2006 SUZUKI SX4 Exhaus

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]
I4RS0B140015-01
I3RM0A140033-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-35
6) Check position of camshaft housings.
Embossed marks are provided on each camshaft
housing, indicating position and direction for
installation. Install housings as indicated by these
marks.
7) After applying engine oil to housing bolts, tighten
them temporarily first. Tighten bolts evenly and
gradually in numerical order (“1” through “21”) by
repeating tightening sequence two or three times
until specified torque is obtained.
Tightening torque
Camshaft housing bolt (a): Tighten 11 N⋅m (1.1
kgf-m, 8.0 lb-ft) by the specified procedure8) For engine with VVT, with hexagonal section (1) of
intake camshaft (2) held stationary with spanner or
the like, tighten bolt of intake cam timing sprocket
assembly (3) to specification.
Tightening torque
Intake cam timing sprocket bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)
9) Install timing chain with crankshaft sprocket referring
to “Timing Chain and Chain Tensioner Removal and
Installation”.
10) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
11) Check valve lashes referring to “Valve Lash
(Clearance) Inspection”.
12) Perform Steps 10) to 14) of “Installation” of “Timing
Chain Cover Removal and Installation”.
A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
I2RH0B140078-01
“10”“9”
“2” “1”,(a) “6”“5” “14” “13”
“20”
“17”
“19”
“18”
“21”
“12”
“11”
“4” “3” “8”“7” “16” “15”
I3RH0B140041-01
1
2 3
(a)
I3RH0B140042-01

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
I3RH0B140043-01
I2RH0B140080-01
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
I2RH0B140083-01
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 Engine Mechanical: 1D-39
Valves and Cylinder Head ComponentsS6RW0D1406025
I4RS0A140015-01
1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8)
: Be sure to tighten cylinder head bolt (M8) after
securing the other cylinder head bolt (M10).
2. Valve spring retainer 8. Valve guide : 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.
3. Valve spring 9. Cylinder head bolt (M10)
: Check cylinder head bolt (M10), plastic deformation
tightening bolt, for deformation referring to “Valves and
Cylinder Head Removal and Installation”, if it is reused.: Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure
4. Valve stem seal 10. Cylinder head : Do not reuse.
5. Valve spring seat 11. Cylinder head gasket
: “TOP” mark provided on gasket comes to crankshaft
pulley side, facing up.: Apply engine oil to sliding surface of each part.
6. Intake valve 12. Knock pin

Downloaded from www.Manualslib.com manuals search engine 1D-40 Engine Mechanical:
Valves and Cylinder Head Removal and
Installation
S6RW0D1406026
Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
3) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
4) Remove timing chain cover referring to Steps 2) to
11) of “Removal” in “Timing Chain Cover Removal
and Installation”.
5) Remove timing chain referring to Steps 2) to 6) of
“Removal” in “Timing Chain and Chain Tensioner
Removal and Installation”.
6) Remove intake and exhaust camshafts referring to
Steps 3) to 8) of “Removal” in “Camshaft, Tappet and
Shim Removal and Installation”.
7) Loosen cylinder head bolts in such order as
indicated in figure by using a 12 corner socket
wrenches and remove them.
NOTE
Don’t forget to remove bolt (M8) (1) as shown
in figure.

8) Check all around cylinder head for any other parts
required to be removed or disconnected and remove
or disconnect whatever necessary.
9) Remove exhaust manifold, if necessary referring to
“Exhaust Manifold Removal and Installation in
Section 1K”.
10) Remove cylinder head with intake manifold and
exhaust manifold. Use lifting device, if necessary.
Installation
1) Clean mating surface of cylinder head and cylinder
block. Remove oil, old gasket and dust from mating
surface.
2) Make sure that oil jet (venturi plug) (1) is not
clogged. If it is not installed, install it as specified
torque.
Tightening torque
Venturi plug (a): 5 N·m (0.5 kgf-m, 3.5 lb-ft)
3) Install knock pins (1) to cylinder block.
4) Install new cylinder head gasket (2) to cylinder block.
“Top” or triangle mark provided on gasket comes to
crankshaft pulley side, facing up (toward cylinder
head side).
I2RH0B140088-01
I2RH0B140089-01
I5RW0C140025-01

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.
I2RH0B140093-01
I2RH0B140094-01
I2RH0B140095-01

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.

I2RH0B140096-01
I2RH0B140097-01
I2RH0B140096-01
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