Timing SUZUKI SX4 2006 1.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-25
8) For engine with VVT, install new O-ring (1) to oil
gallery pipes No.2 (2) and No.3 (3).
9) For engine with VVT, install oil gallery pipes No.2
and No.3 to cylinder head (4) and timing chain cover
(5).
Tighten bolts to specified torque.
Tightening torque
Oil gallery pipe No.2 and No.3 bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
10) Install water pump pulley.
11) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
12) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
13) Install crankshaft pulley (1). Tighten bolt (2) to
specified torque. To lock crankshaft pulley, use
special tool with it as shown in figure.
Special tool
(A): 09917–68221
Tightening torque
Crankshaft pulley bolt (a): 150 N·m (15.0 kgf-m,
108.5 lb-ft)
14) Install engine assembly to vehicle referring to
“Engine Assembly Removal and Installation”.Timing Chain Cover InspectionS6RW0D1406016
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Timing Chain Cover (For Engine with VVT)
Inspect strainer (1) of oil passage for driving intake cam
timing sprocket assembly (VVT actuator).
If clog or foreign matter exists, clean strainer.
(a)
(a)1
2
3
4
5
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1
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Oil Control Valve Removal and Installation (For
Engine with VVT)
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Removal
Remove oil gallery pipe No.1 and oil control valve from
timing chain cover.
Installation
1) Install new O-ring (4) to oil control valve (2).
2) Install oil control valve to timing chain cover (3).
Tighten nuts to specification.
Tightening torque
Oil control valve mounting nut (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
3) Install oil gallery pipe No.1 (1) with new copper
washers (5) to timing chain cover.
Tighten bolts to specification.
Tightening torque
Oil gallery pipe No.1 bolt (b): 30 N·m (3.0 kgf-m,
21.5 lb-ft)
Oil Control Valve Inspection (For Engine with
VVT)
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Oil Control Valve
1) Inspect strainer (1) and mating surface (2) of oil
control valve for clog or damage. Clean oil control
valve if clog or foreign matter is present on strainer
or mating surface of oil control valve.
Replace oil control valve if its mating surface is
damaged.
2) Check resistance between terminals of oil control
valve.
Oil control valve resistance
6.7 – 7.7 Ω (at 20 °C (68 °F))
Oil Gallery Pipe
Inspect oil gallery pipes No.1, No.2 (2) and No.3 (3).
Replace if crack, deformation or clog exists.
1
5 (b)3 (a) 24
5
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1
2
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1
3
2
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Timing Chain and Chain Tensioner ComponentsS6RW0D1406019
Timing Chain and Chain Tensioner Removal
and Installation
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Removal
CAUTION!
After timing chain is removed, never turn
crankshaft and camshafts independently
more than its allowable turning range
described in “Installation”.
If turned, interference may occur between
piston and valves and valves themselves,
and parts related to piston and valves may be
damaged.

1) Remove timing chain cover referring to “Timing
Chain Cover Removal and Installation”.
2) By turning crankshaft, align camshafts and
crankshaft at specific position as follows.
a) Align both intake and exhaust camshaft timing
sprocket marks (1) with notches (2) of cylinder
head respectively.
b) Position crankshaft sprocket key (3) at upside of
crankshaft as shown in figure.
3) Remove timing chain tensioner adjuster assembly
(5).4) Remove timing chain tensioner (6).
5) Remove timing chain No.1 guide (7).
6) Remove timing chain (8) with crankshaft timing
sprocket (9).
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1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
2. Timing chain
: Apply engine oil.6. Chain tensioner adjuster mounting bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
3. Timing chain No.1 guide
: Apply engine oil to sliding surface.7. Timing chain tensioner bolt
4. Timing chain tensioner
: Apply engine oil to sliding surface.8. Timing chain No.1 guide bolt
3
1
1
2
5
67
8
9
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Installation
CAUTION!
After timing chain is removed, never turn
crankshaft and camshafts independently
more than such an extent (“a”, “b”) as shown
in figure.
If turned, interference may occur between
piston and valves and valves themselves,
and parts related to piston and valves may be
damaged.

1) Check that match marks (1) on intake and exhaust
camshaft timing sprockets are in match with notches
(2) on cylinder head as shown in figure.
2) Set key (3) and turn crankshaft to position key on
upside of crankshaft.3) Install timing chain to camshaft timing sprockets as
follows.
• For engine with VVT
Install timing chain by aligning dark blue plates (1)
of timing chain and triangle mark (2) on camshaft
timing sprockets.
• For engine without VVT
Install timing chain by aligning dark blue plates (1)
of timing chain and circle mark (5) on intake
camshaft timing sprocket and triangle mark (5) on
exhaust camshaft timing sprocket.
4) Fit crankshaft timing sprocket to timing chain by
aligning gold plate (3) of timing chain and circle mark
(4) on crankshaft timing sprocket. Then install
crankshaft timing sprocket fitted with chain to
crankshaft.
“a”: 90°4. Camshaft (IN and EX) allowable turning range.
By marks on camshaft timing sprocket within 15° from notches
on cylinder head on both right and left.
“b”: 15°5. Crankshaft allowable turning range.
By key on crankshaft, within 90° from top on both right and left.
“a”
“b” “b”“b” “b”
“a”
1
12
4
3
5
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[A]: For engine with VVT [B]: For engine without VVT
34
1 1
Approx. 60 Approx. 30 [A]
1
Appro x. 60 Approx. 30 1 [B]
2
2
2
5
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5) Apply engine oil to sliding surface of timing chain
No.1 guide (1) and install it as shown in figure.
Tighten guide bolts to specified torque.
Tightening torque
Timing chain No.1 guide bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
6) Apply engine oil to sliding surface of chain tensioner
(1) and install chain tensioner and spacer.
Tighten tensioner bolt to specified torque.
Tightening torque
Timing chain tensioner bolt (a): 25 N·m (2.5 kgf-
m, 18.0 lb-ft)7) Check that triangle mark (2) and/or circle mark (5) on
intake and exhaust camshaft timing sprockets are in
match with dark blue plates (1) of timing chain and
match mark (4) on crankshaft timing sprocket is in
match with gold plate (3) of timing chain.
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[A]: For engine with VVT [B]: For engine without VVT
2
1
Appro x. Approx.
1 [B]
34
1 12
2
Approx. Approx.
C [A]
[C]
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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”.
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[A]: For engine with VVT [B]: For engine without VVT
1
1
2
3
21
1
3
[A]
[B]
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Timing Chain and Chain Tensioner InspectionS6RW0D1406021
Timing Chain No.1 Guide
Check shoe (1) for wear or damage.
Timing Chain Tensioner
Check shoe (1) for wear or damage.
Crankshaft Timing Sprocket
Check teeth of sprocket for wear or damage.Timing Chain
Check timing chain for wear or damage.
Timing Chain Tensioner Adjuster
Check that tooth surface (1) are free from damage.
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Camshaft, Tappet and Shim Removal and
Installation
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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
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“12”“13”
“20”“21”
“16”“17” “8”“9”
“2”
“5”
“3”
“4”
“1”
“10”
“11”“18”
“19” “14”“15” “6” “7”
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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.
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[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]
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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
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“10”“9”
“2” “1”,(a) “6”“5” “14” “13”
“20”
“17”
“19”
“18”
“21”
“12”
“11”
“4” “3” “8”“7” “16” “15”
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1
2 3
(a)
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