retaining nut and engine beautification cover.
  6. Remove the air filter snorkel.
  7. Remove the VIS vacuum tank.
  8. Disconnect the fuel pressure regulator vacuum hose.
  9. Disconnect the fuel line.
  10. Remove the breather hose.
  11. Remove the PCV vacuum hose.
  12. Remove the air filter outlet hose. Refer to «Air Intake System Location»(ref-257287-S17761690112007070900000) .
  13. Remove the throttle body assembly. Refer to «Throttle Body Assembly Removal»(ref-257287-S24934732332007070900000) .
  14. Disconnect the charcoal canister purge solenoid connector and hose. Refer to «Air Intake System Location»(ref-257287-S17761690112007070900000) .
  15. Disconnect the Oxygen Sensor (O2S) connector. Refer to «OXYGEN SENSOR (O2S) REMOVAL»(ref-257285-S33269680962007070900000) .
  16. Disconnect the Manifold Absolute Pressure (MAP) sensor connector. Refer to «MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL»(ref-257286-S39307698162007070900000) .
  17. Disconnect the Crankshaft Position (CKP) sensor connector. Refer to «CRANKSHAFT POSITION (CKP) SENSOR REMOVAL»(ref-257286-S08539437692007070900000) .
  18. Disconnect the Exhaust Gas Recirculation (EGR) solenoid connector. Refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL»(ref-257285-S29709039492007070900000) .
  19. Disconnect the Camshaft Position (CMP) sensor connector. Refer to «CAMSHAFT POSITION (CMP) SENSOR REMOVAL»(ref-257286-S29998511292007070900000) .
  20. Remove the Intake Air Temperature (IAT) sensor. Refer to «INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL»(ref-257286-S20252619882007070900000) .
  21. Disconnect the ignition coil connector. Refer to «IGNITION COIL REMOVAL»(ref-257292-S04843213412007070900000) .
  22. Remove the vacuum hose on the brake booster.
  23. Remove the EGR pipe from the intake manifold.
  24. Remove the engine coolant temperature sensor.
  25. Remove the wiring harness from the support bracket on the cylinder block.
  26. Remove the intake manifold retaining nuts/bolts and the intake manifold.
  27. Remove the bolts on the intake manifold support bracket.
  28. Remove the intake manifold gaskets.
  29. Clean the contact surfaces between intake manifold and the cylinder head. NOTE: Remove the fuel rail after removing the intake manifold.

Scheme 148

Scheme 148: Intake Manifold Installation
Scheme 148: Intake Manifold Installation

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Scheme 154
  1. Installation should follow the removal procedure in the reverse order.
  2. Discard used intake manifold gaskets and install new ones.
  3. Tighten the intake manifold retaining nuts and bolts. NOTE: Install the intake manifold after installing the fuel rail. CAUTION: Genuine intake manifold retaining bolts within the specifications should be used to prevent damaged intake manifold from impairing the airflow to the cylinder. Tighten: Tighten the 7 intake manifold retaining bolts to 10 - 14 N.m (89 - 124 lb-in.). Tighten the 4 intake manifold retaining nuts to 10 - 14 N.m (89 - 124 lb-in.). Tighten the 2 bolts on the intake manifold support bracket to 10 - 14 N.m (89 - 124 lb-in.).
  4. Tighten the intake EGR pipe retaining bolts on the intake manifold. Refer to «INTAKE EGR PIPE INSTALLATION»(ref-257285-S12383789252007070900000) . Tighten: Tighten the intake EGR pipe retaining bolts to 8 - 12 N.m (71 - 106 lb-in.).
  5. Install the IAT (Intake Air Temperature) sensor. Refer to «INTAKE AIR TEMPERATURE (IAT) SENSOR INSTALLATION»(ref-257286-S11060207482007070900000) . Tighten: Tighten the IAT sensor to 20 - 30 N.m (15 - 22 lb-ft).
  6. Install the throttle body assembly. Refer to «Throttle Body Assembly Installation»(ref-257287-S34718418962007070900000) . Tighten: Tighten the throttle body assembly retaining bolts to 8 - 18 N.m (6 - 13 lb-ft).
  7. Connect the fuel pressure regulator vacuum hose.
  8. Connect the fuel line.
  9. Install the VIS vacuum tank. Refer to «VIS VACUUM TANK INSTALLATION»(ref-257286-S31711427352007070900000) . Tighten: Tighten the VIS vacuum tank retaining bolts to 7 - 9 N.m (62 - 80 lb-in.).
  10. Install the air filter snorkel. Refer to «Air Intake System Location»(ref-257287-S17761690112007070900000) . Tighten: Tighten the air filter snorkel retaining bolts to 5 - 7 N.m (44 - 62 lb-in.).
  11. Install the engine beautification cover. Tighten: Tighten the engine beautification retaining bolts to 8 - 12 N.m (71 - 106 lb-in.).

