shaft SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 1D-8 Engine Mechanical:
2) Lift down the valve by turning crankshaft to 360°.
3) Hold tappet at that position using special tool as
follows.
a) Remove its housing bolts.
b) Check housing No. and select special tool
corresponding to housing No., referring to
“Special tool selection table”.
Special tool selection table
c) Hold down the tappet so as not to contact the
shim by installing special tool on camshaft
housing with housing bolt (1) tighten housing
bolts by hand.
Special tool
(A): 09916–67020
(A): 09916–670214) Turn camshaft by approximately 90° clockwise and
remove shim (3).
WARNING!
Never put in the hand between camshaft and
tappet.

5) Using a micrometer (2), measure the thickness of
the removed shim (1), and determine replacement
shim by calculating the thickness of new shim with
the following formula and table.
Shim thickness specification
Intake side:
A = B + C – 0.20 mm (0.008 in.)
Exhaust side:
A = B + C – 0.30 mm (0.012 in.)
A: Thickness of new shim
B: Thickness of removed shim
C: Measured valve clearance
For example of intake side:
When thickness of removed shim is 2.40 mm (0.094
in.), and measured valve clearance is 0.45 mm
(0.018 in.).
A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20
mm (0.008 in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104
in.) No. on camshaft
housingEmbossed mark on special
tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
I2RH0B140011-01
I5RW0C140003-01
1. Special tool 2. Magnet
I2RH0B140013-01
I2RH0B140014-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-9
6) Select new shim No. (1) with a thickness as close as
possible to calculated value.
Available new shims No.
7) Install new shim facing shim No. side with tappet.8) Lift valve by turning crankshaft counterclockwise (in
opposite direction against above Step 4)) and
remove special tool.
Special tool
(A): 09916–67020
(A): 09916–67021
9) Install camshaft housing (1) and tighten bolts to
specified torque.
Tightening torque
Camshaft housing bolt (a): Tighten 11 N⋅m (1.1
kgf-m, 8.0 lb-ft) by the specified procedure
10) Check valve clearance again after adjusting it.
11) After checking and adjusting all valves.
12) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”. Thickness mm
(in.)Shim No.Thickness mm
(in.)Shim No.
2.175 (0.0856) 218 2.600 (0.1024) 260
2.200 (0.0866) 220 2.625 (0.1033) 263
2.225 (0.0876) 223 2.650 (0.1043) 265
2.250 (0.0886) 225 2.675 (0.1053) 268
2.275 (0.0896) 228 2.700 (0.1063) 270
2.300 (0.0906) 230 2.725 (0.1073) 273
2.325 (0.0915) 233 2.750 (0.1083) 275
2.350 (0.0925) 235 2.775 (0.1093) 278
2.375 (0.0935) 238 2.800 (0.1102) 280
2.400 (0.0945) 240 2.825 (0.1112) 283
2.425 (0.0955) 243 2.850 (0.1122) 285
2.450 (0.0965) 245 2.875 (0.1132) 288
2.475 (0.0974) 248 2.900 (0.1142) 290
2.500 (0.0984) 250 2.925 (0.1152) 293
2.525 (0.0994) 253 2.950 (0.1161) 295
2.550 (0.1004) 255 2.975 (0.1171) 298
2.575 (0.1014) 258 3.000 (0.1181) 300
I2RH0B140015-01
1. Tappet 2. Camshaft
(A)2
1
I3RM0A140006-01
I2RH0B140149-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-17
Engine Assembly Removal and InstallationS6RW0D1406013
Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure in Section 1G”.
2) Disconnect negative and positive cable at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil referring to “Engine Oil and Filter
Change in Section 0B”.
8) Drain transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
9) Drain transfer oil referring to “Transfer Oil Change in
Section 3C”.
10) Drain coolant referring to “Cooling System Draining
in Section 1F”
11) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation”.
12) With hose connected, detach A/C compressor from
its bracket referring to “Compressor Assembly
Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

