1d-1 SUZUKI SX4 2006 1.G Service Workshop Manual

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Vo l u m e 1
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension.................................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Differential .............................................................. 3B-1
Transfer .................................................................. 3C-1
Propeller Shafts...................................................... 3D-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch ..................................................................... 5C-1
Vo l u m e 2
Precautions ............................................................... 00-i
Precautions ............................................................ 00-1
Steering ....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i
Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i
Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories ...................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i
Precautions ............................................................ 10-1
Body Electrical Control System ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

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

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Engine
Engine Mechanical
General Description
Engine Construction DescriptionS6RW0D1401001
The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft)
valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves/one cylinder). The double
overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through timing chain, and no push
rods are provided in the valve train system.
I5RW0C140032-01

Downloaded from www.Manualslib.com manuals search engine 1D-10 Engine Mechanical:
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.
I6RW0B140001-01
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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I5RW0C140004-01
I2RH0B140150-01

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).
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I5RW0A140004-02
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I5RW0A140005-01
I2RH0B140033-01
I6RS0B141004-01

Downloaded from www.Manualslib.com manuals search engine 1D-12 Engine Mechanical:
Installation
1) Install new spark plug hole gaskets (1) and new
cylinder head cover gasket (2) to cylinder head cover
(3) as shown in figure.
2) Remove oil, old sealant, and dust from sealing
surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface
area (2) as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)• Timing chain cover (1) and cylinder head (2)
mating surface as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
3) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.

4) Tightening bolts in numerical order (“1” through “7”)
as shown in figure a little at a time till they are
tightened to specified torque.
Tightening torque
Cylinder head cover bolt (a): Tighten 8 N⋅m (0.8
kgf-m, 6.0 lb-ft) by the specified procedure
5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).
8) Install ignition coil assemblies to cylinder head cover
referring to “Ignition Coil Assembly (Including Ignitor)
Removal and Installation in Section 1H”.
9) Connect ignition coil couplers and clamp harness
securely.
10) Install cylinder head upper cover.
11) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation”.
12) Connect negative cable at battery.I6RS0B141005-01
I2RH0B140036-01
I2RH0B140037-01
I3RH0B140016-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-13
Throttle Body and Intake Manifold ComponentsS6RW0D1406010
I6RW0D140001-01
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

Downloaded from www.Manualslib.com manuals search engine 1D-14 Engine Mechanical:
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
S6RW0D1406047
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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I5RW0C140006-01
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I4RS0B140005-01
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I5RW0C140008-01

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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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I5RW0A140007-02
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I3RM0A140018-01
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I4RS0A140005-01

Downloaded from www.Manualslib.com manuals search engine 1D-16 Engine Mechanical:
Engine Mountings ComponentsS6RW0D1406012
I6RW0D140002-01
[A]: For 4WD model 4. Engine left mounting
: Be sure to direct paint mark to forward.12. Dynamic damper
[B]: For 2WD model 5. Engine rear mounting
: Be sure to direct paint mark to forward.13. Mounting member cushion
[C]: For M/T model 6. Engine rear mounting No.1 bracket 14. Yellow mark
[D]: For A/T model 7. Engine rear mounting No.2 bracket 15. Mounting member