AIR SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1D-12 Engine Mechanical:
Installation
1) Install new spark plug hole gaskets (1) and new
cylinder head cover gasket (2) to cylinder head cover
(3) as shown in figure.
2) Remove oil, old sealant, and dust from sealing
surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface
area (2) as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)• Timing chain cover (1) and cylinder head (2)
mating surface as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
3) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.

4) Tightening bolts in numerical order (“1” through “7”)
as shown in figure a little at a time till they are
tightened to specified torque.
Tightening torque
Cylinder head cover bolt (a): Tighten 8 N⋅m (0.8
kgf-m, 6.0 lb-ft) by the specified procedure
5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).
8) Install ignition coil assemblies to cylinder head cover
referring to “Ignition Coil Assembly (Including Ignitor)
Removal and Installation in Section 1H”.
9) Connect ignition coil couplers and clamp harness
securely.
10) Install cylinder head upper cover.
11) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation”.
12) Connect negative cable at battery.I6RS0B141005-01
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Downloaded from www.Manualslib.com manuals search engine 1D-14 Engine Mechanical:
Throttle Body On-Vehicle InspectionS6RW0D1406006
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
S6RW0D1406047
CAUTION!
Never disassemble electric throttle body.
Disassembly will spoil its original
performance. If faulty condition is found,
replace it with new one.

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 Assembly Removal and Installation”.
4) Disconnect engine coolant hoses (1) and breather
hose (2) from electric throttle body assembly (3).
5) Disconnect connector (4) from electric throttle body
assembly.
6) 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 body 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 throttle body assembly (1).
5) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation”.
6) Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
7) Connect negative cable at battery.
Throttle Body CleaningS6RW0D1406048
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection in Section 1C”.
2
4
3
1
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2
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3
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-17
Engine Assembly Removal and InstallationS6RW0D1406013
Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure in Section 1G”.
2) Disconnect negative and positive cable at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil referring to “Engine Oil and Filter
Change in Section 0B”.
8) Drain transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
9) Drain transfer oil referring to “Transfer Oil Change in
Section 3C”.
10) Drain coolant referring to “Cooling System Draining
in Section 1F”
11) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation”.
12) With hose connected, detach A/C compressor from
its bracket 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.

13) Remove cylinder upper cover (1).14) Disconnect the following electric wires/connectors
and each clamps.
• TP sensor (1)
• MAP sensor (2)
• ECT sensor (3)
•EGR valve (4)
• CMP sensor (5)
• Ignition coil assembly (6)
• Injector (7)
•HO2S (8)
• Oil control valve (9) (for engine with VVT system)
• Engine oil pressure switch (10)
• CKP sensor (12)
• Knock sensor (13)
• Generator (14)
• Starting motor (15)
• Ground terminal (16) from cylinder block
• Battery ground cable (17) from transaxle
• Back-up light switch (18) (for M/T model)
• Torque sensor (19)
• P/S motor (20)
• Output shaft speed sensor (VSS) (29) (for A/T
model)
• Solenoid valve (30) (for A/T model)
• Transmission range sensor (31) (for A/T model)
• Input shaft speed sensor (32) (for A/T model)
15) Disconnect the following cables, and remove control
cable bracket (23)
• Gear select control cable (21) (for M/T model)
• Gear shift control cable (22) (for M/T model)
• A/T select cable (33) (for A/T model)
16) Disconnect the following hoses.
• Brake booster hose (24) from intake manifold
• Radiator inlet and outlet hoses (25) from radiator
• Heater inlet and outlet hoses (26) from heater
core
• Fuel feed hose (27) from fuel feed pipe
• Fuel vapor hose (11) from fuel vapor pipe
• Clutch hose (28) from transaxle (for M/T model)
• A/T fluid cooler hoses (for A/T model)
F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
1. Engine right mounting bracket 9. Engine front mounting
: Be sure to direct yellow mark to forward.: 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
2. Engine right mounting 10. Transfer : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft)
3. Engine left mounting bracket 11. Suspension frame : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-21
12) Install oil pressure switch bracket (1).
13) Connect right and left drive shaft joints to differential
gear referring to “Front Drive Shaft Assembly
Removal and Installation in Section 3A”.
14) Install suspension control arm referring to
“Suspension Control Arm / Bushing Removal and
Installation in Section 2B”.
15) Install cylinder upper cover (1).16) Install A/C compressor to its bracket (if equipped)
referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installation in Section 7B”.
17) Adjust A/C compressor drive belt referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
18) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation”.
19) Check to ensure that all removed parts are back in
place. Reinstall any necessary parts which have not
been reinstalled.
20) Refill cooling system with coolant referring to
“Cooling System Flush and Refill in Section 1F”.
21) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
22) Refill transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
23) Refill transfer oil referring to “Transfer Oil Change in
Section 3C”.
24) Install battery and battery tray with ECM.
25) Connect ECM wire harness.
26) Connect positive and negative cable at battery.
27) Install right and left side engine under covers.
28) Verify that there is no fuel leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
2. Exhaust manifold
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2
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Downloaded from www.Manualslib.com manuals search engine 1D-46 Engine Mechanical:
Valve head radial runout
Check each valve for radial runout with a dial gauge and
“V” block. To check runout, rotate valve slowly. If runout
exceeds its limit, replace valve.
Valve head radial runout
Limit: 0.08 mm (0.003 in.)
Seating contact width
Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotatingly tapping seat
with valve head. Valve lapper (tool used in valve lapping)
must be used.
Pattern produced on seating face of valve must be a
continuous ring without any break, and the width of
pattern must be within specified range.
Standard seating width “a” revealed by contact
pattern on valve face
Intake and Exhaust: 1.0 – 1.4 mm (0.0389 – 0.0551
in.)Valve seat repair
A valve seat not producing a uniform contact with its
valve or showing width of seating contact that is out of
specified range must be repaired by regrinding or by
cutting and regrinding and finished by lapping.
1)Exhaust valve seat:
Use valve seat cutters (1) to make two cuts as
illustrated in figure. Two cutters must be used: the
first for making 22° angle, and the second for making
45° angle. The second cut must be made to produce
desired seat width.
Seat width for exhaust valve seat
“a”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)
2)Intake valve seat:
Use valve seat cutters (1) to make three cuts as
illustrated in figure. Three cutters must be used: the
1st for making 22° angle, the 2nd for making 60°
angle, and 3rd for making 45° angle. The 3rd cut
(45°) must be made to produce desired seat width.
Seat width for intake valve seat
“b”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)
3)Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.
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Downloaded from www.Manualslib.com manuals search engine 1D-72 Engine Mechanical:
NOTE
The specified tightening torque is also described in the following.
“Air Intake System 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”. Cylinder head bolt for M10 Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft), 40
N⋅m (4.0 kgf-m, 29.0 lb-ft), 60° and 60° by
the specified procedure)
Connecting rod bearing cap nut Tighten 15 N⋅m (1.5 kgf-m, 11.0 lb-ft), 45°
and 45° by the specified procedure) / )
Sensor plate bolt 11 1.1 8.0)
Main bearing cap No.1 bolt 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) / ) / )
Main bearing cap No.2 bolt Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure) / ) / )
Rear oil seal housing bolt 11 1.1 8.0)
Flywheel or drive plate bolt 70 7.0 51.0) Fastening partTightening torque
Note
N⋅mkgf-mlb-ft

