XL-7 2006

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2006 Suzuki XL-7

2006 ENGINE Engine Mechanical - XL-7

2006 ENGINE

Engine Mechanical - XL-7

GENERAL DESCRIPTION
ENGINE GENERAL INFORMATION

The engine is a water-cooled, 60° V6 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead
camshaft) valve mechanism arranged for "V" type valve configuration. The double overhead camshaft is
mounted over the cylinder head; it is driven from crankshaft through timing chains, and no push rods are
provided in the valve train system.

Fig. 1: Identifying Engine


Courtesy of SUZUKI OF AMERICA CORP.

AIR CLEANER ELEMENT INTRODUCTION

This air cleaner element is of dry type. Note that it needs cleaning referring to AIR CLEANER ELEMENT
INSPECTION AND CLEANING.

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08:21:48 p. m. Page 1 © 2011 MSuzuki
2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

DIAGNOSTIC INFORMATION AND PROCEDURES


COMPRESSION CHECK

Check compression pressure on all 6 cylinders as follows:

1. Warm up engine.
2. Stop engine after warming up.
3. Remove ignition coil covers and disconnect ignition coil harness couplers.
4. Remove all ignition coils (1) and spark plugs (2) referring to SPARK PLUG REMOVAL AND
INSTALLATION.

Fig. 2: Identifying Ignition Coil And Spark Plug


Courtesy of SUZUKI OF AMERICA CORP.

5. Remove surge tank cover.


6. Disconnect fuel injector wire harness at connector.
7. Install special tool (Compression gauge) into spark plug hole.

Special Tool

(A): 09915-64510

(B): 09915-64530

(C): 09915-67010

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 3: Identifying Special Tools


Courtesy of SUZUKI OF AMERICA CORP.

8. Disengage clutch (to lighten starting load on engine) for M/T vehicle, and depress accelerator pedal all
the way to make throttle fully open.

Fig. 4: Depressing Accelerator Pedal


Courtesy of SUZUKI OF AMERICA CORP.

9. Crank engine with fully charged battery, and read the highest pressure on compression gauge.

NOTE: For measuring compression pressure, crank engine at least 250 rpm by
using fully charged battery.

Compression pressure

Standard: 1400 - 1600 kPa (14.0 - 16.0 kg/cm2 , 199.0 - 227.5 psi)

Limit: 1300 kPa (13.0 kg/cm2 , 185.0 psi)

Max. difference between any two cylinders: 100 kPa (1.0 kg/cm2 , 14.2 psi)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

10. Carry out steps 7, 8 and 9 on each cylinder to obtain 6 readings.

ENGINE VACUUM CHECK

The engine vacuum that develops in the intake line is a good indicator of the condition of the engine. The
vacuum checking procedure is as follows:

1. Warm up engine to normal operating temperature and make sure that engine idle speed is within
specification.
2. Stop engine and disconnect vacuum hoses from fuel pressure regulator valve (1).
3. Connect special tools (Vacuum gauge and hose joint) and 3-way joint between vacuum hose and valve.

Special Tool

(A): 09915-67311

(B): 09918-08210

(C): 09355-35754-600 Hose, SUZUKI genuine parts

(D): 09367-04002 3-way joint, SUZUKI genuine parts

Fig. 5: Identifying Special Tools


Courtesy of SUZUKI OF AMERICA CORP.

4. Start engine and run engine at specified idle speed, and read vacuum gauge. Vacuum should be within
specification.

Vacuum specifications (sea level)

59 - 79 kPa (450 - 600 mmHg, 17.7 - 23.7 in.Hg) at specified idle speed

5. After checking, remove, all special tools.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

6. Connect vacuum hoses to fuel pressure regulator valve.

REPAIR INSTRUCTIONS
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION

Removal

1. Remove air cleaner upper case (1).

Fig. 6: Identifying Air Cleaner Upper Case


Courtesy of SUZUKI OF AMERICA CORP.

2. Remove air cleaner element.

Installation

Reference: AIR CLEANER ELEMENT INSPECTION AND CLEANING

1. Install element to air cleaner box.


2. Install air cleaner upper case.

AIR CLEANER ELEMENT INSPECTION AND CLEANING

Reference: AIR CLEANER ELEMENT REMOVAL AND INSTALLATION

Inspection

Check element for dirt. Replace if element is excessively dirty.

Cleaning

When cleaning element, blow off dust by blowing compressed air from air outlet side of element (i.e., the side
facing up when installed in air cleaner case).

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 7: Blowing Compressed Air On Air Cleaner Element


Courtesy of SUZUKI OF AMERICA CORP.

ACCELERATOR CABLE ADJUSTMENT

1. Warm up engine to normal operating temperature.


2. With throttle valve closed, check accelerator pedal play "a" which should be within the following
specification.

If measured value is out of specification, adjust accelerator cable (1) so as pedal play to be within
specification with cable adjusting nut (2). Then tighten lock nut (3).

Accelerator pedal play

"a": 2 - 5 mm (0.08 - 0.20 in.)

Fig. 8: Identifying Accelerator Cable, Cable Adjusting Nut And Lock Nut
Courtesy of SUZUKI OF AMERICA CORP.

3. With accelerator pedal depressed fully, check clearance between throttle lever (2) and lever stopper (1)
(throttle body) which should be within the following specification.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

If measured value is out of specification, adjust it to specification by changing height of pedal stopper
bolt (3).

Clearance between throttle lever and lever stopper (throttle body) (with accelerator pedal
depressed fully)

"b": 0.5 - 2.0 mm (0.02 - 0.08 in.)

Fig. 9: Identifying Throttle Lever, Lever Stopper And Pedal Stopper Bolt
Courtesy of SUZUKI OF AMERICA CORP.

THROTTLE BODY COMPONENTS

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 10: Identifying Throttle Body Components


Courtesy of SUZUKI OF AMERICA CORP.

THROTTLE BODY ON-VEHICLE INSPECTION

Check that throttle valve lever moves smoothly.

THROTTLE BODY REMOVAL AND INSTALLATION

Reference: THROTTLE BODY COMPONENTS

Reference: THROTTLE BODY ON-VEHICLE INSPECTION

Removal

1. Disconnect negative (-) cable at battery.


2. Drain engine coolant referring to COOLANT DRAINING .
3. Detach fuse/relay box.
4. Remove strut tower bar.
5. Disconnect accelerator cable (1) from throttle body.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 11: Identifying Accelerator Cable


Courtesy of SUZUKI OF AMERICA CORP.

6. Disconnect water hoses (2) from throttle body.

Fig. 12: Identifying Water Hoses


Courtesy of SUZUKI OF AMERICA CORP.

7. Remove surge tank cover.


8. Remove intake air pipe (1), surge tank pipe (2) and intake control valve (3).

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 13: Identifying Intake Air Pipe, Surge Tank Pipe And Intake Control Valve
Courtesy of SUZUKI OF AMERICA CORP.

9. Disconnect connectors of TP sensor (2) and IAC valve (3).


10. Disconnect ground terminal (5) from intake manifold (4).
11. Remove clamp bracket (1) and harness clamps from intake collector.

Fig. 14: Identifying TP Sensor, IAC Valve, Intake Manifold, Terminal And Clamp Bracket
Courtesy of SUZUKI OF AMERICA CORP.

12. Disconnect connectors of EVAP canister purge valve (1) and EGR valve (5).
13. Disconnect PCV valve hose (6), ground terminal connector (7) and breather hose (3) from cylinder head
and EVAP canister purge valve hose (2).
14. Detach EGR pipe (4) from exhaust manifold.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 15: Identifying EVAP Canister Purge Valve, EGR Valve, PCV Valve Hose, Terminal
Connector, EVAP Canister Purge Valve Hose, EGR Pipe And Breather Hose
Courtesy of SUZUKI OF AMERICA CORP.

15. Remove throttle body (3) and intake collector (2) from intake manifold (1).
16. Disconnect hoses of PCV from throttle body.
17. Remove throttle body from intake collector.

CAUTION: l TP sensor (4), or other components containing rubber must not


be placed in a solvent or cleaner bath. A chemical reaction will
cause these parts to swell, harden or get distorted.
l Don't put drills or wires into passages for cleaning. It causes
damages in passages.

Fig. 16: Identifying Throttle Body, Intake Collector, Intake


Manifold And TP Sensor
Courtesy of SUZUKI OF AMERICA CORP.

Installation

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reference: THROTTLE BODY CLEANING

1. Clean mating surfaces and install new throttle body gasket (2) to intake collector (1).

Fig. 17: Identifying Throttle Body Gasket And Intake Collector


Courtesy of SUZUKI OF AMERICA CORP.

2. Install throttle body to intake collector and tighten bolts and nuts.
3. Connect PCV hose to throttle body.
4. Install throttle body and intake collector to intake manifold with new intake collector gaskets.
5. Install EGR pipe with new gaskets.
6. Connect breather hose, EVAP canister purge valve hose and PCV valve hose.
7. Connect connectors of EVAP canister purge valve and EGR valve.

Fix wire harness with clamps.

8. Install clamp bracket to intake collector.


9. Connect ground wire connector.
10. Connect connectors of TP sensor and IAC valve.
11. Install surge tank pipe and intake control valve to intake manifold with new gaskets and intake air pipe to
throttle body. Install surge tank cover.
12. Connect water hoses to throttle body.
13. Connect accelerator cable.
14. Install strut tower bar (1) and tighten strut tower bar mounting bolts (2) to specification.

Tightening torque

Strut tower bar mounting bolts a: 50 N.m (5.0 kg-m, 36.5 lb-ft)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 18: Identifying Strut Tower Bar And Strut Tower Bar Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.

15. Install fuse/relay box.


16. Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
17. Connect negative (-) cable at battery.
18. Adjust accelerator cable referring to ACCELERATOR CABLE ADJUSTMENT.

THROTTLE BODY CLEANING

Reference: THROTTLE BODY REMOVAL AND INSTALLATION

CAUTION: l Do not blow compressed air through bypass air passage with IAC
valve installed to throttle body. This will cause IAC valve to
malfunction.
l TP sensor, idle air control valve or other components containing
rubber must not be places in a solvent or cleaner bath.

A chemical reaction will cause these parts to swell, harden or get


distorted.

Clean throttle body bore and bypass air passages (1) by blowing compressed air.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 19: Identifying Bypass Air Passage


Courtesy of SUZUKI OF AMERICA CORP.

INTAKE CONTROL VALVE REMOVAL AND INSTALLATION

Refer to THROTTLE BODY REMOVAL AND INSTALLATION.

INTAKE CONTROL VALVE INSPECTION

1. Connect special tool (A) to intake control valve (1).

Special Tool

(A): 09917-47011

Fig. 20: Identifying Special Tool & Intake Control Valve


Courtesy of SUZUKI OF AMERICA CORP.

2. Apply vacuum to intake control valve (1) and verify that throttle (2) fully closes within the specified
range.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

If intake control valve (1) fails the check, replace it.

CAUTION: Do not apply above 88 kPa of negative pressure. Damage may occur
to intake control valve (1).

Valve operation pressure

1.3 - 34 kPa (9.8 - 255 mmHg)

3. Let the throttle (2) close for 15 seconds with no vacuum application and inspect throttle travel. If throttle
travel decreases, replace intake air valve (1).

THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Fig. 21: Identifying Throttle Body And Intake Manifold Components


Courtesy of SUZUKI OF AMERICA CORP.

THROTTLE BODY AND INTAKE MANIFOLD REMOVAL AND INSTALLATION

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Removal

1. Release fuel pressure in fuel feed line by referring to FUEL PRESSURE RELIEF PROCEDURE .
2. Disconnect negative (-) cable at battery.
3. Drain coolant referring to COOLANT DRAINING .
4. Detach fuse/relay box and remove strut tower bar (2).
5. Disconnect coupler from IAT sensor and MAF sensor.
6. Remove surge tank cover (1).

Fig. 22: Identifying Surge Tank Cover And Strut Tower Bar
Courtesy of SUZUKI OF AMERICA CORP.

7. Remove air cleaner upper case, MAF sensor, intake air hose, intake air pipe (1) and surge tank pipe (2) as
one component. Do not disassemble them, when removing and reinstalling.
8. Remove intake control valve (3).

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 23: Identifying Intake Air Pipe, Surge Tank Pipe And Intake Control Valve
Courtesy of SUZUKI OF AMERICA CORP.

9. Disconnect accelerator cable (1) from throttle body.


10. Disconnect water hoses (2) from throttle body.

Fig. 24: Identifying Accelerator Cable And Water Hoses


Courtesy of SUZUKI OF AMERICA CORP.

11. Disconnect injector wire (1) coupler.


12. Disconnect brake booster hose (2), fuel pressure regulator vacuum hose (4) and intake control valve hose
(3) from intake manifold.

Fig. 25: Identifying Injector Wire, Brake Booster Hose, Fuel Pressure Regulator Vacuum Hose And
Intake Control Valve Hose
Courtesy of SUZUKI OF AMERICA CORP.

13. Disconnect couplers of TP sensor (1) and IAC valve (2).


14. Disconnect earth terminal (3) from intake collector.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

15. Remove clamp bracket (4) from intake collector.

Fig. 26: Identifying TP Sensor, IAC Valve, Terminal And Clamp Bracket
Courtesy of SUZUKI OF AMERICA CORP.

16. Disconnect couplers from MAP sensor, EVAP canister purge valve (1), earth terminal (9) and EGR valve
(2).
17. Disconnect PCV hose (6) from cylinder head cover.
18. Disconnect breather hoses (8) from throttle body or cylinder head cover.
19. Disconnect EVAP canister purge valve hose (4), heater hose (5) and water hose (7).
20. Remove EGR pipe (3) and wire harness clamps.

Fig. 27: Identifying EVAP Canister Purge Valve, Terminal, EGR Valve, PCV Hose, EGR Pipe,
Breather Hoses, Water Hose And Heater Hose
Courtesy of SUZUKI OF AMERICA CORP.

21. Disconnect hoses of heater (1), EVAP canister purge (4), fuel feed (2) and fuel return (3).

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 28: Identifying Heater Hose, EVAP Canister Purge, Fuel Feed And Fuel Return
Courtesy of SUZUKI OF AMERICA CORP.

22. Remove throttle body (1) and intake collector (2) from intake manifold (3).

Fig. 29: Identifying Throttle Body, Intake Collector And Intake Manifold
Courtesy of SUZUKI OF AMERICA CORP.

23. Disconnect hoses of PCV valve and EVAP canister purge valve from intake collector.
24. Remove throttle body (1) from intake collector.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 30: Identifying Throttle Body


Courtesy of SUZUKI OF AMERICA CORP.

25. Remove IAC valve from throttle body.


26. Remove EGR valve and EVAP canister purge valve from intake collector.
27. Remove intake manifold bolts (8 pcs.) and nuts (4 pcs.).

Fig. 31: Identifying Intake Manifold Bolts And Nuts


Courtesy of SUZUKI OF AMERICA CORP.

28. Remove intake manifold.

Installation

1. Install new intake manifold gaskets (1) to cylinder heads.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 32: Identifying Intake Manifold Gaskets


Courtesy of SUZUKI OF AMERICA CORP.

2. Install intake manifold (1), and tighten bolts (2) and nuts (3).

Fig. 33: Identifying Intake Manifold, Bolts And Nuts


Courtesy of SUZUKI OF AMERICA CORP.

3. Install throttle body (2) to intake collector (1) with new throttle body gasket.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 34: Identifying Throttle Body And Intake Collector


Courtesy of SUZUKI OF AMERICA CORP.

4. Install IAC valve, EGR valve (1), EVAP canister purge valve (2), MAP sensor and each hoses to intake
collector and throttle body if removed.

NOTE: Use new gasket when installing IAC valve and EGR valve.

Fig. 35: Identifying EGR Valve, EVAP Canister Purge Valve & EVAP Canister Purge Valve Hose
Courtesy of SUZUKI OF AMERICA CORP.

5. Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets.
6. Connect hoses of heater (1), EVAP canister (4), fuel feed (2) and fuel return (3).

