2006 SUZUKI SX4 rear

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

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-59
Main Bearings, Crankshaft and Cylinder Block ComponentsS6RW0D1406037
I6RW0D140003-01
1. CKP sensor
: See “A”11. Rear oil seal 21. Oil filter adapter bolt
2. Knock sensor 12. Input shaft bearing 22. Spring pin
3. Cylinder block 13. Flywheel or drive plate 23. Sensor plate bolt
4. Venturi plug 14. Main bearing cap 24. Oil pressure switch

Downloaded from www.Manualslib.com manuals search engine 1D-60 Engine Mechanical:
Main Bearings, Crankshaft and Cylinder Block
Removal and Installation
S6RW0D1406038
Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove clutch cover, clutch disc and flywheel (drive
plate for A/T) by using special tool.
Special tool
(A): 09924–178103) Remove piston and connecting rod referring to
“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
4) Remove rear oil seal housing (1).
5) Loosen main bearing cap No.1 and No.2 bolts in
such order as indicated in figure and remove them.
6) Remove crankshaft from cylinder block.
7) Remove sensor plate from crankshaft.
5. Main bearing
: See “B”15. Flywheel or drive plate bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft)
6. Sensor plate 16. Rear oil seal housing mounting bolt : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Crankshaft timing sprocket key 17. Main bearing cap No.2 bolt : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
8. Crankshaft 18. Main bearing cap No.1 bolt
: See “D”: Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure.
9. Thrust bearing 19. O-ring : 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.
10. Rear oil seal housing
: See “C”20. Oil filter adapter case : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
“A”: When installing CKP sensor, use new sensor mounting bolt. : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
“B”: Upper half of bearing has an oil groove.
Do not apply oil between connecting rod and bearing or between bearing cap and
bearing.:10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
“C”: Apply sealant 99000-31250 to mating surface. : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
“D”: Make sure main bearing cap No.1 bolt deformation when reuse it due to plastic
deformation tightening referring to “Main Bearings Inspection”.: Do not reuse.
: Apply engine oil to inside / sliding surface.
I2RH0B140125-01
I2RH0B140126-01
I2RH0B140127-01

Downloaded from www.Manualslib.com manuals search engine 1D-62 Engine Mechanical:
6) Install bearing cap to cylinder block, making sure to
point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts ((1) – (10)) and main bearing cap No.2 bolts
((11) – (20)), tighten them gradually as follows.
a) Tighten bolts ((1) – (10)) to 30 N⋅m (3.0 kgf-m,
22.0 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 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them
to 60°.
d) Tighten bolts ((11) – (20)) to 25 N⋅m (2.5 kgf-m,
18.0 lb-ft) according to numerical order as
shown.
Tightening torque
Main bearing cap No.1 bolt ((1) – (10)):
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 ((11) – (20)):
Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the
specified procedure
CAUTION!
After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 N⋅m (1.2 kgf-m, 9.0 lb-ft)
torque or below.

7) If necessary, press-fit rear oil seal (1) to oil seal
housing (2) by using special tool as shown in figure.
Special tool
(A): 09911–97821
Crank rear oil seal installing position
(dimension)
“a”: 2 mm (0.08 in.)
8) Apply sealant to mating surface of rear oil seal
housing (1).
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
I2RH0B140131-01
I5RW0C140027-01
I4RS0A140018-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-63
9) Install rear oil seal housing (1) and tighten new bolts
to specified torque by using special tool.
Special tool
(A): 09911–97720
Tightening torque
Rear oil seal housing bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
10) Install flywheel (drive plate for A/T).
Using special tool, lock flywheel or drive plate, and
tighten flywheel or drive plate bolts to specified
torque.
NOTE
Use new flywheel or drive plate bolts.

