MAIN SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1C-6 Engine Electrical Devices:
Removal
1) Disconnect negative cable at battery.
2) Disconnect connector from APP sensor assembly.
3) Remove APP sensor assembly from its bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten APP sensor assembly upper nut (1) first and
then lower nuts (2) to specified torque.
Tightening torque
APP sensor assembly nut (a): 6 N⋅m (0.6 kgf-m, 4.5
lb-ft)
• Connect connector to APP sensor assembly securely.
Accelerator Pedal Position (APP) Sensor
Assembly Inspection
S6RW0D1306007
Check APP sensor (main and sub) output voltage as
following steps.
1) For APP sensor (main), arrange 3 new 1.5 V
batteries (1) in series (check that total voltage is 4.5
– 5.0 V) and connect its positive terminal to “Vin 1”
terminal (2) and negative terminal to “Ground 1”
terminal (3) of sensor. Then using voltmeter, connect
positive terminal to “Vout 1” terminal (4) of sensor
and negative terminal to battery.2) For APP sensor (sub), arrange 3 new 1.5 V batteries
(1) in series (check that total voltage is 4.5 – 5.0 V)
and connect its positive terminal to “Vin 2” terminal
(2) and negative terminal to “Ground 2” terminal (3)
of sensor. Then using voltmeter, connect positive
terminal to “Vout 2” terminal (4) of sensor and
negative terminal to battery.
3) Measure output voltage variation while accelerator
pedal is no depressed and fully depressed as
following graph.
If sensor voltage is out of specified value or does not
vary linearly as the following graph, replace APP sensor
assembly.
1, (a)
2, (a)
I5RW0A130004-01
1 2 34I5RW0A130005-01
[C]: Voltage
[D]: Idle position of accelerator pedal
[E]: Fully depressed position of accelerator pedal
1 2 3 4I5RW0A130006-02
[C]
[D] [E]
3.50 - 4.27 V
1.74 - 2.17 V
0.65 - 0.82 V
0.30 - 0.44 V
[A]
[B]
I7RW01130020-01

Downloaded from www.Manualslib.com manuals search engine 1C-12 Engine Electrical Devices:
Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control Relay
and Radiator Cooling Fan Relay Inspection
S6RW0D1306017
1) Disconnect negative cable at battery.
2) Remove main relay (1), fuel pump relay (3), starting
motor control relay (2), throttle actuator control relay
(4) and/or radiator cooling fan relay (5) from
individual circuit fuse box No.1.
3) Check that there is no continuity between terminal
“C” and “D”. If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “B”
of relay. Connect battery negative (–) terminal to
terminal “A” of relay. Check for continuity between
terminal “C” and “D”. If there is no continuity when
relay is connected to the battery, replace relay.
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor On-Vehicle
Inspection
S6RW0D1306018
NOTE
Before performed this inspection, be sure to
read the “Precautions of ECM Circuit
Inspection in Section 1A”.

1) Disconnect negative cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Connect voltmeter to “BLK/RED” wire terminal (2) of
MAF and IAT sensor connector (1) disconnected and
ground.
4) Turn ON ignition switch position and check that
voltage is battery voltage.
If not, check if wire harness is open or connection is
poor.
5) Turn OFF ignition switch position and connect
connector to MAF and IAT sensor.
6) Remove ECM from its bracket referring to “Engine
Control Module (ECM) Removal and Installation”.
7) Connect special tool between ECM and ECM
connector referring to “Inspection of ECM and Its
Circuits in Section 1A”.
8) Turn ON ignition switch position and check MAF
signal voltage between “C01-26” terminal circuit and
“C01-27” terminal circuit of special tool.
MAF signal voltage between “C01-26” terminal
circuit and “C01-27” terminal circuit of special
tool
MAF signal voltage of MAF and IAT sensor with
ignition switch turned ON: 0.5 – 1.0 V
9) Start engine and check that voltage is lower than 5 V
and it rises as engine speed increases.
MAF signal voltage between “C01-26” terminal
circuit and “C01-27” terminal circuit of special
tool
MAF signal reference voltage of MAF and IAT
sensor at specified Idle speed: 1.3 – 1.8 V
10) If check result is not as specified above, cause may
lie in wire harness, connector connection, MAF and
IAT sensor or ECM.
"D" "B""A""C"
2
1
4 3
5
I5RW0A130014-01
1. ECM
I3RB0A130009-01
“C01-27” “C01-26”
1
I6RW0D130003-02

