2006 SUZUKI SX4 intake

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-71
Honing or Reboring Cylinders
1) When any cylinder needs reboring, all other
cylinders must also be rebored at the same time.
2) Select oversized piston according to amount of
cylinder wear.
Oversize piston specification
Oversize 0.50: 78.453 – 78.468 mm (3.0887 –
3.0893 in.)
3) Using micrometer, measure piston diameter.
Measurement position for piston diameter
“a”: 19.5 mm (0.77 in.)4) Rebore and hone cylinder to the following
dimension.
NOTE
Before reboring, install all main bearing caps
in place and tighten to specification to avoid
distortion of bearing bores.

Cylinder bore diameter to be rebored
Oversize 0.50: 78.500 – 78.514 mm (3.0906 –
3.0911 in.)
5) Measure piston clearance after honing.
Piston clearance
0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Specifications
Tightening Torque SpecificationsS6RW0D1407001
I2RH01140157-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Camshaft housing bolt Tighten 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) by the
specified procedure) / )
EVAP canister purge valve bracket bolt 5 0.5 4.0) / )
Cylinder head cover bolt Tighten 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) by the
specified procedure)
Engine right mounting bracket nut 65 6.5 47.0)
Engine right mounting bush bolt 55 5.5 40.0)
Engine left mounting bush bolt 85 8.5 61.5)
Suspension frame mounting bolt 150 15.0 108.5)
Front lower cross member bolt 55 5.5 40.0)
Starting motor terminal nut 11 1.1 8.0)
Generator terminal nut 5 0.5 4.0)
Battery ground bolt 25 2.5 18.0)
Ground terminal bolt 11 1.1 8.0)
Timing chain cover bolt 25 2.5 18.0)
Timing chain cover nut 25 2.5 18.0)
Cap bolt 25 2.5 18.0)
Oil gallery pipe No.2 and No.3 bolt 11 1.1 8.0)
Crankshaft pulley bolt 150 15.0 108.5)
Oil control valve mounting nut 11 1.1 8.0)
Oil gallery pipe No.1 bolt 30 3.0 21.5)
Timing chain No.1 guide bolt 11 1.1 8.0)
Timing chain tensioner bolt 25 2.5 18.0)
Timing chain tensioner adjuster bolt 11 1.1 8.0)
Intake cam timing sprocket bolt 60 6.0 43.5)
Camshaft housing bolt 11 1.1 8.0)
Venturi plug 5 0.5 3.5)
Cylinder head bolt for M8 Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure)

Downloaded from www.Manualslib.com manuals search engine 1D-72 Engine Mechanical:
NOTE
The specified tightening torque is also described in the following.
“Air Intake System Components”
“Engine Mountings Components”
“Timing Chain Cover Components”
“Timing Chain and Chain Tensioner Components”
“Camshaft, Tappet and Shim Components”
“Valves and Cylinder Head Components”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components”
“Main Bearings, Crankshaft and Cylinder Block Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Cylinder head bolt for M10 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)
Connecting rod bearing cap nut Tighten 15 N⋅m (1.5 kgf-m, 11.0 lb-ft), 45°
and 45° by the specified procedure) / )
Sensor plate bolt 11 1.1 8.0)
Main bearing cap No.1 bolt Tighten 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50
N⋅m (5.0 kgf-m, 36.5 lb-ft) and 60° by the
specified procedure) / ) / )
Main bearing cap No.2 bolt Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure) / ) / )
Rear oil seal housing bolt 11 1.1 8.0)
Flywheel or drive plate bolt 70 7.0 51.0) Fastening partTightening torque
Note
N⋅mkgf-mlb-ft

