Pump SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-5
4) Install oil pan to cylinder block temporarily.
5) Insert dowel pin (1) in hole (2) of oil pan in order to
locate oil pan precisely.
NOTE
Dowel pin is available as a spare part (part
number: 04211–13189).

6) After fitting oil pan to cylinder block, run in securing
bolts and start tightening at the center: move wrench
outward, tightening one bolt at a time. Tighten bolts
and nuts to specified torque.
Tightening torque
Oil pan bolt (M6) (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Oil pan bolt (M10) (c): 55 N·m (5.5 kgf-m, 40.0 lb-
ft)
Oil pan nut (e): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
7) After applying engine oil to drain plug, install new
gasket and drain plug to oil pan.
Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b): 35 N·m (3.5 kgf-m, 25.5 lb-
ft)
8) Tighten transaxle stiffener bolts to specified torque.
Tightening torque
Transaxle stiffener bolt (d): 55 N·m (5.5 kgf-m,
40.0 lb-ft)9) Install clutch housing lower plate (1) and then tighten
clutch housing lower plate bolt to specified torque.
Tightening torque
Clutch housing lower plate bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
10) For 4WD model, remount transfer referring to
“Transfer Dismounting and Remounting in Section
3C”.
11) Install oil level gauge.
12) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
13) Verify that there is no engine oil leakage and exhaust
gas leakage at each connection.
Oil Pan and Oil Pump Strainer CleaningS6RW0D1506003
• Clean sealing surface between oil pan and cylinder
block.
Remove oil, old sealant, and dust from sealing
surface.
• Clean oil pump strainer screen (1).
21I4RS0A150007-01
(a)
(b)
(c)(e)
(d)I4RS0A150008-01
1,(a)
I5RW0A150003-01
I2RH0B150016-01

Downloaded from www.Manualslib.com manuals search engine 1E-6 Engine Lubrication System:
Oil Pump ComponentsS6RW0D1506004
Oil Pump Removal and InstallationS6RW0D1506005
Oil pump is incorporated with timing chain cover.
For removal and installation, refer to “Timing Chain
Cover Removal and Installation in Section 1D”.
Oil Pump Disassembly and ReassemblyS6RW0D1506006
Disassembly
1) Remove rotor plate (1) by removing its mounting
bolts.2) Remove outer rotor (1) and inner rotor (2).
3) Remove relief valve (1), spring (2) and retainer (3) by
removing circlip (4).
I4RS0A150010-01
1. Rotor plate 6. Rotor plate bolt : 11 N⋅m (1.1 kgf-m 8.0 lb-ft)
2. O-ring 7. Relief valve : Do not reuse.
3. Outer rotor 8. Spring : Apply thin coat of engine oil to sliding surface.
4. Inner rotor 9. Retainer
5. Timing chain cover 10. Circlip
I2RH0B150018-01
I2RH0B150019-01
I2RH0B150020-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-7
Reassembly
1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors,
oil seal lip portion, inside surfaces of oil pump case
and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Apply engine oil to relief valve (1) and spring (2), and
install them with retainer (3) and new circlip (4) to
rotor plate (5).
5) Install rotor plate and tighten all bolts to specified
torque. After installing plate, check to be sure that
rotors turn smoothly by hand (0.3 N⋅m (0.03 kgf-m,
0.25 lb-ft) torque or below).
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)Oil Pump InspectionS6RW0D1506007
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Oil Pump
• Check outer (1) and inner rotors (2), rotor plate, and
oil pump case for excessive wear or damage.
• Check relief valve (1) for excessive wear or damage
and operates smoothly.
I2RH0B150019-01
I3RM0A150005-01
I2RH0B150022-01
I2RH0B150023-01
I2RH0B150019-01
I2RH0B150025-01

