Oil ring SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1E-6 Engine Lubrication System:
Oil Pump ComponentsS6RW0D1506004
Oil Pump Removal and InstallationS6RW0D1506005
Oil pump is incorporated with timing chain cover.
For removal and installation, refer to “Timing Chain
Cover Removal and Installation in Section 1D”.
Oil Pump Disassembly and ReassemblyS6RW0D1506006
Disassembly
1) Remove rotor plate (1) by removing its mounting
bolts.2) Remove outer rotor (1) and inner rotor (2).
3) Remove relief valve (1), spring (2) and retainer (3) by
removing circlip (4).
I4RS0A150010-01
1. Rotor plate 6. Rotor plate bolt : 11 N⋅m (1.1 kgf-m 8.0 lb-ft)
2. O-ring 7. Relief valve : Do not reuse.
3. Outer rotor 8. Spring : Apply thin coat of engine oil to sliding surface.
4. Inner rotor 9. Retainer
5. Timing chain cover 10. Circlip
I2RH0B150018-01
I2RH0B150019-01
I2RH0B150020-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-7
Reassembly
1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors,
oil seal lip portion, inside surfaces of oil pump case
and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Apply engine oil to relief valve (1) and spring (2), and
install them with retainer (3) and new circlip (4) to
rotor plate (5).
5) Install rotor plate and tighten all bolts to specified
torque. After installing plate, check to be sure that
rotors turn smoothly by hand (0.3 N⋅m (0.03 kgf-m,
0.25 lb-ft) torque or below).
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)Oil Pump InspectionS6RW0D1506007
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Oil Pump
• Check outer (1) and inner rotors (2), rotor plate, and
oil pump case for excessive wear or damage.
• Check relief valve (1) for excessive wear or damage
and operates smoothly.
I2RH0B150019-01
I3RM0A150005-01
I2RH0B150022-01
I2RH0B150023-01
I2RH0B150019-01
I2RH0B150025-01

Downloaded from www.Manualslib.com manuals search engine 1E-8 Engine Lubrication System:
Radial clearance
Check radial clearance between outer rotor (1) and case
(2) using thickness gauge (3).
If clearance exceeds its limit, replace outer rotor or case.
Radial clearance between outer rotor and case for oil
pump
Limit: 0.310 mm (0.0122 in.)
Side clearance
Using straightedge (1) and thickness gauge (2),
measure side clearance.
If side clearance exceeds its limit, replace oil pump
assembly.
Side clearance for oil pump inner rotor
Limit: 0.15 mm (0.0059 in.)Relief valve spring free length and load
Check relief valve spring free length and load as shown
in the figure. If the measured valve spring length is lower
than the specification, replace relief valve spring.
Relief valve spring free length and load
I2RH0B150026-01
I2RH0B150027-01
Standard Limit
Free length52.4 mm
(2.06 in.)—
Load at spring
length
38.5 mm (1.52 in.)77 N
(7.7 kgf, 17.0 lb)69 N
(6.9 kgf, 15.0 lb)
I2RH01150023-01

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-2
Schematic and Routing Diagram
Ignition System Wiring Circuit DiagramS6RW0D1802001
E01-60
E01-29
12V5V
5V
E01-1
E01-16
BLK/WHT
BLK/RED
BLK/RED
BLK/RED
80A
BLK/YELBLK/YEL
BLK/YEL
GRN
BLK
WHT
BRN/WHT
BLK/ORN
BLK
BLK
BLK
C01-20
BLK/RED
PNK
BLK/ORN
5V
C01-21
BLK/WHT
7
34
1
125
6 2
11 89 10
GRN/YEL
GRN/WHT
C01-6
C01-55V
5V
RED/YEL
C01-58
C01-15
C01-30
E01-31
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
13
14
15
16
17
BLK
I6RW0D180001-01
1. Ignition switch 7. No.1 spark plug 13. Relay box
2. Main relay 8. No.2 spark plug 14. “IG ACC” fuse
3. Ignition coil assembly for No.1 and No.4 spark plugs 9. No.3 spark plug 15. “FI” fuse
4. Ignition coil assembly for No.2 and No.3 spark plugs 10. No.4 spark plug 16. Junction block assembly
5. CMP sensor 11. Sensed information 17. “IG COIL” fuse
6. CKP sensor 12. Battery fuse box

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Component Location
Ignition System Components LocationS6RW0D1803001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

