2006 SUZUKI SX4 meter

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
I2RH0B140085-01
I2RH0B140086-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-41
5) Install cylinder head to cylinder block.
Apply engine oil to new cylinder head bolts and
tighten them gradually as follows.
a) Tighten cylinder head bolts (“1” – “10”) to 20 N⋅m
(2.0 kgf-m, 14.5 lb-ft) according to numerical
order as shown by using a 12 corner socket
wrenches.
b) In the same manner as in Step a), tighten them
to 40 N⋅m (4.0 kgf-m, 29.0 lb-ft).
c) Turn all bolts 60° according to numerical order in
figure.
d) Repeat Step c).
e) Tighten cylinder head bolt (M8) (1) to specified
torque.
NOTE
Be sure to tighten M8 bolt (1) after securing
the other bolts.

Tightening torque
Cylinder head bolt for M8 (a): Tighten 25 N⋅m
(2.5 kgf-m, 18.0 lb-ft) by the specified
procedure
Cylinder head bolt for M10 (b): 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
NOTE
• If cylinder head bolts (M10) are reused,
check thread diameters of cylinder head
bolt (1) for deformation according to the
follows and replace them with new ones if
thread diameter difference exceeds limit.
• Measure each thread diameter of cylinder
head bolt (1) at “A” on 83.5 mm (2.81 in.)
from seat side of flange bolt and “B” on
115 mm (4.53 in.) from seat side of flange
bolt by using a micrometer (2).
Then calculate difference in diameters (“A”
– “B”). If it exceeds limit, replace with new
one.

Cylinder head bolt diameter measurement
points
“a”: 83.5 mm (2.81 in.)
“b”: 115 mm (4.53 in.)
Cylinder head bolt diameter difference
(deformation)
Limit (“A” – “B”): 0.1 mm (0.004 in.)
6) Install camshafts, tappet and shim referring to
“Camshaft, Tappet and Shim Removal and
Installation”.
7) Install timing chain referring to “Timing Chain and
Chain Tensioner Removal and Installation”.
8) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
9) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
10) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
I5RW0C140030-01

“A”
“a”
“b”“B”

1
12
I2RH0B140092-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-45
Valves and Valve Guides InspectionS6RW0D1406028
Valve Guide
Valve stem-to-guide clearance
Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance.
Be sure to take reading at more than one place along the length of each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem and valve guide specification
Valve stem end deflection
If bore gauge is not available, check end deflection of
valve stem with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end
deflection.
If deflection exceeds its limit, replace valve stem and
valve guide.
Valve stem end deflection limit
In: 0.14 mm (0.005 in.)
Ex: 0.18 mm (0.007 in.)Va l v e
Visual inspection
• Remove all carbon from valves.
• Inspect each valve for wear, burn or distortion at its
face and stem end, as necessary, replace it.
• Inspect valve stem end face for pitting and wear. If
pitting or wear is found there, valve stem end may be
resurfaced, but not too much to grind off its chamber.
When it is worn out too much that its chamber is gone,
replace valve. Item Standard Limit
Valve stem diameter [A]In 5.465 – 5.480 mm (0.2150 – 0.2157 in.) —
Ex 5.440 – 5.455 mm (0.2142 – 0.2148 in.) —
Valve guide bore [B] In & Ex 5.500 – 5.512 mm (0.2165 – 0.2170 in.) —
Stem-to-guide clearanceIn 0.020 – 0.047 mm (0.0008 – 0.0018 in.) 0.070 mm (0.0028 in.)
Ex 0.045 – 0.072 mm (0.0017 – 0.0028 in.) 0.090 mm (0.0035 in.)
I4RS0B140016-01
IYSQ01141096-01I2RH01140135-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-49
Pistons, Piston Rings, Connecting Rods and Cylinders ComponentsS6RW0D1406031
Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation
S6RW0D1406032
Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove cylinder head referring to “Valves and
Cylinder Head Removal and Installation”.
3) Mark cylinder number on all pistons, connecting rods
and connecting rod caps using silver pencil or quick
drying paint.
4) Remove rod bearing caps.
5) Install guide hose (1) over threads of rod bolts.
This prevents damage to crank pin and rod bolt
threads when removing connecting rod.6) Decarbonize top of cylinder bore before removing
piston from cylinder.
7) Push piston and connecting rod assembly out
through the top of cylinder bore.
1. Top ring 8. Piston pin
2. 2nd ring 9. Piston pin circlip
3. Oil ring 10. Bearing cap nut
4. Piston : Tighten 15 N⋅m (1.5 kgf-m, 11.0 lb-ft), 45° and 45° by the specified procedure.
5. Connecting rod
: See “A”: Apply engine oil to sliding surface of each part.
6. Connecting rod bearing cap
: See “B”: Do not reuse.
7. Connecting rod bearing
: See “C”
“A”: Apply engine oil to sliding surface except inner surface of big end, and rod bolts. Make sure rod bolt diameter when reuse it due to plastic deformation
tightening. Refer to “Piston Pins and Connecting Rods Inspection”.
“B”: Point arrow mark on cap to crankshaft pulley side.
“C”: Do not apply oil between connecting rod and bearing or between bearing cap and bearing.
I5RW0C140045-01
I2RH0B140109-01