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-59
Main Bearings, Crankshaft and Cylinder Block ComponentsS6RW0D1406037
I6RW0D140003-01
1. CKP sensor
: See “A”11. Rear oil seal 21. Oil filter adapter bolt
2. Knock sensor 12. Input shaft bearing 22. Spring pin
3. Cylinder block 13. Flywheel or drive plate 23. Sensor plate bolt
4. Venturi plug 14. Main bearing cap 24. Oil pressure switch

Downloaded from www.Manualslib.com manuals search engine 1D-60 Engine Mechanical:
Main Bearings, Crankshaft and Cylinder Block
Removal and Installation
S6RW0D1406038
Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove clutch cover, clutch disc and flywheel (drive
plate for A/T) by using special tool.
Special tool
(A): 09924–178103) 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 sensor plate from crankshaft.
5. Main bearing
: See “B”15. Flywheel or drive plate bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft)
6. Sensor plate 16. Rear oil seal housing mounting bolt : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Crankshaft timing sprocket key 17. Main bearing cap No.2 bolt : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
8. Crankshaft 18. Main bearing cap No.1 bolt
: See “D”: Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure.
9. Thrust bearing 19. O-ring : 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”20. Oil filter adapter case : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
“A”: When installing CKP sensor, use new sensor mounting bolt. : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
“B”: Upper half of bearing has an oil groove.
Do not apply oil between connecting rod and bearing or between bearing cap and
bearing.:10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
“C”: Apply sealant 99000-31250 to mating surface. : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
“D”: Make sure main bearing cap No.1 bolt deformation when reuse it due to plastic
deformation tightening referring to “Main Bearings Inspection”.: Do not reuse.
: Apply engine oil to inside / sliding surface.
I2RH0B140125-01
I2RH0B140126-01
I2RH0B140127-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-61
Installation
NOTE
• Use new bearing cap No.1 bolts. They are
deformed once they are used because they
are plastic deformation tightening bolts.
• All parts to be installed must be perfectly
clean.
• Be sure to oil crankshaft journals, journal
bearings, thrust bearings, crankpins,
connecting rod bearings, pistons, piston
rings and cylinder bores.
• Journal bearings, bearing caps,
connecting rods, rod bearings, rod bearing
caps, pistons and piston rings are in
combination sets. Do not disturb such
combination and make sure that each part
goes back to where it came from, when
installing.

1) Install sensor plate (1) to crankshaft (2) and tighten
bolts to specified torque.
NOTE
When installing sensor plate, align spring pin
(3) on crankshaft and hole of sensor plate.

Tightening torque
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)2) Install main bearings to cylinder block.
Upper half of bearing (1), has an oil groove (2).
Install it to cylinder block (3), and the other half
without oil groove to bearing cap.
Make sure that two halves are painted in the same
color.
3) Confirm that dowel pins (1) are installed to intake
side of each journal.
4) Install crankshaft to cylinder block.
5) Install thrust bearings (1) to cylinder block between
No.2 and No.3 cylinders. Face oil groove (2) sides to
crank webs.
I2RH0B140128-01
I2RH0B140129-01
I6RW0B140013-02
I6RW0B140014-01

Downloaded from www.Manualslib.com manuals search engine 1D-62 Engine Mechanical:
6) Install bearing cap to cylinder block, making sure to
point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts ((1) – (10)) and main bearing cap No.2 bolts
((11) – (20)), tighten them gradually as follows.
a) Tighten bolts ((1) – (10)) to 30 N⋅m (3.0 kgf-m,
22.0 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 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them
to 60°.
d) Tighten bolts ((11) – (20)) to 25 N⋅m (2.5 kgf-m,
18.0 lb-ft) according to numerical order as
shown.
Tightening torque
Main bearing cap No.1 bolt ((1) – (10)):
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 ((11) – (20)):
Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure
CAUTION!
After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 N⋅m (1.2 kgf-m, 9.0 lb-ft)
torque or below.