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 36: Identifying Heater Hose, EVAP Canister Hose, Fuel Feed Hose And Fuel Return Hose
Courtesy of SUZUKI OF AMERICA CORP.

7. Install EGR pipe (3) with new gaskets.


8. Connect hoses of EVAP canister purge valve (4) and heater (5).
9. Connect hoses of PCV (6), breather (8) and water (7).
10. Connect couplers of manifold absolute pressure (MAP) sensor, EVAP canister purge valve (1), EGR
valve (2) and earth terminal (9).

Fix wire harness with clamps.

Fig. 37: Identifying EGR Pipe, EVAP Canister Purge Valve Hose, Heater Hose, PCV Hose,
Breather Hose, Water Hose, EVAP Canister Purge Valve, EGR Valve And Earth Terminal
Courtesy of SUZUKI OF AMERICA CORP.

11. Install clamp bracket (4) to intake collector.


12. Connect earth terminal (3) to intake collector.
13. Connect couplers of TP sensor (1) and IAC valve (2).

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 38: Identifying Clamp Bracket, Earth Terminal, TP Sensor Coupler And IAC Valve Coupler
Courtesy of SUZUKI OF AMERICA CORP.

14. Connect brake booster hose (2), fuel pressure regulator vacuum hose (4) and intake control valve hose (3)
to intake manifold.
15. Connect injector wire (1) coupler.

Fig. 39: Identifying Brake Booster Hose, Fuel Pressure Regulator Vacuum Hose, Intake Control
Valve Hose & Injector Wire
Courtesy of SUZUKI OF AMERICA CORP.

16. Connect water hoses (2) to throttle body.


17. Connect accelerator cable (1) to throttle body.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 40: Identifying Water Hoses And Accelerator Cable


Courtesy of SUZUKI OF AMERICA CORP.

18. Install surge tank pipe (2) and intake control valve (3) to intake manifold with new gaskets and intake air
pipe (1) to throttle body.

Fig. 41: Identifying Surge Tank Pipe, Intake Control Valve And Intake Air Pipe
Courtesy of SUZUKI OF AMERICA CORP.

19. Install surge tank cover (1).

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 42: Identifying Surge Tank Cover


Courtesy of SUZUKI OF AMERICA CORP.

20. Install air cleaner upper case.


21. Connect coupler to intake air temp. sensor and MAF sensor.
22. Install strut tower bar (1) and tighten strut tower bar mounting bolts (2) to specification.

Tightening torque

Strut tower bar mounting bolts a: 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig. 43: Identifying Strut Tower Bar And Strut Tower Bar Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.

23. Install fuse/relay box.


24. Check to ensure that all removed parts are back in place.

Reinstall any necessary parts which have not been reinstalled.

25. Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
26. Connect negative cable (-) at battery.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

27. Upon completion of installation, verify that there is no fuel leakage at each connection according to
FUEL LEAKAGE CHECK PROCEDURE .

CYLINDER HEAD COVERS REMOVAL AND INSTALLATION

Removal

1. Remove throttle body and intake manifold referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION.
2. Remove ignition coil covers.
3. Disconnect ignition coil couplers and remove ignition coils referring to IGNITION COIL ASSEMBLY
(IGNITER AND IGNITION COIL) REMOVAL AND INSTALLATION .
4. Remove cylinder head covers (1).

Fig. 44: Identifying Cylinder Head Cover, Nut, Seal Washer And Cylinder Head Cover Gasket
Courtesy of SUZUKI OF AMERICA CORP.

Installation

1. Clean sealing surfaces on cylinder heads and covers.


2. Remove oil, old sealant, and dust from sealing surfaces. After cleaning, apply sealant "A" to cylinder
heads sealing surface area as shown in figure.

"A": Water tight sealant 99000-31250 SUZUKI Bond No.1207F

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 45: Identifying Cylinder Heads Sealant Application Area


Courtesy of SUZUKI OF AMERICA CORP.

3. Install new cylinder head cover gaskets (4) to head covers (1).
4. Install cylinder head covers (1) to cylinder heads.
5. Using new seal washers (3), tighten nuts (2) to specified torque.

Tightening torque

Cylinder head cover nut a: 10.5 N.m (1.1 kg-m, 7.5 lb-ft)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 46: Identifying Cylinder Head Cover, Seal Washer, Nut And Cylinder Head Cover Gasket
Courtesy of SUZUKI OF AMERICA CORP.

6. Install ignition coils and connect ignition coil couplers referring to IGNITION COIL ASSEMBLY
(IGNITER AND IGNITION COIL) REMOVAL AND INSTALLATION .
7. Install ignition coil covers.
8. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..

TIMING CHAIN COVER COMPONENTS

Fig. 47: Identifying Timing Chain Cover Components With Torque Specifications
Courtesy of SUZUKI OF AMERICA CORP.

TIMING CHAIN COVER REMOVAL AND INSTALLATION

Reference: TIMING CHAIN COVER COMPONENTS

Removal

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

1. Disconnect negative (-) cable at battery.


2. Drain engine oil.
3. Drain coolant referring to COOLANT DRAINING .
4. Remove throttle body and intake manifold referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
5. Remove cylinder head covers. Refer to CYLINDER HEAD COVERS REMOVAL AND
INSTALLATION.
6. Remove P/S pump (A/C compressor) drive belt. Refer to P/S PUMP DRIVE BELT INSPECTION
AND ADJUSTMENT.
7. Remove cooling fan, fan clutch and water pump pulley. Refer to COOLING FAN AND FAN CLUTCH
REMOVAL AND INSTALLATION.
8. Remove radiator. Refer to RADIATOR REMOVAL AND INSTALLATION.
9. Remove thermostat cap. Refer to THERMOSTAT REMOVAL AND INSTALLATION.
10. Remove P/S pump and P/S pump bracket. Refer to P/S PUMP REMOVAL AND INSTALLATION.
11. Raise vehicle.
12. Remove oil pan. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
13. Remove crankshaft pulley bolt (1). To lock crankshaft pulley, use special tool (camshaft pulley holder) as
shown in figure.

Special Tool

(A): 09917-68221

Fig. 48: Identifying Crankshaft Pulley Bolt, Wrench And Special Tool
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Be sure to use the following bolt for fixing special tool to crankshaft

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

pulley.
Bolt size: M8, P1.25 L=45 mm
Strength: 7T

Fig. 49: Identifying Bolt Length


Courtesy of SUZUKI OF AMERICA CORP.

14. Remove crankshaft pulley (1).

If it is hard to remove, use special tools (Steering wheel remover, Bearing puller attachment) as shown in
figure.

If bolts of steering wheel remover are too long, replace them with those of suitable length.

Special Tool

(B): 09944-36011

(C): 09926-58010

Fig. 50: Identifying Crankshaft Pulley And Special Tools


Courtesy of SUZUKI OF AMERICA CORP.

15. Disconnect CKP sensor connector and remove CKP sensor if necessary.
16. Remove timing chain cover.

Installation

Reference: TIMING CHAIN COVER INSPECTION

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reverse removal sequence to install timing chain cover noting the following points.

l Clean sealing surface on timing chain cover, crankcase, cylinder block and cylinder heads. Remove oil,
old sealant, and dust from sealing surface.

Fig. 51: Identifying Timing Chain Cover


Courtesy of SUZUKI OF AMERICA CORP.

l Apply sealant "A" to timing chain cover sealing surface area as shown in figure.

"A": Water tight sealant 99000-31250 SUZUKI Bond No.1207F

Fig. 52: Identifying Timing Chain Cover Sealant Application Area


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

l Apply sealant "B" to mating surfaces of cylinder head and cylinder block as shown.

"B": Water tight sealant 99000-31140 SUZUKI Bond No.1207B

Fig. 53: Identifying Cylinder Head And Cylinder Block Sealant Application Area
Courtesy of SUZUKI OF AMERICA CORP.

l Apply engine oil to new oil seal lip and water pump O-ring. Using special tool (bearing installer), install

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

new oil seal (2) with its surface is flash with edge of timing chain cover (1).

Special Tool

(D): 09913-75510

Fig. 54: Identifying Oil Seal, Timing Chain Cover & Special Tool
Courtesy of SUZUKI OF AMERICA CORP.

l Install timing chain cover.

Tightening torque

Timing chain cover bolt: 11 N.m (1.1 kg-m, 8.0 lb-ft)

l Apply engine oil to O-ring of CKP sensor and install CKP sensor (4) to timing chain cover.

Tightening torque

CKP sensor bolt b: 6 N.m (0.6 kg-m, 4.5 lb-ft)

l Install crankshaft pulley (1).

To lock crankshaft pulley, use special tool (camshaft pulley holder) with it at shown in figure.

Special Tool

(A): 09917-68221

Tightening torque

Crankshaft pulley bolt a: 150 N.m (15 kg-m, 108.5 lb-ft)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 55: Identifying CKP Sensor, Bolt, Wrench, Crankshaft Pulley And Special Tool
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Be sure to use the following bolt for fixing special tool to crank pulley.
Bolt size: M8, P1.25 L=45 mm
Strength: 7T

Fig. 56: Identifying Bolt Length


Courtesy of SUZUKI OF AMERICA CORP.

TIMING CHAIN COVER INSPECTION

Reference: TIMING CHAIN COVER REMOVAL AND INSTALLATION

Check oil seal lip for damages or deterioration. Replace as necessary.

LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER COMPONENTS

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 57: Identifying LH (No.1) Bank 2nd Timing Chain And Chain Tensioner Components With Torque
Specifications
Courtesy of SUZUKI OF AMERICA CORP.

LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER REMOVAL

Reference: TIMING CHAIN COVER COMPONENTS

1. Disconnect negative (-) cable at battery.


2. Drain engine oil.
3. Drain coolant referring to COOLANT DRAINING .
4. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
5. Turn crankshaft to meet the following condition.
l Key (1) on crankshaft positions as shown.

l Arrow mark on idler sprocket No.2 (2) points the center of crankshaft.

l The marks on sprockets (3) match with marks on cylinder head.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 58: Identifying Key, Sprockets And Idler Sprocket No. 2


Courtesy of SUZUKI OF AMERICA CORP.

6. Remove timing chain tensioner adjuster No.3 (1).

To remove it, slacken LH bank 2nd timing chain by turning intake camshaft (2) counterclockwise a little
while pushing back pad.

Fig. 59: Identifying Timing Chain Tensioner Adjuster No. 3 And Intake Camshaft
Courtesy of SUZUKI OF AMERICA CORP.

7. Remove LH bank intake and exhaust camshaft sprocket bolts.

To remove it, fit a spanner to hexagonal part (3) at the center of camshaft to hold it stationary.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 60: Identifying LH Bank Intake And Exhaust Camshaft Sprocket


Courtesy of SUZUKI OF AMERICA CORP.

8. Remove LH bank exhaust camshaft sprocket (1).

CAUTION: Removing sprocket (1) from camshaft (2) may cause cam to turn,
resulting in damage to valve and piston. To prevent this, when
removing sprocket, hold camshaft stationary by using a spanner at
its hexagonal part.

Fig. 61: Identifying LH Bank Exhaust Camshaft & Sprocket


Courtesy of SUZUKI OF AMERICA CORP.

9. Remove LH bank intake camshaft sprocket.


10. Remove LH bank 2nd timing chain.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSPECTION

Reference: LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Removal

Timing Chain Guide No.4 and No.5

Check shoe (3) for wear or damage.

Fig. 62: Identifying Shoe, Timing Chain Guide No. 4 And No. 5
Courtesy of SUZUKI OF AMERICA CORP.

Camshaft Sprocket

Check teeth of sprocket for wear or damage.

Fig. 63: Identifying Camshaft Sprocket


Courtesy of SUZUKI OF AMERICA CORP.

Timing Chain

Check timing chain for wear or damage.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 64: Identifying Timing Chain


Courtesy of SUZUKI OF AMERICA CORP.

Tensioner Adjuster No. 3

l Check shoe (1) for wear or damage.

Fig. 65: Identifying Shoe


Courtesy of SUZUKI OF AMERICA CORP.

l Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.

Fig. 66: Identifying Latch And Tooth Surface


Courtesy of SUZUKI OF AMERICA CORP.

LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION

Reference: LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Components

Reference: LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Removal

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reference: LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Inspection

1. Check timing mark on crankshaft as shown in figure.

Fig. 67: Identifying Crank Timing Pulley Key And Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.

2. Check timing mark on idler sprocket No.2 (1) as shown in figure.

Fig. 68: Identifying Timing Mark On Idler Sprocket No. 2, Match Mark Of Idler Sprocket No. 2 &
Crankshaft
Courtesy of SUZUKI OF AMERICA CORP.

3. Install timing chain guide No.4 (1).

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Tightening torque

Timing chain guide No.4 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Fig. 69: Identifying Timing Chain Guide No. 4 & Bolts


Courtesy of SUZUKI OF AMERICA CORP.

4. Check that knock-pins of intake and exhaust camshafts are aligned with match marks on cylinder head as
shown in figure.

Fig. 70: Identifying Knock-Pins Of LH Bank Intake And Exhaust Camshafts & Match Marks
Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

5. Install by aligning match marks (2) on yellow plate (1) of LH bank 2nd timing chain and idler sprocket
No.2.

Fig. 71: Identifying Match Marks & Yellow Plate


Courtesy of SUZUKI OF AMERICA CORP.

6. Install sprockets to intake and exhaust camshafts by aligning silver plate (1) of LH bank 2nd timing chain,
match marks on intake sprocket and exhaust sprocket respectively.

CAUTION: Do not turn camshaft more than necessary. If turned excessively,


valve and piston may get damaged.

7. Install LH bank intake and exhaust camshaft timing sprockets.

To install it, fit a spanner to hexagonal part at the center of camshaft to hold stationary.

Tightening torque

Camshaft timing sprocket bolt b: 80 N.m (8.0 kg-m, 58.0 lb-ft)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 72: Identifying Silver Plate, Arrow Mark On Intake And Exhaust Camshaft Timing Sprockets
& Sprocket Bolt
Courtesy of SUZUKI OF AMERICA CORP.

8. With latch (2) of tensioner adjuster No.3 returned and plunger (1) pushed back into body, insert stopper
(pin) (4) into set hole (3).

After inserting it, check to make sure that plunger will not come out.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 73: Identifying Tensioner Adjuster No. 3 Latch, Plunger, Set Hole And Stopper Pin
Courtesy of SUZUKI OF AMERICA CORP.

9. Install timing chain tensioner adjuster No.3 (1) in tightening order below.

Tightening torque

Timing chain tensioner adjuster No.3 bolt c: Tighten 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified
procedure

Timing chain tensioner adjuster No.3 nut d: Tighten 55 N.m (5.5 kgf-m, 40.0 lb-ft) by the specified
procedure

Tightening order for tensioner bolt and nuts

"1"-->"2"-->"3"

10. Pull out stopper (pin) (2) from set hole.

Fig. 74: Identifying Timing Chain Tensioner Adjuster No. 3, Stopper Pin & Bolts Tightening
Sequence
Courtesy of SUZUKI OF AMERICA CORP.

11. Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on
cylinder block as shown in figure.

Check each other timing marks that align them shown in figure.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 75: Identifying Timing Marks On Crankshaft And Cylinder Block


Courtesy of SUZUKI OF AMERICA CORP.

12. Apply oil to timing chains, tensioner adjusters sprockets and guides.
13. Install timing chain cover referring to TIMING CHAIN COVER REMOVAL AND
INSTALLATION.
14. Install oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
15. Install front differential referring to FRONT DIFFERENTIAL DISMOUNTING AND
REMOUNTING : Front.
16. Install P/S system referring to P/S PUMP REMOVAL AND INSTALLATION.
17. Install cooling system referring to COOLING FAN AND FAN CLUTCH REMOVAL AND
INSTALLATION. and RADIATOR REMOVAL AND INSTALLATION. .
18. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
19. Refill coolant referring to COOLING SYSTEM FLUSH AND REFILL .