Downloaded from www.Manualslib.com manuals search engine 1D-52 Engine Mechanical:
Cylinders, Pistons and Piston Rings InspectionS6RW0D1406034
Cylinder
Visual inspection
Inspect cylinder walls for scratches, roughness or ridges
which indicate excessive wear. If cylinder bore is very
rough or deeply scratched, or ridged, rebore cylinder and
use over size piston.
Cylinder bore diameter, taper and out-of-round
Using a cylinder gauge (1), measure cylinder bore in
thrust and axial directions at two positions (“a” and “b”)
as shown in figure.
If any of the following conditions is noted, rebore
cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions
exceeds taper limit.
3) Difference between thrust and axial measurements
exceeds out-of-round limit.
Cylinder bore diameter
Standard: 78.000 – 78.014 mm (3.0709 – 3.0714
in.)
Limit: 78.050 mm (3.073 in.)
Cylinder taper and out-of-round
Limit: 0.10 mm (0.004 in.)
NOTE
If any one of four cylinders has to be rebored,
rebore all four to the same next oversize.
This is necessary for the sake of uniformity
and balance.

Piston
Visual inspection
Inspect piston for faults, cracks or other damages.
Damaged or faulty piston should be replaced.
Piston diameter
As indicated in figure, piston diameter should be
measured at a position 19.5 mm (0.77 in.) (“a”) from
piston skirt end in the direction perpendicular to piston
pin.
Piston diameter specification
Standard size (used piston): 77.953 – 77.968 mm
(3.0690 – 3.0696 in.)
Standard size (new piston with coating): 77.963 –
77.990 mm (3.0694 – 3.0704 in.)
Oversize (0.50 mm (0.0196 in.)) (used piston): 78.453
– 78.468 mm (3.0887 – 3.0893 in.)
Oversize (0.50 mm (0.0196 in)) (new piston with
coating): 78.463 – 78.490 mm (3.0891 – 3.0901 in.)
“a”: 50 mm (1.96 in.)
“b”: 100 mm (3.94 in.)
I2RH0B140117-01
I2RH01140157-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-53
Piston clearance
Measure cylinder bore diameter and piston diameter to
find their difference which is piston clearance. Piston
clearance should be within specification as follows. If it is
out of specification, rebore cylinder and use oversize
piston.
NOTE
Cylinder bore diameters used here are
measured in thrust direction at two positions.

Piston clearance
Standard (used piston): 0.032 – 0.061 mm (0.0013 –
0.0024 in.)
Standard (new piston with coating): 0.010 – 0.051
mm (0.0004 – 0.0020 in.)
Limit: 0.161 mm (0.0065 in.)
Ring groove clearance
Before checking, piston grooves must be clean, dry and
free of carbon deposits.
Fit new piston ring (1) into piston groove, and measure
clearance between ring and ring land by using thickness
gauge (2). If clearance is out of specification, replace
piston.
Ring groove clearance
Piston Ring
Piston ring end gap
To measure end gap, insert piston ring (2) into cylinder
bore and then measure the gap by using thickness
gauge (1).
If measured gap exceeds limit, replace ring.
NOTE
Decarbonize and clean top of cylinder bore
before inserting piston ring.

