Can SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-13
Throttle Body and Intake Manifold ComponentsS6RW0D1406010
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1. Intake manifold 8. To cylinder head cover 15. Brake booster hose 22. Throttle body outlet water hose
No.2
2. O-ring 9. Gasket (with EGR) 16. To brake booster 23. EGR pipe plate (without EGR)
3. Throttle body: Do not
disassemble10. MAP sensor 17. Throttle body mounting bolt 24. MAP sensor plate (without MAP
sensor)
: Be sure to direct paint mark to
upward.
4. Intake manifold bolt 11. PCV valve hose 18. To EGR valve : Do not reuse.
5. Intake manifold nut 12. Breather pipe 19. Breather hose No.1
6. To PCV valve 13. To EVAP canister purge valve
hose20. Breather hose No.2
7. EGR pipe 14. EVAP canister purge valve hose 21. Throttle body outlet water hose No.1

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Intake Manifold Removal and InstallationS6RW0D1406011
Removal
1) Remove throttle body referring to “Electric Throttle
Body Assembly Removal and Installation”.
2) Disconnect MAP sensor connector (1).
3) Disconnect the following hoses:
• Brake booster hose (2) from cylinder head cover
• PCV hose (3) from PCV valve
4) Remove EGR pipe bolt (4) from EGR valve.
5) Remove intake manifold (1) and EGR pipe (2) from
cylinder head, and then remove its gasket and O-
ring.Installation
Reverse removal procedure for installation noting the
following.
• Use new gasket and O-ring.
• Tighten EVAP canister purge valve bracket bolt to
specified torque.
Tightening torque
EVAP canister purge valve bracket bolt: 5 N·m (
0.5 kgf-m, 4.0 lb-ft)
• Install intake manifold bolt (2) and nut (1) as shown in
figure.
• Check to ensure that all removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
• Refill cooling system referring to “Cooling System
Flush and Refill in Section 1F”.
• Upon completion of installation, turn ignition switch
ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant
leaks.
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Downloaded from www.Manualslib.com manuals search engine 1D-42 Engine Mechanical:
Valves and Cylinder Head Disassembly and
Assembly
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Disassembly
1) For ease in servicing cylinder head, remove intake
manifold, injectors, exhaust manifold from cylinder
head.
2) Using special tools (Valve lifter), compress valve
spring and then remove valve cotters (1) also by
using special tool (Forceps).
Special tool
(A): 09916–14510
(B): 09916–14521
(C): 09916–845113) Release special tools (Valve lifter), and remove
spring retainer and valve spring.
4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide and
valve spring seat (2).
NOTE
Do not reuse valve stem seal once
disassembled. Be sure to use new seal when
assembling.

6) Using special tool (Valve guide remover), drive valve
guide out from combustion chamber side to valve
spring side.
Special tool
(A): 09916–44910
NOTE
Do not reuse valve guide once disassembled.
Be sure to use new valve guide (oversize)
when assembling.