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2006 ENGINE Engine Mechanical - XL-7

20. Refill engine oil referring to ENGINE OIL AND FILTER CHANGE.
21. Refill P/S fluid and bleed air in P/S system referring to P/S SYSTEM AIR BLEEDING
PROCEDURE .
22. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
23. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.

1ST TIMING CHAIN AND CHAIN TENSIONER COMPONENTS

Fig. 76: Identifying 1st Timing Chain And Chain Tensioner Components With Torque Specifications

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Courtesy of SUZUKI OF AMERICA CORP.

1ST TIMING CHAIN AND CHAIN TENSIONER REMOVAL

Reference: 1st Timing Chain and Chain Tensioner Components

1. Disconnect negative cable at battery.


2. Drain engine oil.
3. Drain coolant referring to COOLANT DRAINING .
4. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
5. For reinstallation of timing chain, align 8 timing marks as shown in figure by turning crankshaft.

Fig. 77: Identifying Crankshaft Timing Marks


Courtesy of SUZUKI OF AMERICA CORP.

6. Remove LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Removal.
7. Remove the following parts referring to 1ST TIMING CHAIN AND CHAIN TENSIONER
COMPONENTS.
l Timing chain guide No.1 and No.2.

l Timing chain tensioner.

l Timing chain tensioner adjuster.

l Idler sprocket No.1 and 1st timing chain.

l Idler sprocket No.2 and sprocket shaft.

8. Remove RH bank 1st timing chain intake camshaft sprocket bolt. To remove it, fit a spanner to hexagonal
part (3) at the center of camshaft (2) to hold it stationary.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

9. Remove RH bank 1st timing chain intake camshaft sprocket (1).

Fig. 78: Identifying Camshaft Sprocket, Center & Hexagonal Part


Courtesy of SUZUKI OF AMERICA CORP.

10. Remove 1st timing chain crankshaft sprocket.

1ST TIMING CHAIN AND CHAIN TENSIONER INSPECTION

Reference: 1st Timing Chain and Chain Tensioner Removal

Timing Chain Guides No.1 and No.2

Check shoe for excessive wear or damage.

If any malfunction is found, replace it.

Fig. 79: Identifying Timing Chain Guide No. 1 And No. 2


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Timing Chain Tensioner

Check shoe (1) for wear or damage.

If any malfunction is found, replace it.

Fig. 80: Identifying Shoe


Courtesy of SUZUKI OF AMERICA CORP.

1st Timing Chain Crankshaft Sprocket

Check teeth of sprocket for wear or damage.

If any malfunction is found, replace it.

Fig. 81: Identifying 1st Timing Chain Crankshaft Sprocket


Courtesy of SUZUKI OF AMERICA CORP.

RH Bank 1st Timing Chain Intake Camshaft Sprocket

Check teeth of sprocket for wear or damage.

If any malfunction is found, replace it.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 82: Identifying RH Bank 1st Timing Chain Intake Camshaft Sprocket
Courtesy of SUZUKI OF AMERICA CORP.

Idler Sprocket No.1

Check teeth of sprocket for wear or damage.

If any malfunction is found, replace it.

Fig. 83: Identifying Idler Sprocket No. 1 And Bearing


Courtesy of SUZUKI OF AMERICA CORP.

Idler Sprocket No.2

Check teeth of sprocket for wear or damage.

If any malfunction is found, replace it.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 84: Identifying Idler Sprocket No. 2 And Bush


Courtesy of SUZUKI OF AMERICA CORP.

1st Timing Chain

Check timing chain for wear or damage.

If any malfunction is found, replace it.

Fig. 85: Identifying 1st Timing Chain


Courtesy of SUZUKI OF AMERICA CORP.

Timing Chain Tensioner Adjuster No.1

Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.

If any malfunction is found, replace it.

Fig. 86: Identifying Timing Chain Tensioner Adjuster No. 1 Latch And Tooth Surface
Courtesy of SUZUKI OF AMERICA CORP.

1ST TIMING CHAIN AND CHAIN TENSIONER INSTALLATION

Reference: 1st Timing Chain and Chain Tensioner Components

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reference: 1st Timing Chain and Chain Tensioner Removal

Reference: 1st Timing Chain and Chain Tensioner Inspection

1. Check timing mark on crankshaft as shown in figure.

Fig. 87: Identifying Crank Timing Pulley Key And Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.

2. Install 1st timing chain crankshaft sprocket (2) to crankshaft (1) as shown in figure.

Confirm that tooth for CKP sensor are free from metal particles and damage.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 88: Identifying 1st Timing Chain Crankshaft Sprocket, Lower Crankcase And Crankshaft
Courtesy of SUZUKI OF AMERICA CORP.

3. Check timing mark on RH bank intake camshaft as shown in figure.

Fig. 89: Identifying Knock Pin Of Intake Camshaft & Match Mark
Courtesy of SUZUKI OF AMERICA CORP.

4. Install RH bank 1st timing chain intake camshaft sprocket (1) noting the following points.
l The sprocket should be set in such way that its RH mark (4) can be seen.

l Camshaft (2) should be held stationary by using a spanner at its hexagonal parts (3) as shown in
figure.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Tightening torque

RH bank 1st timing chain intake camshaft sprocket bolt a: 80 N.m (8.0 kg-m, 58.0 lb-ft)

Fig. 90: Identifying RH Bank 1st Timing Chain Intake Camshaft Sprocket, Camshaft,
Hexagonal Part & RH Mark
Courtesy of SUZUKI OF AMERICA CORP.

5. Install timing chain tensioner (1) as shown in figure.

Tightening torque

Timing chain tensioner nut b: 27 N.m (2.7 kg-m, 19.5 lb-ft)

Fig. 91: Identifying Timing Chain Tensioner, Spacer & RH Bank Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.

6. Install 1st timing chain by aligning match marks (2) on RH silver plate (1) of 1st timing chain and RH

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

bank 1st timing chain intake camshaft sprocket.

Fig. 92: Identifying Match Marks, RH Silver Plate & RH Bank Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.

7. Apply oil to bush of idler sprocket No.2.


8. Install idler sprocket No.2 and sprocket shaft.
9. Install idler sprocket No.2 by aligning match marks (2) on LH silver plate (1) of 1st timing chain.

Fig. 93: Identifying Match Marks, LH Silver Plate & RH Bank Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.

10. Install crankshaft sprocket by aligning match marks (2) on yellow plate (1) of 1st timing chain and
crankshaft timing sprocket.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

To install it, fit a spanner to hexagonal part at the center of RH bank intake camshaft to turn a little.

CAUTION: Do not turn camshaft more than necessary. If turned excessively,


valve and piston may get damaged.

Fig. 94: Identifying Match Marks, Yellow Plate & Crankshaft


Courtesy of SUZUKI OF AMERICA CORP.

11. Apply oil to bearing of idler sprocket No.1.


12. Install idler sprocket No.1.

Tightening torque

Idler sprocket No.1 bolt c: 45 N.m (4.5 kg-m, 32.5 lb-ft)

Fig. 95: Identifying Idler Sprocket No. 1 Bolt


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

13. With latch of tensioner adjuster No.1 returned and plunger (1) pushed back into body, insert stopper (3)
into latch (2) and body.

After inserting it, check to make sure that plunger (1) will not come out.

Fig. 96: Identifying Stopper, Plunger And Latch


Courtesy of SUZUKI OF AMERICA CORP.

14. Install timing chain tensioner adjuster No.1 (1).

Tightening torque

Timing chain tensioner adjuster No.1 bolt d: 11 N.m (1.1 kg-m, 8.0 lb-ft)

15. Pull out stopper (3) from adjuster No.1 (1).

Fig. 97: Identifying Timing Chain Tensioner Adjuster No. 1, Stopper & Timing Chain Tensioner
Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

16. Install timing chain guide No.1 (2) and No.2 (1).

Tightening torque

Timing chain guide No.1 and No.2 bolt e: 9 N.m (0.9 kg-m, 6.5 lb-ft)

Fig. 98: Identifying Timing Chain Guide No. 1 & No. 2 & Guide Bolts
Courtesy of SUZUKI OF AMERICA CORP.

17. Check each aligned timing marks as shown in figure.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 99: Identifying Timing Marks


Courtesy of SUZUKI OF AMERICA CORP.

18. Install LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Installation.
19. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
20. Install oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
21. Install front differential housing referring to FRONT DIFFERENTIAL DISMOUNTING AND
REMOUNTING : Front.
22. Install P/S system referring to P/S PUMP REMOVAL AND INSTALLATION.
23. Install cooling system referring to COOLING FAN AND FAN CLUTCH REMOVAL AND
INSTALLATION. and RADIATOR REMOVAL AND INSTALLATION. .
24. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

MANIFOLD REMOVAL AND INSTALLATION..


25. Refill cooling system with coolant, front differential with gear oil, P/S system with specified fluid and
engine with engine oil.
26. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
27. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.

RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER COMPONENTS

Fig. 100: Identifying RH (No. 2) Bank 2nd Timing Chain And Chain Tensioner Components With
Torque Specifications
Courtesy of SUZUKI OF AMERICA CORP.

RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER REMOVAL

Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Components

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

1. For reinstallation of timing chain, align 12 timing marks as shown in figure by turning crankshaft.

Fig. 101: Identifying Timing Marks


Courtesy of SUZUKI OF AMERICA CORP.

2. Remove LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Removal.
3. Remove 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Removal.
4. Remove timing chain guide No.3 referring to RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN
TENSIONER COMPONENTS.
5. Loosen camshaft housing bolts in such order ("1"-"17") as indicated in figure and remove them.
6. Remove camshaft housings.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 102: Identifying Camshaft Housing Bolts Loosening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

7. Remove RH bank intake camshaft, RH bank exhaust camshaft, and RH bank 2nd timing chain as a set
referring to RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER COMPONENTS.
8. Remove timing chain tensioner adjuster No.2, referring to RH (NO.2) BANK 2ND TIMING CHAIN
AND CHAIN TENSIONER COMPONENTS.

RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSPECTION

Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Removal

Timing Chain Guide No.3

Check shoe (1) for excessive wear or damage.

If any malfunction is found, replace it.

Fig. 103: Identifying Timing Chain Guide No. 3 Shoe


Courtesy of SUZUKI OF AMERICA CORP.

RH Bank 2nd Timing Chain Sprockets

Check teeth of sprocket for wear or damage.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 104: Identifying RH Bank 2nd Timing Chain Sprockets


Courtesy of SUZUKI OF AMERICA CORP.

RH Bank 2nd Timing Chain

Check timing chain for wear or damage.

Fig. 105: Identifying RH Bank 2nd Timing Chain


Courtesy of SUZUKI OF AMERICA CORP.

Timing Chain Tensioner Adjuster No.2

l Check shoe (1) for wear or damage.


l Check that plunger slides smoothly.

Fig. 106: Identifying Timing Chain Tensioner Adjuster No. 2 Shoe


Courtesy of SUZUKI OF AMERICA CORP.

RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION

Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Components

Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Removal

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reference: RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Inspection

1. Check timing mark on crankshaft as shown in figure.

Fig. 107: Identifying Crank Timing Pulley Key And Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.

2. Apply oil to timing chain tensioner adjuster No.2 (1).


3. Install timing chain tensioner adjuster No.2 (1).

Tightening torque

Timing chain tensioner adjuster No.2 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 108: Identifying Timing Chain Tensioner Adjuster No. 2, Water Pump & Engine Front Side
Courtesy of SUZUKI OF AMERICA CORP.

4. Apply oil to sliding surface of each camshafts and camshaft journals.


5. Install RH bank 2nd timing chain by aligning match marks on yellow or silver plates (1) of RH bank 2nd
timing chain, RH bank 2nd timing chain intake camshaft sprocket and RH bank 2nd timing chain exhaust
camshaft sprocket as shown in figure.

Fig. 109: Identifying Silver Plates & Match Marks Of RH Bank 2nd Timing Chain Intake &
Exhaust Camshaft Sprockets
Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

6. Install camshaft housing pins (3) as shown in figure.

Fig. 110: Identifying Camshaft Housing Pins, RH Bank Intake Camshaft & RH Bank Exhaust
Camshaft
Courtesy of SUZUKI OF AMERICA CORP.

7. 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.

Fig. 111: Identifying Marks On Camshaft Housing

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Courtesy of SUZUKI OF AMERICA CORP.

8. After applying oil to housing bolts, tighten them temporarily first.

Then tighten them by following sequence ("1"-"17") as indicated in figure. Tighten a little at a time and
evenly among bolts and repeat tightening sequence 2 or 3 times before they are tightened to specified
torque below.

Tightening torque

Camshaft housing bolt: Tighten 12 N.m (1.2 kgf-m, 9.0 lb-ft) by the specified procedure

Fig. 112: Identifying Housing Bolts Tightening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

9. Install timing chain guide No.3 (1).

Tightening torque

Timing chain guide No.3 bolt c: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Fig. 113: Identifying Timing Chain Guide No. 3 & Bolt


Courtesy of SUZUKI OF AMERICA CORP.

10. Install 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Installation.
11. Install LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Installation.
12. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.

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2006 Suzuki XL-7
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13. Install oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
14. Install front differential housing referring to FRONT DIFFERENTIAL DISMOUNTING AND
REMOUNTING : Front.
15. Install P/S system referring to P/S PUMP REMOVAL AND INSTALLATION.
16. Install cooling system referring to RADIATOR REMOVAL AND INSTALLATION. .
17. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
18. Refill cooling system with coolant, front differential with gear oil, P/S system with specified fluid and
engine with engine oil.
19. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
20. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.

CAMSHAFTS AND VALVE LASH ADJUSTERS COMPONENTS

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Fig. 114: Identifying Camshafts And Valve Lash Adjusters Components With Torque Specifications
Courtesy of SUZUKI OF AMERICA CORP.

CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION

Reference: CAMSHAFTS AND VALVE LASH ADJUSTERS COMPONENTS

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2006 Suzuki XL-7
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Removal

1. Disconnect negative (-) cable at battery.


2. Drain engine oil.
3. Drain coolant referring to COOLANT DRAINING .
4. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
5. Remove LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Removal.
6. Remove 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Installation.
7. Remove RH bank camshafts. Refer to RH (No.2) Bank 2nd Timing Chain and Chain Tensioner
Removal.
8. Remove CMP sensor referring to CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND
INSTALLATION .
9. Loosen LH bank camshaft housing bolts in such order ("1"-"19") as indicated in figure and remove them.

Fig. 115: Identifying LH Bank Camshaft Housing Bolts Loosening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

10. Remove LH bank camshaft housings.


11. Remove LH bank camshafts.
12. Remove valve lash adjuster.

CAUTION: l Never disassemble hydraulic valve lash adjuster.


l Don't apply force (1) to body of adjuster, oil in high pressure
chamber in adjuster will leak.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 116: Identifying Adjuster Body


Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Immerse removed adjuster (2) in clean engine oil (1) and keep it there till
reinstalling it so as to prevent oil leakage. If it is left in air, place it with its
bucket body facing down. Don't place on its side or with bucket body facing up.

Fig. 117: Identifying Adjuster Immersed In Clean Engine Oil


Courtesy of SUZUKI OF AMERICA CORP.

Installation

Reference: CAMSHAFTS AND CAMSHAFT HOUSINGS INSPECTION

Reference: VALVE LASH ADJUSTERS INSPECTION

CAUTION: l Don't turn camshafts or start engine (i.e., valves should not be
operated) for about half an hour after reinstalling hydraulic valve lash
adjusters and camshafts. As it takes time for valves to settle in place,
operating engine within half an hour after their installation may cause
interference to occur between valves themselves or valves and
piston.
l If air is trapped in valve lash adjuster, valve may make tapping sound
when engine is operated after valve lash adjuster is installed. In such
a case, run engine for about half an hour at about 2000 to 3000 rpm,

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

and then air will be purged and tapping sound will cease. Should
tapping sound not cease, it is possible that valve lash adjuster is
defective. Replace it if defective.

If defective adjuster can't be located by hearing among 24 of them,


check as follows.

¡ Stop engine and remove cylinder head cover.


