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

Downloaded from www.Manualslib.com manuals search engine 1D-24 Engine Mechanical:
Installation
1) Clean sealing surface on timing chain cover, cylinder
block and cylinder head.
Remove oil, old sealant and dust from sealing
surface.
2) Install oil seal (1) to timing chain cover, if removed.
NOTE
When installing new oil seal, press fit to
timing chain cover (2) by using special tool
(bearing installer) as shown in figure.

Drive in dimension
“a”: 1.0 mm (0.04 in.)
Special tool
(A): 09913–75810
3) For engine with VVT, install oil control valve to timing
chain cover referring to “Oil Control Valve Removal
and Installation (For Engine with VVT)”.
4) Apply sealant “A” to mating surface of cylinder and
cylinder head and “B” to mating surface of timing
chain cover as shown in figure.
“A”: Water tight sealant 99000–31140 (SUZUKI
Bond No.1207B)
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for timing chain cover
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)5) Apply engine oil to oil seal lip, then install timing
chain cover (1). Tighten bolts and nut to specified
torque.
NOTE
Before installing timing chain cover, check
that pin is securely fitted.

Tightening torque
Timing chain cover bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Timing chain cover nut (b): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
6) Apply engine oil to new O-rings (2) and install them
to cap (3).
7) Install cap (3) to timing chain cover (1).
Tighten bolts to specified torque.
Tightening torque
Cap bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
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(a) (b) (c)
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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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Downloaded from www.Manualslib.com manuals search engine 1D-26 Engine Mechanical:
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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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-29
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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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”.
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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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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
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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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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-37
6) Tighten camshaft housing bolts evenly and gradually
in numerical order (“1” through “21”) by repeating
tightening sequence two or three times until
specified torque is obtained.
NOTE
Do not rotate camshaft while gauging plastic
is installed.

Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
7) Remove housing, and using scale (2) on gauging
plastic envelop, measure gauging plastic (1) width at
its widest point.
Camshaft journal clearance
[For engine with VVT system]
[For engine without VVT system]If measured camshaft journal clearance exceeds
limit, measure journal (housing) bore and outside
diameter of camshaft journal. Replace camshaft or
cylinder head assembly whichever the difference
from specification is greater.
Camshaft journal diameter [A]
[For engine with VVT system]
[For engine without VVT system]
Camshaft journal bearing bore [B]
[For engine with VVT system]
[For engine without VVT system] Standard Limit
Intake side
No.1 housing0.020 – 0.072 mm
(0.0008 – 0.0028 in.)0.10 mm
(0.0039 in.)
Others0.045 – 0.087 mm
(0.0018 – 0.0034 in.)0.12 mm
(0.0047 in.)
Standard Limit
0.045 – 0.087 mm
(0.0018 – 0.0034 in.)0.12 mm
(0.0047 in.)
“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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Item Standard
Intake side No.1 housing26.940 – 26.955 mm
(1.0606 – 1.0612 in.)
Exhaust side No.1
housing26.934 – 26.955 mm
(1.0604 – 1.0612 in.)
Others22.934 – 22.955 mm
(0.9029 – 0.9037 in.)
Item Standard
Intake and Exhaust side
No.1 housing26.934 – 26.955 mm
(1.0604 – 1.0612 in.)
Others22.934 – 22.955 mm
(0.9029 – 0.9037 in.)
Item Standard
Intake side No.1 housing30.000 – 30.015 mm
(1.1811 – 1.1816 in.)
Exhaust side No.1
housing27.000 – 27.021 mm
(1.0630 – 1.0638 in.)
Others23.000 – 23.021 mm
(0.9055 – 0.9063 in.)
Item Standard
Intake and Exhaust side
No.1 housing27.000 – 27.021 mm
(1.0630 – 1.0638 in.)
Others23.000 – 23.021 mm
(0.9055 – 0.9063 in.)

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).
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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
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Downloaded from www.Manualslib.com manuals search engine 1D-50 Engine Mechanical:
Installation
1) Apply engine oil to pistons, rings, cylinder walls,
connecting rod bearings and crank pins.
NOTE
Do not apply oil between connecting rod and
bearing or between bearing cap and bearing.

2) Install guide hoses (1) over connecting rod bolts.
These guide hoses protect crank pin and threads of
rod bolt from damage during installation of
connecting rod and piston assembly.
3) When installing piston and connecting rod assembly
into cylinder bore, point front mark (1) on piston head
to crankshaft pulley side.4) Install piston and connecting rod assembly into
cylinder bore. Use special tool (Piston ring
compressor) to compress rings. Guide connecting
rod into place on crankshaft.
Using a hammer handle, tap piston head to install
piston into bore. Hold ring compressor firmly against
cylinder block until all piston rings have entered
cylinder bore.
Special tool
(A): 09916–77310
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley
side.
After applying engine oil to rod bolts and 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.
NOTE
Before installing bearing cap, make sure that
checking for connecting rod bolt
deformation. Refer to “Piston Pins and
Connecting Rods Inspection”.

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
6) Install cylinder head referring to “Valves and Cylinder
Head Removal and Installation”.A: Crankshaft pulley side B: Flywheel side
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