intake SUZUKI SX4 2006 1.G Service Manual PDF

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7) Install air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
8) Run engine at specified idle speed and read vacuum
gauge. Vacuum should be within specification.
Vacuum specification (at sea level)
59 – 73 kPa (45 – 55 cmHg, 17.7 – 21.6 in.Hg) at
specified idle speed
9) After checking, disconnect special tool (Vacuum
gauge) from PCV valve.
10) Detach blind cap from PCV valve.
11) Install air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
Valve Lash (Clearance) InspectionS6RW0D1404003
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
3) Remove right side engine under cover, if necessary.
4) Using 17 mm wrench, turn crankshaft pulley (1)
clockwise until cam lobes (2) become perpendicular
to shim faces (3) at valves “1” and “7” as shown in
figure.
5) Check valve lashes with thickness gauge (4)
according to the following procedure.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90° (by turning crankshaft
with wrench).
c) Make sure that cam lobes are perpendicular to
shim faces at valves to be checked (in this case,
“3” and “8”), if not, adjust it by turning crankshaft.
Check valve lashes.
d) In the same manner as b) – c), check valve
lashes at valves “4” and “6”.
e) In the same manner as b) – c) again, check
valve lashes at valves “2” and “5”.
If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.
Valve clearance specification
When cold (Coolant temperature is 15 – 25 °C (59 –
77 °F)):
• Intake: 0.18 – 0.22 mm (0.007 – 0.009 in.)
• Exhaust: 0.28 – 0.32 mm (0.011 – 0.013 in.)
When hot (Coolant temperature is 60 – 68 °C (140 –
154 °F)):
• Intake: 0.21 – 0.27 mm (0.008 – 0.011 in.)
• Exhaust: 0.30 – 0.36 mm (0.012 – 0.014 in.)Replacement of Shim
1) Close the valve whose shim (2) is to be replaced by
turning crankshaft, then turn tappet (3) till its cut
section (1) faces inside as shown in figure.
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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
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1. Special tool 2. Magnet
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Repair Instructions
Air Intake System ComponentsS6RW0D1406045
Air Cleaner Filter Removal and InstallationS6RW0D1406001
Removal
1) Open air cleaner case (1) by unhooking its clamps
(2).
2) Remove air cleaner filter from case.
Installation
Reverse removal procedure for installation.
Air Cleaner Filter Inspection and CleaningS6RW0D1406002
Inspection
Check air cleaner filter for dirt. Replace excessive dirty
filter.
Cleaning
Blow off dust by compressed air from air outlet side of
filter.
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1. Air cleaner assembly5. To throttle body
2. Air cleaner outlet hose
: Align marking (6) of air cleaner assembly with marking (6) of air cleaner outlet hose.6. Marking
3. Air cleaner inlet hose
: Align marking (6) of air cleaner suction pipe with marking (6) of air cleaner inlet hose.:2 N⋅m (0.2 kgf-m, 1.5 lb-ft)
4. Air cleaner suction pipe:3 N⋅m (0.3 kgf-m, 2.5 lb-ft)
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Throttle Body and Intake Manifold ComponentsS6RW0D1406010
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1. Intake manifold 8. To cylinder head cover 15. Brake booster hose 22. Throttle body outlet water hose
No.2
2. O-ring 9. Gasket (with EGR) 16. To brake booster 23. EGR pipe plate (without EGR)
3. Throttle body: Do not
disassemble10. MAP sensor 17. Throttle body mounting bolt 24. MAP sensor plate (without MAP
sensor)
: Be sure to direct paint mark to
upward.
4. Intake manifold bolt 11. PCV valve hose 18. To EGR valve : Do not reuse.
5. Intake manifold nut 12. Breather pipe 19. Breather hose No.1
6. To PCV valve 13. To EVAP canister purge valve
hose20. Breather hose No.2
7. EGR pipe 14. EVAP canister purge valve hose 21. Throttle body outlet water hose No.1

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Throttle Body On-Vehicle InspectionS6RW0D1406006
Check electric throttle body assembly referring to
“Throttle Valve Operation Check” and “Electric Throttle
Body Assembly Operation Check” under “Electric
Throttle Body Assembly On-Vehicle Inspection in
Section 1C”.
Electric Throttle Body Assembly Removal and
Installation
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CAUTION!
Never disassemble electric throttle body.
Disassembly will spoil its original
performance. If faulty condition is found,
replace it with new one.

Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining
in Section 1F”.
3) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation”.
4) Disconnect engine coolant hoses (1) and breather
hose (2) from electric throttle body assembly (3).
5) Disconnect connector (4) from electric throttle body
assembly.
6) Remove electric throttle body assembly from intake
manifold.Installation
1) Clean mating surfaces and install new throttle body
gasket (1) to intake manifold.
2) Install electric throttle body assembly (1) to intake
manifold.
3) Connect connector (2) to electric throttle body
assembly securely.
4) Connect engine coolant hoses (3) and breather hose
(4) to electric throttle body assembly (1).
5) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation”.
6) Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
7) Connect negative cable at battery.
Throttle Body CleaningS6RW0D1406048
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection in Section 1C”.
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4
3
1
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Intake Manifold Removal and InstallationS6RW0D1406011
Removal
1) Remove throttle body referring to “Electric Throttle
Body Assembly Removal and Installation”.
2) Disconnect MAP sensor connector (1).
3) Disconnect the following hoses:
• Brake booster hose (2) from cylinder head cover
• PCV hose (3) from PCV valve
4) Remove EGR pipe bolt (4) from EGR valve.
5) Remove intake manifold (1) and EGR pipe (2) from
cylinder head, and then remove its gasket and O-
ring.Installation
Reverse removal procedure for installation noting the
following.
• Use new gasket and O-ring.
• Tighten EVAP canister purge valve bracket bolt to
specified torque.
Tightening torque
EVAP canister purge valve bracket bolt: 5 N·m (
0.5 kgf-m, 4.0 lb-ft)
• Install intake manifold bolt (2) and nut (1) as shown in
figure.
• Check to ensure that all removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
• Refill cooling system referring to “Cooling System
Flush and Refill in Section 1F”.
• Upon completion of installation, turn ignition switch
ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant
leaks.
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1
24
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2
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2
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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
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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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Timing Chain and Chain Tensioner ComponentsS6RW0D1406019
Timing Chain and Chain Tensioner Removal
and Installation
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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).
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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
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Installation
CAUTION!
After timing chain is removed, never turn
crankshaft and camshafts independently
more than such an extent (“a”, “b”) as shown
in figure.
If turned, interference may occur between
piston and valves and valves themselves,
and parts related to piston and valves may be
damaged.

1) Check that match marks (1) on intake and exhaust
camshaft timing sprockets are in match with notches
(2) on cylinder head as shown in figure.
2) Set key (3) and turn crankshaft to position key on
upside of crankshaft.3) Install timing chain to camshaft timing sprockets as
follows.
• For engine with VVT
Install timing chain by aligning dark blue plates (1)
of timing chain and triangle mark (2) on camshaft
timing sprockets.
• For engine without VVT
Install timing chain by aligning dark blue plates (1)
of timing chain and circle mark (5) on intake
camshaft timing sprocket and triangle mark (5) on
exhaust camshaft timing sprocket.
4) Fit crankshaft timing sprocket to timing chain by
aligning gold plate (3) of timing chain and circle mark
(4) on crankshaft timing sprocket. Then install
crankshaft timing sprocket fitted with chain to
crankshaft.
“a”: 90°4. Camshaft (IN and EX) allowable turning range.
By marks on camshaft timing sprocket within 15° from notches
on cylinder head on both right and left.
“b”: 15°5. Crankshaft allowable turning range.
By key on crankshaft, within 90° from top on both right and left.
“a”
“b” “b”“b” “b”
“a”
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12
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[A]: For engine with VVT [B]: For engine without VVT
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1 1
Approx. 60 Approx. 30 [A]
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Appro x. 60 Approx. 30 1 [B]
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2
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