2006 SUZUKI SX4 service

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-65
Main Bearings InspectionS6RW0D1406040
General Information
• Service main bearings are available in standard size
and 0.25 mm (0.0098 in.) undersize, and each of them
has 5 kinds of bearings differing in tolerance.
• Upper half of bearing (1) has oil groove (2) as shown
in figure.
Install this half with oil groove to cylinder block.
• Lower half of bearing does not have an oil groove.
Visual Inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and
lower halves. Never replace either half without replacing
the other half.
Main Bearing Clearance
NOTE
Do not rotate crankshaft while gauging
plastic is installed.

Check clearance by using gauging plastic according to
the following procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) the full width of
bearing (parallel to crankshaft) on journal, avoiding
oil hole.4) Tighten main bearing cap No.1 bolts (1) – (10) and
main bearing cap No.2 bolts (11) – (20) gradually as
follows.
a) Tighten bolts (1) – (10) to 30 N⋅m (3.0 kgf-m,
22.0 lb-ft) according to numerical order in figure.
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 in figure.
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
5) Remove bearing caps and using scale (1) on
gauging plastic envelop (2), measure gauging plastic
width at its widest point. If clearance exceeds its
limit, replace bearing. Always replace both upper
and lower inserts as a unit.
A new standard bearing may produce proper
clearance. If not, it will be necessary to regrind
crankshaft journal for use of 0.25 mm undersize
bearing.
After selecting new bearing, recheck clearance.
Main bearing clearance
Standard: 0.021 – 0.041 mm (0.0008 – 0.0016 in.)
Limit: 0.054 mm (0.0021 in.)
I2RH0B140139-01
I2RH0B140140-01
I2RH0B140137-01
I2RH0B140141-01

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Special Tools and Equipment
Recommended Service MaterialS6RW0D1408001
NOTE
Required service material is also described in the following.
“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”

Special ToolS6RW0D1408002
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140)
SUZUKI Bond No.1207F P/No.: 99000–31250) / ) / )
09911–97720 09911–97821
Oil seal installer Oil seal installer
))
09913–75810 09915–64512
Bearing installer Compression gauge
))
09915–64530 09915–67010
Compression gauge hose Compression gauge
attachment (C)
))
09915–67311 09916–14510
Vacuum gauge Valve lifter
)) / )
09916–14521 09916–34542
Valve spring compressor
attachmentReamer handle
) / )) / )

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS6RW0D1504001
WARNING!
To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality
If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks
If leak is found, repair it.

1) Disconnect oil pressure switch coupler (1).
2) Remove oil pressure switch (2) from cylinder block.3) Install special tools (oil pressure gauge) to vacated
threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
4) Start engine and warm engine up to normal
operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral”, set parking brake and block drive
wheels.

5) After warming up, raise engine speed to 4,000 r/min.
and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kgf/cm2, 39.8 psi) at 4,000
r/min. (rpm)
6) After checking oil pressure, stop engine and remove
oil pressure gauge and attachment.
7) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
2. Low level mark (hole)
I2RH0B150002-01
I2RH0B150003-01
I2RH0B150004-01
I2RH0B150005-01

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Specifications
Tightening Torque SpecificationsS6RW0D1507001
NOTE
The specified tightening torque is also described in the following.
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D1508001
NOTE
Required service material is also described in the following.
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Special ToolS6RW0D1508002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Oil pressure switch 13 1.3 9.5)
Oil pump strainer bolt 11 1.1 8.0)
Oil pump strainer bracket bolt 11 1.1 8.0)
Oil pan bolt (M6) 11 1.1 8.0)
Oil pan bolt (M10) 55 5.5 40.0)
Oil pan nut 11 1.1 8.0)
Oil pan drain plug 35 3.5 25.5)
Transaxle stiffener bolt 55 5.5 40.0)
Clutch housing lower plate bolt 11 1.1 8.0)
Oil pump rotor plate bolt 11 1.1 8.0)
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
09915–77310 09915–78211
Oil pressure gauge (0-10kg/
cm2)Oil pressure gauge
attachment
))

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Water Pump InspectionS6RW0D1606017
CAUTION!
Do not disassemble water pump.
If any repair is required on pump, replace it
as assembly.

Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
Specifications
Tightening Torque SpecificationsS6RW0D1607001
NOTE
The specified tightening torque is also described in the following.
“Cooling System Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D1608001
I2RH0B160019-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Radiator support bracket bolt 33 3.3 24.0)
Generator bracket bolt 25 2.5 18.0)
Generator pivot bolt 50 5.0 36.0)
Generator adjusting bolt Tighten 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft) by the
specified procedure.)
Water pump bolt and nut 25 2.5 18.0)
Material SUZUKI recommended product or Specification Note
Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250)

Downloaded from www.Manualslib.com manuals search engine 1G-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS6RW0D1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot
heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the
risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each
hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing injector or fuel feed pipe, lubricate its O-ring with gasoline.
• When servicing the fuel tank, it should be treated with respect, with no contact with sharp edges or
hot surfaces. In addition, the fuel tank should not be dropped since fuel tank, fuel pump and other
components can be damaged by the impact. If dropped, all components should be replaced because
there is a risk of damage.
• The fuel tank is made of resin.
Be sure not to allow solvent (chemical article such as grease and sealant) to attach to the fuel tank
as some chemical reaction may occur, causing the fuel tank to be swollen, hardened or distorted
leakage and resulting in fuel leakage from the fuel tank.

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
Schematic and Routing Diagram
Fuel Delivery System DiagramS6RW0D1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS6RW0D1704001
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed
hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
73 6
1 4
5
8
9
2
I7RW01170002-02
1. Fuel tank 4. Delivery pipe 7. Fuel filter
2. Fuel pump assembly 5. Fuel injector 8. Fuel level sensor (gauge)
3. Fuel pressure regulator 6. Fuel feed line 9. Fuel pump
(C) (B)
(A)
1I5RW0A170002-02

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-6
Fuel Hose Disconnecting and ReconnectingS6RW0D1706002
WARNING!
Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in
order to reduce the risk of fire and personal injury.

For Connection Other Than Quick Joint
• Clamp around fuel tank
NOTE
Be sure to install hose to spool of pipe surely.

9. Fuel tank bolt 19. Grommet
10. Fuel tank belt 20. O-ring
I7RW01170005-01
[A]: Connection A “b”: 30 mm (1.18 in.) 1. Pipe
[B]: Connection B “c”: 38 mm (1.50 in.) 2. Hose
[C]: Connection C “d”: 5 – 12 mm (0.20 – 0.48 in.) 3. Clamp
[D]: Connection D “e”: 7 – 14 mm (0.28 – 0.55 in.) : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft)
“a”: 3 – 7 mm (0.12 – 0.28 in.) “f”: 2 mm (0.08 in.)