¡ Push adjuster downward by hand (with less than 200 N (20 kg,
44 lbs) of force) when can crest is not on adjuster to be checked
and check if clearance exists between cam and adjuster. If it
does, adjuster is defective and needs replacement.

1. Before installing valve lash adjuster to cylinder head, fill oil passage of cylinder head (1) with engine oil
according to the following procedure.

Pour engine oil through oil holes (2) and check that oil comes out from oil holes (2) in sliding part of
valve lash adjuster.

Perform this check on both intake and exhaust sides.

Fig. 118: Identifying Oil Holes & Cylinder Head


Courtesy of SUZUKI OF AMERICA CORP.

2. Apply engine oil around valve lash adjuster and then install it to cylinder head.

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2006 Suzuki XL-7
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Fig. 119: Installing Valve Lash Adjuster To Cylinder Head


Courtesy of SUZUKI OF AMERICA CORP.

3. Check timing mark on crankshaft as shown in figure.

Fig. 120: Identifying Crank Timing Pulley Key & Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.

4. Install RH bank camshafts referring to RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN
TENSIONER INSTALLATION.
5. Install LH bank camshafts.

Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match
marks (4) on cylinder head (3) and LH bank camshafts as shown in figure.

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2006 Suzuki XL-7
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Fig. 121: Identifying Match Marks, Cylinder Head And LH Bank Camshafts
Courtesy of SUZUKI OF AMERICA CORP.

6. Install LH bank camshaft housing pins as shown in figure.


7. Apply sealant "A" to LH bank exhaust camshaft housing No.5 sealing surface area as shown in figure.

"A": Water tight sealant 99000-31250 SUZUKI Bond No.1207F

Fig. 122: Identifying LH Bank Intake & Exhaust Camshafts & Pin Installation Position
Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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8. Check position of LH bank camshaft housings.

Embossed marks are provided on each camshaft housing, indicating position and direction for
installation. Install housings as indicated by these marks.

Fig. 123: Identifying Intake Side, Exhaust Side, Position From Timing Chain Side & Timing Chain
Side
Courtesy of SUZUKI OF AMERICA CORP.

9. After applying oil to housing bolts, tighten them temporarily first.

Then tighten them by following sequence ("1"-"19") as indicated in figure. Tighten a little at a time and
evenly among bolts and repeat tightening sequence 2 or 3 times before they are tightened to specified
torque below.

Tightening torque

Camshaft housing bolt: Tighten 12 N.m (1.2 kgf-m, 9.0 lb-ft) by the specified procedure

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2006 Suzuki XL-7
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Fig. 124: Identifying Housing Bolts Tightening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

10. Install 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Inspection.
11. Install LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Installation.
12. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
13. Install oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
14. Install front differential housing referring to FRONT DIFFERENTIAL DISMOUNTING AND
REMOUNTING : Front.
15. Install P/S system referring to P/S PUMP REMOVAL AND INSTALLATION.
16. Install cooling system referring to COOLING FAN AND FAN CLUTCH REMOVAL AND
INSTALLATION and RADIATOR REMOVAL AND INSTALLATION. .
17. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
18. Install CMP sensor referring to CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND
INSTALLATION .
19. Refill cooling system with coolant, front differential with gear oil, P/S system with specified fluid and
engine with engine oil.
20. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .
21. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.
22. Check ignition timing, referring to IGNITION TIMING CHECK AND ADJUSTMENT .

CAMSHAFTS AND CAMSHAFT HOUSINGS INSPECTION

Reference: CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION

Cam Wear

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2006 Suzuki XL-7
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Using a micrometer, measure cam height "a". If measured height is below its limit, replace camshaft.

Cam height specifications

CAM HEIGHT SPECIFICATIONS


Intake cam Exhaust cam
Standard 40.402 - 40.562 mm (1.5906 - 39.428 - 39.588 mm (1.5523 -
1.5969 in.) 1.586 in.)
Limit 40.300 mm (1.3581 in.) 39.400 mm (1.5512 in.)

Fig. 125: Measuring Cam Height


Courtesy of SUZUKI OF AMERICA CORP.

Camshaft Runout

Set camshaft between two "V" blocks, and measure its runout by using a dial gauge.

If measured runout exceeds specified limit, replace camshaft.

Camshaft runout limit

: 0.04 mm (0.002 in.)

Fig. 126: Measuring Camshaft Runout


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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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.

Fig. 127: Identifying Camshaft Journal


Courtesy of SUZUKI OF AMERICA CORP.

Check clearance by using gauging plastic. The procedure is as follows.

1. Clean housings and camshaft journals.


2. Make sure that all valve lash adjusters are removed and install camshaft to cylinder head.
3. Place a piece of gauging plastic the full width of journal of camshaft (parallel to camshaft).
4. Install camshaft housing.
5. Tighten camshaft housing bolts in such order ([A]: "1"-->"17", [B]: "1"-->"19") as shown in figure a little
at a time till they are tightened to specified torque.

NOTE: Do not rotate camshaft while gauging plastic is installed.

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Fig. 128: Identifying Camshaft Housing Bolts Tightening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

6. Remove housing, and using scale (2) on gauging plastic (1) envelop, measure gauging plastic (1) width at
its widest point.

Camshaft journal clearance

Standard: 0.020 - 0.074 mm (0.0008 - 0.0029 in.)

Limit: 0.12 mm (0.0047 in.)

Fig. 129: Identifying Scale & Gauging Plastic

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Courtesy of SUZUKI OF AMERICA CORP.

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 bore via. (IN and EX)

Standard: 26.000 - 26.033 mm (1.0236 - 1.0249 in.)

Camshaft journal O.D. (IN and EX)

Standard: 25.959 - 25.980 mm (1.0220 - 1.0228 in.)

Fig. 130: Measuring Journal (Housing) Bore And Outside Diameter Of Camshaft Journal
Courtesy of SUZUKI OF AMERICA CORP.

VALVE LASH ADJUSTERS INSPECTION

Reference: CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION

Check adjuster for pitting, scratches, or damage.

If any malcondition is found, replace.

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2006 Suzuki XL-7
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Fig. 131: Inspecting Valve Lash Adjusters


Courtesy of SUZUKI OF AMERICA CORP.

Measure cylinder head bore and adjuster outside diameter to determine cylinder head-to-adjuster clearance. If
clearance exceeds limit, replace adjuster or cylinder head.

Hydraulic valve lash adjuster O.D .

Standard: 30.959 - 30.975 mm (1.2188 - 1.2194 in.)

Cylinder head bore

Standard: 31.000 - 31.025 mm (1.2205 - 1.2214 in.)

Cylinder head to adjuster clearance

Standard: 0.025 - 0.066 mm (0.0010 - 0.0025 in.)

Limit: 0.15 mm (0.0059 in.)

Fig. 132: Measuring Cylinder Head Bore And Adjuster Outside Diameter
Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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VALVE LASH ADJUSTERS NOISE INSPECTION

In case of the followings, valve lash adjuster noise may be caused by air trapped into valve lash adjusters.

l Vehicle is left for 24 hours or more.


l Engine oil is changed.
l Hydraulic lash adjuster is replaced or reinstalled.
l Engine is overhauled.

If noise from valve lash adjusters is suspected, perform the following checks.

1. Check engine oil for the followings.


l Oil level in oil pan - If oil level is low, add oil up to full level hole on oil level gauge.

l Oil quality - If oil is discolored, or deteriorated, change it. For particular oil to be used, refer to
ENGINE OIL AND FILTER CHANGE.
l Oil leaks - If leak is found, repair it.

l Oil pressure (refer to OIL PRESSURE CHECK. ) - If defective pressure is found, repair it.

2. Run engine for about half an hour at about 2000 to 3000 rpm, and then air will be purge and tapping
sound will cease.
3. Should tapping sound not cease, it is possible that hydraulic valve lash adjuster is defective.

Replace it if defective. If defective adjuster can't be located by hearing among 16 of them. check as
follows.

a. Stop engine and remove cylinder head cover.


b. Push adjuster downward by hard (with less than 200 N (20 kg, 44 lbs) of force) when cam crest is
not on adjuster to be check if clearance exists between cam and adjuster. If it does, adjuster is
defective and needs replacement.

VALVES AND CYLINDER HEADS COMPONENTS

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2006 Suzuki XL-7
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Fig. 133: Identifying Valves And Cylinder Heads Components With Torque Specifications
Courtesy of SUZUKI OF AMERICA CORP.

VALVES AND CYLINDER HEADS REMOVAL AND INSTALLATION

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reference: VALVES AND CYLINDER HEADS COMPONENTS

Removal

1. Relieve fuel pressure according to FUEL PRESSURE RELIEF PROCEDURE .


2. Disconnect negative (-) cable at battery.
3. Drain engine oil.
4. Drain coolant referring to COOLANT DRAINING .
5. Remove CMP sensor, camshaft and valve lash adjuster referring to CAMSHAFT POSITION (CMP)
SENSOR REMOVAL AND INSTALLATION for CMP sensor removal and CAMSHAFTS AND
VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION for camshaft and valve lash
adjuster removal.
6. Remove exhaust manifold referring to EXHAUST MANIFOLD REMOVAL AND INSTALLATION.
7. Remove water outlet cap.
8. Loosen cylinder head bolts in such order ("1"-->"8") as shown in figure and remove them.

NOTE: Be sure to remove 2 hex bolts (1) shown in figure.

Fig. 134: Identifying Cylinder Head Bolts Loosening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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9. Remove cylinder heads.

Installation

1. Clean mating surface on cylinder head and cylinder block. Remove oil, old gasket and dust from mating
surface.
2. Install knock pin (4) to cylinder block.
3. Install new cylinder head gasket (1) to cylinder block as shown in figure. Carved lot number (5) on
cylinder head gasket (1) should face up (toward cylinder head side).

Fig. 135: Identifying Cylinder Head Gasket, Crankshaft Pulley Side, Flywheel Side, Knock Pin &
Lot Number
Courtesy of SUZUKI OF AMERICA CORP.

4. Install cylinder head to block.

After applying oil to cylinder head bolts, tighten them gradually as follows.

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2006 Suzuki XL-7
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a. Tighten cylinder head bolts (except hex hole bolt) to 53 N.m (5.3 kgf-m, 38.5 lb-ft) according to
numerical order in figure.
b. In the same manner as Step a, tighten them to 84 N.m (8.4 kgf-m, 61.0 lb-ft).
c. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
d. In the same manner as Step a, tighten them to 53 N.m (5.3 kgf-m, 38.5 lb-ft).
e. In the same manner as Step a again, tighten them to specified torque.
f. Tighten cylinder head bolts (hex hole bolt) to specified torque.

Tightening torque

Cylinder head bolt a: Tighten 53 N.m (5.3 kgf-m, 38.5 lb-ft), 84 N.m (8.4 kgf-m, 61.0 lb-ft), 0
N.m (0 kgf-m, 0 lb-ft), 53 N.m (5.3 kgf-m, 38.5 lb-ft) and 105 N.m (10.5 kgf-m, 76.0 lb-ft) by
the specified procedure

Cylinder head bolt (hex hole bolt) b: Tighten 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified
procedure

NOTE: Be sure to install hex hole bolts (1) as shown in figure.

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2006 Suzuki XL-7
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Fig. 136: Identifying Crankshaft Pulley Side, Flywheel Side & Hex Hole Bolts Tightening
Sequence
Courtesy of SUZUKI OF AMERICA CORP.

5. Install water outlet cap.


6. Check timing mark on crankshaft as shown in figure.

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2006 Suzuki XL-7
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Fig. 137: Identifying Crank Timing Pulley Key & Oil Jet
Courtesy of SUZUKI OF AMERICA CORP.

7. Install valve lash adjuster, camshaft, CMP sensor and RH bank 2nd timing chain.

Refer to CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION and
RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION. For CMP
sensor, refer to CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION .

8. Install 1st timing chain referring to 1st Timing Chain and Chain Tensioner Installation.
9. Install LH bank 2nd timing chain referring to LH (No.1) Bank 2nd Timing Chain and Chain
Tensioner Installation.
10. Install timing chain cover referring to TIMING CHAIN COVER REMOVAL AND
INSTALLATION.
11. Install oil pan and oil pump strainer referring to OIL PAN AND OIL PUMP STRAINER REMOVAL
AND INSTALLATION.
12. Install cylinder head cover referring to CYLINDER HEAD COVERS REMOVAL AND
INSTALLATION.
13. Install exhaust manifold referring to EXHAUST MANIFOLD REMOVAL AND INSTALLATION.
14. Install radiator outlet pipe, radiator, cooling fan and water hose.

Refer to COOLING WATER PIPES OR HOSES REMOVAL AND INSTALLATION ,


RADIATOR REMOVAL AND INSTALLATION and COOLING FAN AND FAN CLUTCH
REMOVAL AND INSTALLATION. .

15. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
16. Adjust water pump drive belt tension.

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Refer to COOLING FAN / GENERATOR BELT TENSION CHECK AND ADJUSTMENT .

17. Adjust power steering pump drive belt tension referring to P/S PUMP DRIVE BELT INSPECTION
AND ADJUSTMENT. .
18. Adjust accelerator cable play referring to ACCELERATOR CABLE ADJUSTMENT
19. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not
been reinstalled.
20. Refill engine with engine oil referring to ENGINE OIL AND FILTER CHANGE.
21. Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
22. Refill front differential housing with gear oil if drained referring to FRONT DIFFERENTIAL GEAR
OIL INSPECTION AND CHANGE : Front.
23. Connect negative (-) cable at battery.
24. Check ignition timing and adjust as necessary referring to IGNITION TIMING CHECK AND
ADJUSTMENT .
25. Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each
connection.
26. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .

VALVES AND CYLINDER HEADS DISASSEMBLY AND ASSEMBLY

Reference: VALVES AND CYLINDER HEADS REMOVAL AND INSTALLATION

Disassembly

1. Using special tools (A), (B) and (C), compress valve springs and then remove valve cotters (1) by using
special tool (D).
2. Release special tool, and remove spring retainer and valve spring.

Special Tool

(A): 09916-14510

(B): 09916-14910

(C): 09919-28610

(D): 09916-84511

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2006 Suzuki XL-7
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Fig. 138: Identifying Valve Cotters & Special Tools


Courtesy of SUZUKI OF AMERICA CORP.

3. Remove valve from combustion chamber side.


4. Remove valve stem seal (1) from valve guide, and then valve spring seat (2).

NOTE: Do not reuse seal once disassembled. Be sure to use new seal when
assembling.

Fig. 139: Identifying Valve Stem Seal And Valve Spring Seat
Courtesy of SUZUKI OF AMERICA CORP.

5. Using special tool (E) (Valve guide remover), drive valve guide out from combustion chamber side to

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

valve spring side.

Special Tool

(E): 09916-44910

NOTE: Do not reuse valve guide once disassembled. Be sure to use new valve
guide (Oversize) when assembling.

Fig. 140: Driving Out Valve Guide Using Valve Guide Remover
Courtesy of SUZUKI OF AMERICA CORP.

6. Place disassembled parts except valve stem seal and valve guide in order so that they can be installed in
their original positions.

Assembly

Reference: VALVES AND VALVE GUIDES INSPECTION

Reference: CYLINDER HEAD INSPECTION

Reference: VALVE SPRINGS INSPECTION

1. Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as
to remove burrs and make it truly round.

Special Tool

(E): 09916-34542

(F): 09916-38210

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

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

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 protrusions (1) by specified height from cylinder head.

Special Tool

(G): 09916-58210

(H): 09917-87810

NOTE: l Do not reuse valve guide once disassembled. Install new valve guide
(Oversize).
l Intake and exhaust valve guides are identical.

Width of oversized valve guide

11.088 - 11.103 mm (0.4365 - 0.4371 in.)

Valve guide protrusion (In and Ex)

13.5 mm (0.53 in.)

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2006 Suzuki XL-7
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Fig. 141: Identifying Valve Guide Protrusion & Special Tools


Courtesy of SUZUKI OF AMERICA CORP.

3. Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore.

