2006 SUZUKI SX4 Oil ring

Downloaded from www.Manualslib.com manuals search engine 1D-32 Engine Mechanical:
Camshaft, Tappet and Shim ComponentsS6RW0D1406022
I4RS0B140014-03
[A]: For engine with VVT 4. Exhaust camshaft 9. Camshaft bearing
: Install a bearing half with some holes to upper side of intake
camshaft No.1 bearing.
[B]: For engine without VVT 5. Shim
: Shim No. on it faces tappet side.: 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
1. Intake camshaft 6. Tappet : Tighten 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) by the specified procedure
2. Intake camshaft sprocket assembly 7. Camshaft housing : Apply engine oil to sliding surface of each part.
3. Intake camshaft sprocket bolt 8. Camshaft housing bolt

Downloaded from www.Manualslib.com manuals search engine 1D-34 Engine Mechanical:
Installation
1) Install tappets and shims to cylinder head.
Apply engine oil around tappet and then install it to
cylinder head.
NOTE
When installing shim, make sure to direct
shim No. side toward tappet.

2) For engine with VVT, install camshaft bearings (1) to
cylinder head (2) and camshaft housing (3).
CAUTION!
Do not apply engine oil to camshaft bearing
back.
Only a upper half bearing of intake camshaft
bearing No.1 has some holes.

3) Install intake camshaft (1) and exhaust camshaft (2).
Align knock pin (3) and match mark (4) with notches
(5) as shown in figure.
NOTE
Before installing camshafts, turn crankshaft
until key position faces upward.
Refer to “Timing Chain and Chain Tensioner
Removal and Installation”.

4) Apply engine oil to sliding surface of each camshaft
and camshaft journal then install them as shown in
figure.
5) Install camshaft housing pins (1) as shown in figure.
I2RH0B140075-01
I5RW0C140024-01
[A]: For engine with VVT “a”: Approx. 30°
[B]: For engine without VVT “b”: Approx. 60°
12
3
4
5
“a”
12
44
5
“a”“b”
[A]
[B]
I4RS0B140015-01
I3RM0A140033-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-35
6) Check position of camshaft housings.
Embossed marks are provided on each camshaft
housing, indicating position and direction for
installation. Install housings as indicated by these
marks.
7) After applying engine oil to housing bolts, tighten
them temporarily first. Tighten bolts evenly and
gradually in numerical order (“1” through “21”) by
repeating tightening sequence two or three times
until specified torque is obtained.
Tightening torque
Camshaft housing bolt (a): Tighten 11 N⋅m (1.1
kgf-m, 8.0 lb-ft) by the specified procedure8) For engine with VVT, with hexagonal section (1) of
intake camshaft (2) held stationary with spanner or
the like, tighten bolt of intake cam timing sprocket
assembly (3) to specification.
Tightening torque
Intake cam timing sprocket bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)
9) Install timing chain with crankshaft sprocket referring
to “Timing Chain and Chain Tensioner Removal and
Installation”.
10) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
11) Check valve lashes referring to “Valve Lash
(Clearance) Inspection”.
12) Perform Steps 10) to 14) of “Installation” of “Timing
Chain Cover Removal and Installation”.
A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
I2RH0B140078-01
“10”“9”
“2” “1”,(a) “6”“5” “14” “13”
“20”
“17”
“19”
“18”
“21”
“12”
“11”
“4” “3” “8”“7” “16” “15”
I3RH0B140041-01
1
2 3
(a)
I3RH0B140042-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-39
Valves and Cylinder Head ComponentsS6RW0D1406025
I4RS0A140015-01
1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8)
: Be sure to tighten cylinder head bolt (M8) after
securing the other cylinder head bolt (M10).
2. Valve spring retainer 8. Valve guide : 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.
3. Valve spring 9. Cylinder head bolt (M10)
: Check cylinder head bolt (M10), plastic deformation
tightening bolt, for deformation referring to “Valves and
Cylinder Head Removal and Installation”, if it is reused.: Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure
4. Valve stem seal 10. Cylinder head : Do not reuse.
5. Valve spring seat 11. Cylinder head gasket
: “TOP” mark provided on gasket comes to crankshaft
pulley side, facing up.: Apply engine oil to sliding surface of each part.
6. Intake valve 12. Knock pin

Downloaded from www.Manualslib.com manuals search engine 1D-40 Engine Mechanical:
Valves and Cylinder Head Removal and
Installation
S6RW0D1406026
Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
3) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
4) Remove timing chain cover referring to Steps 2) to
11) of “Removal” in “Timing Chain Cover Removal
and Installation”.
5) Remove timing chain referring to Steps 2) to 6) of
“Removal” in “Timing Chain and Chain Tensioner
Removal and Installation”.
6) Remove intake and exhaust camshafts referring to
Steps 3) to 8) of “Removal” in “Camshaft, Tappet and
Shim Removal and Installation”.
7) Loosen cylinder head bolts in such order as
indicated in figure by using a 12 corner socket
wrenches and remove them.
NOTE
Don’t forget to remove bolt (M8) (1) as shown
in figure.