12*
15*
13
1 689
11
10
74
5
14
2 3
16
I5RW0C180002-01
1. ECM 7. ECT sensor 13. Battery fuse box
2. Ignition coil assembly for No.1 and No.4 spark plugs 8. MAF and IAT sensor 14. Relay box
3. Ignition coil assembly for No.2 and No.3 spark plugs 9. Electric throttle body assembly 15. Junction block assembly
4. CMP sensor (VVT model) 10. High-tension cords 16. CMP sensor (VVT model)
5. CKP sensor 11. Knock sensor
6. MAP sensor (if equipped) 12. Data link connector

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-4
Diagnostic Information and Procedures
Ignition System Symptom DiagnosisS6RW0D1804001
Reference Waveform of Ignition SystemS6RW0D1804002
Refer to “Reference waveform No.5”, “Reference waveform No.6” and “Reference waveform No.7” under “Inspection
of ECM and Its Circuits in Section 1A” for waveform of Ignition trigger signal.
Ignition System CheckS6RW0D1804003
Condition Possible cause Correction / Reference Item
Engine cranks, but will
not start or hard to start
(No spark)Blown fuse for ignition coilReplace.
Loose connection or disconnection of
lead wire or high-tension cord(s)Connect securely.
Faulty high-tension cord(s)Replace.
Faulty spark plug(s)Replace.
Faulty ignition coilReplace ignition coil assembly.
Faulty CKP sensor or CKP sensor plateClean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaftClean, tighten or replace.
Faulty ECMReplace.
Poor fuel economy or
engine performanceIncorrect ignition timingCheck related sensors and CKP sensor plate.
Faulty spark plug(s) or high-tension
cord(s)Adjust, clean or replace.
Faulty ignition coil assemblyReplace.
Faulty CKP sensor or CKP sensor plateClean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaftClean, tighten or replace.
Faulty knock sensorReplace.
Faulty ECMReplace.
Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check in
Section 1A”.
2Ignition spark test
1) Check all spark plugs for condition and type referring to
“Spark Plug Inspection”.
2) If OK, perform ignition spark test referring to “Ignition
Spar k Tes t”.
Is spark emitted from all spark plugs?Go to Step 12. Go to Step 3.
3DTC check
1) Perform DTC check referring to “DTC Check in Section
1A”.
Is DTC stored in ECM?Go to applicable DTC
diag. flow.Go to Step 4.
4Electrical connection check
1) Check ignition coil assemblies and high-tension cords
for electrical connection.
Are they connected securely?Go to Step 5. Connect securely.
5High-tension cords check
1) Check high-tension cord for resistance referring to
“High-Tension Cord Inspection”.
Is check result satisfactory?Go to Step 6. Replace high-tension
cord(s).

Downloaded from www.Manualslib.com manuals search engine 1H-5 Ignition System:
6Ignition coil assembly power supply and ground circuit
check
1) Check ignition coil assembly power supply and ground
circuits for open and short.
Are circuits in good condition?Go to Step 7. Repair or replace.
7Ignition coil assembly check
1) Check ignition coil for resistance referring to “Ignition
Coil Assembly (Including Ignitor) Inspection”.
Is check result satisfactory?Go to Step 8. Replace ignition coil
assembly.
8CKP sensor check
1) Check CKP sensor referring to “Crankshaft Position
(CKP) Sensor Inspection in Section 1C”.
Is check result satisfactory?Go to Step 9. Tighten CKP sensor
bolt, replace CKP
sensor or CKP sensor
plate.
9CMP sensor check
1) Check CMP sensor referring to “Camshaft Position
(CMP) Sensor Inspection in Section 1C”.
Is check result satisfactory?Go to Step 10. Tighten CMP sensor
bolt, replace CMP
sensor or intake
camshaft.
10Ignition trigger signal circuit check
1) Check ignition trigger signal wire for open, short and
poor connection.
Is circuit in good condition?Go to Step 11. Repair or replace.
11A known-good ignition coil assembly substitution
1) Substitute a known-good ignition coil assembly and then
repeat Step 2.
Is check result of Step 2 satisfactory?Go to Step 12. Substitute a known-
good ECM and then
repeat Step 2.
12Ignition timing check
1) Check initial ignition timing and ignition timing advance
referring to “Ignition Timing Inspection”.
Is check result satisfactory?System is in good
condition.Go to Step 13.
13Knock sensor check
1) Confirm that knock sensor circuit is in good condition
referring to “DTC P0327 / P0328: Knock Sensor Circuit
Low / High in Section 1A”.
2) Check oscilloscope waveform of knock sensor signal
referring to “Reference waveform No.19” and
“Reference waveform No.20” under “Inspection of ECM
and Its Circuits in Section 1A”.
Is check result satisfactory?Check CMP sensor,
CMP sensor rotor tooth
of camshaft, CKP
sensor, CKP sensor
plate and/or input
signals related to this
system.Substitute a known-
good knock sensor and
recheck. Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-6
Ignition Spark TestS6RW0D1804004
1) Remove air cleaner assembly with air intake pipe.
2) Disconnect all injector couplers from injectors.
WARNING!
Without disconnection of injector couplers,
combustible gas may come out from spark
plug holes during this test and may get
ignited in engine room.