Special Tool

(E): 09916-34542

(I): 09916-37810

Fig. 142: Reaming Valve Guide Bore With Special Tools


Courtesy of SUZUKI OF AMERICA CORP.

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

(J): 09917-98221

(K): 09916-58210

NOTE: l Do not reuse seal once disassembled. Be sure to install new seal.
l 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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2006 Suzuki XL-7
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Fig. 143: Identifying Valve Stem Seal & Special Tools


Courtesy of SUZUKI OF AMERICA CORP.

6. Install valve (1) to valve guide.

Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem.

Fig. 144: Identifying Valve


Courtesy of SUZUKI OF AMERICA CORP.

7. Install valve springs (inner and outer) and spring retainer.

Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Be sure to
position spring in place with its bottom end (valve spring retainer side (3)) facing the bottom (valve
spring seat side (4)).

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Fig. 145: Identifying Top End And Bottom End Of Valve Spring
Courtesy of SUZUKI OF AMERICA CORP.

8. Using special tool (Valve lifter), compress valve spring and fit 2 valve cotters (1) into groove in valve
stem.

Special Tool

(A): 09916-14510

(B): 09916-14910

(C): 09916-84511

(D): 09919-28610

Fig. 146: Identifying Valve Cotters & Special Tools


Courtesy of SUZUKI OF AMERICA CORP.

VALVES AND VALVE GUIDES INSPECTION

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reference: VALVES AND CYLINDER HEADS REMOVAL AND INSTALLATION

Reference: VALVES AND CYLINDER HEADS DISASSEMBLY AND ASSEMBLY

Valve Guides

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-to-guide clearance

VALVE STEM-TO-GUIDE CLEARANCE SPECIFICATION


Item Standard Limit
Intake 5.965 - 5.980 mm (0.2348 -
- 0.2354 in.)
Valve stem diameter
Exhaust 5.940 - 5.955 mm (0.2339 -
- 0.2344 in.)
Valve guide I.D. In and Ex 6.000 - 6.012 mm (0.2362 -
- 0.2367 in.)
Intake 0.020 - 0.047 mm (0.0008 0.07 mm (0.0028 in.)
- 0.0019 in.)
Stem-to-guide clearance
Exhaust 0.045 - 0.072 mm (0.0018 0.09 mm (0.0035 in.)
- 0.0028 in.)

Fig. 147: Measuring Valve Stem & Guide Diameter


Courtesy of SUZUKI OF AMERICA CORP.

Valves

l Remove all carbon from valves.


l Inspect each valve for wear, burn or distortion at its face and stem and, as necessary, replace it.
l Measure thickness of valve head. If measured thickness exceeds limit, replace valve.

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2006 Suzuki XL-7
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Valve specifications

VALVE SPECIFICATIONS
Item Standard Limit
Intake 1.0 mm (0.039 in.) 0.6 mm (0.024 in.)
Exhaust 1.2 mm (0.047 in.) 0.7 mm (0.028 in.)

Fig. 148: Identifying Valve Head Thickness


Courtesy of SUZUKI OF AMERICA CORP.

l Inspect valve stem end face for pitting and wear. If pitting or wear is found, valve stem end may be
resurfaced. But do not grind its taper excessively. When valve is excessively worn out too much or its
taper is gone, replace it.

Fig. 149: Identifying Valve Stem End Face


Courtesy of SUZUKI OF AMERICA CORP.

l Check each valve for radial runout with a dial gauge and "V" block.

To check runout, rotate valve slowly. If runout exceeds its limit, replace valve.

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2006 Suzuki XL-7
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Valve head radial runout

Limit: 0.08 mm (0.003 in.)

Fig. 150: Checking Valve Head Radial Runout


Courtesy of SUZUKI OF AMERICA CORP.

l Seating contact width

Create contact pattern on each valve in the usual manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotatingly tapping seat with valve head. Valve lapper (tool used in valve
lapping) must be used.

Pattern produced on seating face of valve must be a continuous ring without any break, and the width of
pattern must be within specified range.

Standard seating width revealed by contact pattern on valve face

Intake and Exhaust: 1.1 - 1.3 mm (0.0433 - 0.0512 in.)

Fig. 151: Identifying Valve Seating Width


Courtesy of SUZUKI OF AMERICA CORP.

l Valve seat repair

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out
of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.

a. Exhaust valve seat

Use valve seat cutters (1) to make two cuts as illustrated in figure. Two cutters must be used: the
1st for making 15° angle, and the 2nd for making 45° angle. The 2nd cut must be made to produce
desired seat width.

Seat width for exhaust valve seat

1.1 - 1.3 mm (0.0433 - 0.0512 in.)

b. Intake valve seat

Use valve seat cutters (1) to make three cuts as illustrated in figure. Three cutters must be used: the
1st for making 15° angle, the 2nd for making 60° angle, and the 3rd for making 45° angle. The 3rd
cut (45°) must be made to produce desired seat width.

Seat width for intake valve seat

1.1 - 1.3 mm (0.0433 - 0.0512 in.)

Fig. 152: Identifying Valve Seat Cutter


Courtesy of SUZUKI OF AMERICA CORP.

c. Valve lapping

Lap valve on seat in two steps, first with coarse size lapping compound applied to face and the
second with fine-size compound, each time using valve lapper according to usual lapping method.

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2006 Suzuki XL-7
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Fig. 153: Identifying Intake & Exhaust Valve Lapping


Courtesy of SUZUKI OF AMERICA CORP.

CYLINDER HEAD INSPECTION

Reference: VALVES AND CYLINDER HEADS REMOVAL AND INSTALLATION

Reference: VALVES AND CYLINDER HEADS DISASSEMBLY AND ASSEMBLY

l Remove all carbon from combustion chambers.

NOTE: Do not use any sharp-edged tool to scrape off carbon. Be careful not to
scuff or nick metal surfaces when decarboning. The same applies to
valves and valve seats, too.

Fig. 154: Removing Carbon From Combustion Chambers


Courtesy of SUZUKI OF AMERICA CORP.

l Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface.
Using straightedge (1) and thickness gauge (2), check flatness of gasketed surface at a total of 6 locations.
If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

paper of about #400 (Waterproof silicon carbide abrasive paper): Place abrasive paper on and over
surface plate, and rub gasketed surface against paper to grind off high spots. Should this fail to reduce
thickness gauge readings to within limit, replace cylinder head.

Leakage of combustion gases from this gasketed joint is often due to warped gasketed surface: such
leakage results in reduced power output.

Cylinder head gasketed surface distortion

Limit: 0.05 mm (0.002 in.)

Fig. 155: Checking Flatness Of Gasketed Surface Using Straightedge & Thickness Gauge
Courtesy of SUZUKI OF AMERICA CORP.

l Distortion of manifold seating faces

Check seating faces of cylinder head for manifolds, using a straightedge (1) and thickness gauge (2), in
order to determine whether these faces should be corrected or cylinder head replaced.

Manifold seating surface distortion

Limit: 0.10 mm (0.004 in.)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 156: Checking Seating Faces Of Cylinder Head Using Straightedge & Thickness Gauge
Courtesy of SUZUKI OF AMERICA CORP.

VALVE SPRINGS INSPECTION

Reference: VALVES AND CYLINDER HEADS REMOVAL AND INSTALLATION

Reference: VALVES AND CYLINDER HEADS DISASSEMBLY AND ASSEMBLY

l Referring to data given below, check to be sure that each spring is in sound condition, free of any
evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention
possibility of reducing power output due to gas leakage caused by decreased seating pressure.

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2006 Suzuki XL-7
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Fig. 157: Inspecting Valve Spring


Courtesy of SUZUKI OF AMERICA CORP.

Valve spring free length

VALVE SPRING FREE LENGTH SPECIFICATION


Item Standard Limit
Inner 36.08 mm (1.4205 in.) 35.00 mm (1.3780 in.)
Outer 40.44 mm (1.5921 in.) 39.22 mm (1.5441 in.)

Valve spring preload

VALVE SPRING PRELOAD


Item Standard Limit
Inner 6.9 - 7.9 kg for 27.5 mm (15.2 - 5.9 kg for 27.5 mm (13.0 lb/1.08
17.4 lb/1.08 in.) in.)
Outer 15.4 - 17.8 kg for 31.7 mm (34.0 - 13.3 kg for 31.7 mm (29.3 lb/1.25
39.2 lb/1.25 in.) in.)

l Spring squareness

Use a square and surface plate to check each spring for squareness in terms of clearance between end of
valve spring and square. Valve springs found to exhibit a larger clearance than limit given below must be
replaced.

Valve spring squareness limit

Inner spring: 1.6 mm (0.063 in.)

Outer spring: 1.8 mm (0.071 in.)

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2006 Suzuki XL-7
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Fig. 158: Checking Valve Spring For Squareness


Courtesy of SUZUKI OF AMERICA CORP.

PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS COMPONENTS

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2006 Suzuki XL-7
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Fig. 159: Identifying Pistons, Piston Rings, Connecting Rods And Cylinders Components With Torque
Specifications
Courtesy of SUZUKI OF AMERICA CORP.

PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

INSTALLATION

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS COMPONENTS

Removal

1. Disconnect negative (-) cable at battery.


2. Drain engine oil.
3. Drain coolant referring to COOLANT DRAINING .
4. Remove cylinder heads. Refer to VALVES AND CYLINDER HEADS REMOVAL AND
INSTALLATION.
5. Remove oil pump. Refer to OIL PUMP REMOVAL AND INSTALLATION.
6. Mark cylinder number on all pistons, connecting rods and connecting rod caps.
7. Remove rod bearing caps.
8. Install guide hose (1) over threads of rod bolts. This prevents damage to bearing journal and rod bolt
threads when removing connecting rod.

Fig. 160: Identifying Guide Hose


Courtesy of SUZUKI OF AMERICA CORP.

9. Clean carbon from top of cylinder bore before removing piston from cylinder.
10. Push piston and connecting rod assembly out through the top of cylinder bore.

Installation

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY


AND ASSEMBLY

Reference: CYLINDERS, PISTONS AND PISTON RINGS INSPECTION

Reference: PISTON PINS AND CONNECTING RODS INSPECTION

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2006 Suzuki XL-7
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Reference: CRANK PINS AND CONNECTING ROD BEARINGS INSPECTION

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 (1) protect crank pin and threads of rod bolt from damage during installation of
connecting rod and piston assembly.

Fig. 161: Identifying Guide Hoses


Courtesy of SUZUKI OF AMERICA CORP.

3. When installing piston and connecting rod assembly into cylinder bore, point mark (1) on piston head to
crankshaft pulley side (2).

Fig. 162: Identifying Mark On Piston Head & Crankshaft Pulley Side
Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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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

Fig. 163: Compressing Rings Using Piston Ring Compressor


Courtesy of SUZUKI OF AMERICA CORP.

5. Install bearing cap

Point mark (1) on cap to crankshaft pulley side (2). Tighten cap nuts to specification.

Tightening torque

Connecting rod bearing cap nut a: 45 N.m (4.5 kg-m, 32.5 lb-ft)

Fig. 164: Identifying Mark On Connecting Rod Bearing Cap, Connecting Rod Bearing Cap Nuts &

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Crankshaft Pulley Side


Courtesy of SUZUKI OF AMERICA CORP.

6. Install cylinder heads to cylinder block referring to VALVES AND CYLINDER HEADS REMOVAL
AND INSTALLATION.
7. Install oil pump to cylinder block referring to OIL PUMP REMOVAL AND INSTALLATION.
8. Install valve lash adjusters and camshafts referring to CAMSHAFTS AND VALVE LASH
ADJUSTERS REMOVAL AND INSTALLATION.
9. Install RH bank 2nd timing chain referring to RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN
TENSIONER INSTALLATION.
10. Install 1st timing chain. Refer to 1st Timing Chain and Chain Tensioner Installation.
11. Install LH bank 2nd timing chain. Refer to LH (No.1) Bank 2nd Timing Chain and Chain Tensioner
Installation.
12. Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
13. Install oil pan and pump strainer. Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND
INSTALLATION.
14. Install cylinder head cover. Refer to CYLINDER HEAD COVERS REMOVAL AND
INSTALLATION.
15. Install exhaust manifold. Refer to EXHAUST MANIFOLD REMOVAL AND INSTALLATION.
16. Install radiator outlet pipe, radiator, cooling fan and water hose.

Refer to COOLING WATER PIPES OR HOSES REMOVAL AND INSTALLATION ,


RADIATOR REMOVAL AND INSTALLATION. and COOLING FAN AND FAN CLUTCH
REMOVAL AND INSTALLATION.

17. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION..
18. Adjust water pump drive belt tension. Refer to COOLING FAN / GENERATOR BELT TENSION
CHECK AND ADJUSTMENT
19. Adjust power steering pump drive belt tension. Refer to DRIVE BELT INSPECTION AND
ADJUSTMENT.
20. Adjust accelerator cable play referring to ACCELERATOR CABLE ADJUSTMENT
21. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not
been reinstalled.
22. Refill engine with engine oil referring to ENGINE OIL AND FILTER CHANGE.
23. Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
24. Refill front differential housing with gear oil if drained, referring to FRONT DIFFERENTIAL GEAR
OIL INSPECTION AND CHANGE : Front.
25. Connect negative cable at battery.
26. Check ignition timing and adjust as necessary, referring to IGNITION TIMING CHECK AND
ADJUSTMENT .
27. Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

connection.
28. Check wheel alignment referring to FRONT ALIGNMENT INSPECTION AND ADJUSTMENT .

PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY AND


ASSEMBLY

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION

Disassembly

1. Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston.
2. Remove piston pin from connecting rod.
a. Ease out piston pin circlips (1) as shown in figure.

Fig. 165: Identifying Piston Pin Circlips


Courtesy of SUZUKI OF AMERICA CORP.

b. Force piston pin out.

Fig. 166: Removing Piston Pin


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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Assembly

Reference: CYLINDERS, PISTONS AND PISTON RINGS INSPECTION

Reference: PISTON PINS AND CONNECTING RODS INSPECTION

Reference: CRANK PINS AND CONNECTING ROD BEARINGS INSPECTION

1. 2 sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder
clearance. When installing a standard size piston, make sure to match piston with cylinder as follows.
a. Each piston has stamped number (1 or 2) on its piston head. It represents outer diameter of piston.
b. There are also stamped numbers of 1 and 2 on the cylinder block as shown in figure.
c. Stamped number on piston and cylinder block must correspond. That is, install number "2" stamped
piston to cylinder which is stamped also number "2" and a number "1" piston to cylinder with
number "1".

Piston outer diameter

PISTON OUTER DIAMETER SPECIFICATION


Number at the top (mark) Outer diameter
1 87.98 - 87.99 mm (3.4638 - 3.4642 in.)
2 87.97 - 87.98 mm (3.4634 - 3.4638 in.)

Cylinder outer diameter

CYLINDER OUTER DIAMETER SPECIFICATION


Number on cylinder block (mark) Outer diameter
1 88.01 - 88.02 mm (3.4650 - 3.4653 in.)
2 88.00 - 88.01 mm (3.4646 - 3.4650 in.)

Piston-to-cylinder clearance

0.02 - 0.04 mm (0.0008 - 0.0016 in.)

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2006 Suzuki XL-7
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Fig. 167: Identifying Piston Stamped Numbers & Cylinders


Courtesy of SUZUKI OF AMERICA CORP.

2. Install piston pin to piston and connecting rod:

After applying engine oil to piston pin and piston pin holes in piston (1) and connecting rod (3), fit
connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install
piston pin circlips.

NOTE: "86F" mark on connecting rod must face toward crankshaft pulley side.

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2006 Suzuki XL-7
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Fig. 168: Identifying Piston, Arrow Mark & Connecting Rod


Courtesy of SUZUKI OF AMERICA CORP.

NOTE: l Install circlip with its cut part facing as shown in figure.
l Install so that circlip end gap comes within such range as indicated
by arrow "A".

