2006 SUZUKI SX4 check oil

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.

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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-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.)
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Downloaded from www.Manualslib.com manuals search engine 1D-56 Engine Mechanical:
Connecting Rod Bearing General Information
Service connecting rod bearings are available in
standard size and 0.25 mm (0.0098 in.) undersize
bearing, and standard size bearing has 5 kinds of
bearings differing in tolerance.
For identification of undersize bearing, it is painted red at
the position as indicated in figure, undersize bearing
thickness is 1.605 – 1.615 mm (0.0632 – 0.0635 in.) at
the center of it.
Connecting Rod Bearing Visual Inspection
Inspect bearing shells for signs of fusion, pitting, burn or
flaking and observe contact pattern. Bearing shells
found in defective condition must be replaced.
Connecting Rod Bearing Clearance
1) Before checking bearing clearance, clean bearing
and crank pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gauging plastic (1) to full width of
crank pin as contacted by bearing (parallel to
crankshaft), avoiding oil hole.4) Install rod bearing cap (1) to connecting rod.
When installing cap, be sure to point arrow mark (2)
on cap to crankshaft pulley side, as shown in figure.
After applying engine oil to rod bolts, 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.
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
5) Remove cap and using a scale (1) on gauging
plastic envelope (2), measure gauging plastic (2)
width at the widest point (clearance).
If clearance exceed its limit, use a new standard size
bearing referring to “Selection of Connecting Rod
Bearings: ”.
After selecting new bearing, recheck clearance.
Connecting rod bearing clearance
Standard: 0.029 – 0.047 mm (0.0011 – 0.0018 in.)
Limit: 0.065 mm (0.0026 in.)
6) If clearance can not be brought to its limit even by
using a new standard size bearing, use next thicker
bearing and recheck clearance or regrind crank pin
to undersize and use 0.25 mm undersize bearing.
1. Red paint
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Downloaded from www.Manualslib.com manuals search engine 1D-62 Engine Mechanical:
6) Install bearing cap to cylinder block, making sure to
point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts ((1) – (10)) and main bearing cap No.2 bolts
((11) – (20)), tighten them gradually as follows.
a) Tighten bolts ((1) – (10)) to 30 N⋅m (3.0 kgf-m,
22.0 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 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 as
shown.
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
CAUTION!
After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 N⋅m (1.2 kgf-m, 9.0 lb-ft)
torque or below.

7) If necessary, press-fit rear oil seal (1) to oil seal
housing (2) by using special tool as shown in figure.
Special tool
(A): 09911–97821
Crank rear oil seal installing position
(dimension)
“a”: 2 mm (0.08 in.)
8) Apply sealant to mating surface of rear oil seal
housing (1).
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
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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.)
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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 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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