Downloaded from www.Manualslib.com manuals search engine 1E-8 Engine Lubrication System:
Radial clearance
Check radial clearance between outer rotor (1) and case
(2) using thickness gauge (3).
If clearance exceeds its limit, replace outer rotor or case.
Radial clearance between outer rotor and case for oil
pump
Limit: 0.310 mm (0.0122 in.)
Side clearance
Using straightedge (1) and thickness gauge (2),
measure side clearance.
If side clearance exceeds its limit, replace oil pump
assembly.
Side clearance for oil pump inner rotor
Limit: 0.15 mm (0.0059 in.)Relief valve spring free length and load
Check relief valve spring free length and load as shown
in the figure. If the measured valve spring length is lower
than the specification, replace relief valve spring.
Relief valve spring free length and load
I2RH0B150026-01
I2RH0B150027-01
Standard Limit
Free length52.4 mm
(2.06 in.)—
Load at spring
length
38.5 mm (1.52 in.)77 N
(7.7 kgf, 17.0 lb)69 N
(6.9 kgf, 15.0 lb)
I2RH01150023-01

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Specifications
Tightening Torque SpecificationsS6RW0D1507001
NOTE
The specified tightening torque is also described in the following.
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D1508001
NOTE
Required service material is also described in the following.
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Special ToolS6RW0D1508002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Oil pressure switch 13 1.3 9.5)
Oil pump strainer bolt 11 1.1 8.0)
Oil pump strainer bracket bolt 11 1.1 8.0)
Oil pan bolt (M6) 11 1.1 8.0)
Oil pan bolt (M10) 55 5.5 40.0)
Oil pan nut 11 1.1 8.0)
Oil pan drain plug 35 3.5 25.5)
Transaxle stiffener bolt 55 5.5 40.0)
Clutch housing lower plate bolt 11 1.1 8.0)
Oil pump rotor plate bolt 11 1.1 8.0)
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
09915–77310 09915–78211
Oil pressure gauge (0-10kg/
cm2)Oil pressure gauge
attachment
))

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 Engine Cooling System: 1F-2
Schematic and Routing Diagram
Coolant CirculationS6RW0D1602001
While the engine is warmed up (thermostat closed), coolant circulates as follows.
When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator
core to be cooled as follows.
7
5
6
4
3
2
81
I5RW0C160001-02
1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core
2. Radiator outlet hose 4. Water pump 6. Engine 8. Radiator
7
5
6
4
3
2
81
I5RW0C160002-02
1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core
2. Radiator outlet hose 4. Water pump 6. Engine 8. Radiator

Downloaded from www.Manualslib.com manuals search engine 1F-3 Engine Cooling System:
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS6RW0D1604001
Condition Possible cause Correction / Reference Item
Engine overheats
(Radiator fan operates)Loose or broken water pump beltAdjust or replace.
Not enough coolantCheck coolant level and add as necessary.
Faulty thermostatReplace.
Faulty water pumpReplace.
Dirty or bent radiator finsClean or remedy.
Coolant leakage on cooling systemRepair.
Clogged radiatorCheck and replace radiator as necessary.
Faulty radiator capReplace.
Dragging brakesAdjust brake.
Slipping clutchReplace.
Poor charge batteryCheck and replace as necessary.
Poor generation generatorCheck and repair.
ECT sensor faultyCheck and replace as necessary.
Radiator fan motor faultyCheck and replace as necessary.
ECM faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
Equipped with too much electric load
part(s)Dismount.
Engine overheats
(Radiator fan does not
operate)Fuse blownCheck fuse of relay/fuse box and check for
short circuit to ground.
Radiator cooling fan relay faultyCheck and replace as necessary.
ECT sensor faultyCheck and replace as necessary.
Radiator cooling fan motor faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
ECM faultyCheck and replace as necessary.

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Repair Instructions
Cooling System ComponentsS6RW0D1606001
I5RW0C160012-01
1. Radiator 11. Thermostat case water outlet pipe 21. Heater outlet No.1 hose
2. Reservoir 12. Thermostat case 22. Radiator cooling fan assembly
For disassembly and reassembly, refer
to “Radiator Cooling Fan Disassembly
and Reassembly”.
3. Radiator cap 13. Thermostat 23. To cylinder head
4. Drain plug 14. Thermostat cap 24. To water pump
5. Radiator outlet hose 15. Water bypass No.1 hose 25. To heater core
6. Radiator inlet hose 16. Water inlet No.1 pipe : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
7. Water outlet cap 17. Water inlet hose : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
8. ECT sensor 18. Water inlet No.2 pipe : Do not reuse.
9. Water outlet cap gasket 19. Radiator support bracket bolt
10. O-ring 20. Heater inlet hose

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Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1606014
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
S6RW0D1606015
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
I5RW0C160006-01
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I5RW0C160008-01