7) Place disassembled parts except valve stem seal
and valve guide in order so that they can be installed
in their original position.
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Downloaded from www.Manualslib.com manuals search engine 1D-48 Engine Mechanical:
Valve Spring InspectionS6RW0D1406030
Valve Spring Free Length and Preload
Referring to data, check to be sure that each spring is in
sound condition, free of any evidence of breakage or
weakening. Remember, weakened valve springs can
cause chatter, not to mention possibility of reducing
power output due to gas leakage caused by decreased
seating pressure.
Valve spring free length
Standard: 36.83 mm (1.450 in.)
Limit: 35.83 mm (1.411 in.)
Valve spring preload
Standard: 107 – 125 N (10.7 – 12.5 kgf) for 31.50 mm
(23.6 – 27.6 lb/1.240 in.)
Limit: 102 N (10.2 kgf) for 31.50 mm (22.5 lb/1.240 in.)Spring Squareness
Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. Valve springs found to exhibit a
larger clearance than limit must be replaced.
Valve spring squareness
Limit: 1.6 mm (0.063 in.)
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Downloaded from www.Manualslib.com manuals search engine 1D-56 Engine Mechanical:
Connecting Rod Bearing General Information
Service connecting rod bearings are available in
standard size and 0.25 mm (0.0098 in.) undersize
bearing, and standard size bearing has 5 kinds of
bearings differing in tolerance.
For identification of undersize bearing, it is painted red at
the position as indicated in figure, undersize bearing
thickness is 1.605 – 1.615 mm (0.0632 – 0.0635 in.) at
the center of it.
Connecting Rod Bearing Visual Inspection
Inspect bearing shells for signs of fusion, pitting, burn or
flaking and observe contact pattern. Bearing shells
found in defective condition must be replaced.
Connecting Rod Bearing Clearance
1) Before checking bearing clearance, clean bearing
and crank pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gauging plastic (1) to full width of
crank pin as contacted by bearing (parallel to
crankshaft), avoiding oil hole.4) Install rod bearing cap (1) to connecting rod.
When installing cap, be sure to point arrow mark (2)
on cap to crankshaft pulley side, as shown in figure.
After applying engine oil to rod bolts, tighten cap nuts
(3) gradually as follows.
a) Tighten all cap nuts to 15 N⋅m (1.5 kgf-m, 11.0 lb-
ft)
b) Retighten them to 45°
c) Repeat Step b) once again.
Tightening torque
Connecting rod bearing cap nut (a): Tighten
15 N⋅m (1.5 kgf-m, 11.0 lb-ft) 45° and 45° by
the specified procedure
5) Remove cap and using a scale (1) on gauging
plastic envelope (2), measure gauging plastic (2)
width at the widest point (clearance).
If clearance exceed its limit, use a new standard size
bearing referring to “Selection of Connecting Rod
Bearings: ”.
After selecting new bearing, recheck clearance.
Connecting rod bearing clearance
Standard: 0.029 – 0.047 mm (0.0011 – 0.0018 in.)
Limit: 0.065 mm (0.0026 in.)
6) If clearance can not be brought to its limit even by
using a new standard size bearing, use next thicker
bearing and recheck clearance or regrind crank pin
to undersize and use 0.25 mm undersize bearing.
1. Red paint
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-71
Honing or Reboring Cylinders
1) When any cylinder needs reboring, all other
cylinders must also be rebored at the same time.
2) Select oversized piston according to amount of
cylinder wear.
Oversize piston specification
Oversize 0.50: 78.453 – 78.468 mm (3.0887 –
3.0893 in.)
3) Using micrometer, measure piston diameter.
Measurement position for piston diameter
“a”: 19.5 mm (0.77 in.)4) Rebore and hone cylinder to the following
dimension.
NOTE
Before reboring, install all main bearing caps
in place and tighten to specification to avoid
distortion of bearing bores.

Cylinder bore diameter to be rebored
Oversize 0.50: 78.500 – 78.514 mm (3.0906 –
3.0911 in.)
5) Measure piston clearance after honing.
Piston clearance
0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Specifications
Tightening Torque SpecificationsS6RW0D1407001
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Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Camshaft housing bolt Tighten 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) by the
specified procedure) / )
EVAP canister purge valve bracket bolt 5 0.5 4.0) / )
Cylinder head cover bolt Tighten 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) by the
specified procedure)
Engine right mounting bracket nut 65 6.5 47.0)
Engine right mounting bush bolt 55 5.5 40.0)
Engine left mounting bush bolt 85 8.5 61.5)
Suspension frame mounting bolt 150 15.0 108.5)
Front lower cross member bolt 55 5.5 40.0)
Starting motor terminal nut 11 1.1 8.0)
Generator terminal nut 5 0.5 4.0)
Battery ground bolt 25 2.5 18.0)
Ground terminal bolt 11 1.1 8.0)
Timing chain cover bolt 25 2.5 18.0)
Timing chain cover nut 25 2.5 18.0)
Cap bolt 25 2.5 18.0)
Oil gallery pipe No.2 and No.3 bolt 11 1.1 8.0)
Crankshaft pulley bolt 150 15.0 108.5)
Oil control valve mounting nut 11 1.1 8.0)
Oil gallery pipe No.1 bolt 30 3.0 21.5)
Timing chain No.1 guide bolt 11 1.1 8.0)
Timing chain tensioner bolt 25 2.5 18.0)
Timing chain tensioner adjuster bolt 11 1.1 8.0)
Intake cam timing sprocket bolt 60 6.0 43.5)
Camshaft housing bolt 11 1.1 8.0)
Venturi plug 5 0.5 3.5)
Cylinder head bolt for M8 Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure)

