head SUZUKI SX4 2006 1.G Service Repair Manual

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
) / )) / )

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-1
Engine
Engine Lubrication System
General Description
Engine Lubrication DescriptionS6RW0D1501001
The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and
passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
In one path, oil reaches the crankshaft journal bearings. Oil from the crankshaft journal bearings is supplied to the
connecting rod bearings by means of intersecting passages drilled in the crankshaft, and then injected from the big
end of connecting rod to lubricate piston, rings and cylinder wall.
In the other path oil goes up to the cylinder head and lubricates valves and camshafts, etc., after passing through the
internal oil way of camshafts.
An oil relief valve is provided on the oil pump. This valve starts relieving oil pressure when the pressure exceeds
specified pressure.
I5RW0C150002-01

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-4
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

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-10
Installation
Reverse removal procedure for installation noting the
following.
• Replace injector O-ring (1) with new one using care
not to damage it.
• Check if cushion (2) is scored or damaged. If it is,
replace with new one.
• Apply thin coat of fuel to O-rings (1), and then install
injectors (3) into delivery pipe (4) and cylinder head.
Make sure that injectors rotate smoothly (6). If not,
probable cause is incorrect installation of O-ring.
Replace O-ring with new one.
• Tighten delivery pipe bolts (5) to specified torque and
make sure that injectors rotate smoothly.
Tightening torque
Fuel delivery pipe bolt (a): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
• After installation, with engine OFF and ignition switch
ON, check for fuel leaks around fuel line connection.Fuel Injector InspectionS6RW0D1706009
WARNING!
• Before starting the following procedure, be
sure to observe “Precautions on Fuel
System Service” in order to reduce the risk
of fire and personal injury.
• Put injector and battery as far away as
possible in order to reduce risk of fire and
personal injury when connecting/
disconnecting test lead to/from battery.

1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure” if equipped.
2) Disconnect fuel feed hose from delivery pipe.
3) Set special tools as follows.
Special tool
(A): 09912–58421
(B): 09930–88530
(C): 09912–57610
a) Fit washer (1) (inside diameter 13.5 – 14.5
mm(0.532 – 0.570 in.)) to injector (2), and then
install injector to special tool (A).
b) Connect special tool (B) to injector.
c) Install special tool (C) to special tool (A).
d) Connect fuel feed hose to special tool (A).
I3RM0A170011-01
(B)
(A)
(A)(C)
2
1
I6RW0B170014-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-12
Fuel Filler Cap InspectionS6RW0D1706010
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Remove cap (1), and check gasket for even filler neck
imprint, and deterioration or any damage. If gasket (2) is
in malcondition, replace cap.
NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
personal injury.

Fuel Tank Inlet Valve Removal and InstallationS6RW0D1706017
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Remove fuel tank referring to “Fuel Tank Removal
and Installation”.
2) Remove fuel tank inlet valve (1) using flat head rod
(2) or the like.
CAUTION!
Be careful not to damage fuel tank inlet
valve(1) with flat head rod (2) or the like.

Installation
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel tank referring to “Fuel Tank Removal and
Installation”.
Fuel Tank Inlet Valve InspectionS6RW0D1706018
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
•Damage
• Smooth opening and closing
I2RH01170008-01
I7RW01170013-01
I2RH0B170018-01
I2RH0B170019-01

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-6
Ignition Spark TestS6RW0D1804004
1) Remove air cleaner assembly with air intake pipe.
2) Disconnect all injector couplers from injectors.
WARNING!
Without disconnection of injector couplers,
combustible gas may come out from spark
plug holes during this test and may get
ignited in engine room.

3) Remove spark plug and check it for condition and
type referring to “Spark Plug Inspection”.
4) If OK, connect ignition coil coupler to ignition coil
assembly and connect spark plug to ignition coil
assembly or high-tension cord. Ground spark plug.5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as
described in “Ignition System Symptom Diagnosis”.
Repair Instructions
High-Tension Cord Removal and InstallationS6RW0D1806001
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Disconnect No.1 cylinder (2) and No.3 cylinder (3)
high-tension cords from ignition coil assemblies (1)
while gripping each cap.
3) Pull out high-tension cords from spark plugs while
gripping each cap.
CAUTION!
• Removal of high-tension cords together
with clamps will be recommended so as
not to damage their inside wire (resistive
conductor).
• For the same reason, pull out each
connection by gripping cap portion.

Installation
1) Install No.1 cylinder (2) and No.3 cylinder (3) high-
tension cords to spark plugs and ignition coil
assemblies (1) while gripping each cap.
CAUTION!
• Never attempt to use metal conductor
high-tension cords as replacing parts.
• Insert each cap portion fully when
installing high-tension cords.

I4RS0A180006-01
I4RS0A180003-01
I4RS0A180004-01

Downloaded from www.Manualslib.com manuals search engine 1H-7 Ignition System:
High-Tension Cord InspectionS6RW0D1806002
Measure resistance of high-tension cord (1) by using
ohmmeter.
If resistance exceeds specification, replace high-tension
cord(s).
High-tension cord resistance
No.1 cylinder high-tension cord resistance: 1.4 – 4.0
kΩ
No.3 cylinder high-tension cord resistance: 0.6 – 2.0
kΩ
Spark Plug Removal and InstallationS6RW0D1806003
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Pull out high-tension cords by gripping their caps
and then remove ignition coil assemblies referring to
“Ignition Coil Assembly (Including Ignitor) Removal
and Installation”.
3) Remove spark plugs.
Installation
1) Install spark plugs and tighten them to specified
torque.
Tightening torque
Spark plug: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Install ignition coil assemblies referring to “Ignition
Coil Assembly (Including Ignitor) Removal and
Installation”.
3) Install high-tension cords securely by gripping their
caps.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
Spark Plug InspectionS6RW0D1806004
CAUTION!
• When servicing the iridium / platinum
spark plugs (slender center electrode type
plugs), do not touch the center electrode
to avoid damage to it. The electrode is not
strong enough against mechanical force
as it is slender and its material is not
mechanically tough.
• Do not clean or adjust gap for the iridium /
platinum spark plugs.

Inspect spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
If any abnormality is found for nickel spark plugs, adjust
air gap, clean with spark plug cleaner or replace it with
specified new plug.
For iridium / platinum spark plugs, replace it with new
plug.
Spark plug air gap
“a”
: 1.0 – 1.1 mm (0.040 – 0.043 in.)
Spark plug type
NGK: BKR6E-11 (Nickel) / IFR6J11 (Iridium)
DENSO: K20PR-U11 (Nickel)
NOTE
NGK IFR6J11 is highly recommended for
better engine starting performance under –25
°C (–13 °F).

I2RH0B180005-01
IYSQ01181012-01

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-8
Ignition Coil Assembly (Including Ignitor)
Removal and Installation
S6RW0D1806005
Removal
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil
assembly (2).
5) Remove ignition coil bolts (1) and then pull out
ignition coil assembly.
Installation
1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and
then connect ignition coil coupler.
Tightening torque
Ignition coil bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly
while gripping its cap.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
5) Connect negative cable to battery.
Ignition Coil Assembly (Including Ignitor)
Inspection
S6RW0D1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.6 – 10.2 kΩ at 20 ° (68 °F)
Ignition Timing InspectionS6RW0D1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission
gear shift lever in “Neutral”, and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch
OFF.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A) 1I 5 R W 0 C 11 0 0 11 - 0 1