Downloaded from www.Manualslib.com manuals search engine 1F-7 Engine Cooling System:
Thermostat Removal and InstallationS6RW0D1606007
Removal
1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold
Removal and Installation in Section 1D”.
3) Disconnect water hose (1) and heater hose (2) from
each pipe.
4) Remove thermostat case (3) with thermostat cap (4)
and water inlet pipe (5).
5) Remove water inlet pipe with thermostat cap from
thermostat case.
6) Remove thermostat from thermostat case (3).
Installation
Reverse removal procedure for installation noting the
following points.
• Install thermostat (5) to thermostat case (2) by
aligning air bleed valve (4) of thermostat with mark (3)
of thermostat case and, then install thermostat cap (1)
to thermostat case.
• Use new O-rings when installing.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• Verify that there is no coolant leakage at each
connection.
Thermostat InspectionS6RW0D1606008
• Make sure that air bleed valve (1) of thermostat is
clean.
• Check to make sure that valve seat (2) is free from
foreign matters which would prevent valve from
seating tight.
• Check thermostat seal (3) for breakage, deterioration
or any other damage.
• Check thermostatic movement of wax pellet as
follows:
a. Immerse thermostat (1) in water, and heat water
gradually.
b. Check that valve starts to open at specific
temperature.
Temperature at which valve begins to open
80 – 84 °C (176 – 183 °F)
Temperature at which valve become fully open
95 – 97 °C (203 – 206 °F)
Va l v e l i ft
More than 8 mm (0.31 in.) at 95 °C (203 °F)
If valve starts to open at a temperature substantially
below or above specific temperature, thermostat unit
should be replaced with a new one. Such a unit, if
reused, will bring about overcooling or overheating
tendency.
I6RW0B160007-01
4
53
12
I6RW0B160008-01
2. Thermometer 3. Heater
I3RM0A160008-01
I2RH01160012-01

Downloaded from www.Manualslib.com manuals search engine 1H-5 Ignition System:
6Ignition coil assembly power supply and ground circuit
check
1) Check ignition coil assembly power supply and ground
circuits for open and short.
Are circuits in good condition?Go to Step 7. Repair or replace.
7Ignition coil assembly check
1) Check ignition coil for resistance referring to “Ignition
Coil Assembly (Including Ignitor) Inspection”.
Is check result satisfactory?Go to Step 8. Replace ignition coil
assembly.
8CKP sensor check
1) Check CKP sensor referring to “Crankshaft Position
(CKP) Sensor Inspection in Section 1C”.
Is check result satisfactory?Go to Step 9. Tighten CKP sensor
bolt, replace CKP
sensor or CKP sensor
plate.
9CMP sensor check
1) Check CMP sensor referring to “Camshaft Position
(CMP) Sensor Inspection in Section 1C”.
Is check result satisfactory?Go to Step 10. Tighten CMP sensor
bolt, replace CMP
sensor or intake
camshaft.
10Ignition trigger signal circuit check
1) Check ignition trigger signal wire for open, short and
poor connection.
Is circuit in good condition?Go to Step 11. Repair or replace.
11A known-good ignition coil assembly substitution
1) Substitute a known-good ignition coil assembly and then
repeat Step 2.
Is check result of Step 2 satisfactory?Go to Step 12. Substitute a known-
good ECM and then
repeat Step 2.
12Ignition timing check
1) Check initial ignition timing and ignition timing advance
referring to “Ignition Timing Inspection”.
Is check result satisfactory?System is in good
condition.Go to Step 13.
13Knock sensor check
1) Confirm that knock sensor circuit is in good condition
referring to “DTC P0327 / P0328: Knock Sensor Circuit
Low / High in Section 1A”.
2) Check oscilloscope waveform of knock sensor signal
referring to “Reference waveform No.19” and
“Reference waveform No.20” under “Inspection of ECM
and Its Circuits in Section 1A”.
Is check result satisfactory?Check CMP sensor,
CMP sensor rotor tooth
of camshaft, CKP
sensor, CKP sensor
plate and/or input
signals related to this
system.Substitute a known-
good knock sensor and
recheck. Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-6
Ignition Spark TestS6RW0D1804004
1) Remove air cleaner assembly with air intake pipe.
2) Disconnect all injector couplers from injectors.
WARNING!
Without disconnection of injector couplers,
combustible gas may come out from spark
plug holes during this test and may get
ignited in engine room.