13) Remove cylinder upper cover (1).14) Disconnect the following electric wires/connectors
and each clamps.
• TP sensor (1)
• MAP sensor (2)
• ECT sensor (3)
•EGR valve (4)
• CMP sensor (5)
• Ignition coil assembly (6)
• Injector (7)
•HO2S (8)
• Oil control valve (9) (for engine with VVT system)
• Engine oil pressure switch (10)
• CKP sensor (12)
• Knock sensor (13)
• Generator (14)
• Starting motor (15)
• Ground terminal (16) from cylinder block
• Battery ground cable (17) from transaxle
• Back-up light switch (18) (for M/T model)
• Torque sensor (19)
• P/S motor (20)
• Output shaft speed sensor (VSS) (29) (for A/T
model)
• Solenoid valve (30) (for A/T model)
• Transmission range sensor (31) (for A/T model)
• Input shaft speed sensor (32) (for A/T model)
15) Disconnect the following cables, and remove control
cable bracket (23)
• Gear select control cable (21) (for M/T model)
• Gear shift control cable (22) (for M/T model)
• A/T select cable (33) (for A/T model)
16) Disconnect the following hoses.
• Brake booster hose (24) from intake manifold
• Radiator inlet and outlet hoses (25) from radiator
• Heater inlet and outlet hoses (26) from heater
core
• Fuel feed hose (27) from fuel feed pipe
• Fuel vapor hose (11) from fuel vapor pipe
• Clutch hose (28) from transaxle (for M/T model)
• A/T fluid cooler hoses (for A/T model)
F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
1. Engine right mounting bracket 9. Engine front mounting
: Be sure to direct yellow mark to forward.: 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
2. Engine right mounting 10. Transfer : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft)
3. Engine left mounting bracket 11. Suspension frame : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1
I5RW0A140009-01

Downloaded from www.Manualslib.com manuals search engine 1D-18 Engine Mechanical:
17) Remove oil pressure switch bracket (1).
18) Remove suspension control arm referring to
“Suspension Control Arm / Bushing Removal and
Installation in Section 2B”.
19) Disconnect right and left drive shaft joints from
differential gear referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
20) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust System Components in Section
1K”.
21) Disconnect propeller shaft referring to “Propeller
Shaft Assembly Removal and Installation in Section
3D” (for 4WD model).
22) Disconnect steering lower shaft from pinion shaft
referring to “Steering Lower Shaft Removal and
Installation in Section 6B”.
23) Fix radiator to body with rope in order to avoid the
radiator fall off when front lower cross member
lowered.
24) Support front suspension frame, front lower cross
member and oil pan using jack at hatched parts (1)
indicated in figure.
[A]: View A [C]: For A/T model
6
3 45
1 7 7
2
8
9
10
A
15
14
16
20 19
26
24
27
12
13 [A]
11
34
232122
25
17 2818 [B] [C]
2930
31
32
17
33
I5RW0C140010-01
[B]: For M/T model 34. steering gear box
2. Exhaust manifold
1
2
I5RW0A140011-01
11
I5RW0A140012-01

Downloaded from www.Manualslib.com manuals search engine 1D-20 Engine Mechanical:
6) Install engine right mounting bracket (1) and engine
left mounting bush bolt (2), and then tighten bolt and
nuts to specified torque.
Tightening torque
Engine right mounting bracket nut (a): 65 N·m (
6.5 kgf-m, 47.0 lb-ft)
Engine right mounting bush bolt (b): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Engine left mounting bush bolt (c): 85 N·m (8.5
kgf-m, 61.5 lb-ft)
7) Install suspension frame mounting bolts (1) and front
lower cross member bolts (2). And then tighten bolts
to specified torque.
Tightening torque
Suspension frame mounting bolt (a): 150 N·m (
15.0 kgf-m, 108.5 lb-ft)
Front lower cross member bolt (b): 55 N·m (5.5
kgf-m, 40.0 lb-ft)8) Connect steering lower shaft from pinion shaft
referring to “Steering Lower Shaft Removal and
Installation in Section 6B”.
9) Connect propeller shaft referring to “Propeller Shaft
Assembly Removal and Installation in Section 3D”
(for 4WD model)
10) Install exhaust No.1, No.2 and center pipes referring
to “Exhaust System Components in Section 1K”.
11) Reverse disconnected hoses, cables and electric
wires for connection noting the following.
• Tighten bolts and nuts to specified torque.
Tightening torque
Starting motor terminal nut (a): 11 N·m (1.1 kgf-
m, 8.0 lb-ft)
Generator terminal nut (b): 5 N·m (0.5 kgf-m, 4.0
lb-ft)
Battery ground bolt (c): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
Ground terminal bolt (d): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
1
(b)(a)
2,(c)
I5RW0C140031-01
2,(b)
1,(a)
I5RW0A140016-01
[A]: For M/T model [B]: For A/T model
(d)
(a)
(b)
(c)
(c)
[A]
[B]
I5RW0C140013-02

