cam chain SUZUKI SX4 2006 1.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 1D-30 Engine Mechanical:
8) Screw in plunger (1) by turning body (2) in arrow
direction and install a retainer (3) (wire) to hold
plunger in place.
9) Install timing chain tensioner adjuster assembly (1)
with a retainer (2).
Tighten adjuster bolts to specified torque and then
remove a retainer from chain tensioner adjuster
assembly.
Tightening torque
Timing chain tensioner adjuster bolt (a): 11 N·m
(1.1 kgf-m, 8.0 lb-ft)10) Apply engine oil to timing chain, and then turn
crankshaft clockwise by 2 revolutions and check that
match marks (1) are at the following specific
positions.
• Intake and exhaust camshaft timing sprockets are
in match with notches (2) on cylinder head.
• Crankshaft sprocket key (3) is on upside of
crankshaft as shown in figure.
11) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
12) Perform Steps 10) to 14) of “Installation” of “Timing
Chain Cover Removal and Installation”.
I2RH0B140065-01
I2RH0B140066-01
[A]: For engine with VVT [B]: For engine without VVT
1
1
2
3
21
1
3
[A]
[B]
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-33
Camshaft, Tappet and Shim Removal and
Installation
S6RW0D1406023
CAUTION!
• Keep working table, tools and hands clean
while overhauling.
• Use special care to handle aluminum parts
so as not to damage them.
• Do not expose removed parts to dust.
Keep them always clean.

Removal
1) Remove timing chain cover referring to “Timing
Chain Cover Removal and Installation”.
2) Remove timing chain referring to “Timing Chain and
Chain Tensioner Removal and Installation”.
3) For engine with VVT, with hexagonal section (1) of
intake camshaft (2) held stationary with spanner or
the like, loosen mounting bolt of intake cam timing
sprocket assembly (3) and remove it.
CAUTION!
Never attempt to loosen mounting bolt with
intake cam timing sprocket assembly held
stationary. Failure to follow this could result
in damage to lock pin.
Do not loosen bolt “a” because intake cam
timing sprocket assembly is not serviceable.

4) Loosen camshaft housing bolts in such order as
indicated in figure and remove them.
5) Remove camshaft housings.
6) Remove intake and exhaust camshafts.
7) For engine with VVT, remove camshaft bearings (1).
8) Remove tappets (2) with shims (1).
3“a”
1
2
I3RM0A140030-01
“12”“13”
“20”“21”
“16”“17” “8”“9”
“2”
“5”
“3”
“4”
“1”
“10”
“11”“18”
“19” “14”“15” “6” “7”
I3RM0A140031-01
I5RW0C140023-01
I2RH0B140074-01

Downloaded from www.Manualslib.com manuals search engine 1D-34 Engine Mechanical:
Installation
1) Install tappets and shims to cylinder head.
Apply engine oil around tappet and then install it to
cylinder head.
NOTE
When installing shim, make sure to direct
shim No. side toward tappet.

2) For engine with VVT, install camshaft bearings (1) to
cylinder head (2) and camshaft housing (3).
CAUTION!
Do not apply engine oil to camshaft bearing
back.
Only a upper half bearing of intake camshaft
bearing No.1 has some holes.

3) Install intake camshaft (1) and exhaust camshaft (2).
Align knock pin (3) and match mark (4) with notches
(5) as shown in figure.
NOTE
Before installing camshafts, turn crankshaft
until key position faces upward.
Refer to “Timing Chain and Chain Tensioner
Removal and Installation”.