Downloaded from www.Manualslib.com manuals search engine 1F-1 Engine Cooling System:
Engine
Engine Cooling System
General Description
Cooling System DescriptionS6RW0D1601001
The cooling system consists of the radiator cap, radiator,
coolant reservoir, hoses, water pump, cooling fan and
thermostat. The radiator is of tube-and-fin type.
Coolant DescriptionS6RW0D1601002
WARNING!
• Do not remove radiator cap to check
engine coolant level; check coolant
visually at the see-through coolant
reservoir. Coolant should be added only to
reservoir as necessary.
• As long as there is pressure in the cooling
system, the temperature can be
considerably higher than the boiling
temperature of the solution in the radiator
without causing the solution to boil.
Removal of the radiator cap while engine is
hot and pressure is high will cause the
solution to boil instantaneously and
possibly with explosive force, spewing the
solution over engine, fenders and person
removing cap. If the solution contains
flammable anti-freeze such as alcohol (not
recommended for use at any time), there is
also the possibility of causing a serious
fire.
• Check to make sure that engine coolant
temperature is cold before removing any
part of cooling system.
• Also be sure to disconnect negative cable
from battery terminal before removing any
part.

The coolant recovery system is standard. The coolant in
the radiator expands with heat, and the coolant is
overflowed to the reservoir.
When the system cools down, the coolant is drawn back
into the radiator.
The cooling system has been filled with a quality coolant
that is a 50/50 mixture of water and ethylene glycol
antifreeze.
This 50/50 mixture coolant solution provides freezing
protection to –36 °C (–33 °F).
• Maintain cooling system freeze protection at –36 °C (–
33 °F) to ensure protection against corrosion and loss
of coolant from boiling. This should be done even if
freezing temperatures are not expected.
• Add ethylene glycol base coolant when coolant has to
be added because of coolant loss or to provide added
protection against freezing at temperature lower than
–36 °C (–33 °F).
NOTE
• Alcohol or methanol base coolant or plain
water alone should not be used in cooling
system at any time as damage to cooling
system could occur.
• Coolant must be mixed with demineralized
water or distilled water.

Anti-freeze proportioning table
Coolant capacity
M/T:
• Engine, radiator and heater: 6.8 liters (14.37/11.97
US/lmp pt.)
• Reservoir: 0.7 liters (1.48/1.23 us/lmp pt.)
• Total: 7.5 liters (15.85/13.20 US/lmp pt.)
A/T:
• Engine, radiator and heater: 6.9 liters (14.58/16.63
US/lmp pt.)
• Reservoir: 0.7 liters (1.48/1.23 us/lmp pt.)
• Total: 7.6 liters (16.06/13.38 US/lmp pt.)For M/T
modelFor A/T
model
Freezing
temperature°C–36–36
°F–33–33
Anti-freeze / Anti-
corrosion coolant
concentration%5050
Ratio of compound
to cooling waterltr. 3.75/3.75 3.8/3.8
US pt. 7.92/7.92 8.03/8.03
Imp pt. 6.60/6.60 6.69/6.69

Downloaded from www.Manualslib.com manuals search engine 1F-5 Engine Cooling System:
Coolant Level CheckS6RW0D1606002
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if radiator
cap is taken off too soon.

To check level, lift hood and look at “see-through”
coolant reservoir.
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
A normal coolant level should be between FULL mark
(2) and LOW mark (3) on reservoir (1).
If coolant level is below LOW mark (3), remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to FULL mark (2).
NOTE
If proper quality antifreeze is used, there is
no need to add extra inhibitors or additives
that claim to improve system. They may be
harmful to proper operation of system, and
are unnecessary expense.