8) Check all around cylinder head for any other parts
required to be removed or disconnected and remove
or disconnect whatever necessary.
9) Remove exhaust manifold, if necessary referring to
“Exhaust Manifold Removal and Installation in
Section 1K”.
10) Remove cylinder head with intake manifold and
exhaust manifold. Use lifting device, if necessary.
Installation
1) Clean mating surface of cylinder head and cylinder
block. Remove oil, old gasket and dust from mating
surface.
2) Make sure that oil jet (venturi plug) (1) is not
clogged. If it is not installed, install it as specified
torque.
Tightening torque
Venturi plug (a): 5 N·m (0.5 kgf-m, 3.5 lb-ft)
3) Install knock pins (1) to cylinder block.
4) Install new cylinder head gasket (2) to cylinder block.
“Top” or triangle mark provided on gasket comes to
crankshaft pulley side, facing up (toward cylinder
head side).
I2RH0B140088-01
I2RH0B140089-01
I5RW0C140025-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-41
5) Install cylinder head to cylinder block.
Apply engine oil to new cylinder head bolts and
tighten them gradually as follows.
a) Tighten cylinder head bolts (“1” – “10”) to 20 N⋅m
(2.0 kgf-m, 14.5 lb-ft) according to numerical
order as shown by using a 12 corner socket
wrenches.
b) In the same manner as in Step a), tighten them
to 40 N⋅m (4.0 kgf-m, 29.0 lb-ft).
c) Turn all bolts 60° according to numerical order in
figure.
d) Repeat Step c).
e) Tighten cylinder head bolt (M8) (1) to specified
torque.
NOTE
Be sure to tighten M8 bolt (1) after securing
the other bolts.

Tightening torque
Cylinder head bolt for M8 (a): Tighten 25 N⋅m
(2.5 kgf-m, 18.0 lb-ft) by the specified
procedure
Cylinder head bolt for M10 (b): 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
NOTE
• If cylinder head bolts (M10) are reused,
check thread diameters of cylinder head
bolt (1) for deformation according to the
follows and replace them with new ones if
thread diameter difference exceeds limit.
• Measure each thread diameter of cylinder
head bolt (1) at “A” on 83.5 mm (2.81 in.)
from seat side of flange bolt and “B” on
115 mm (4.53 in.) from seat side of flange
bolt by using a micrometer (2).
Then calculate difference in diameters (“A”
– “B”). If it exceeds limit, replace with new
one.

Cylinder head bolt diameter measurement
points
“a”: 83.5 mm (2.81 in.)
“b”: 115 mm (4.53 in.)
Cylinder head bolt diameter difference
(deformation)
Limit (“A” – “B”): 0.1 mm (0.004 in.)
6) Install camshafts, tappet and shim referring to
“Camshaft, Tappet and Shim Removal and
Installation”.
7) Install timing chain referring to “Timing Chain and
Chain Tensioner Removal and Installation”.
8) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
9) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
10) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
I5RW0C140030-01

“A”
“a”
“b”“B”

1
12
I2RH0B140092-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-43
Assembly
1) Before installing valve guide into cylinder head, ream
guide hole with special tool (10.5 mm reamer) so as
to remove burrs and make it truly round.
Special tool
(A): 09916–34542
(B): 09916–37320
2) Install valve guide to cylinder head.
Heat cylinder head uniformly at a temperature of 80
to 100 °C (176 to 212 °F) so that head will not be
distorted, and drive new valve guide into hole with
special tools.
Drive in new valve guide until special tool (Valve
guide installer) contacts cylinder head.
After installing, make sure that valve guide protrudes
by specified dimension “a” from cylinder head.
Special tool
(A): 09916–58210
(B): 09916–56011
NOTE
• Never reuse valve guide once
disassembled. Make sure to install new
valve guide (Oversize).
• Intake and exhaust valve guides are
identical.

Valve guide protrusion (In and Ex)
“a”: 11.1 – 11.5 mm (0.437 – 0.452 in.)3) Ream valve guide bore with special tool (5.5 mm
reamer). After reaming, clean bore.
Special tool
(A): 09916–34542
(B): 09916–34550
4) Install valve spring seat to cylinder head.
5) Install new valve stem seal (1) to valve guide.
After applying engine oil to seal and spindle of
special tool (Valve guide installer handle), fit oil seal
to spindle, and then install seal to valve guide by
pushing special tool by hand.
After installing, check to be sure that seal is properly
fixed to valve guide.
Special tool
(A): 09917–98221
(B): 09916–58210
NOTE
• Do not reuse seal once disassembled. Be
sure to install new seal.
• When installing, never tap or hit special
tool with a hammer or else. Install seal to
guide only by pushing special tool by
hand. Tapping or hitting special tool may
cause damage to seal.

I2RH0B140096-01
I2RH0B140097-01
I2RH0B140096-01
I2RH0B140098-01

Downloaded from www.Manualslib.com manuals search engine 1D-44 Engine Mechanical:
6) Install valve to valve guide.
Before installing valve to valve guide, apply engine
oil to stem seal, valve guide bore and valve stem.
7) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end (1))
and bottom end (small-pitch end (2)). Be sure to
position spring in place with its bottom end (small-
pitch end) facing the bottom (valve spring seat side).8) Using special tools (Valve lifter), compress valve
spring and fit two valve cotters (1) into groove in
valve stem.
NOTE
When compressing the valve spring, be
carefully to free from damage in inside face
of tappet installing hole.

Special tool
(A): 09916–14510
(B): 09916–14521
(C): 09916–84511
9) Install intake manifold referring to “Intake Manifold
Removal and Installation”.
10) Install fuel injectors referring to “Fuel Injector
Removal and Installation in Section 1G”.
11) Install exhaust manifold referring to “Exhaust
Manifold Removal and Installation in Section 1K”.
A: Valve spring retainer side B: Valve spring seat side
I2RH0B140099-01
I2RH0B140100-01
I2RH0B140101-01