4) Apply engine oil to sliding surface of each camshaft
and camshaft journal then install them as shown in
figure.
5) Install camshaft housing pins (1) as shown in figure.
I2RH0B140075-01
I5RW0C140024-01
[A]: For engine with VVT “a”: Approx. 30°
[B]: For engine without VVT “b”: Approx. 60°
12
3
4
5
“a”
12
44
5
“a”“b”
[A]
[B]
I4RS0B140015-01
I3RM0A140033-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-35
6) Check position of camshaft housings.
Embossed marks are provided on each camshaft
housing, indicating position and direction for
installation. Install housings as indicated by these
marks.
7) After applying engine oil to housing bolts, tighten
them temporarily first. Tighten bolts evenly and
gradually in numerical order (“1” through “21”) by
repeating tightening sequence two or three times
until specified torque is obtained.
Tightening torque
Camshaft housing bolt (a): Tighten 11 N⋅m (1.1
kgf-m, 8.0 lb-ft) by the specified procedure8) For engine with VVT, with hexagonal section (1) of
intake camshaft (2) held stationary with spanner or
the like, tighten bolt of intake cam timing sprocket
assembly (3) to specification.
Tightening torque
Intake cam timing sprocket bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)
9) Install timing chain with crankshaft sprocket referring
to “Timing Chain and Chain Tensioner Removal and
Installation”.
10) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
11) Check valve lashes referring to “Valve Lash
(Clearance) Inspection”.
12) Perform Steps 10) to 14) of “Installation” of “Timing
Chain Cover Removal and Installation”.
A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
I2RH0B140078-01
“10”“9”
“2” “1”,(a) “6”“5” “14” “13”
“20”
“17”
“19”
“18”
“21”
“12”
“11”
“4” “3” “8”“7” “16” “15”
I3RH0B140041-01
1
2 3
(a)
I3RH0B140042-01

Downloaded from www.Manualslib.com manuals search engine 1D-40 Engine Mechanical:
Valves and Cylinder Head Removal and
Installation
S6RW0D1406026
Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
3) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
4) Remove timing chain cover referring to Steps 2) to
11) of “Removal” in “Timing Chain Cover Removal
and Installation”.
5) Remove timing chain referring to Steps 2) to 6) of
“Removal” in “Timing Chain and Chain Tensioner
Removal and Installation”.
6) Remove intake and exhaust camshafts referring to
Steps 3) to 8) of “Removal” in “Camshaft, Tappet and
Shim Removal and Installation”.
7) Loosen cylinder head bolts in such order as
indicated in figure by using a 12 corner socket
wrenches and remove them.
NOTE
Don’t forget to remove bolt (M8) (1) as shown
in figure.

8) Check all around cylinder head for any other parts
required to be removed or disconnected and remove
or disconnect whatever necessary.
9) Remove exhaust manifold, if necessary referring to
“Exhaust Manifold Removal and Installation in
Section 1K”.
10) Remove cylinder head with intake manifold and
exhaust manifold. Use lifting device, if necessary.
Installation
1) Clean mating surface of cylinder head and cylinder
block. Remove oil, old gasket and dust from mating
surface.
2) Make sure that oil jet (venturi plug) (1) is not
clogged. If it is not installed, install it as specified
torque.
Tightening torque
Venturi plug (a): 5 N·m (0.5 kgf-m, 3.5 lb-ft)
3) Install knock pins (1) to cylinder block.
4) Install new cylinder head gasket (2) to cylinder block.
“Top” or triangle mark provided on gasket comes to
crankshaft pulley side, facing up (toward cylinder
head side).
I2RH0B140088-01
I2RH0B140089-01
I5RW0C140025-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-41
5) Install cylinder head to cylinder block.
Apply engine oil to new cylinder head bolts and
tighten them gradually as follows.
a) Tighten cylinder head bolts (“1” – “10”) to 20 N⋅m
(2.0 kgf-m, 14.5 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 40 N⋅m (4.0 kgf-m, 29.0 lb-ft).
c) Turn all bolts 60° according to numerical order in
figure.
d) Repeat Step c).
e) Tighten cylinder head bolt (M8) (1) to specified
torque.
NOTE
Be sure to tighten M8 bolt (1) after securing
the other bolts.

