2006 SUZUKI SX4 CYLINDER HEAD

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-25
8) For engine with VVT, install new O-ring (1) to oil
gallery pipes No.2 (2) and No.3 (3).
9) For engine with VVT, install oil gallery pipes No.2
and No.3 to cylinder head (4) and timing chain cover
(5).
Tighten bolts to specified torque.
Tightening torque
Oil gallery pipe No.2 and No.3 bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
10) Install water pump pulley.
11) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
12) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
13) Install crankshaft pulley (1). Tighten bolt (2) to
specified torque. To lock crankshaft pulley, use
special tool with it as shown in figure.
Special tool
(A): 09917–68221
Tightening torque
Crankshaft pulley bolt (a): 150 N·m (15.0 kgf-m,
108.5 lb-ft)
14) Install engine assembly to vehicle referring to
“Engine Assembly Removal and Installation”.Timing Chain Cover InspectionS6RW0D1406016
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Timing Chain Cover (For Engine with VVT)
Inspect strainer (1) of oil passage for driving intake cam
timing sprocket assembly (VVT actuator).
If clog or foreign matter exists, clean strainer.
(a)
(a)1
2
3
4
5
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1
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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).
I5RW0C140044-01
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
3
1
1
2
5
67
8
9
I5RW0C140016-01

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”
1
12
4
3
5
I4RS0A140021-01
[A]: For engine with VVT [B]: For engine without VVT
34
1 1
Approx. 60 Approx. 30 [A]
1
Appro x. 60 Approx. 30 1 [B]
2
2
2
5
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Downloaded from www.Manualslib.com manuals search engine 1D-30 Engine Mechanical:
8) Screw in plunger (1) by turning body (2) in arrow
direction and install a retainer (3) (wire) to hold
plunger in place.
9) Install timing chain tensioner adjuster assembly (1)
with a retainer (2).
Tighten adjuster bolts to specified torque and then
remove a retainer from chain tensioner adjuster
assembly.
Tightening torque
Timing chain tensioner adjuster bolt (a): 11 N·m
(1.1 kgf-m, 8.0 lb-ft)10) Apply engine oil to timing chain, and then turn
crankshaft clockwise by 2 revolutions and check that
match marks (1) are at the following specific
positions.
• Intake and exhaust camshaft timing sprockets are
in match with notches (2) on cylinder head.
• Crankshaft sprocket key (3) is on upside of
crankshaft as shown in figure.
11) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
12) Perform Steps 10) to 14) of “Installation” of “Timing
Chain Cover Removal and Installation”.
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[A]: For engine with VVT [B]: For engine without VVT
1
1
2
3
21
1
3
[A]
[B]
I5RW0C140022-01

Downloaded from www.Manualslib.com manuals search engine 1D-34 Engine Mechanical:
Installation
1) Install tappets and shims to cylinder head.
Apply engine oil around tappet and then install it to
cylinder head.
NOTE
When installing shim, make sure to direct
shim No. side toward tappet.

2) For engine with VVT, install camshaft bearings (1) to
cylinder head (2) and camshaft housing (3).
CAUTION!
Do not apply engine oil to camshaft bearing
back.
Only a upper half bearing of intake camshaft
bearing No.1 has some holes.

3) Install intake camshaft (1) and exhaust camshaft (2).
Align knock pin (3) and match mark (4) with notches
(5) as shown in figure.
NOTE
Before installing camshafts, turn crankshaft
until key position faces upward.
Refer to “Timing Chain and Chain Tensioner
Removal and Installation”.

