torque SUZUKI SX4 2006 1.G Service Service Manual

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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Installation
NOTE
• Use new bearing cap No.1 bolts. They are
deformed once they are used because they
are plastic deformation tightening bolts.
• All parts to be installed must be perfectly
clean.
• Be sure to oil crankshaft journals, journal
bearings, thrust bearings, crankpins,
connecting rod bearings, pistons, piston
rings and cylinder bores.
• Journal bearings, bearing caps,
connecting rods, rod bearings, rod bearing
caps, pistons and piston rings are in
combination sets. Do not disturb such
combination and make sure that each part
goes back to where it came from, when
installing.

1) Install sensor plate (1) to crankshaft (2) and tighten
bolts to specified torque.
NOTE
When installing sensor plate, align spring pin
(3) on crankshaft and hole of sensor plate.

Tightening torque
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)2) Install main bearings to cylinder block.
Upper half of bearing (1), has an oil groove (2).
Install it to cylinder block (3), and the other half
without oil groove to bearing cap.
Make sure that two halves are painted in the same
color.
3) Confirm that dowel pins (1) are installed to intake
side of each journal.
4) Install crankshaft to cylinder block.
5) Install thrust bearings (1) to cylinder block between
No.2 and No.3 cylinders. Face oil groove (2) sides to
crank webs.
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Downloaded from www.Manualslib.com manuals search engine 1D-62 Engine Mechanical:
6) Install bearing cap to cylinder block, making sure to
point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts ((1) – (10)) and main bearing cap No.2 bolts
((11) – (20)), tighten them gradually as follows.
a) Tighten bolts ((1) – (10)) to 30 N⋅m (3.0 kgf-m,
22.0 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 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them
to 60°.
d) Tighten bolts ((11) – (20)) to 25 N⋅m (2.5 kgf-m,
18.0 lb-ft) according to numerical order as
shown.
Tightening torque
Main bearing cap No.1 bolt ((1) – (10)):
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 ((11) – (20)):
Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure
CAUTION!
After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 N⋅m (1.2 kgf-m, 9.0 lb-ft)
torque or below.

7) If necessary, press-fit rear oil seal (1) to oil seal
housing (2) by using special tool as shown in figure.
Special tool
(A): 09911–97821
Crank rear oil seal installing position
(dimension)
“a”: 2 mm (0.08 in.)
8) Apply sealant to mating surface of rear oil seal
housing (1).
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
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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
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Downloaded from www.Manualslib.com manuals search engine 1D-64 Engine Mechanical:
2) Tighten main bearing cap No.1 bolts (1) – (10) and
main bearing cap No.2 bolts (11) – (20) gradually as
follows.
a) Tighten bolts (1) – (10) to 30 N⋅m (3.0 kgf-m,
22.0 lb-ft) according to numerical order in figure.
b) In the same manner as in Step a), tighten them
to 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them
to 60°.
d) Tighten bolts (11) – (20) to 25 N⋅m (2.5 kgf-m,
18.0 lb-ft) according to numerical order in figure.
Tightening torque
Main bearing cap No.1 bolt ((1) – (10)):
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 ((11) – (20)):
Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure3) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
If its limit is exceeded, replace thrust bearing with
new standard one or oversize one to obtain standard
thrust play.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0043 – 0.0122 in.)
Limit: 0.35 mm (0.0138 in.)
NOTE
After checking the thrust play, make sure that
thread deformation of each bearing cap No.1
bolt referring to “Main Bearing Cap No.1
Bolt” in “Main Bearings Inspection”.

Out-of-Round and Taper (Uneven Wear) of Journals
An unevenly worn crankshaft journal shows up as a
difference in diameter at a cross section or along its
length (or both). This difference, if any, is determined by
taking micrometer readings. If any one of journals is
badly damaged or if amount of uneven wear in the sense
exceeds its limit, regrind or replace crankshaft.
Crankshaft out-of-round and taper
Limit: 0.01 mm (0.0004 in.)
Out-of-round
A – B
Ta p e r
a – b
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Main Bearings InspectionS6RW0D1406040
General Information
• Service main bearings are available in standard size
and 0.25 mm (0.0098 in.) undersize, and each of them
has 5 kinds of bearings differing in tolerance.
• Upper half of bearing (1) has oil groove (2) as shown
in figure.
Install this half with oil groove to cylinder block.
• Lower half of bearing does not have an oil groove.
Visual Inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and
lower halves. Never replace either half without replacing
the other half.
Main Bearing Clearance
NOTE
Do not rotate crankshaft while gauging
plastic is installed.

Check clearance by using gauging plastic according to
the following procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) the full width of
bearing (parallel to crankshaft) on journal, avoiding
oil hole.4) Tighten main bearing cap No.1 bolts (1) – (10) and
main bearing cap No.2 bolts (11) – (20) gradually as
follows.
a) Tighten bolts (1) – (10) to 30 N⋅m (3.0 kgf-m,
22.0 lb-ft) according to numerical order in figure.
b) In the same manner as in Step a), tighten them
to 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them
to 60°.
d) Tighten bolts (11) – (20) to 25 N⋅m (2.5 kgf-m,
18.0 lb-ft) according to numerical order in figure.
Tightening torque
Main bearing cap No.1 bolt ((1) – (10)):
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 ((11) – (20)):
Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure
5) Remove bearing caps and using scale (1) on
gauging plastic envelop (2), measure gauging plastic
width at its widest point. If clearance exceeds its
limit, replace bearing. Always replace both upper
and lower inserts as a unit.
A new standard bearing may produce proper
clearance. If not, it will be necessary to regrind
crankshaft journal for use of 0.25 mm undersize
bearing.
After selecting new bearing, recheck clearance.
Main bearing clearance
Standard: 0.021 – 0.041 mm (0.0008 – 0.0016 in.)
Limit: 0.054 mm (0.0021 in.)
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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 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 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS6RW0D1504001
WARNING!
To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality
If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks
If leak is found, repair it.

1) Disconnect oil pressure switch coupler (1).
2) Remove oil pressure switch (2) from cylinder block.3) Install special tools (oil pressure gauge) to vacated
threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
4) Start engine and warm engine up to normal
operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral”, set parking brake and block drive
wheels.

5) After warming up, raise engine speed to 4,000 r/min.
and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kgf/cm2, 39.8 psi) at 4,000
r/min. (rpm)
6) After checking oil pressure, stop engine and remove
oil pressure gauge and attachment.
7) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
2. Low level mark (hole)
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8) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, repair it.
9) Connect oil pressure switch coupler (1).
Repair Instructions
Oil Pan and Oil Pump Strainer ComponentsS6RW0D1506001
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1
23
4
(a) 5
(b) 6
(b) 8
(b) 9
(b) 7
10
(c)10
(c)
11 12
(d) 13
(d) 1514
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1. Oil pan:
Apply sealant 99000-31260 to
mating surface.6. Strainer bolt 11. Dowel pin : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
2. Strainer 7. Bracket bolt 12. Baffle plate : Tighten 11 N⋅m (1.1 kgf-m, 8.0 lb-
ft) by the specified procedure.
3. O-ring 8. Oil pan nut 13. Baffle plate bolt : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
4. Gasket 9. Oil pan bolt
(M6)14. Clutch housing lower plate (M/T
vehicle) or torque converter housing
lower plate (A/T vehicle):11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
5. Drain plug 10. Oil pan bolt
(M10)15. Lower plate bolt : Do not reuse.