Tightening torque
Cylinder head bolt for M8 (a): Tighten 25 N⋅m
(2.5 kgf-m, 18.0 lb-ft) by the specified
procedure
Cylinder head bolt for M10 (b): 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
NOTE
• If cylinder head bolts (M10) are reused,
check thread diameters of cylinder head
bolt (1) for deformation according to the
follows and replace them with new ones if
thread diameter difference exceeds limit.
• Measure each thread diameter of cylinder
head bolt (1) at “A” on 83.5 mm (2.81 in.)
from seat side of flange bolt and “B” on
115 mm (4.53 in.) from seat side of flange
bolt by using a micrometer (2).
Then calculate difference in diameters (“A”
– “B”). If it exceeds limit, replace with new
one.

Cylinder head bolt diameter measurement
points
“a”: 83.5 mm (2.81 in.)
“b”: 115 mm (4.53 in.)
Cylinder head bolt diameter difference
(deformation)
Limit (“A” – “B”): 0.1 mm (0.004 in.)
6) Install camshafts, tappet and shim referring to
“Camshaft, Tappet and Shim Removal and
Installation”.
7) Install timing chain referring to “Timing Chain and
Chain Tensioner Removal and Installation”.
8) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
9) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
10) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
I5RW0C140030-01

“A”
“a”
“b”“B”

1
12
I2RH0B140092-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-63
9) Install rear oil seal housing (1) and tighten new bolts
to specified torque by using special tool.
Special tool
(A): 09911–97720
Tightening torque
Rear oil seal housing bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
10) Install flywheel (drive plate for A/T).
Using special tool, lock flywheel or drive plate, and
tighten flywheel or drive plate bolts to specified
torque.
NOTE
Use new flywheel or drive plate bolts.

Special tool
(A): 09924–17810
Tightening torque
Flywheel or drive plate bolt (a): 70 N·m (7.0 kgf-
m, 51.0 lb-ft)
11) Install piston and connecting rod referring to
“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
12) Install cylinder head referring to “Valves and Cylinder
Head Removal and Installation”.13) Install camshafts, tappet and shim referring to
“Camshaft, Tappet and Shim Removal and
Installation”.
14) Install timing chain referring to “Timing Chain and
Chain Tensioner Removal and Installation”.
15) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
16) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
17) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
18) Install engine assembly to vehicle referring to
“Engine Assembly Removal and Installation”.
Crankshaft InspectionS6RW0D1406039
Crankshaft Runout
Using a dial gauge, measure runout at center journal.
Rotate crankshaft slowly. If runout exceeds its limit,
replace crankshaft.
Crankshaft runout
Limit: 0.02 mm (0.0008 in.)
Crankshaft Thrust Play
1) Measure this play with crankshaft set in cylinder
block in the normal manner, that is with thrust
bearing (1) and journal bearing caps installed.
Thickness of crankshaft thrust bearing
Standard: 2.470 – 2.520 mm (0.0972 – 0.0992 in.)
Oversize (0.125 mm (0.0049 in.)): 2.533 – 2.583
mm (0.0997 – 0.1017 in.)
A: Crankshaft side
I4RS0A140019-01
I2RH0B140134-01
I2RH0B140135-01
I2RH0B140136-01

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
I2RH01140157-01
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 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 Engine Mechanical: 1D-73
Special Tools and Equipment
Recommended Service MaterialS6RW0D1408001
NOTE
Required service material is also described in the following.
“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”

Special ToolS6RW0D1408002
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140)
SUZUKI Bond No.1207F P/No.: 99000–31250) / ) / )
09911–97720 09911–97821
Oil seal installer Oil seal installer
))
09913–75810 09915–64512
Bearing installer Compression gauge
))
09915–64530 09915–67010
Compression gauge hose Compression gauge
attachment (C)
))
09915–67311 09916–14510
Vacuum gauge Valve lifter
)) / )
09916–14521 09916–34542
Valve spring compressor
attachmentReamer handle
) / )) / )