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Scheme 158
  1. Remove the fuel pump fuse.
  2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257290-S30388178292007070900000) .
  5. Remove the intake manifold. Refer to «Intake Manifold Removal»(ref-257287-S00484189752007070900000) .
  6. Remove the coolant reservoir. Refer to «SURGE TANK REMOVAL»(ref-257290-S14034785052007070900000) .
  7. Remove the front support bracket retaining bolt and the front support bracket.
  8. Remove the air filter housing.
  9. Remove the rear support bracket retaining bolts and the rear support bracket.
  10. Remove the ignition coils. Refer to «IGNITION COIL REMOVAL»(ref-257292-S04843213412007070900000) .
  11. Remove the cylinder head cover bolts and the cylinder head cover.
  12. Remove the cylinder head cover gasket.

Scheme 159

Scheme 159: Cylinder Head Cover Installation
Scheme 159: Cylinder Head Cover Installation

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Scheme 164
  1. Installation should follow the removal procedure in the reverse order.
  2. Discard used cylinder head gasket and install new one.
  3. Tighten the cylinder head cover bolts. Tighten: Tighten the cylinder head cover bolts to 12 - 14 N.m (106 - 124 lb-in.).
  4. Install the ignition coils. Tighten: Tighten the ignition coil retaining bolts to 6 - 8 N.m (53 - 71 lb-in.).
  5. Install the rear support bracket. Tighten: Tighten the rear support bracket retaining bolt (Intake-side) to 8 - 12 N.m (71 - 106 lb-in.). Tighten the rear support bracket retaining bolt (Exhaust-side) to 18 - 25 N.m (13 - 18 lb-ft).
  6. Install the air filter housing. Tighten: Tighten the air filter housing bolt to 8 - 12 N.m (71 - 106 lb-in.).
  7. Install the front support bracket. Tighten: Tighten the front support bracket retaining bolt to 15 - 25 N.m (11 - 18 lb-ft).
  8. Install the coolant reservoir. Refer to «SURGE TANK INSTALLATION»(ref-257290-S37072799822007070900000) . Tighten: Tighten the coolant reservoir retaining bolts to 35 - 45 N.m (26 - 33 lb-ft).
  9. Discard used intake manifold gaskets and install new ones.
  10. Tighten the intake manifold retaining nuts and bolts. Refer to «Intake Manifold Installation»(ref-257287-S15190862132007070900000) . Tighten: Tighten the 7 intake manifold retaining bolts to 10 - 14 N.m (89 - 124 lb-in.). Tighten the 4 intake manifold retaining nuts to 10 - 14 N.m (89 - 124 lb-in.). Tighten the 2 bolts on the intake manifold support bracket to 10 - 14 N.m (89 - 124 lb-in.).

Scheme 165

Scheme 165: Engine Mount (RH) Removal
Scheme 165: Engine Mount (RH) Removal
  1. Disconnect the negative battery cable.
  2. Remove the engine mount bracket-to-hydro mount nut and engine mount bracket nuts/bolt.

Scheme 166

Scheme 166: Engine Mount (RH) Installation
Scheme 166: Engine Mount (RH) Installation
  1. Installation should follow the removal procedure in the reverse order.
  2. Install the engine mount (RH). Tighten: Tighten the engine mount bracket-to-hydro mount nut to 55 - 70 N.m (41 - 52 lb-ft). Tighten the engine mount bracket bolt to 42 - 60 N.m (31 - 44 lb-ft). Tighten the 2 engine mount bracket nuts to 42 - 60 N.m (31 - 44 lb-ft).

Scheme 167

Scheme 167: Engine Mount (LH) Removal
Scheme 167: Engine Mount (LH) Removal
  1. Disconnect the negative battery cable.
  2. Remove the transaxle mount cage nut/bolts.

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