3) Remove spark plug and check it for condition and
type referring to “Spark Plug Inspection”.
4) If OK, connect ignition coil coupler to ignition coil
assembly and connect spark plug to ignition coil
assembly or high-tension cord. Ground spark plug.5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as
described in “Ignition System Symptom Diagnosis”.
Repair Instructions
High-Tension Cord Removal and InstallationS6RW0D1806001
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Disconnect No.1 cylinder (2) and No.3 cylinder (3)
high-tension cords from ignition coil assemblies (1)
while gripping each cap.
3) Pull out high-tension cords from spark plugs while
gripping each cap.
CAUTION!
• Removal of high-tension cords together
with clamps will be recommended so as
not to damage their inside wire (resistive
conductor).
• For the same reason, pull out each
connection by gripping cap portion.

Installation
1) Install No.1 cylinder (2) and No.3 cylinder (3) high-
tension cords to spark plugs and ignition coil
assemblies (1) while gripping each cap.
CAUTION!
• Never attempt to use metal conductor
high-tension cords as replacing parts.
• Insert each cap portion fully when
installing high-tension cords.

I4RS0A180006-01
I4RS0A180003-01
I4RS0A180004-01

Downloaded from www.Manualslib.com manuals search engine 1H-7 Ignition System:
High-Tension Cord InspectionS6RW0D1806002
Measure resistance of high-tension cord (1) by using
ohmmeter.
If resistance exceeds specification, replace high-tension
cord(s).
High-tension cord resistance
No.1 cylinder high-tension cord resistance: 1.4 – 4.0
kΩ
No.3 cylinder high-tension cord resistance: 0.6 – 2.0
kΩ
Spark Plug Removal and InstallationS6RW0D1806003
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Pull out high-tension cords by gripping their caps
and then remove ignition coil assemblies referring to
“Ignition Coil Assembly (Including Ignitor) Removal
and Installation”.
3) Remove spark plugs.
Installation
1) Install spark plugs and tighten them to specified
torque.
Tightening torque
Spark plug: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Install ignition coil assemblies referring to “Ignition
Coil Assembly (Including Ignitor) Removal and
Installation”.
3) Install high-tension cords securely by gripping their
caps.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
Spark Plug InspectionS6RW0D1806004
CAUTION!
• When servicing the iridium / platinum
spark plugs (slender center electrode type
plugs), do not touch the center electrode
to avoid damage to it. The electrode is not
strong enough against mechanical force
as it is slender and its material is not
mechanically tough.
• Do not clean or adjust gap for the iridium /
platinum spark plugs.

Inspect spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
If any abnormality is found for nickel spark plugs, adjust
air gap, clean with spark plug cleaner or replace it with
specified new plug.
For iridium / platinum spark plugs, replace it with new
plug.
Spark plug air gap
“a”
: 1.0 – 1.1 mm (0.040 – 0.043 in.)
Spark plug type
NGK: BKR6E-11 (Nickel) / IFR6J11 (Iridium)
DENSO: K20PR-U11 (Nickel)
NOTE
NGK IFR6J11 is highly recommended for
better engine starting performance under –25
°C (–13 °F).

I2RH0B180005-01
IYSQ01181012-01

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-8
Ignition Coil Assembly (Including Ignitor)
Removal and Installation
S6RW0D1806005
Removal
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil
assembly (2).
5) Remove ignition coil bolts (1) and then pull out
ignition coil assembly.
Installation
1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and
then connect ignition coil coupler.
Tightening torque
Ignition coil bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly
while gripping its cap.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
5) Connect negative cable to battery.
Ignition Coil Assembly (Including Ignitor)
Inspection
S6RW0D1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.6 – 10.2 kΩ at 20 ° (68 °F)
Ignition Timing InspectionS6RW0D1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission
gear shift lever in “Neutral”, and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch
OFF.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A) 1I 5 R W 0 C 11 0 0 11 - 0 1