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-21
12) Install oil pressure switch bracket (1).
13) Connect right and left drive shaft joints to differential
gear referring to “Front Drive Shaft Assembly
Removal and Installation in Section 3A”.
14) Install suspension control arm referring to
“Suspension Control Arm / Bushing Removal and
Installation in Section 2B”.
15) Install cylinder upper cover (1).16) Install A/C compressor to its bracket (if equipped)
referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installation in Section 7B”.
17) Adjust A/C compressor drive belt referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
18) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation”.
19) Check to ensure that all removed parts are back in
place. Reinstall any necessary parts which have not
been reinstalled.
20) Refill cooling system with coolant referring to
“Cooling System Flush and Refill in Section 1F”.
21) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
22) Refill transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
23) Refill transfer oil referring to “Transfer Oil Change in
Section 3C”.
24) Install battery and battery tray with ECM.
25) Connect ECM wire harness.
26) Connect positive and negative cable at battery.
27) Install right and left side engine under covers.
28) Verify that there is no fuel leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
2. Exhaust manifold
1
2
I5RW0A140011-01
1
I5RW0A140009-01

Downloaded from www.Manualslib.com manuals search engine 1D-22 Engine Mechanical:
Timing Chain Cover ComponentsS6RW0D1406014
I5RW0C140041-01
[A]: For engine with VVT 8. Timing chain cover mounting
nut17. Oil control valve
[B]: For engine without VVT 9. Oil gallery pipe No.1 18. Oil control valve mounting nut
1. Crankshaft pulley bolt 10. Copper washer 19. Cap
2. Crankshaft pulley 11. Oil gallery pipe No.1 bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
3. Oil seal
: Apply engine oil to oil seal lip.12. Oil gallery pipe No.2 : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
4. Timing chain cover
: Apply sealant 99000-31140 to the mating
surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating
surface of timing chain cover referring to the
figure of Step 4) of “Installation” under “Timing
Chain Cover Removal and Installation”.13. Oil gallery pipe No.2 bolt : 30 N⋅m (3.0 kgf-m, 22.0 lb-ft)
5. Pin 14. Oil gallery pipe No.3 : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft)
6. Cap bolt 15. Oil gallery pipe No.3 bolt : Do not reuse.
7. Timing chain cover mounting bolts 16. O-ring
: Apply engine oil.

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-23
Timing Chain Cover Removal and InstallationS6RW0D1406015
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 engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove water pump / generator drive belt referring
to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1F”.
3) Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool with it
as shown in figure.
Special tool
(A): 09917–68221
4) Remove crankshaft pulley (1).
If it is hard to remove, use special tools as shown in
figure.
Special tool
(A): 09944–36011
(B): 09926–580105) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
6) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
7) Remove water pump pulley.
8) Remove A/C bracket from cylinder block.
9) For engine with VVT, remove oil gallery pipes No.2
(1) and No.3 (2).
10) Remove cap (1) from timing chain cover (2).
11) Remove timing chain cover (2).
12) For engine with VVT, remove oil control valve from
timing chain cover referring to “Oil Control Valve
Removal and Installation (For Engine with VVT)”.
I2RH0B140051-01
I2RH0B140052-01
1
2
I3RH0B140021-01
1
2
I5RW0C140042-01

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
I3RH0B140027-01
I2RH0B140056-01
1
I3RH0B140028-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-27
Timing Chain and Chain Tensioner ComponentsS6RW0D1406019
Timing Chain and Chain Tensioner Removal
and Installation
S6RW0D1406020
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).
I5RW0C140044-01
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
I5RW0C140016-01