2006 SUZUKI SX4 CYLINDER HEAD

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-117
System Description
The CMP sensor located on the transmission side of cylinder head (VVT model) or timing chain cover (non-VVT
model) consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion (VVT model) or
exhaust camshaft timing sprocket (non-VVT model)).
The signal generator generates reference signal through slits in the slit plate which turns together with the camshaft.
Reference signal
The CMP sensor generates 6 pulses of signals each of which has a different waveform length while the camshaft
makes one full rotation. Refer to “Inspection of ECM and Its Circuits”.
Based on these signals, ECM judges which cylinder piston is in the compression stroke and the engine speed.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Crank engine for 5 sec.
4) Check DTC and pending DTC.
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

DTC detecting condition Trouble area
• CMP sensor pulse is less than 20 pulses per crankshaft 8 revolutions
or
• CMP sensor pulse is more than 28 pulses per crankshaft 8
revolutions
or
• CMP sensor pulse is less than 20 pulses between BTDC 75° CA and
BTDC 5° CA with crankshaft 8 revolutions from engine start.
(1 driving cycle detection logic)• CMP sensor circuit open or short
• Signal rotor teeth damaged
• CMP sensor malfunction, foreign material
being attached or improper installation
•ECM
Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check”.
2CMP sensor and connector for proper installation check
Is CMP sensor installed properly and connector connected
securely?Go to Step 3. Correct.

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-4
EVAP Canister InspectionS6RW0D1206006
WARNING!
DO NOT SUCK nozzles on EVAP canister.
Fuel vapor inside EVAP canister is harmful.

1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there is no restriction of flow through
purge pipe (1) and air pipe (2) when air is blown (4)
into tank pipe (3).
If any faulty condition is found in this inspection,
replace EVAP canister.
EGR Valve Removal and Installation (If
Equipped)
S6RW0D1206007
Removal
1) Disconnect negative cable at battery.
2) Remove air intake pipe.
3) Remove EGR pipe and gaskets.
4) Disconnect EGR valve connector.
5) Remove EGR valve and gasket from cylinder head.
Installation
Reverse removal procedure noting the following.
• Clean mating surface of valve and cylinder head.
• Use new gaskets.
EGR Valve Inspection (If Equipped)S6RW0D1206008
1) Check resistance between following terminals of
EGR valve (1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance (A – B, C – B, F – E, D – E
terminal)
20 – 24 Ω
2) Remove carbon from EGR valve gas passage.
CAUTION!
Do not use any sharp-edged tool to remove
carbon.
Be careful not to damage or bend EGR valve
(1), valve seat (3) and rod.

3) Inspect valve (2), valve seat and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve assembly.
4
3 1
2
I6RW0D120003-01
I2RH0B120005-01
I2RH0B120006-01

Downloaded from www.Manualslib.com manuals search engine 1B-5 Aux. Emission Control Devices:
PCV Hose InspectionS6RW0D1206009
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC throttle valve opening, for obstructed
PCV valve or hose hampers its accurate
adjustment.

Check hoses for connection, leakage, clog and
deterioration.
Replace as necessary.
PCV Valve InspectionS6RW0D1206010
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC throttle valve opening, for obstructed
PCV valve or hose hampers its accurate
adjustment.

1) Detach air cleaner assembly.
2) Disconnect PCV valve from cylinder head cover and
install plug to head cover hole.
3) Install air cleaner assembly temporarily.
4) Run engine at idle.5) Place your finger over end of PCV valve (1) to check
for vacuum.
If there is no vacuum, check for clogged valve.
Replace as necessary.
6) After checking vacuum, stop engine and remove
PCV valve (1).
Shake valve and listen for rattle of check needle
inside the valve. If valve does not rattle, replace PCV
valve.
7) After checking, remove plug and install PCV valve.
8) Install air cleaner assembly securely.
Special Tools and Equipment
Special ToolS6RW0D1208001
I2RH0B120007-01
I2RH0B120008-01
09917–47011 SUZUKI scan tool (SUZUKI-
SDT)
Vacuum pump gauge —
) / )This kit includes following
items. 1. SUZUKI-SDT 2.
DLC3 cable 3. USB cable 4.
AC/DC power supply 5.
Voltage meter probe 6.
Storage case ) / )
1
2
34
56

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-9
Camshaft Position (CMP) Sensor Removal and
Installation
S6RW0D1306012
Removal
1) Disconnect negative cable at battery.
2) Disconnect connector from CMP sensor.
3) Remove camshaft position sensor from timing chain
cover (non-VVT model) or cylinder head (VVT
model).
Installation
1) Install camshaft position sensor to timing chain cover
(non-VVT model) or cylinder head (VVT model).
Tightening torque
CMP sensor bolt (non-VVT model) (a): 10 N·m (
1.0 kgf-m, 7.5 lb-ft)
CMP sensor bolt (VVT model) (b): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
2) Connect connector to CMP sensor securely.
3) Connect negative cable to battery.
Camshaft Position (CMP) Sensor InspectionS6RW0D1306013
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal rotor tooth
are free from any metal particles and damage.
[A]: Non-VVT model [B]: VVT model
I6RW0D130002-02
I4RS0B130015-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-1
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 Engine Mechanical: 1D-5
Targeted Timing Varying Operation
Diagnostic Information and Procedures
Compression CheckS6RW0D1404001
Check compression pressure on all 4 cylinders as
follows:
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
NOTE
After warming up engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake and block drive wheels.