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS6RW0D1504001
WARNING!
To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.

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) Disconnect oil pressure switch coupler (1).
2) Remove oil pressure switch (2) from cylinder block.3) Install special tools (oil pressure gauge) to vacated
threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
4) Start engine and warm engine up to normal
operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral”, set parking brake and block drive
wheels.

5) After warming up, raise engine speed to 4,000 r/min.
and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kgf/cm2, 39.8 psi) at 4,000
r/min. (rpm)
6) After checking oil pressure, stop engine and remove
oil pressure gauge and attachment.
7) 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)
2. Low level mark (hole)
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Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-3
8) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, repair it.
9) Connect oil pressure switch coupler (1).
Repair Instructions
Oil Pan and Oil Pump Strainer ComponentsS6RW0D1506001
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1
23
4
(a) 5
(b) 6
(b) 8
(b) 9
(b) 7
10
(c)10
(c)
11 12
(d) 13
(d) 1514
I5RH0A150002-02
1. Oil pan:
Apply sealant 99000-31260 to
mating surface.6. Strainer bolt 11. Dowel pin : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
2. Strainer 7. Bracket bolt 12. Baffle plate : Tighten 11 N⋅m (1.1 kgf-m, 8.0 lb-
ft) by the specified procedure.
3. O-ring 8. Oil pan nut 13. Baffle plate bolt : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
4. Gasket 9. Oil pan bolt
(M6)14. Clutch housing lower plate (M/T
vehicle) or torque converter housing
lower plate (A/T vehicle):11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
5. Drain plug 10. Oil pan bolt
(M10)15. Lower plate bolt : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 1F-3 Engine Cooling System:
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS6RW0D1604001
Condition Possible cause Correction / Reference Item
Engine overheats
(Radiator fan operates)Loose or broken water pump beltAdjust or replace.
Not enough coolantCheck coolant level and add as necessary.
Faulty thermostatReplace.
Faulty water pumpReplace.
Dirty or bent radiator finsClean or remedy.
Coolant leakage on cooling systemRepair.
Clogged radiatorCheck and replace radiator as necessary.
Faulty radiator capReplace.
Dragging brakesAdjust brake.
Slipping clutchReplace.
Poor charge batteryCheck and replace as necessary.
Poor generation generatorCheck and repair.
ECT sensor faultyCheck and replace as necessary.
Radiator fan motor faultyCheck and replace as necessary.
ECM faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
Equipped with too much electric load
part(s)Dismount.
Engine overheats
(Radiator fan does not
operate)Fuse blownCheck fuse of relay/fuse box and check for
short circuit to ground.
Radiator cooling fan relay faultyCheck and replace as necessary.
ECT sensor faultyCheck and replace as necessary.
Radiator cooling fan motor faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
ECM faultyCheck and replace as necessary.

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Repair Instructions
Cooling System ComponentsS6RW0D1606001
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1. Radiator 11. Thermostat case water outlet pipe 21. Heater outlet No.1 hose
2. Reservoir 12. Thermostat case 22. Radiator cooling fan assembly
For disassembly and reassembly, refer
to “Radiator Cooling Fan Disassembly
and Reassembly”.
3. Radiator cap 13. Thermostat 23. To cylinder head
4. Drain plug 14. Thermostat cap 24. To water pump
5. Radiator outlet hose 15. Water bypass No.1 hose 25. To heater core
6. Radiator inlet hose 16. Water inlet No.1 pipe : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
7. Water outlet cap 17. Water inlet hose : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
8. ECT sensor 18. Water inlet No.2 pipe : Do not reuse.
9. Water outlet cap gasket 19. Radiator support bracket bolt
10. O-ring 20. Heater inlet hose