2006 SUZUKI SX4 Valve

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-15
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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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)
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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)”.
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Downloaded from www.Manualslib.com manuals search engine 1D-24 Engine Mechanical:
Installation
1) Clean sealing surface on timing chain cover, cylinder
block and cylinder head.
Remove oil, old sealant and dust from sealing
surface.
2) Install oil seal (1) to timing chain cover, if removed.
NOTE
When installing new oil seal, press fit to
timing chain cover (2) by using special tool
(bearing installer) as shown in figure.

Drive in dimension
“a”: 1.0 mm (0.04 in.)
Special tool
(A): 09913–75810
3) For engine with VVT, install oil control valve to timing
chain cover referring to “Oil Control Valve Removal
and Installation (For Engine with VVT)”.
4) Apply sealant “A” to mating surface of cylinder and
cylinder head and “B” to mating surface of timing
chain cover as shown in figure.
“A”: Water tight sealant 99000–31140 (SUZUKI
Bond No.1207B)
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for timing chain cover
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)5) Apply engine oil to oil seal lip, then install timing
chain cover (1). Tighten bolts and nut to specified
torque.
NOTE
Before installing timing chain cover, check
that pin is securely fitted.

Tightening torque
Timing chain cover bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Timing chain cover nut (b): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
6) Apply engine oil to new O-rings (2) and install them
to cap (3).
7) Install cap (3) to timing chain cover (1).
Tighten bolts to specified torque.
Tightening torque
Cap bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
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(a) (b) (c)
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Downloaded from www.Manualslib.com manuals search engine 1D-26 Engine Mechanical:
Oil Control Valve Removal and Installation (For
Engine with VVT)
S6RW0D1406017
Removal
Remove oil gallery pipe No.1 and oil control valve from
timing chain cover.
Installation
1) Install new O-ring (4) to oil control valve (2).
2) Install oil control valve to timing chain cover (3).
Tighten nuts to specification.
Tightening torque
Oil control valve mounting nut (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
3) Install oil gallery pipe No.1 (1) with new copper
washers (5) to timing chain cover.
Tighten bolts to specification.
Tightening torque
Oil gallery pipe No.1 bolt (b): 30 N·m (3.0 kgf-m,
21.5 lb-ft)
Oil Control Valve Inspection (For Engine with
VVT)
S6RW0D1406018
Oil Control Valve
1) Inspect strainer (1) and mating surface (2) of oil
control valve for clog or damage. Clean oil control
valve if clog or foreign matter is present on strainer
or mating surface of oil control valve.
Replace oil control valve if its mating surface is
damaged.
2) Check resistance between terminals of oil control
valve.
Oil control valve resistance
6.7 – 7.7 Ω (at 20 °C (68 °F))
Oil Gallery Pipe
Inspect oil gallery pipes No.1, No.2 (2) and No.3 (3).
Replace if crack, deformation or clog exists.
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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).
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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
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Downloaded from www.Manualslib.com manuals search engine 1D-28 Engine Mechanical:
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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[A]: For engine with VVT [B]: For engine without VVT
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Approx. 60 Approx. 30 [A]
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