Engine Cooling System Inspection and
Cleaning
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WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

1) Check cooling system for leakage or damage.
2) Wash radiator cap and filler neck with clean water by
removing radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester (1), check system and
radiator cap (2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap
for this vehicle.
NOTE
After installing radiator cap to radiator, make
sure that the ear of cap lines is parallel to
radiator.

Cooling system and radiator cap holding
pressure (for inspection)
110 kPa (1.1 kgf/cm2, 15.6 psi)
5) Tighten hose clamps and inspect all hoses. Replace
hoses whenever cracked, swollen or otherwise
deteriorated.
6) Clean frontal area of radiator core.
Cooling System DrainingS6RW0D1606004
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

1) Remove radiator cap.
2) Drain coolant from radiator drain plug (1).
3) After draining coolant, be sure to tighten drain plug
(1) securely.
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Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-6
Cooling System Flush and RefillS6RW0D1606005
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

NOTE
For detail of coolant specification, refer to
“Coolant Description”.

1) Remove radiator cap when engine is cool as follows.
a) Turn cap counterclockwise slowly until it reaches
a “stop” (Do not press down while turning it).
b) Wait until pressure is relieved (indicated by a
hissing sound) then press down on cap and
continue to turn it counterclockwise.
2) With radiator cap removed, run engine until upper
radiator hose is hot (this shows that thermostat is
open and coolant is flowing through system).
3) Stop engine and drain coolant from radiator drain
plug (1).
4) Close radiator drain plug. Add water until system is
filled and run engine until upper radiator hose is hot
again.
5) Repeat Steps 3) and 4) several times until drained
liquid is nearly colorless.
6) Close radiator drain plug (1) tightly.7) Remove reservoir cap (2) and reservoir (1).
8) Pour out any fluid, scrub and clean inside of
reservoir with soap and water.
Flush it well with clean water and drain, Reinstall
reservoir.
9) Fill reservoir with coolant up to “FULL” level mark (3).
10) Install reservoir cap (2) on reservoir.
11) Fill radiator with coolant up to bottom of radiator filler
neck and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.
12) Run engine at idle speed.
13) Run engine until radiator fan motor is operated.
14) Stop engine and wait until engine comes cooled
down to help avoid danger of being burned.
15) Add coolant to radiator up to bottom of radiator filler
neck, and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.
16) Repeat Step 12) through 15).
17) Confirm that reservoir coolant level is “FULL” level
mark (3). If coolant is insufficient, repeat Step 9) and
10).
Cooling Water Pipes or Hoses Removal and
Installation
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Removal
1) Drain coolant referring to “Cooling System Draining”.
2) To remove these pipes or hoses, loosen clamp on
each hose and pull hose end off.
Installation
Install removed parts in reverse order of removal
procedure, noting the following.
• Tighten each clamp securely referring to “Cooling
System Components”.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
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Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
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WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• To help avoid danger of being burned, do
not remove radiator cap while engine and
radiator are still hot. Scalding fluid and
steam can be blown out under pressure if
cap is taken off too soon.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 100 N (10kgf, 22 lbs.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”: 4.5 – 5.5 mm (0.18 – 0.22 in.) as deflection /
100 N (10kgf, 22lbs)
NOTE
When replacing belt with a new one, adjust
belt tension to 4.0 – 4.5 mm (0.16 – 0.18 in.).

3) After loosening generator bracket bolts (2) and pivot
bolt (3), adjust belt tension to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as
specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)5) Check belt tension for specification after turning
crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified
torque.
Tightening torque
Generator adjusting bolt (c): Tighten 7.0 N⋅m
(0.7 kgf-m, 5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.
Water Pump / Generator Drive Belt Removal and
Installation
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Removal
1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor
drive belt before removing water pump belt (1).
Refer to “Compressor Drive Belt Removal and
Installation in Section 7B” or “Compressor Drive Belt
Removal and Installation in Section 7B”.
3) Loosen generator bracket bolts (2) and generator
pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then
remove water pump belt.
a
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2, (a)
3, (b)
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