1D-11 SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-iii
EGR Valve Removal and Installation (If
Equipped).......................................................... 1B-4
EGR Valve Inspection (If Equipped) ................... 1B-4
PCV Hose Inspection .......................................... 1B-5
PCV Valve Inspection ......................................... 1B-5
Special Tools and Equipment ............................. 1B-5
Special Tool ........................................................ 1B-5
Engine Electrical Devices ....................... 1C-1
Repair Instructions .............................................. 1C-1
Engine Control Module (ECM) Removal and
Installation ......................................................... 1C-1
Manifold Absolute Pressure (MAP) Sensor
Inspection (If Equipped) .................................... 1C-2
Electric Throttle Body Assembly On-Vehicle
Inspection.......................................................... 1C-2
Electric Throttle Body System Calibration ........... 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly On-Vehicle Inspection ...................... 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly Removal and Installation .................. 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly Inspection ......................................... 1C-6
Engine Coolant Temperature (ECT) Sensor
Removal and Installation................................... 1C-7
Engine Coolant Temperature (ECT) Sensor
Inspection.......................................................... 1C-7
Heated Oxygen Sensor (HO2S-1 and HO2S-
2) Heater On-Vehicle Inspection (If
Equipped).......................................................... 1C-8
Heated Oxygen Sensor (HO2S-1 and HO2S-
2) Removal and Installation (If Equipped) ......... 1C-8
Camshaft Position (CMP) Sensor Removal
and Installation .................................................. 1C-9
Camshaft Position (CMP) Sensor Inspection ...... 1C-9
Crankshaft Position (CKP) Sensor Removal
and Installation ................................................ 1C-10
Crankshaft Position (CKP) Sensor Inspection .. 1C-11
Knock Sensor Removal and Installation ........... 1C-11
Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control
Relay and Radiator Cooling Fan Relay
Inspection........................................................ 1C-12
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor On-Vehicle
Inspection........................................................ 1C-12
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor Removal and
Installation ....................................................... 1C-13
Intake Air Temperature (IAT) Sensor
Inspection........................................................ 1C-13
Specifications..................................................... 1C-14
Tightening Torque Specifications ...................... 1C-14
Engine Mechanical .................................. 1D-1
General Description ............................................. 1D-1
Engine Construction Description ......................... 1D-1
Camshaft Position Control (VVT Variable
Valve Timing) System Description .................... 1D-3Diagnostic Information and Procedures ............1D-5
Compression Check ............................................1D-5
Engine Vacuum Check........................................1D-6
Valve Lash (Clearance) Inspection .....................1D-7
Repair Instructions ............................................1D-10
Air Intake System Components.........................1D-10
Air Cleaner Filter Removal and Installation .......1D-10
Air Cleaner Filter Inspection and Cleaning........1D-10
Air Cleaner Assembly Removal and
Installation .......................................................1D-11
Cylinder Head Cover Removal and
Installation .......................................................1D-11
Throttle Body and Intake Manifold
Components ....................................................1D-13
Throttle Body On-Vehicle Inspection.................1D-14
Electric Throttle Body Assembly Removal and
Installation .......................................................1D-14
Throttle Body Cleaning......................................1D-14
Intake Manifold Removal and Installation .........1D-15
Engine Mountings Components ........................1D-16
Engine Assembly Removal and Installation ......1D-17
Timing Chain Cover Components .....................1D-22
Timing Chain Cover Removal and Installation ..1D-23
Timing Chain Cover Inspection .........................1D-25
Oil Control Valve Removal and Installation
(For Engine with VVT) .....................................1D-26
Oil Control Valve Inspection (For Engine with
VVT) ................................................................1D-26
Timing Chain and Chain Tensioner
Components ....................................................1D-27
Timing Chain and Chain Tensioner Removal
and Installation ................................................1D-27
Timing Chain and Chain Tensioner Inspection ..1D-31
Camshaft, Tappet and Shim Components ........1D-32
Camshaft, Tappet and Shim Removal and
Installation .......................................................1D-33
Camshaft, Tappet and Shim Inspection ............1D-36
Valves and Cylinder Head Components ...........1D-39
Valves and Cylinder Head Removal and
Installation .......................................................1D-40
Valves and Cylinder Head Disassembly and
Assembly.........................................................1D-42
Valves and Valve Guides Inspection.................1D-45
Cylinder Head Inspection ..................................1D-47
Valve Spring Inspection ....................................1D-48
Pistons, Piston Rings, Connecting Rods and
Cylinders Components ....................................1D-49
Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation .................1D-49
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly ............1D-51
Cylinders, Pistons and Piston Rings
Inspection ........................................................1D-52
Piston Pins and Connecting Rods Inspection ...1D-54
Crank Pin and Connecting Rod Bearings
Inspection ........................................................1D-55
Main Bearings, Crankshaft and Cylinder
Block Components ..........................................1D-59
Main Bearings, Crankshaft and Cylinder
Block Removal and Installation .......................1D-60

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-11
Air Cleaner Assembly Removal and InstallationS6RW0D1406046
Removal
1) Disconnect negative cable at battery.
2) Disconnect MAF sensor connector (1).
3) Remove EVAP canister purge valve (2).
4) Remove air cleaner assembly (3) with air suction
hose (4).
Installation
Reverse removal procedure noting the following.
• 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)
Cylinder Head Cover Removal and InstallationS6RW0D1406003
Removal
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
3) Remove cylinder head upper cover (1).
4) Remove ignition coil assemblies with high-tension
cord from cylinder head cover referring to “Ignition
Coil Assembly (Including Ignitor) Removal and
Installation in Section 1H”.
5) Remove oil level gauge (1).
6) Disconnect PCV hose (2) from PCV valve (3) and
disconnect breather hose (4) from cylinder head
cover.
7) Remove cylinder head cover mounting bolts in
numerical order (“1” through “7”) as shown in figure.
8) Remove cylinder head cover (1) with cylinder head
cover gasket (2) and spark plug hole gasket (3).
1
2
3
4
I5RW0A140004-02
1
I5RW0A140005-01
I2RH0B140033-01
I6RS0B141004-01