Fig. 169: Identifying Circlip End Gap Range, Piston, Arrow Mark,
Connecting Rod, Oil Hole, Crankshaft Pulley Side & Circlip
Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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3. Install piston rings to piston:


l As shown in figure, 1st (1) and 2nd rings (2) have "RN" or "R" mark respectively. When installing
these piston rings to piston, direct marked side of each ring toward top of piston.
l 1st rings differs from 2nd ring in thickness, shape and color of surface contacting cylinder wall.

Distinguish 1st ring from 2nd ring by referring to the figure.

l When installing oil ring (3), install spacer first and then 2 rails.

Fig. 170: Identifying Piston Rings & Oil Ring


Courtesy of SUZUKI OF AMERICA CORP.

4. After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.

Fig. 171: Identifying Piston Ring End Gaps


Courtesy of SUZUKI OF AMERICA CORP.

CYLINDERS, PISTONS AND PISTON RINGS INSPECTION

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY


AND ASSEMBLY

NOTE: Before the following inspection, clean carbon from piston head and ring
grooves, using a suitable tool.

Cylinders

l 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.
l Using a cylinder gauge, measure cylinder bore in thrust and axial directions at 2 positions (1, 2) as shown
in figure. If any of the following condition is noted, rebore cylinder.
¡ Cylinder bore via. exceeds limit.

¡ Difference of measurements at 2 positions exceeds taper limit.

¡ Difference between thrust and axial measurements exceeds out-of-round limit.

Cylinder bore dia. limit

: 88.050 mm (3.4665 in.)

Taper and out-of-round

Limit: 0.10 mm (0.004 in.)

NOTE: If any one of six cylinders has to be rebored, rebore all six to the
same oversize. This is necessary for the sake of uniformity and
balance.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 172: Measuring Cylinder Bore Diameter, Taper & Out-Of-Round


Courtesy of SUZUKI OF AMERICA CORP.

Pistons

l Inspect piston for faults, cracks or other damages.

Damaged or faulty piston should be replaced.

l Piston diameter:

As shown in figure, piston diameter should be measured at a position 26.5 mm (1.04 in.) ("a") from piston
skirt end in the direction perpendicular to piston pin.

Piston diameter

Standard: 83.970 - 83.990 mm (3.3059 - 3.3067 in.)

Oversize 0.50 mm: 84.470 - 84.490 mm (3.3256 - 3.3264 in.)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 173: Measuring Piston Diameter


Courtesy of SUZUKI OF AMERICA CORP.

l Piston clearance:

Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance.
Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder
and use oversize piston.

Piston-to-cylinder clearance

0.02 - 0.04 mm (0.0008 - 0.0015 in.)

NOTE: Cylinder bore diameter should be measured in 2 places 90 degrees apart.

Fig. 174: Identifying Piston-To-Cylinder Clearance


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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l Ring groove clearance:

Before checking, piston grooves must be clean, dry and free of carbon.

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

Top: 0.03 - 0.07 mm (0.0012 - 0.0027 in.)

2nd: 0.02 - 0.06 mm (0.0008 - 0.0023 in.)

Fig. 175: Identifying Piston Ring & Thickness Gauge


Courtesy of SUZUKI OF AMERICA CORP.

Piston Rings

To measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge.

If measure gap is out of specification, replace ring.

NOTE: Clean carbon and any other dirt from top of cylinder bore before inserting
piston ring.

Piston ring end gap

PISTON RING END GAP SPECIFICATION


Item Standard Limit
Top ring 0.20 - 0.35 mm (0.0079 - 0.0138 0.7 mm (0.0276 in.)
in.)
2nd ring 0.35 - 0.47 mm (0.0138 - 0.0197 0.7 mm (0.0276 in.)
in.)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Oil ring 0.20 - 0.70 mm (0.0079 - 0.0276 1.8 mm (0.0709 in.)


in.)

Fig. 176: Identifying Cylinder Block, Feeler Gauge, Piston Ring & 120 MM
Courtesy of SUZUKI OF AMERICA CORP.

PISTON PINS AND CONNECTING RODS INSPECTION

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY


AND ASSEMBLY

Piston Pins

l Check piston pin, connecting rod small end bore and piston bore for wear or damage, paying particular
attention to condition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly
worn or damaged, replace pin, connecting rod or piston.
l Piston pin clearance:

Check piston pin clearance in small end. Replace connecting rod if its small end is badly worn or
damaged or if measured clearance exceeds limit.

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2006 Suzuki XL-7
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Piston pin clearance in small end

0.003 - 0.014 mm (0.0001 - 0.0006 in.)

Small-end bore

21.003 - 21.011 mm (0.8269 - 0.8272 in.)

Piston pin diameter

20.997 - 21.000 mm (0.8267 - 0.8268 in.)

Fig. 177: Measuring Piston Pin Diameter, Small-End Bore & Piston Pin Clearance In Small End
Courtesy of SUZUKI OF AMERICA CORP.

Connecting Rods

l Big-end side clearance:

Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the
normal manner. If measured clearance is found to exceed its limit, replace connecting rod.

Big-end side clearance

Standard: 0.25 - 0.35 mm (0.0098 - 0.0138 in.)

Limit: 0.45 mm (0.0177 in.)

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2006 Suzuki XL-7
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Fig. 178: Checking Big-End Of Connecting Rod For Side Clearance


Courtesy of SUZUKI OF AMERICA CORP.

l Connecting rod alignment:

Mount connecting rod on aligner to check it for bow and twist. If limit is exceeded, replace it.

Connecting rod alignment

Limit on bow: 0.05 mm (0.0020 in.)

Limit on twist: 0.10 mm (0.0039 in.)

CRANK PINS AND CONNECTING ROD BEARINGS INSPECTION

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND
INSTALLATION

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY


AND ASSEMBLY

l 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 then inspect rod bearing clearance referring to "Rod bearing clearance".

Crank pin diameter

CRANK PIN DIAMETER SPECIFICATION


Connecting rod bearing size Crank pin diameter
Standard 49.982 - 50.000 mm (1.9678 - 1.9685 in.)
0.25 mm (0.0098 in.) undersize 49.732 - 49.750 mm (1.9580 - 1.9587 in.)

Crank pin out-of-round (a - b)

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2006 Suzuki XL-7
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Limit: 0.01 mm (0.0004 in.)

Crank pin taper (c - d)

Limit: 0.01 mm (0.0004 in.)

Fig. 179: Measuring Crank Pin For Out-Of-Round Or Taper With Micrometer
Courtesy of SUZUKI OF AMERICA CORP.

l Connecting rod bearing general information:

Service connecting rod bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, 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.

Fig. 180: Identifying Red Painting On Undersize Bearing


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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l 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.

l Connecting rod bearing clearance:


a. Before checking bearing clearance, clean bearing and crank pin.
b. Install bearing in connecting rod and bearing cap.
c. Place a piece of gaging plastic (1) to full width of crank pin as contacted by bearing (parallel to
crankshaft), avoiding oil hole.

Fig. 181: Identifying Gaging Plastic


Courtesy of SUZUKI OF AMERICA CORP.

d. Install rod bearing cap to connecting rod.

When installing cap, be sure to point arrow mark on cap to crankshaft pulley side, as shown in
figure.

After applying engine oil to rod bolts, tighten cap nuts to specified torque.

Tightening torque

Connecting rod bearing cap nut a: 45 N.m (4.5 kg-m, 32.5 lb-ft)

NOTE: DO NOT turn crankshaft with gaging plastic installed.

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2006 Suzuki XL-7
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Fig. 182: Identifying Connecting Rod Bearing Cap Nuts


Courtesy of SUZUKI OF AMERICA CORP.

e. Remove cap and using a scale (2) on gaging plastic (1) envelope, measure gaging plastic (1) width
at the widest point (clearance).

If clearance exceed its limit, use a new standard size bearing referring to "Selection of Connecting
Rod Bearings" in this section.

After selecting new bearing, recheck clearance.

Bearing clearance

Standard: 0.045 - 0.063 mm (0.0018 - 0.0024 in.)

Limit: 0.08 mm (0.0031 in.)

Fig. 183: Identifying Scale & Gaging Plastic


Courtesy of SUZUKI OF AMERICA CORP.

f. If clearance can not be brought to within its limit even by using a new standard size bearing,
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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

regrind crankpin to undersize and use 0.25 mm undersize bearing as follows.


i. Install 0.25 mm undersize bearing to connecting rod big end.
ii. Measure bore diameter of connecting rod big end.
iii. Regrind crank pin to following finished diameter:

Finished crank pin dia. = Measured big end bore dia. (including under-size bearing) - 0.054
mm (0.0021 in.)

iv. Confirm that bearing clearance is within above standard value.


l Selection of connecting rod bearings:

NOTE: l 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.
l 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 No.3.

a. 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 53.0000 - 53.0060 mm (2.0867 - 2.0868 in.).

Connecting rod big end inside diameter

CONNECTING ROD BIG END INSIDE DIAMETER SPECIFICATION


Stamped numbers connecting rod big end inside diameter
1 53.0000 - 53.0060 mm (2.0867 - 2.0868 in.)
2 53.0061 - 53.0120 mm (2.0869 - 2.0870 in.)
3 53.0121 - 53.0180 mm (2.0871 - 2.0873 in.)

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2006 Suzuki XL-7
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Fig. 184: Identifying Weight Indication Mark And Connecting Rod Big End Inside Diameter
Number
Courtesy of SUZUKI OF AMERICA CORP.

b. Next, check crankshaft pin diameter. On crank web No.3, six 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
49.9940 - 50.0000 mm (1.9683 - 1.9685 in.).

Crankshaft pin diameter

CRANKSHAFT PIN DIAMETER SPECIFICATION


Stamped alphabet Crankshaft pin diameter
A 49.9940 - 50.0000 mm (1.9683 - 1.9685 in.)
B 49.9880 - 49.9939 mm (1.9681 - 1.9682 in.)
C 49.9820 - 49.9879 mm (1.9677 - 1.9680 in.)

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2006 Suzuki XL-7
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Fig. 185: Identifying Crankshaft Pin Diameter For Cylinders


Courtesy of SUZUKI OF AMERICA CORP.

c. There are five kinds of standard bearings differing in thickness. To distinguish them, they are
painted in the following colors at the position as indicated in figure.

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2006 Suzuki XL-7
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Each color indicated the following thickness at the center of bearing.

Standard size of connecting rod bearing thickness

STANDARD SIZE OF CONNECTING ROD BEARING THICKNESS


Color painted Bearing thickness
Blue 1.494 - 1.497 mm (0.05882 - 0.05893 in.)
Yellow 1.491 - 1.494 mm (0.05871 - 0.05881 in.)
Nothing 1.488 - 1.491 mm (0.05859 - 0.05870 in.)
Black 1.485 - 1.488 mm (0.05847 - 0.05858 in.)
Green 1.482 - 1.485 mm (0.05835 - 0.05846 in.)

Fig. 186: Identifying Paint Mark On Bearing


Courtesy of SUZUKI OF AMERICA CORP.

d. From number stamped on connecting rod and its cap and alphabets stamped on crank web No.3,
determine new standard bearing to be installed to connecting rod big end inside, by referring to
table. For example, if number stamped on connecting rod and its cap is "1" and alphabet stamped
on crank web No.3 is "B", install a new standard bearing painted in "Black" to its connecting rod
big end inside.

Specification of new standard connecting rod bearing size

SPECIFICATION OF NEW STANDARD CONNECTING ROD BEARING SIZE


Number stamped on connecting rod and its cap
(connecting rod big end inside diameter)
1 2 3
Alphabet stamped A Green Black Nothing
on crank web No.3 B Black Nothing Yellow
(Crankshaft pin
outer diameter) C Nothing Yellow Blue
New standard bearing to be installed.

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2006 Suzuki XL-7
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e. Check bearing clearance with newly selected standard bearing referring to "Selection of Connecting
Rod Bearing" under "Connecting Rod Bearings" in this section.

If clearance still exceeds its limit, use next thicker bearing and recheck clearance.

ENGINE ASSEMBLY REMOVAL AND INSTALLATION

Removal

1. Release fuel pressure in fuel feed line referring to FUEL PRESSURE RELIEF PROCEDURE .
2. Disconnect negative (-) cable at battery.
3. Remove engine hood.
4. Drain engine oil.
5. Drain coolant referring to COOLANT DRAINING .
6. Remove radiator, radiator fan shroud, cooling fan and radiator reservoir. Refer to COOLING FAN AND
FAN CLUTCH REMOVAL AND INSTALLATION.
7. Disconnect accelerator cable (1) from throttle body.

Fig. 187: Identifying Accelerator Cable


Courtesy of SUZUKI OF AMERICA CORP.

8. Detach fuse/relay box, then remove strut tower bar and surge tank cover.
9. Disconnect IAT sensor coupler and MAF sensor coupler then remove air cleaner upper case, intake air
hose, intake air pipe and surge tank pipe as a component.
10. Remove intake control valve, referring to THROTTLE BODY REMOVAL AND INSTALLATION.
11. Remove engine oil level gauge guide and A/T fluid level gauge guide (for A/T vehicle).
12. Remove ignition coil covers.
13. Disconnect the following electric lead wires:
l Injector wire coupler

l CMP sensor coupler

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2006 Suzuki XL-7
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Ignition coil couplers


l

l CKP sensor coupler

l MAP sensor coupler

l TP sensor (1) coupler

l IAC valve (2) coupler

l Earth wire (3) from surge tank

l EVAP canister purge valve (5) coupler

l EGR valve (6) coupler

l Oxygen sensor-1 and -2 couplers (Refer to EXHAUST MANIFOLD REMOVAL AND


INSTALLATION. )
l Coolant temperature sensor coupler

l Knock sensor coupler

l Generator wires

l Starter wires

l Oil pressure wire

l P/S pump wire

l Earth wire from generator bracket

l Engine block heater (if equipped)

14. Remove clamps and brackets (4).


15. Disconnect the following hoses:
l Heater hose (7) from heater water pipe and water outlet cap

l Tank pressure control solenoid valve hose from intake manifold

l EVAP canister hose from canister purge pipe

l Brake booster vacuum hose

16. Remove EVAP canister purge valve (5).

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Fig. 188: Identifying TP Sensor, IAC Valve, Wire, EVAP Canister Purge Valve, EGR Valve,
Brackets And Heater Hose
Courtesy of SUZUKI OF AMERICA CORP.

17. Disconnect the following hoses at the location shown in figure:


l Fuel feed hose (1) from fuel feed pipe

l Fuel return hose (2) from fuel return pipe

Fig. 189: Identifying Fuel Feed Hose And Return Hose


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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18. Remove P/S pump assembly referring to P/S PUMP REMOVAL AND INSTALLATION.
19. Remove A/C compressor assembly referring to COMPRESSOR ASSEMBLY REMOVAL AND
INSTALLATION : Manual Type, Compressor Assembly Removal and Installation: Automatic Type.
20. Remove steering shaft lower assembly referring to STEERING LOWER SHAFT ASSEMBLY
REMOVAL AND INSTALLATION .
21. Raise vehicle.
22. Remove front differential housing with differential from chassis if equipped. Refer to FRONT
DIFFERENTIAL DISMOUNTING AND REMOUNTING : Front.
23. Remove exhaust No.1 pipe referring to EXHAUST MANIFOLD REMOVAL AND
INSTALLATION.
24. Remove exhaust manifold stiffener from transmission.
25. Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle)

Fig. 190: Identifying A/T Fluid Hose Clamps And Engine Mounting Bracket
Courtesy of SUZUKI OF AMERICA CORP.

26. Remove clutch housing lower plate.


27. Remove torque converter bolts (for A/T vehicle).
28. Remove starter motor.
29. Lower vehicle.
30. Support transmission.

CAUTION: Do not support A/T by placing a jacking equipment under oil pan. If
may damage to A/T.

31. Remove bolts and nuts fastening cylinder block and transmission.

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Fig. 191: Identifying Transmission Case Bolts And Nuts


Courtesy of SUZUKI OF AMERICA CORP.