3) Remove air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
4) Remove cylinder head upper cover.
5) Remove ignition coil assemblies and all spark plugs
referring to “Spark Plug Removal and Installation in
Section 1H”.
6) Disconnect fuel injector wires at the coupler.7) Install special tools (Compression gauge) into spark
plug hole.
Special tool
(A): 09915–64512
(B): 09915–64530
(C): 09915–67010 Driving condition Valve timing Target of control Effect
Engine running at idle
speedMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Stabilization of the engine
rotation at idle speed.
Average engine load
rangeTo the advanced
sideTo lengthen the valve opening overlap
in order to enhance the internal
exhaust gas recirculation and reduce
the pumping loss.Improvement of the fuel
efficiency.
Lowering of the exhaust
emission.
Light engine load
rangeTo the retarded sideTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Keeping of the engine stability.
Low or average
engine speed range
with heavy engine
loadTo the advanced
sideTo advance the closing timing of the
intake valve in order to improve the
volumetric efficiency.Improvement of generating the
engine torque at low and
average engine speed.
High engine speed
range with heavy
engine loadTo the retarded sideTo retard the closing timing of the
intake valve in order to improve the
volumetric efficiency.Improvement of generating the
engine power.
Low engine coolant
temperatureMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold and
reduce the fuel increasing.
To slow the fast idle speed of the
engine as a result of stabilizing the
engine idling.Stabilization of the fast idling of
the engine.
Improvement of the fuel
efficiency.
At engine starting and
stoppingMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Improvement of start ability.
(A)
(C)
(B)
I3RH0B140009-01

Downloaded from www.Manualslib.com manuals search engine 1D-6 Engine Mechanical:
8) Disengage clutch (1) (to lighten starting load on
engine) for M/T vehicle, and depress accelerator
pedal (2) all the way to make throttle fully open.
9) Crank engine with fully charged battery, and read the
highest pressure on compression gauge.
NOTE
• For measuring compression pressure,
crank engine at least 250 r/min. by using
fully charged battery.
• If measured compression pressure is
lower than limit value, check installation
condition of special tool. If it is properly
installed, possibility is compression
pressure leakage from where piston ring
and valve contact.

Compression pressure
Standard: 1400 kPa (14.0 kgf/cm2, 199.0 psi)
Limit: 1100 kPa (11.0 kgf/cm2, 156.0 psi)
Max. difference between any two cylinders: 100
kPa (1.0 kgf/cm
2, 14.2 psi)
10) Carry out Steps 7) through 9) on each cylinder to
obtain 4 readings.
11) After checking, install spark plugs and ignition coil
assemblies with high-tension cord referring to “Spark
Plug Removal and Installation in Section 1H”.
12) Connect ignition coil couplers.
13) Connect fuel injector wires at the coupler.
14) Install cylinder head upper cover.
15) Install air cleaner assembly with air section hose
referring to “Air Cleaner Assembly Removal and
Installation”.
Engine Vacuum CheckS6RW0D1404002
The engine vacuum that develops in the intake line is a
good indicator of the condition of the engine. The
vacuum checking procedure is as follows:
1) Warm up engine to normal operating temperature.
NOTE
After warming up engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake and block drive wheels.

2) Stop engine and turn off the all electric switches.
3) Remove air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
4) Remove PCV hose (1) from PCV valve (2).
5) Connect special tool (Vacuum gauge) to PCV hose
(1).
Special tool
(A): 09915–67311
6) Blind PCV valve (2) using tape (3) or the like.I2RH0B140005-01
12
I5RW0C140038-01
(A)
1
2
3
I5RW0A140003-02

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-7
7) Install air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
8) Run engine at specified idle speed and read vacuum
gauge. Vacuum should be within specification.
Vacuum specification (at sea level)
59 – 73 kPa (45 – 55 cmHg, 17.7 – 21.6 in.Hg) at
specified idle speed
9) After checking, disconnect special tool (Vacuum
gauge) from PCV valve.
10) Detach blind cap from PCV valve.
11) Install air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
Valve Lash (Clearance) InspectionS6RW0D1404003
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
3) Remove right side engine under cover, if necessary.
4) Using 17 mm wrench, turn crankshaft pulley (1)
clockwise until cam lobes (2) become perpendicular
to shim faces (3) at valves “1” and “7” as shown in
figure.
5) Check valve lashes with thickness gauge (4)
according to the following procedure.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90° (by turning crankshaft
with wrench).
c) Make sure that cam lobes are perpendicular to
shim faces at valves to be checked (in this case,
“3” and “8”), if not, adjust it by turning crankshaft.
Check valve lashes.
d) In the same manner as b) – c), check valve
lashes at valves “4” and “6”.
e) In the same manner as b) – c) again, check
valve lashes at valves “2” and “5”.
If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.
Valve clearance specification
When cold (Coolant temperature is 15 – 25 °C (59 –
77 °F)):
• Intake: 0.18 – 0.22 mm (0.007 – 0.009 in.)
• Exhaust: 0.28 – 0.32 mm (0.011 – 0.013 in.)
When hot (Coolant temperature is 60 – 68 °C (140 –
154 °F)):
• Intake: 0.21 – 0.27 mm (0.008 – 0.011 in.)
• Exhaust: 0.30 – 0.36 mm (0.012 – 0.014 in.)Replacement of Shim
1) Close the valve whose shim (2) is to be replaced by
turning crankshaft, then turn tappet (3) till its cut
section (1) faces inside as shown in figure.
I3RM0A140004-01
I2RH0B140006-01