2006 SUZUKI SX4 cylinder

Downloaded from www.Manualslib.com manuals search engine 1D-22 Engine Mechanical:
Timing Chain Cover ComponentsS6RW0D1406014
I5RW0C140041-01
[A]: For engine with VVT 8. Timing chain cover mounting
nut17. Oil control valve
[B]: For engine without VVT 9. Oil gallery pipe No.1 18. Oil control valve mounting nut
1. Crankshaft pulley bolt 10. Copper washer 19. Cap
2. Crankshaft pulley 11. Oil gallery pipe No.1 bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
3. Oil seal
: Apply engine oil to oil seal lip.12. Oil gallery pipe No.2 : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
4. Timing chain cover
: Apply sealant 99000-31140 to the mating
surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating
surface of timing chain cover referring to the
figure of Step 4) of “Installation” under “Timing
Chain Cover Removal and Installation”.13. Oil gallery pipe No.2 bolt : 30 N⋅m (3.0 kgf-m, 22.0 lb-ft)
5. Pin 14. Oil gallery pipe No.3 : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft)
6. Cap bolt 15. Oil gallery pipe No.3 bolt : Do not reuse.
7. Timing chain cover mounting bolts 16. O-ring
: Apply engine oil.

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-23
Timing Chain Cover Removal and InstallationS6RW0D1406015
CAUTION!
• Keep working table, tools and hands clean
while overhauling.
• Use special care to handle aluminum parts
so as not to damage them.
• Do not expose removed parts to dust.
Keep them always clean.

Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove water pump / generator drive belt referring
to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1F”.
3) Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool with it
as shown in figure.
Special tool
(A): 09917–68221
4) Remove crankshaft pulley (1).
If it is hard to remove, use special tools as shown in
figure.
Special tool
(A): 09944–36011
(B): 09926–580105) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
6) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
7) Remove water pump pulley.
8) Remove A/C bracket from cylinder block.
9) For engine with VVT, remove oil gallery pipes No.2
(1) and No.3 (2).
10) Remove cap (1) from timing chain cover (2).
11) Remove timing chain cover (2).
12) For engine with VVT, remove oil control valve from
timing chain cover referring to “Oil Control Valve
Removal and Installation (For Engine with VVT)”.
I2RH0B140051-01
I2RH0B140052-01
1
2
I3RH0B140021-01
1
2
I5RW0C140042-01

Downloaded from www.Manualslib.com manuals search engine 1D-24 Engine Mechanical:
Installation
1) Clean sealing surface on timing chain cover, cylinder
block and cylinder head.
Remove oil, old sealant and dust from sealing
surface.
2) Install oil seal (1) to timing chain cover, if removed.
NOTE
When installing new oil seal, press fit to
timing chain cover (2) by using special tool
(bearing installer) as shown in figure.

Drive in dimension
“a”: 1.0 mm (0.04 in.)
Special tool
(A): 09913–75810
3) For engine with VVT, install oil control valve to timing
chain cover referring to “Oil Control Valve Removal
and Installation (For Engine with VVT)”.
4) Apply sealant “A” to mating surface of cylinder and
cylinder head and “B” to mating surface of timing
chain cover as shown in figure.
“A”: Water tight sealant 99000–31140 (SUZUKI
Bond No.1207B)
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for timing chain cover
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)5) Apply engine oil to oil seal lip, then install timing
chain cover (1). Tighten bolts and nut to specified
torque.
NOTE
Before installing timing chain cover, check
that pin is securely fitted.

Tightening torque
Timing chain cover bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Timing chain cover nut (b): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
6) Apply engine oil to new O-rings (2) and install them
to cap (3).
7) Install cap (3) to timing chain cover (1).
Tighten bolts to specified torque.
Tightening torque
Cap bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
I2RH0B140058-01
I5RW0C140043-01
(a) (b) (c)
1 2 3
I4RS0B140011-02

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
I3RH0B140027-01
I2RH0B140056-01
1
I3RH0B140028-01

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
I5RW0C140018-01

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”.
I2RH0B140065-01
I2RH0B140066-01
[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]
I4RS0B140015-01
I3RM0A140033-01