32. Install lifting device.


33. Disconnect engine side mounting brackets (1) from engine mountings (2) by removing nuts (3).

Fig. 192: Identifying Engine Side Mounting Brackets, Engine Mountings & Nuts
Courtesy of SUZUKI OF AMERICA CORP.

34. Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
35. Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist
engine assembly.

Installation

Reverse removal procedure for installation noting the following points.

l Tighten engine side mounting bracket nuts to specified torque.

Tightening torque

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2006 Suzuki XL-7
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Engine side mounting bracket nut a: 55 N.m (5.5 kg-m, 40.0 lb-ft)

Fig. 193: Identifying Engine Side Mounting Bracket Nuts


Courtesy of SUZUKI OF AMERICA CORP.

l Tighten transmission case bolts and nuts to specified torque.

Tightening torque

Transmission case bolt and nut b: 85 N.m (8.5 kg-m, 61.5 lb-ft) (for M/T vehicle)

Transmission case bolt and nut b: 80 N.m (8.0 kg-m, 58.0 lb-ft) (for A/T vehicle)

Fig. 194: Identifying Transmission Case Bolts And Nuts


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
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l Tighten torque converter bolts to specified torque (for A/T vehicle).

Tightening torque

Torque converter bolt c: 65 N.m (6.5 kg-m, 47.0 lb-ft)

Fig. 195: Identifying Torque Converter Bolts


Courtesy of SUZUKI OF AMERICA CORP.

l Tighten bolts and nuts of exhaust No.1 pipe (1) to specified torque.

Tightening torque

Exhaust No.1 pipe bolt and nut d: 50 N.m (5.0 kg-m, 36.5 lb-ft)

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2006 Suzuki XL-7
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Fig. 196: Identifying Exhaust No. 1 Pipe, Bolts And Nuts


Courtesy of SUZUKI OF AMERICA CORP.

l Install front differential housing with differential to chassis referring to FRONT DIFFERENTIAL
DISMOUNTING AND REMOUNTING : Front, if necessary.
l Install steering shaft lower assembly referring to STEERING LOWER SHAFT ASSEMBLY
REMOVAL AND INSTALLATION .
l Install A/C compressor assembly, referring to COMPRESSOR ASSEMBLY REMOVAL AND
INSTALLATION : Manual Type, COMPRESSOR ASSEMBLY REMOVAL AND
INSTALLATION : Automatic Type.
l Install P/S pump assembly referring to P/S PUMP REMOVAL AND INSTALLATION.
l Adjust accelerator cable play referring to ACCELERATOR CABLE ADJUSTMENT
l Refill engine with engine oil referring to ENGINE OIL AND FILTER CHANGE.
l Refill cooling system referring to COOLING SYSTEM FLUSH AND REFILL .
l Check to ensure that all fasteners and clamps are tightened.
l Upon completion of installation, verify that there is no fuel leakage, coolant leakage, P/S fluid leakage or
exhaust gas leakage at each connection.

MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 197: Identifying Main Bearings, Crankshaft And Cylinder Block Components With Torque
Specifications
Courtesy of SUZUKI OF AMERICA CORP.

MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Removal

1. Remove engine assembly from vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.
2. Remove clutch and flywheel (for M/T vehicle) or drive plate (for A/T vehicle). For clutch removal, refer
to CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION.

Using special tool (flywheel holder), remove flywheel (M/T vehicle) or drive plate (A/T vehicle).

Special Tool

(A): 09924-17811

Fig. 198: Identifying Special Tool (Flywheel Holder) And Flywheel Bolt
Courtesy of SUZUKI OF AMERICA CORP.

3. Remove throttle body with intake manifold and exhaust manifold referring to THROTTLE BODY AND
INTAKE MANIFOLD REMOVAL AND INSTALLATION. and EXHAUST MANIFOLD
REMOVAL AND INSTALLATION.
4. Remove oil pans (lower and upper) and oil pump strainer. Refer to OIL PAN AND OIL PUMP
STRAINER REMOVAL AND INSTALLATION.
5. Remove cylinder head cover referring to CYLINDER HEAD COVERS REMOVAL AND
INSTALLATION.

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6. Remove timing chain cover. Refer to TIMING CHAIN COVER REMOVAL AND INSTALLATION.
7. Remove LH bank 2nd timing chain and tensioner referring to LH (No.1) Bank 2nd Timing Chain and
Chain Tensioner Removal.
8. Remove 1st timing chain and tensioner referring to 1st Timing Chain and Chain Tensioner Removal.
9. Remove RH bank 2nd timing chain and tensioner referring to RH (No.2) Bank 2nd Timing Chain and
Chain Tensioner Removal.
10. Remove cylinder head assembly referring to VALVES AND CYLINDER HEADS REMOVAL AND
INSTALLATION.
11. Remove pistons and connecting rods referring to PISTONS, PISTON RINGS, CONNECTING RODS
AND CYLINDERS REMOVAL AND INSTALLATION.
12. Remove oil pump referring to OIL PUMP REMOVAL AND INSTALLATION.
13. Remove oil pump chain referring to OIL PUMP CHAIN REMOVAL AND INSTALLATION .
14. Loosen crankcase bolts, following sequence in figure and remove them.

NOTE: Loosen 8 mm (0.31 in.) thread diameter bolts first, then loosen 10 mm (0.39
in.) thread diameter bolts following the order shown in figure.

Fig. 199: Identifying Crankcase Bolts Loosening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

15. Remove crankshaft from cylinder block.

Installation

Reference: CRANKSHAFT INSPECTION

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2006 Suzuki XL-7
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Reference: MAIN BEARINGS INSPECTION

Reference: REAR OIL SEAL AND FLYWHEEL INSPECTION

Reference: CYLINDER BLOCK INSPECTION

NOTE: l All parts to be installed must be perfectly clean.


l Be sure to oil crankshaft journals, journal bearings, thrust bearings, crank
pins, connecting rod bearings, pistons, piston rings and cylinder bores.
l Journal bearings, crankcase (bearings caps), connecting rods, rod
bearings, rod bearing caps, pistons and piston rings are in combination
sets. Do not disturb combination and try to see that each part goes back to
where it came from, when installing.
l Clean mating surface of cylinder block and crankcase, remove oil, old
sealant and dust from mating surface.

1. Fit main bearings (4) to cylinder block (1).

One of two halves of main bearing, has oil groove (3). Install this half with oil groove to cylinder block,
and another half without oil groove to crankcase.

Make sure that two halves are painted in the same color.

2. Install O-ring (2) to cylinder block.

Fig. 200: Identifying Main Bearing, Cylinder Block, O-Ring, Oil Groove And Knock Pin
Courtesy of SUZUKI OF AMERICA CORP.

3. Fit thrust bearings (1) to cylinder block between No.2 and No.3 cylinders.

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2006 Suzuki XL-7
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Face oil groove (2) sides to crank webs.

Fig. 201: Identifying Thrust Bearing And Oil Groove


Courtesy of SUZUKI OF AMERICA CORP.

4. Put crankshaft to cylinder block.


5. Apply sealant "A" to crankcase mating surface area as shown in figure.

"A": Water tight sealant 99000-31250 SUZUKI Bond No.1207F

Fig. 202: Identifying Lower Crankcase, Bearing & Sealant Application Area
Courtesy of SUZUKI OF AMERICA CORP.

6. Install crankcase to cylinder block. Apply oil to crankcase bolts before installing them. Tighten crankcase
bolts gradually as follows.
a. Tighten crankcase bolts (10 mm (0.39 in.) thread diameter) to 42 N.m (4.2 kgf-m, 30.5 lb-ft)
according to numerical order in figure.

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2006 Suzuki XL-7
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b. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
c. In the same manner as Step a, tighten them to 42 N.m (4.2 kgf-m, 30.5 lb-ft).
d. In the same manner as Step a again, tighten them to specified torque.
e. Tighten crankcase bolts (8 mm (0.31 in.) thread diameter) to specified torque.

NOTE: Tighten 10 mm (0.39 in.) thread diameter bolts first (the following the
order shown in figure), then tighten 8 mm (0.31 in.) thread diameter
bolts.

Tightening torque

Crankcase bolt a: Tighten 42 N.m (4.2 kgf-m, 30.5 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 42 N.m (4.2
kgf-m, 30.5 lb-ft) and 60 N.m (6.0 kgf-m, 43.5 lb-ft) by the specified procedure (10 mm (0.39
in.) thread diameter)

Crankcase bolt b: Tighten 27 N.m (2.7 kgf-m, 19.5 lb-ft) by the specified procedure (8 mm
(0.31 in.) thread diameter)

NOTE: After tightening crankcase bolts, check to be sure that crankshaft


rotates smoothly when turned by hand.

Fig. 203: Identifying Crankcase Bolts Tightening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

7. Using special tools (Oil seal installer and oil seal guide), install rear oil seal (1).

Special Tool

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

(A): 09911-97710

(B): 09911-97811

Fig. 204: Identifying Rear Oil Seal, Crankshaft Side, Oil Seal Side & Special Tools
Courtesy of SUZUKI OF AMERICA CORP.

8. Install flywheel (M/T vehicle) or drive plate (A/T vehicle). Using special tool, lock flywheel or drive
plate, and tighten flywheel or drive plate bolts to specification.

"A": Sealant 99000-31110 SUZUKI Bond No.1215

Special Tool

(A): 09924-17811

Tightening torque

Flywheel (or drive plate) bolt c: 70 N.m (7.0 kg-m, 51.0 lb-ft)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 205: Identifying Flywheel Bolt, Sealant Application Area & Special Tool
Courtesy of SUZUKI OF AMERICA CORP.

9. Install oil pump referring to OIL PUMP REMOVAL AND INSTALLATION.


10. Install pistons and connecting rods referring to PISTONS, PISTON RINGS, CONNECTING RODS
AND CYLINDERS REMOVAL AND INSTALLATION.
11. Install oil pump strainer and oil pan referring to OIL PAN AND OIL PUMP STRAINER REMOVAL
AND INSTALLATION.
12. Install cylinder heads assembly to cylinder block referring to VALVES AND CYLINDER HEADS
REMOVAL AND INSTALLATION.
13. Install oil pump chain referring to OIL PUMP CHAIN REMOVAL AND INSTALLATION .
14. Install RH bank 2nd timing chain and tensioner referring to RH (NO.2) BANK 2ND TIMING CHAIN
AND CHAIN TENSIONER INSTALLATION.
15. Install 1st timing chain and tensioner referring to 1st Timing Chain and Chain Tensioner Installation.
16. Install LH bank 2nd timing chain and tensioner referring to LH (No.1) Bank 2nd Timing Chain and
Chain Tensioner Installation.
17. Install timing chain cover and crankshaft pulley referring to TIMING CHAIN COVER REMOVAL
AND INSTALLATION.
18. Install cylinder head covers referring to CYLINDER HEAD COVERS REMOVAL AND
INSTALLATION.
19. Install exhaust manifold referring to EXHAUST MANIFOLD REMOVAL AND INSTALLATION.
20. Install intake manifold with throttle body referring to THROTTLE BODY AND INTAKE
MANIFOLD REMOVAL AND INSTALLATION.
21. Install clutch to flywheel (for M/T vehicle). For clutch installation, refer to CLUTCH COVER,
CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION.
22. Install engine assembly to vehicle referring to ENGINE ASSEMBLY REMOVAL AND
INSTALLATION.

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2006 Suzuki XL-7
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CRANKSHAFT INSPECTION

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND


INSTALLATION

Crankshaft Runout

Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit,
replace crankshaft.

Crankshaft runout

Limit: 0.06 mm (0.0023 in.)

Fig. 206: Measuring Crankshaft Runout


Courtesy of SUZUKI OF AMERICA CORP.

Crankshaft Thrust Play

Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and
journal bearing caps installed. Tighten crankcase bolts gradually as follows.

1. Tighten crankcase bolts (10 mm (0.39 in.) thread diameter) to 42 N.m (4.2 kgf-m, 30.5 lb-ft) according to
numerical order in figure.
2. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
3. In the same manner as Step a), tighten them to 42 N.m (4.2 kgf-m, 30.5 lb-ft).
4. In the same manner as Step a) again tighten them to specified torque.
5. Tighten crankcase bolts (8 mm (0.31 in.) thread diameter) to specified torque.

NOTE: Tighten 10 mm (0.394 in.) thread diameter bolts first (following the order
shown in figure), then tighten 8 mm (0.315 in.) thread diameter bolts.

Tightening torque

Crankcase bolt a: Tighten 42 N.m (4.2 kgf-m, 30.5 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 42 N.m (4.2 kgf-

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2006 Suzuki XL-7
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m, 30.5 lb-ft) and 60 N.m (6.0 kgf-m, 43.5 lb-ft) by the specified procedure (10 mm (0.39 in.) thread
diameter)

Crankcase bolt b: Tighten 27 N.m (2.7 kgf-m, 19.5 lb-ft) by the specified procedure (8 mm (0.31 in.)
thread diameter)

Fig. 207: Identifying Crankcase Bolts Tightening Sequence


Courtesy of SUZUKI OF AMERICA CORP.

Use a dial gauge to read displacement in axial (thrust) direction of crankshaft.

If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard
thrust play.

Crankshaft thrust play

Standard: 0.1 - 0.35 mm (0.0039 - 0.0138 in.)

Limit: 0.38 mm (0.0150 in.)

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2006 Suzuki XL-7
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Fig. 208: Checking Crankshaft Thrust Play


Courtesy of SUZUKI OF AMERICA CORP.

Thickness of crankshaft thrust bearing

Standard: 2.500 mm (0.984 in.)

Oversize (0.125 mm (0.0049 in.)): 2.563 mm (0.1009 in.)

Fig. 209: Identifying Thrust Bearings And Oil Grooves


Courtesy of SUZUKI OF AMERICA CORP.

Out-of-Round and Taper (Uneven Wear) of Journals

An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length
(or both). This difference, if any, is determined by taking micrometer readings. If any one of journals is badly
damaged or if amount of uneven wear in the sense explained above exceeds its limit, regrind or replace
crankshaft.

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2006 Suzuki XL-7
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Crank journal out-of-round (a - b) and taper (c - d)

Limit: 0.01 mm (0.0004 in.)

Fig. 210: Checking Crank Journal Out-Of-Round And Taper


Courtesy of SUZUKI OF AMERICA CORP.

MAIN BEARINGS INSPECTION

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND


INSTALLATION

Main Bearing General Information

NOTE: Before inspecting main bearings, note the following points.

l 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.
l Upper half of bearing (1) has oil groove (2) as shown in figure. Install this half with oil groove toward
cylinder block.

Fig. 211: Identifying Bearing And Oil Groove


Courtesy of SUZUKI OF AMERICA CORP.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

l Lower half of bearing does not have 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 (1) according to the following procedure.

1. Remove lower crankcase.


2. Clean bearings and main journals.
3. Place a piece of gauging plastic (1) to full width of bearing (parallel to crankshaft) on journal, avoiding
oil hole.

Fig. 212: Identifying Gauging Plastic


Courtesy of SUZUKI OF AMERICA CORP.

4. Install lower crankcase to cylinder block without applying sealant referring to MAIN BEARINGS,
CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION.
5. Remove lower crankcase, and using scale (2) on gauging plastic (1) envelop, measure gauging plastic (1)
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.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Main bearing clearance

Standard: 0.0210 - 0.0390 mm (0.0009 - 0.0015 in.)

Undersize: 0.0240 - 0.0420 mm (0.0010 - 0.0016 in.)

Limit: 0.0550 mm (0.0021 in.)

Fig. 213: Identifying Scale & Gauging Plastic


Courtesy of SUZUKI OF AMERICA CORP.

Selection of Main Bearings

Standard bearing

NOTE: The meaning of "Upper" and "Lower" described in this procedure are the
following.

l Upper: It is meaning of main bearing installed in cylinder block side


journal.
l Lower: It is meaning of main bearing installed in lower crankcase side
journal.

If engine is under one of the following conditions, select a new standard bearing as follow, and install it.

l Bearing is in malcondition.
l Bearing clearance is out of specification.
l Crankshaft or cylinder block is replaced.