7) If necessary, press-fit rear oil seal (1) to oil seal
housing (2) by using special tool as shown in figure.
Special tool
(A): 09911–97821
Crank rear oil seal installing position
(dimension)
“a”: 2 mm (0.08 in.)
8) Apply sealant to mating surface of rear oil seal
housing (1).
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
I2RH0B140131-01
I5RW0C140027-01
I4RS0A140018-01

Downloaded from www.Manualslib.com manuals search engine 1D-64 Engine Mechanical:
2) Tighten main bearing cap No.1 bolts (1) – (10) and
main bearing cap No.2 bolts (11) – (20) gradually as
follows.
a) Tighten bolts (1) – (10) to 30 N⋅m (3.0 kgf-m,
22.0 lb-ft) according to numerical order in figure.
b) In the same manner as in Step a), tighten them
to 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them
to 60°.
d) Tighten bolts (11) – (20) to 25 N⋅m (2.5 kgf-m,
18.0 lb-ft) according to numerical order in figure.
Tightening torque
Main bearing cap No.1 bolt ((1) – (10)):
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 ((11) – (20)):
Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure3) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
If its limit is exceeded, replace thrust bearing with
new standard one or oversize one to obtain standard
thrust play.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0043 – 0.0122 in.)
Limit: 0.35 mm (0.0138 in.)
NOTE
After checking the thrust play, make sure that
thread deformation of each bearing cap No.1
bolt referring to “Main Bearing Cap No.1
Bolt” in “Main Bearings Inspection”.

Out-of-Round and Taper (Uneven Wear) of Journals
An unevenly worn crankshaft journal shows up as a
difference in diameter at a cross section or along its
length (or both). This difference, if any, is determined by
taking micrometer readings. If any one of journals is
badly damaged or if amount of uneven wear in the sense
exceeds its limit, regrind or replace crankshaft.
Crankshaft out-of-round and taper
Limit: 0.01 mm (0.0004 in.)
Out-of-round
A – B
Ta p e r
a – b
I2RH0B140137-01
I2RH01140183-01
I2RH0B140138-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-65
Main Bearings InspectionS6RW0D1406040
General Information
• Service main bearings are available in standard size
and 0.25 mm (0.0098 in.) undersize, and each of them
has 5 kinds of bearings differing in tolerance.
• Upper half of bearing (1) has oil groove (2) as shown
in figure.
Install this half with oil groove to cylinder block.
• Lower half of bearing does not have an oil groove.
Visual 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.
Main Bearing Clearance
NOTE
Do not rotate crankshaft while gauging
plastic is installed.

Check clearance by using gauging plastic according to
the following procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) the full width of
bearing (parallel to crankshaft) on journal, avoiding
oil hole.4) Tighten main bearing cap No.1 bolts (1) – (10) and
main bearing cap No.2 bolts (11) – (20) gradually as
follows.
a) Tighten bolts (1) – (10) to 30 N⋅m (3.0 kgf-m,
22.0 lb-ft) according to numerical order in figure.
b) In the same manner as in Step a), tighten them
to 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them
to 60°.
d) Tighten bolts (11) – (20) to 25 N⋅m (2.5 kgf-m,
18.0 lb-ft) according to numerical order in figure.
Tightening torque
Main bearing cap No.1 bolt ((1) – (10)):
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 ((11) – (20)):
Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure
5) Remove bearing caps and using scale (1) on
gauging plastic envelop (2), measure gauging plastic
width at its widest point. If clearance exceeds its
limit, replace bearing. Always replace both upper
and lower inserts as a unit.
A new standard bearing may produce proper
clearance. If not, it will be necessary to regrind
crankshaft journal for use of 0.25 mm undersize
bearing.
After selecting new bearing, recheck clearance.
Main bearing clearance
Standard: 0.021 – 0.041 mm (0.0008 – 0.0016 in.)
Limit: 0.054 mm (0.0021 in.)
I2RH0B140139-01
I2RH0B140140-01
I2RH0B140137-01
I2RH0B140141-01