4) Apply engine oil to sliding surface of each camshaft
and camshaft journal then install them as shown in
figure.
5) Install camshaft housing pins (1) as shown in figure.
I2RH0B140075-01
I5RW0C140024-01
[A]: For engine with VVT “a”: Approx. 30°
[B]: For engine without VVT “b”: Approx. 60°
12
3
4
5
“a”
12
44
5
“a”“b”
[A]
[B]
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Downloaded from www.Manualslib.com manuals search engine 1D-36 Engine Mechanical:
Camshaft, Tappet and Shim InspectionS6RW0D1406024
Intake Cam Timing Sprocket Assembly (For engine
with VVT)
Fit intake cam timing sprocket assembly to camshaft (2)
and hold hexagonal section of camshaft by using
spanner or the like.
Check if sprocket (1) is not turned by hand.
If moved, replace intake cam timing sprocket assembly.
Cam Wear
Using a micrometer, measure cam height “a”. If
measured height underruns its limit, replace camshaft.
Cam height “a”
[For engine with VVT]
[For engine without VVT]Camshaft Runout
Set camshaft between two “V” blocks, and measure its
runout by using a dial gauge.
If measured runout exceeds limit, replace camshaft.
Camshaft runout limit
0.10 mm (0.0039 in.)
Camshaft Journal Wear
Check camshaft journals and camshaft housings for
pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder
head with housing. Never replace cylinder head without
replacing housings.
Check clearance by using gauging plastic. Checking
procedure is as follows.
1) Clean housings and camshaft journals.
2) Remove all tappets with shims.
3) Install camshafts to cylinder head.
4) Place a piece of gauging plastic to full width of
journal of camshaft (parallel to camshaft).
5) Install camshaft housing. Cam height Standard Limit
Intake cam44.929 – 45.089 mm
(1.769 – 1.775 in.)44.80 mm
(1.764 in.)
Exhaust cam44.399 – 44.559 mm
(1.748 – 1.754 in.)44.28 mm
(1.743 in.)
Cam height Standard Limit
Intake cam44.919 – 45.079 mm
(1.768 – 1.775 in.)44.80 mm
(1.764 in.)
Exhaust cam44.399 – 44.559 mm
(1.748 – 1.754 in.)44.28 mm
(1.743 in.)
2 1
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I2RH0B140081-01
I2RH0B140082-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-37
6) Tighten camshaft housing bolts evenly and gradually
in numerical order (“1” through “21”) by repeating
tightening sequence two or three times until
specified torque is obtained.
NOTE
Do not rotate camshaft while gauging plastic
is installed.

Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
7) Remove housing, and using scale (2) on gauging
plastic envelop, measure gauging plastic (1) width at
its widest point.
Camshaft journal clearance
[For engine with VVT system]
[For engine without VVT system]If measured camshaft journal clearance exceeds
limit, measure journal (housing) bore and outside
diameter of camshaft journal. Replace camshaft or
cylinder head assembly whichever the difference
from specification is greater.
Camshaft journal diameter [A]
[For engine with VVT system]
[For engine without VVT system]
Camshaft journal bearing bore [B]
[For engine with VVT system]
[For engine without VVT system] Standard Limit
Intake side
No.1 housing0.020 – 0.072 mm
(0.0008 – 0.0028 in.)0.10 mm
(0.0039 in.)
Others0.045 – 0.087 mm
(0.0018 – 0.0034 in.)0.12 mm
(0.0047 in.)
Standard Limit
0.045 – 0.087 mm
(0.0018 – 0.0034 in.)0.12 mm
(0.0047 in.)
“10”“9”
“2” “1”,(a) “6”“5” “14” “13”
“20”
“17”
“19”
“18”
“21”
“12”
“11”
“4” “3” “8”“7” “16” “15”
I3RH0B140041-01
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Item Standard
Intake side No.1 housing26.940 – 26.955 mm
(1.0606 – 1.0612 in.)
Exhaust side No.1
housing26.934 – 26.955 mm
(1.0604 – 1.0612 in.)
Others22.934 – 22.955 mm
(0.9029 – 0.9037 in.)
Item Standard
Intake and Exhaust side
No.1 housing26.934 – 26.955 mm
(1.0604 – 1.0612 in.)
Others22.934 – 22.955 mm
(0.9029 – 0.9037 in.)
Item Standard
Intake side No.1 housing30.000 – 30.015 mm
(1.1811 – 1.1816 in.)
Exhaust side No.1
housing27.000 – 27.021 mm
(1.0630 – 1.0638 in.)
Others23.000 – 23.021 mm
(0.9055 – 0.9063 in.)
Item Standard
Intake and Exhaust side
No.1 housing27.000 – 27.021 mm
(1.0630 – 1.0638 in.)
Others23.000 – 23.021 mm
(0.9055 – 0.9063 in.)

Downloaded from www.Manualslib.com manuals search engine 1D-38 Engine Mechanical:
Camshaft bearing thickness (For engine with
VVT)
: 1.5120 – 1.5180 mm (0.0596 – 0.0597 in.)Wear of Tappet and Shim
Check tappet and shim for pitting, scratches, or damage.
If any malcondition is found, replace.
Measure cylinder head bore and tappet outside diameter
to determine cylinder head-to-tappet clearance. If
clearance exceeds limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 – 0.066 mm (0.0010 – 0.025 in.)
Limit: 0.15 mm (0.0059 in.)
Tappet outside diameter [A]
Standard: 30.959 – 30.975 mm (1.2189 – 1.2195 in.)
Cylinder head tappet bore [B]
Standard: 31.000 – 31.025 mm (1.2205 – 1.2215 in.)I2RH0B140084-01
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