Special tool
(A): 09924–17810
Tightening torque
Flywheel or drive plate bolt (a): 70 N·m (7.0 kgf-
m, 51.0 lb-ft)
11) Install piston and connecting rod referring to
“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
12) Install cylinder head referring to “Valves and Cylinder
Head Removal and Installation”.13) Install camshafts, tappet and shim referring to
“Camshaft, Tappet and Shim Removal and
Installation”.
14) Install timing chain referring to “Timing Chain and
Chain Tensioner Removal and Installation”.
15) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
16) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
17) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
18) Install engine assembly to vehicle referring to
“Engine Assembly Removal and Installation”.
Crankshaft InspectionS6RW0D1406039
Crankshaft Runout
Using a dial gauge, measure runout at center journal.
Rotate crankshaft slowly. If runout exceeds its limit,
replace crankshaft.
Crankshaft runout
Limit: 0.02 mm (0.0008 in.)
Crankshaft Thrust Play
1) Measure this play with crankshaft set in cylinder
block in the normal manner, that is with thrust
bearing (1) and journal bearing caps installed.
Thickness of crankshaft thrust bearing
Standard: 2.470 – 2.520 mm (0.0972 – 0.0992 in.)
Oversize (0.125 mm (0.0049 in.)): 2.533 – 2.583
mm (0.0997 – 0.1017 in.)
A: Crankshaft side
I4RS0A140019-01
I2RH0B140134-01
I2RH0B140135-01
I2RH0B140136-01

Downloaded from www.Manualslib.com manuals search engine 1D-70 Engine Mechanical:
Main Bearing Cap No.1 Bolt
Measure each thread diameter main bearing cap No.1
bolts (1) at “A” on 60 mm (2.36 in.) from seat side of
flange bolt and “B” on 90 mm (3.54 in.) from seat side of
flange bolt by using a micrometer (2).
Calculate difference in diameters (“A” – “B”).
If it exceeds limit, replace with new one.
Main bearing cap No.1 bolt diameter measurement
points
“a”: 60 mm (2.36 in.)
“b”: 90 mm (3.54 in.)
Main bearing cap No.1 bolt diameter difference
Limit (“A” – “B”): 0.2 mm (0.008 in.)
Sensor Plate InspectionS6RW0D1406041
Check sensor plate for crack damage.
If malcondition is found, replace it.
Rear Oil Seal InspectionS6RW0D1406042
Carefully inspect oil seal (1) for wear or damage. If its lip
is worn or damaged, replace it.
Flywheel InspectionS6RW0D1406043
Visual Inspection
• If ring gear is damaged, cracked or worn, replace
flywheel.
• If the surface contacting clutch disc is damaged, or
excessively worn, replace flywheel.
Flywheel Face Runout
Check flywheel face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel face runout
Limit: 0.2 mm (0.0079 in.)
Cylinder Block InspectionS6RW0D1406044
Distortion of Gasketed Surface
Using straightedge and thickness gauge, check
gasketed surface for distortion and, if flatness exceeds
its limit, correct It.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)

“A”
“a”
“b”“B”

1
1
2
I2RH0B140145-01
I2RH0B140151-01
I4RS0A140020-01
I2RH01140198-01
I2RH01140199-01

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-9 Engine Cooling System:
5) Remove cooling fan mounting bolts (1).
6) Remove radiator cooling fan assembly (2).
Installation
Reverse removal procedure for installation noting the
following.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• After installation, verify there is no coolant leakage at
each connection.
Radiator Cooling Fan Disassembly and
Reassembly
S6RW0D1606018
Disassembly
1) Remove fan (1) from cooling fan motor (2).
2) Remove fan motor (2) from cooling fan guide (3).
Reassembly
Reverse disassembly procedures for reassembly.
Radiator On-Vehicle Inspection and CleaningS6RW0D1606012
Inspection
Check radiator for leakage or damage. Straighten bent
fins, if any.
Cleaning
Clean frontal area of radiator cores.
Radiator Removal and InstallationS6RW0D1606013
Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining”.
3) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
4) Remove cooling fan assembly referring to “Radiator
Cooling Fan Assembly Removal and Installation”.
5) Remove condenser fan referring to “Condenser
Cooling Fan Removal and Installation in Section 7B”.
6) Remove radiator outlet hose from radiator.
7) Remove radiator from vehicle.
Installation
Reverse removal procedures, noting the following.
Tighten radiator support bracket bolts to specified
torque.
Tightening torque
Radiator support bracket bolt: 33 N·m (3.3 kgf-m,
24.0 lb-ft)
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• After installation, verify there is no coolant leakage
each connection.
I5RW0C160014-01
I5RW0C160005-01
I2RH01160014-01