Downloaded from www.Manualslib.com manuals search engine Table of Contents 7- i
7
Section 7
CONTENTS
HVAC
Precautions ................................................. 7-1
Precautions............................................................. 7-1
Precautions on HVAC ........................................... 7-1
Heater and Ventilation............................. 7A-1
General Description ............................................. 7A-1
Heater and Ventilation Construction ................... 7A-1
Schematic and Routing Diagram ........................ 7A-2
Heater and Ventilation Wiring Circuit Diagram .... 7A-2
Component Location ........................................... 7A-2
Electronic Control System Components
Location ............................................................ 7A-2
Diagnostic Information and Procedures ............ 7A-3
Heater and Ventilation Symptom Diagnosis........ 7A-3
Repair Instructions .............................................. 7A-4
HVAC Unit Components ..................................... 7A-4
HVAC Unit Removal and Installation (Non-A/
C) ...................................................................... 7A-4
Blower Motor Removal and Installation............... 7A-4
Blower Motor Inspection ..................................... 7A-4
Blower Motor Resistor Removal and
Installation ......................................................... 7A-5
Blower Motor Resistor Inspection ....................... 7A-5
Blower Motor Relay Inspection ........................... 7A-6
HVAC Control Unit Components ......................... 7A-6
HVAC Control Unit Removal and Installation ...... 7A-7
Blower Speed Selector Inspection ...................... 7A-9
Air Intake Selector Inspection ............................. 7A-9
Air Intake Control Actuator Removal and
Installation ......................................................... 7A-9
Air Intake Control Actuator Inspection .............. 7A-10
Center Ventilation Louver Removal and
Installation ....................................................... 7A-11
Side Ventilation Louver Removal and
Installation ....................................................... 7A-11
Rear Duct Removal and Installation (If
Equipped)........................................................ 7A-12
HVAC Air Filter Removal and Installation (If
Equipped)........................................................ 7A-12
HVAC Air Filter Inspection (If Equipped) ........... 7A-12
Air Conditioning System......................... 7B-1
Manual Type ............................................................ 7B-1
Precautions........................................................... 7B-1A/C System Caution ............................................ 7B-1
Precautions on Servicing A/C System ................ 7B-1
General Description .............................................7B-2
Sub-Cool A/C System Description ...................... 7B-2
Manual A/C Electronic Input Output Table .......... 7B-3
A/C Operation Description at ECM ..................... 7B-3
Schematic and Routing Diagram ........................7B-4
A/C System Air Flow Diagram............................. 7B-4
A/C System Wiring Diagram ............................... 7B-5
Component Location ...........................................7B-6
A/C System Major Components Location ........... 7B-6
Electronic Control System Components
Location............................................................. 7B-7
Diagnostic Information and Procedures ............7B-8
A/C System Performance Inspection .................. 7B-8
Trouble Diagnosis for Abnormal Pressure ........ 7B-11
A/C System Inspection at ECM ......................... 7B-12
A/C System Symptom Diagnosis ...................... 7B-13
Abnormal Noise Symptom Diagnosis of A/C
System ............................................................ 7B-15
Repair Instructions ............................................7B-17
Operation Procedure for Refrigerant Charge .... 7B-17
Condenser Cooling Fan Removal and
Installation ....................................................... 7B-22
Condenser Cooling Fan Inspection ................... 7B-23
Condenser Assembly On-Vehicle Inspection .... 7B-23
Condenser Assembly Removal and
Installation ....................................................... 7B-23
Desiccant Removal and Installation .................. 7B-24
HVAC Unit Components ................................... 7B-25
HVAC Unit Removal and Installation ................ 7B-26
Evaporator Inspection ....................................... 7B-27
Evaporator Temperature Sensor Removal
and Installation ................................................ 7B-27
Evaporator Temperature Sensor Inspection ..... 7B-28
Expansion Valve Removal and Installation ....... 7B-28
Expansion Valve Inspection .............................. 7B-28
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection............................................. 7B-29
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................ 7B-29
A/C Switch Inspection ....................................... 7B-29
A/C System Relay Inspection............................ 7B-30
Compressor Drive Belt Inspection and
Adjustment ...................................................... 7B-30