3) Remove spark plug and check it for condition and
type referring to “Spark Plug Inspection”.
4) If OK, connect ignition coil coupler to ignition coil
assembly and connect spark plug to ignition coil
assembly or high-tension cord. Ground spark plug.5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as
described in “Ignition System Symptom Diagnosis”.
Repair Instructions
High-Tension Cord Removal and InstallationS6RW0D1806001
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Disconnect No.1 cylinder (2) and No.3 cylinder (3)
high-tension cords from ignition coil assemblies (1)
while gripping each cap.
3) Pull out high-tension cords from spark plugs while
gripping each cap.
CAUTION!
• Removal of high-tension cords together
with clamps will be recommended so as
not to damage their inside wire (resistive
conductor).
• For the same reason, pull out each
connection by gripping cap portion.

Installation
1) Install No.1 cylinder (2) and No.3 cylinder (3) high-
tension cords to spark plugs and ignition coil
assemblies (1) while gripping each cap.
CAUTION!
• Never attempt to use metal conductor
high-tension cords as replacing parts.
• Insert each cap portion fully when
installing high-tension cords.

I4RS0A180006-01
I4RS0A180003-01
I4RS0A180004-01

Downloaded from www.Manualslib.com manuals search engine 1H-7 Ignition System:
High-Tension Cord InspectionS6RW0D1806002
Measure resistance of high-tension cord (1) by using
ohmmeter.
If resistance exceeds specification, replace high-tension
cord(s).
High-tension cord resistance
No.1 cylinder high-tension cord resistance: 1.4 – 4.0
kΩ
No.3 cylinder high-tension cord resistance: 0.6 – 2.0
kΩ
Spark Plug Removal and InstallationS6RW0D1806003
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Pull out high-tension cords by gripping their caps
and then remove ignition coil assemblies referring to
“Ignition Coil Assembly (Including Ignitor) Removal
and Installation”.
3) Remove spark plugs.
Installation
1) Install spark plugs and tighten them to specified
torque.
Tightening torque
Spark plug: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Install ignition coil assemblies referring to “Ignition
Coil Assembly (Including Ignitor) Removal and
Installation”.
3) Install high-tension cords securely by gripping their
caps.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
Spark Plug InspectionS6RW0D1806004
CAUTION!
• When servicing the iridium / platinum
spark plugs (slender center electrode type
plugs), do not touch the center electrode
to avoid damage to it. The electrode is not
strong enough against mechanical force
as it is slender and its material is not
mechanically tough.
• Do not clean or adjust gap for the iridium /
platinum spark plugs.

Inspect spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
If any abnormality is found for nickel spark plugs, adjust
air gap, clean with spark plug cleaner or replace it with
specified new plug.
For iridium / platinum spark plugs, replace it with new
plug.
Spark plug air gap
“a”
: 1.0 – 1.1 mm (0.040 – 0.043 in.)
Spark plug type
NGK: BKR6E-11 (Nickel) / IFR6J11 (Iridium)
DENSO: K20PR-U11 (Nickel)
NOTE
NGK IFR6J11 is highly recommended for
better engine starting performance under –25
°C (–13 °F).

I2RH0B180005-01
IYSQ01181012-01

Downloaded from www.Manualslib.com manuals search engine 1I-1 Starting System:
Engine
Starting System
Schematic and Routing Diagram
Cranking System Circuit DiagramS6RW0D1902001
Diagnostic Information and Procedures
Cranking System Symptom DiagnosisS6RW0D1904001
Possible symptoms due to starting system trouble would be as follows:
• Starting motor does not run (or runs slowly)
• Starting motor runs but fails to crank engine
• Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery, wiring harness,
(including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of
possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
I4RS0A190001-01
1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch
2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery
3. Magnetic switch 8. Starting motor 13. To ECM
4. Hold-in coil 9. Starting motor control relay
5. Plunger 10. A/T: Transmission range sensor (shift switch)