1. First check journal diameter. As shown in figure, crank web has stamped numbers and alphabet at the
center.

Six kinds of numbers ("4" through "9") represent the following journal diameters.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Journal diameter

JOURNAL DIAMETER SPECIFICATION


Stamped numbers Journal diameter
4 65.0030 - 65.0060 mm (2.55917 - 2.55928 in.)
5 65.0000 - 65.0029 mm (2.55905 - 2.55916 in.)
6 64.9970 - 64.9999 mm (2.55893 - 2.55904 in.)
7 64.9940 - 64.9969 mm (2.55882 - 2.55892 in.)
8 64.9910 - 64.9939 mm (2.55870 - 2.55881 in.)
9 64.9880 - 64.9909 mm (2.55858 - 2.55869 in.)

Fig. 214: Identifying Crankshaft And Crank Web


Courtesy of SUZUKI OF AMERICA CORP.

2. Next, check journal bore diameter.

On lower crankcase, 4 alphabets (1) are stamped as shown in figure.

Three kinds of alphabets (A, B and C) represent the following journal bore diameters.

Journal bore diameter

JOURNAL BORE DIAMETER SPECIFICATION


Stamped alphabet Bearing cap bore diameter (without bearing)
A 70.0000 - 70.0060 mm (2.75590 - 2.75613 in.)
B 70.0061 - 70.0120 mm (2.75614 - 2.75637 in.)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

C 70.0121 - 70.0180 mm (2.75638 - 2.75660 in.)

Fig. 215: Identifying Crankshaft Pulley Side, Stamped Alphabets & Bearings
Courtesy of SUZUKI OF AMERICA CORP.

3. There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the
following colors at the position as indicated in figure.

Each color indicates the following thickness at the center of bearing.

NOTE: The following bearing are not supplied because they are unnecessary in
this selection procedure.

l Upper main bearing: Brown


l Lower main bearing: Black

Standard size main bearing thickness

MAIN BEARING THICKNESS STANDARD SIZE SPECIFICATION


Color painted Bearing thickness
Black 2.4970 - 2.5000 mm (0.09831 - 0.09842 in.)
Colorless (no paint) 2.5000 - 2.5030 mm (0.09843 - 0.09854 in.)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Yellow 2.5030 - 2.5060 mm (0.09855 - 0.09866 in.)


Blue 2.5060 - 2.5090 mm (0.09867 - 0.09877 in.)
Pink 2.5090 - 2.5120 mm (0.09878 - 0.09889 in.)
Brown 2.5120 - 2.5150 mm (0.09890 - 0.09901 in.)

Fig. 216: Identifying Paint Mark On Bearing


Courtesy of SUZUKI OF AMERICA CORP.

4. From number stamped on crank webs at its center and alphabets stamped on cylinder block lower side,
determine new standard bearing to be installed to journal referring to cross-reference table below. For
example, if number stamped on crank webs is "5" and alphabet stamped on cylinder block is "A", install
new standard bearing painted in "Black" to cylinder block side journal and "Colorless" to lower crankcase
side journal.

Main bearing cross-reference table (standard bearing)

MAIN BEARING CROSS-REFERENCE TABLE (STANDARD BEARING)


Stamped number on crank web
4 5 6 7 8 9
A Upper: Colorless Upper: Yellow Upper: Blue
Black Colorless Yellow
Lower: Lower: Lower: Blue
Colorless Yellow
Stamped
B Upper: Yellow Upper: Blue Upper: Blue Pink
alphabet on
Colorless Yellow Lower: Pink
lower
Lower: Lower: Blue
crankcase
Yellow
C Upper: Blue Upper: Blue Pink Upper: Pink Upper: Pink
Yellow Lower: Pink Lower: Lower:
Lower: Blue Brown Brown

5. Using gauging plastic, check bearing clearance with newly selected standard bearing referring to MAIN

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

BEARING CLEARANCE.

If clearance still exceeds its limit, use next thicker bearing and recheck clearance.

Undersize bearing (0.25 mm)

0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness.

To distinguish them, each bearing is painted in the following colors at such position as indicated in figure. Each
color represents the following thickness at the center of bearing.

Undersize main bearing thickness

MAIN BEARING THICKNESS UNDERSIZE SPECIFICATION


Color painted Bearing thickness
Black & Red 2.6220 - 2.6250 mm (0.10322 - 0.10334 in.)
Red only 2.6250 - 2.6280 mm (0.10335 - 0.10346 in.)
Yellow & Red 2.6280 - 2.6310 mm (0.10347 - 0.10358 in.)
Blue & Red 2.6310 - 2.6340 mm (0.10359 - 0.10370 in.)
Pink & Red 2.6340 - 2.6370 mm (0.10371 - 0.10382 in.)

Fig. 217: Identifying Paint Mark On Bearing


Courtesy of SUZUKI OF AMERICA CORP.

l If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows.
a. Regrind journal to the following finished diameter.

Finished journal diameter

64.7380 - 64.7560 mm (2.54874 - 2.54944 in.)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

b. Using micrometer, measure reground journal diameter.

Measurement should be taken in two directions perpendicular to each other in order to check for
out-of-round.

Fig. 218: Measuring Reground Journal Diameter


Courtesy of SUZUKI OF AMERICA CORP.

c. Using journal diameter measured and alphabets stamped on cylinder block, select undersize bearing
referring to cross-reference table below.

Check bearing clearance with newly selected undersize bearing referring to MAIN BEARING
CLEARANCE.

Main bearing cross-reference table (undersize bearing)

MAIN BEARING CROSS-REFERENCE TABLE (UNDERSIZE BEARING)


Measured journal diameter
64.7500 - 64.7560 64.7440 - 64.7499 64.7380 - 64.7439
mm (2.54921 - mm (2.54897 - mm (2.54873 -
2.54944 in.) 2.54920 in.) 2.54896 in.)
A Black & Red Red only Yellow & Red
Alphabets stamped
B Red only Yellow & Red Blue & Red
on lower crankcase
C Yellow & Red Blue & Red Pink & Red

REAR OIL SEAL AND FLYWHEEL INSPECTION

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND


INSTALLATION

Rear Oil Seal

Carefully inspect oil seal for wear or damage. If lip portion is worn or damaged, replace oil seal.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 219: Identifying Oil Seal


Courtesy of SUZUKI OF AMERICA CORP.

Flywheel

l If ring gear is damaged, cracked or worn, replace flywheel.


l If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel.
l Check flywheel for face runout with a dial gauge. If runout exceeds its limit, replace flywheel.

Flywheel runout

Limit: 0.2 mm (0.0078 in.)

Fig. 220: Checking Flywheel Runout


Courtesy of SUZUKI OF AMERICA CORP.

CYLINDER BLOCK INSPECTION

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND


INSTALLATION

Distortion of Gasketed Surface

Using straightedge and thickness gauge, check gasketed surface for distortion. If flatness exceeds its limit,
correct or replace it.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Gasketed surface flatness

Limit: 0.06 mm (0.0024 in.)

Fig. 221: Checking Gasketed Surface Flatness


Courtesy of SUZUKI OF AMERICA CORP.

Honing or reboring cylinders

1. When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
2. Select oversized piston according to amount of cylinder wear.

Oversize piston diameter specifications

OVERSIZE PISTON DIAMETER SPECIFICATIONS


Standard Oversize 0.50
83.970 - 83.990 mm (3.3059 - 3.3067 in.) 84.470 - 84.490 mm (3.3256 - 3.3264 in.)

3. Using micrometer, measure piston diameter.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 222: Measuring Piston Diameter


Courtesy of SUZUKI OF AMERICA CORP.

4. Calculate cylinder bore diameter to be rebored as follows.

D=A+B-C

D: Cylinder bore diameter to be rebored

A: Piston diameter as measured

B: Piston clearance = 0.02 - 0.04 mm (0.0008 - 0.0015 in.)

C: Allowance for honing = 0.02 mm (0.0008 in.)

5. Rebore and hone cylinder to calculated dimension.

NOTE: Before reboring, install all main bearing caps in place and tighten to
specification to avoid distortion of bearing bores.

6. Measure piston clearance after honing.

ENGINE BLOCK HEATER (IF EQUIPPED) REMOVAL AND INSTALLATION

Removal

1. Disconnect negative (-) cable at battery.


2. Drain engine coolant referring to COOLANT DRAINING .

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2006 Suzuki XL-7
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3. Remove strut tower bar. if equipped. Refer to STRUT DAMPER REMOVAL AND
INSTALLATION .
4. Remove right side exhaust manifold. Refer to EXHAUST MANIFOLD REMOVAL AND
INSTALLATION.
5. Disconnect engine block heater and remove engine block heater (1).

Fig. 223: Identifying Engine Block Heater


Courtesy of SUZUKI OF AMERICA CORP.

Installation

Reference: ENGINE BLOCK HEATER (IF EQUIPPED) INSPECTION

Reverse removal procedure for installation, noting the followings.

l Install engine block heater (1) in the direction as shown in figure.

Fig. 224: Identifying Engine Block Heater


Courtesy of SUZUKI OF AMERICA CORP.

l Tighten engine block heater mounting bolt to specified torque.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

a. Apply thread lock cement to block heater bolt (1).

"A": Thread lock cement 99000-32020 Thread Lock Cement Super 1333B

b. Tighten engine block heater mounting bolt to specified torque.

Tightening torque

Engine block heater mounting bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Fig. 225: Identifying Engine Block Heater Mounting Bolts


Courtesy of SUZUKI OF AMERICA CORP.

l Use new exhaust manifold gasket.


l Tighten exhaust manifold mounting bolts and nuts to specified torque referring to EXHAUST
MANIFOLD REMOVAL AND INSTALLATION.
l Refill coolant referring to COOLING SYSTEM FLUSH AND REFILL .
l Refill P/S fluid and bleed air in P/S system referring to P/S SYSTEM AIR BLEEDING
PROCEDURE .
l Refill engine oil referring to ENGINE OIL AND FILTER CHANGE.
l Refill front differential gear oil referring to FRONT DIFFERENTIAL GEAR OIL INSPECTION
AND CHANGE : Front.
l Finally, start engine and check for engine coolant leaks and exhaust gas leakage.

ENGINE BLOCK HEATER (IF EQUIPPED) INSPECTION

Reference: ENGINE BLOCK HEATER (IF EQUIPPED) REMOVAL AND INSTALLATION

l Check continuity between terminal "a" and "c". If there is no continuity, replace it.
l Check that there is no continuity between terminal "a" or "b" and "c". If there is continuity, replace it.
l Check continuity between terminal "c" and engine block heater body. If there is no continuity, replace it.

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Fig. 226: Identifying Engine Block Heater Terminals


Courtesy of SUZUKI OF AMERICA CORP.

SPECIFICATIONS
TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE SPECIFICATIONS


Tightening torque
Fastening part Note
N.m kgf-m lb-ft
Strut tower bar 50 5.0 36.5
mounting bolts
Cylinder head cover 10.5 1.1 7.5
nut
Timing chain cover 11 1.1 8.0
bolt
CKP sensor bolt 6 0.6 4.5
Crankshaft pulley 150 15 108.5
bolt
Timing chain guide 11 1.1 8.0
No.4 bolt
Camshaft timing 80 8.0 58.0
sprocket bolt
Timing chain Tighten 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified
tensioner adjuster procedure
No.3 bolt
Timing chain Tighten 55 N.m (5.5 kgf-m, 40.0 lb-ft) by the specified
tensioner adjuster procedure
No.3 nut
RH bank 1st timing 80 8.0 58.0
chain intake camshaft
sprocket bolt
Timing chain 27 2.7 19.5
tensioner nut
Idler sprocket No.1 45 4.5 32.5

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2006 Suzuki XL-7
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bolt
Timing chain 11 1.1 8.0
tensioner adjuster
No.1 bolt
Timing chain guide 9 0.9 6.5
No.1 and No.2 bolt
Timing chain 11 1.1 8.0
tensioner adjuster
No.2 bolt
Camshaft housing Tighten 12 N.m (1.2 kgf-m, 9.0 lb-ft) by the specified
bolt procedure
Timing chain guide 11 1.1 8.0
No.3 bolt
Cylinder head bolt Tighten 53 N.m (5.3 kgf-m, 38.5 lb-ft), 84 N.m (8.4 kgf-m,
61.0 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 53 N.m (5.3 kgf-m, 38.5
lb-ft) and 105 N.m (10.5 kgf-m, 76.0 lb-ft) by the specified
procedure
Cylinder head bolt Tighten 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified
(hex hole bolt) procedure
Connecting rod 45 4.5 32.5
bearing cap nut
Engine side 55 5.5 40.0
mounting bracket nut
Transmission case 85 8.5 61.5 for M/T vehicle
bolt and nut
Transmission case 80 8.0 58.0 for A/T vehicle
bolt and nut
Torque converter bolt 65 6.5 47.0
Exhaust No.1 pipe 50 5.0 36.5
bolt and nut
Crankcase bolt Tighten 42 N.m (4.2 kgf-m, 30.5 lb-ft), 0 N.m (0 kgf-m, 0 lb- 10 mm (0.39 in.)
ft), 42 N.m (4.2 kgf-m, 30.5 lb-ft) and 60 N.m (6.0 kgf-m, thread diameter
43.5 lb-ft) by the specified procedure
Crankcase bolt Tighten 27 N.m (2.7 kgf-m, 19.5 lb-ft) by the specified 8 mm (0.31 in.)
procedure thread diameter
Flywheel (or drive 70 7.0 51.0
plate) bolt
Engine block heater 11 1.1 8.0
mounting bolt

NOTE: The specified tightening torque is also described in the following.

TIMING CHAIN COVER COMPONENTS

LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Components

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

1st Timing Chain and Chain Tensioner Components

RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Components

CAMSHAFTS AND VALVE LASH ADJUSTERS COMPONENTS

VALVES AND CYLINDER HEADS 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 Fastener Information.

SPECIAL TOOLS AND EQUIPMENT


RECOMMENDED SERVICE MATERIAL

RECOMMENDED SERVICE MATERIAL SPECIFICATION


Material SUZUKI recommended product or Specification
Sealant SUZUKI Bond No.1215 P/No.: 99000-31110
Thread lock cement Thread Lock Cement Super 1333B P/No.: 99000-32020
Water tight sealant SUZUKI Bond No.1207B P/No.: 99000-31140
SUZUKI Bond No.1207F P/No.: 99000-31250

NOTE: Required service material is also described in the following.

TIMING CHAIN COVER COMPONENTS

LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Components

1st Timing Chain and Chain Tensioner Components

RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Components

CAMSHAFTS AND VALVE LASH ADJUSTERS COMPONENTS

VALVES AND CYLINDER HEADS COMPONENTS

PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS


COMPONENTS

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

SPECIAL TOOL

SPECIAL TOOLS DESCRIPTION


09355-35754-600 09367-04002

Hose 3-way joint

09911-97710 09911-97811

Oil seal guide Oil seal installer

09913-75510 09915-64510

Bearing installer Compression gauge


set (0-20 kg/cm2 ,
M14)

09915-64530 09915-67010

Compression gauge Compression gauge


hose attachment (C)

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

09915-67311 09916-14510

Vacuum gauge Valve lifter

09916-14910 09916-34542

Valve spring Reamer handle


compressor
attachment

09916-37810 09916-38210

Valve guide reamer (6 Valve guide reamer


mm) (11 mm)

09916-44910 09916-58210

Valve guide installer Valve guide installer

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

& remover handle

09916-77310 09916-84511

Piston ring Forceps


compressor (50-125
mm)

09917-47011 09917-68221

Vacuum pump gauge Camshaft pulley


holder

09917-87810 09917-98221

Valve guide installer Valve guide stem


attachment attachment
(protrusion: 13.5 mm)

09918-08210 09919-28610

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2006 Suzuki XL-7
2006 ENGINE Engine Mechanical - XL-7

Vacuum gauge hose Protector sleeve


joint

09924-17811 09926-58010

Flywheel holder Bearing remover


attachment

09944-36011

Steering wheel
remover

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