Piston ring end gap
“a”: 19.5 mm (0.77 in.)
Standard Limit
To p r i n g0.03 – 0.07 mm
(0.0012 – 0.0028 in.)0.12 mm (0.0047 in.)
2nd ring0.02 – 0.06 mm
(0.0008 – 0.0024 in.)0.10 mm (0.0039 in.)
Oil ring0.03 – 0.17 mm
(0.0012 – 0.0067 in.)—
I4RS0A140022-01
Item Standard Limit
To p r i n g0.20 – 0.35 mm
(0.0079 – 0.0138 in.)0.7 mm (0.0276 in.)
2nd ring0.35 – 0.50 mm
(0.0138 – 0.0197 in.)1.0 mm (0.0394 in.)
Oil ring0.20 – 0.70 mm
(0.0079 – 0.0276 in.)1.2 mm (0.0472 in.)
“a”: 120 mm (4.72 in.)
I2RH01140159-01
I2RH01140161-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-55
Connecting rod bolt deformation (Plastic
deformation tightening bolt)
Measure each thread diameter of connecting rod bolt (2)
at “A” on 32 mm (1.25 in.) from bolt mounting surface
and “B” on 40 mm (1.57 in.) from bolt mounting surface
by using a micrometer (3).
Calculate difference in diameters (“A” – “B”). If it is
exceeds limit, replace connected rod (1).
Connecting rod bolt measurement points
“a”: 32 mm (1.25 in.)
“b”: 40 mm (1.57 in.)
Connecting rod bolt diameter difference
Limit (“A” – “B”): 0.1 mm (0.004 in.)
Crank Pin and Connecting Rod Bearings
Inspection
S6RW0D1406036
Crank Pin Diameter
Inspect crank pin for uneven wear or damage. Measure
crank pin for out-of-round or taper with a micrometer. If
crank pin is damaged or out-of round or taper is out of
limit, replace crankshaft or regrind crank pin to undersize
and use undersize bearing.
Crank pin diameter
Out-of-round
A – B
Ta p e r
a – b
Crank pin taper and out-of-round
Limit: 0.01 mm (0.0004 in.)
I2RH0B140119-01
Connecting rod bearing
sizeCrank pin diameter
Standard41.982 – 42.000 mm
(1.6528 – 1.6535 in.)
0.25 mm (0.0098 in.)
undersize41.732 – 41.750 mm
(1.6430 – 1.6437 in.)
I2RH0B140120-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-57
Selection of Connecting Rod Bearings
NOTE
• If bearing is in malcondition, or bearing
clearance is out of specification, select a
new standard bearing according to the
following procedure and install it.
• When replacing crankshaft or connecting
rod and its bearing due to any reason,
select new standard bearings to be
installed by referring to numbers stamped
on connecting rod and its cap and/or
alphabets stamped on crank web of No.3
cylinder.

1) Check stamped numbers on connecting rod and its
cap as shown.
Three kinds of numbers (“1”, “2” and “3”) represent
the following connecting rod big end inside
diameters.
For example, stamped number “1” indicates that
corresponding connecting rod big end inside
diameter is 45.000 – 45.006 mm (1.7717 – 1.7718
in.).
Connecting rod big end inside diameter
2) Next, check crankshaft pin diameter. On crank web
No.3, four alphabets are stamped as shown in figure.
Three kinds of alphabet (“A”, “B” and “C”) represent
the following crankshaft pin diameter respectively.
For example, stamped “A” indicates that
corresponding crankshaft pin diameter is 41.994 –
42.000 mm (1.6533 – 1.6534 in.).
Crankshaft pin outer diameter
Stamped
numbersConnecting rod big end inside diameter
1 45.0000 – 45.0060 mm (1.7717 – 1.7718 in.)
2 45.0061 – 45.0120 mm (1.7719 – 1.7721 in.)
3 45.0121 – 45.0180 mm (1.7722 – 1.7723 in.)
[A]: Connecting rod big end inside diameter number
[B]: Weight indication mark
I3RH0A140017-01
Stamped
alphabetCrankshaft pin diameter
A 41.9940 – 42.0000 mm (1.6533 – 1.6534 in.)
B 41.9880 – 41.9939 mm (1.6531 – 1.6532 in.)
C 41.9820 – 41.9879 mm (1.6529 – 1.6530 in.)
[A]: Crankshaft pin diameter for No.1 cylinder
[B]: Crankshaft pin diameter for No.2 cylinder
[C]: Crankshaft pin diameter for No.3 cylinder
[D]: Crankshaft pin diameter for No.4 cylinder
I3RH0A140018-01