Downloaded from www.Manualslib.com manuals search engine 1D-66 Engine Mechanical:
Selection of Main Bearings
Standard bearing
If bearing is in malcondition, or bearing clearance is out
of specification, select a new standard bearing according
to the following procedure and install it.
1) First check journal diameter. As shown in figure,
crank web No.2 has stamped numbers.
Three kinds of numbers (“1”, “2” and “3”) represent
the following journal diameters.
Stamped numbers on crank web No.2 represent
journal diameters marked with an arrow in figure
respectively. For example of M15 engine, stamped
number “1” indicates that corresponding journal
diameter is 51.9940 – 52.0000 mm (2.0471 – 2.0472
in.).
Crankshaft journal diameter2) Next, check bearing cap bore diameter without
bearing. On mating surface of cylinder block, five
alphabets are stamped as shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) or
numbers (“1”, “2” and “3”) represent the following
cap bore diameters.
Stamped alphabets or numbers on cylinder block
represent bearing cap bore diameter marked with an
arrow in figure respectively.
For example, stamped “A” or “1” indicates that
corresponding bearing cap bore diameter is 56.0000
– 56.0060 mm (2.2048 – 2.2049 in.).
Crankshaft bearing cap bore
Stamped
numbersJournal diameter
151.9940 – 52.0000 mm
(2.0471 – 2.0472 in.)
251.9880 – 51.9939 mm
(2.0468 – 2.0470 in.)
351.9820 – 51.9879 mm
(2.0465 – 2.0467 in.)
I2RH0B140142-01
Stamped
alphabet
(number)Bearing cap bore diameter (without
bearing)
A or 156.0000 – 56.0060 mm
(2.2048 – 2.2049 in.)
B or 256.0061 – 56.0120 mm
(2.2050 – 2.2051 in.)
C or 356.0121 – 56.0180 mm
(2.2052 – 2.2054 in.)
I2RH0B140143-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-67
3) There are 5 kinds of standard bearings differing in
thickness. To distinguish them, they are painted in
the following colors at the position as indicated in
figure.
Each color indicated the following thickness at the
center of bearing.
Standard size of crankshaft main bearing
thickness
4) From number stamped on crank web No.2 and alphabets stamped on cylinder block, determine new standard
bearing to be installed to journal, by referring to the table shown.
For example, if number stamped on crank web No.2 is “1” and alphabet stamped on cylinder block is “B”, install a
new standard bearing painted in “Brown” to its journal.
New standard size crankshaft main bearing specification
Color
paintedBearing thickness
Purple 1.992 – 1.996 mm (0.07843 – 0.07858 in.)
Brown 1.995 – 1.999 mm (0.07855 – 0.07870 in.)
Green 1.998 – 2.002 mm (0.07867 – 0.07882 in.)
Black 2.001 – 2.005 mm (0.07878 – 0.07893 in.)
Colorless
(no paint)2.004 – 2.008 mm (0.07890 – 0.07906 in.)
1. Paint
I2RH01140191-01
Number stamped on crank web No.2 (Journal diameter)
123
Alphabet stamped on cylinder
block (Cap bore dia.)A or 1 Purple Brown Green
B or 2 Brown Green Black
C or 3 Green Black Colorless
New standard bearing to be installed