2006 SUZUKI SX4 wheel

Downloaded from www.Manualslib.com manuals search engine 1D-50 Engine Mechanical:
Installation
1) Apply engine oil to pistons, rings, cylinder walls,
connecting rod bearings and crank pins.
NOTE
Do not apply oil between connecting rod and
bearing or between bearing cap and bearing.

2) Install guide hoses (1) over connecting rod bolts.
These guide hoses protect crank pin and threads of
rod bolt from damage during installation of
connecting rod and piston assembly.
3) When installing piston and connecting rod assembly
into cylinder bore, point front mark (1) on piston head
to crankshaft pulley side.4) Install piston and connecting rod assembly into
cylinder bore. Use special tool (Piston ring
compressor) to compress rings. Guide connecting
rod into place on crankshaft.
Using a hammer handle, tap piston head to install
piston into bore. Hold ring compressor firmly against
cylinder block until all piston rings have entered
cylinder bore.
Special tool
(A): 09916–77310
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley
side.
After applying engine oil to rod bolts and tighten cap
nuts (3) gradually as follows.
a) Tighten all cap nuts to 15 N⋅m (1.5 kgf-m, 11.0 lb-
ft).
b) Retighten them to 45°.
c) Repeat Step b) once again.
NOTE
Before installing bearing cap, make sure that
checking for connecting rod bolt
deformation. Refer to “Piston Pins and
Connecting Rods Inspection”.

Tightening torque
Connecting rod bearing cap nut (a): Tighten
15 N⋅m (1.5 kgf-m, 11.0 lb-ft), 45° and 45° by
the specified procedure
6) Install cylinder head referring to “Valves and Cylinder
Head Removal and Installation”.A: Crankshaft pulley side B: Flywheel side
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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.
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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
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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 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 1D-74 Engine Mechanical:
09916–34550 09916–37320
Reamer handle Valve guide outer reamer
(10.5 mm)
))
09916–44910 09916–56011
Valve guide installer &
removerValve guide installer
attachment (protrusion: 11.5
mm)
))
09916–58210 09916–67020
Valve guide installer handle Tappet holder (Overseas)
) / )) / )
09916–67021 09916–77310
Tappet holder Piston ring compressor (50-
125 mm)
) / ))
09916–84511 09917–68221
Forceps Camshaft pulley holder
) / )) / )
09917–98221 09924–17810
Valve guide stem
attachmentFlywheel holder (drive plate
stopper)
)) / )
09926–58010 09944–36011
Bearing remover attachment Steering wheel remover
))

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)
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