2006 SUZUKI SX4 seat

Downloaded from www.Manualslib.com manuals search engine 1D-42 Engine Mechanical:
Valves and Cylinder Head Disassembly and
Assembly
S6RW0D1406027
Disassembly
1) For ease in servicing cylinder head, remove intake
manifold, injectors, exhaust manifold from cylinder
head.
2) Using special tools (Valve lifter), compress valve
spring and then remove valve cotters (1) also by
using special tool (Forceps).
Special tool
(A): 09916–14510
(B): 09916–14521
(C): 09916–845113) Release special tools (Valve lifter), and remove
spring retainer and valve spring.
4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide and
valve spring seat (2).
NOTE
Do not reuse valve stem seal once
disassembled. Be sure to use new seal when
assembling.

6) Using special tool (Valve guide remover), drive valve
guide out from combustion chamber side to valve
spring side.
Special tool
(A): 09916–44910
NOTE
Do not reuse valve guide once disassembled.
Be sure to use new valve guide (oversize)
when assembling.

7) Place disassembled parts except valve stem seal
and valve guide in order so that they can be installed
in their original position.
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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.

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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
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Downloaded from www.Manualslib.com manuals search engine 1D-46 Engine Mechanical:
Valve head radial runout
Check each valve for radial runout with a dial gauge and
“V” block. To check runout, rotate valve slowly. If runout
exceeds its limit, replace valve.
Valve head radial runout
Limit: 0.08 mm (0.003 in.)
Seating contact width
Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotatingly tapping seat
with valve head. Valve lapper (tool used in valve lapping)
must be used.
Pattern produced on seating face of valve must be a
continuous ring without any break, and the width of
pattern must be within specified range.
Standard seating width “a” revealed by contact
pattern on valve face
Intake and Exhaust: 1.0 – 1.4 mm (0.0389 – 0.0551
in.)Valve seat repair
A valve seat not producing a uniform contact with its
valve or showing width of seating contact that is out of
specified range must be repaired by regrinding or by
cutting and regrinding and finished by lapping.
1)Exhaust valve seat:
Use valve seat cutters (1) to make two cuts as
illustrated in figure. Two cutters must be used: the
first for making 22° angle, and the second for making
45° angle. The second cut must be made to produce
desired seat width.
Seat width for exhaust valve seat
“a”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)
2)Intake valve seat:
Use valve seat cutters (1) to make three cuts as
illustrated in figure. Three cutters must be used: the
1st for making 22° angle, the 2nd for making 60°
angle, and 3rd for making 45° angle. The 3rd cut
(45°) must be made to produce desired seat width.
Seat width for intake valve seat
“b”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)
3)Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-47
Cylinder Head InspectionS6RW0D1406029
• Remove all carbon deposits from combustion
chambers.
NOTE
Do not use any sharp-edged tool to scrape
off carbon deposits. Be careful not to scuff or
nick metal surfaces when decarbonizing. The
same applies to valves and valve seats, too.

• Check cylinder head for cracks on intake and exhaust
ports, combustion chambers, and head surface. Using
a straightedge and thickness gauge, check flatness of
gasketed surface at a total of 6 locations. If distortion
limit is exceeded, correct gasketed surface with a
surface plate and abrasive paper of about #400
(Waterproof silicon carbide abrasive paper): place
abrasive paper on and over surface plate, and rub
gasketed surface against paper to grind off high spots.
Should this fail to reduce thickness gauge readings to
within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint
is often due to warped gasketed surface: such
leakage results in reduced power output.Distortion for cylinder head surface on piston side
Limit: 0.03 mm (0.001 in.)
• Distortion of manifold seating faces:
Check seating faces of cylinder head for manifolds,
using a straightedge and thickness gauge, in order to
determine whether these faces should be corrected or
cylinder head replaced.
Distortion for cylinder head surface on intake and
exhaust manifold
Limit: 0.05 mm (0.002 in.)
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Downloaded from www.Manualslib.com manuals search engine 1D-48 Engine Mechanical:
Valve Spring InspectionS6RW0D1406030
Valve Spring Free Length and Preload
Referring to data, check to be sure that each spring is in
sound condition, free of any evidence of breakage or
weakening. Remember, weakened valve springs can
cause chatter, not to mention possibility of reducing
power output due to gas leakage caused by decreased
seating pressure.
Valve spring free length
Standard: 36.83 mm (1.450 in.)
Limit: 35.83 mm (1.411 in.)
Valve spring preload
Standard: 107 – 125 N (10.7 – 12.5 kgf) for 31.50 mm
(23.6 – 27.6 lb/1.240 in.)
Limit: 102 N (10.2 kgf) for 31.50 mm (22.5 lb/1.240 in.)Spring Squareness
Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. Valve springs found to exhibit a
larger clearance than limit must be replaced.
Valve spring squareness
Limit: 1.6 mm (0.063 in.)
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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
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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.
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2. Thermometer 3. Heater
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