check engine SUZUKI JIMNY 2005 3.G Service Workshop Manual

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Piston pin clearance:
Check piston pin clearance in small end and piston. Replace
connecting rod and/or piston if its small end is badly worn or
damaged or if measured clearance exceeds limit.
Piston pin clearance in connecting rod small end
0.003 – 0.014 mm (0.0001 – 0.0006 in.)
Piston pin clearance in piston
0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Small-end bore for connecting rod
20.003 – 20.011 mm (0.7875 – 0.7878 in.)
Piston pin diameter
19.997 – 20.000 mm (0.7873 – 0.7874 in.)
Piston bore
20.006 – 20.014 mm (0.7876 – 0.7880 in.)
Piston Rings
To measure end gap, insert piston ring (1) into cylinder bore and
then measure the gap by using thickness gauge (2).
If measured gap is out of specification, replace ring.
Piston ring end gap
Connecting Rod
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 con-
necting rod.
Side clearance for connecting rod big-end
Standard : 0.25 – 0.40 mm (0.0098 – 0.0157 in.)
Limit : 0.55 mm (0.0217 in.)
NOTE:
Decarbon and clean top of cylinder bore before inserting
piston ring.
Item Standard Limit
Top ring0.20 – 0.35 mm
(0.0079 – 0.0138 in.)0.7 mm
(0.0276 in.)
2nd ring0.30 – 0.45 mm
(0.0118 – 0.0177 in.)1.0 mm
(0.0039 in.)
Oil ring0.20 – 0.70 mm
(0.0079 – 0.0276 in.)1.5 mm
(0.059 in.)
“a” : 120 mm (4.72 in.)

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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.)
Connecting rod bolt diameter (Plastic deformation tightening
bolt)
Measure connecting rod (1) bolt (2) for diameter “A” on 32
mm (1.25 in.) from bolt mounting surface and diameter “B”
on 40 mm (1.57 in.) from bolt mounting surface by using a
micrometer (3).
Calculate difference in diameters (“A” – “B”). If it exceeds
limit, replace connecting rod.
Connecting rod bolt measurement points
“a” : 32 mm (1.25 in.)
“b” : 40 mm (1.57 in.)
Connecting rod bolt diameter difference
Limit (“A” – “B”) : 0.1 mm (0.004 in.)
Crank Pin and Connecting Rod Bearings
Inspect crank pin for uneven wear or damage. Measure
crank pin for out-of-round or taper with a micrometer. If crank
pin is damaged or out-of-round or taper is out of limit,
replace crankshaft or regrind crank pin to undersize and use
undersize bearing.
Crank pin diameter
Out-of-round : A – B
Taper : a – b
Crank pin taper and out-of-round
Limit : 0.01 mm (0.0004 in.)
Connecting rod
bearing sizeCrank pin diameter
Standard41.982 – 42.000 mm
(1.6528 – 1.6535 in.)
0.25 mm (0.0098 in.)
undersize41.732 – 41.750 mm
(1.6430 – 1.6437 in.)

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Rod bearing :
Inspect bearing shells for signs of fusion, pitting, burn or flak-
ing and observe contact pattern. Bearing shells found in
defective condition must be replaced.
Two kinds of rod bearing are available; standard size bear-
ing and 0.25 mm (0.0098 in.) undersize bearing. For identifi-
cation 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.
Rod bearing clearance:
1) Before checking bearing clearance, clean bearing and crank
pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gauging plastic (1) to full width of crank pin
as contacted by bearing (parallel to crankshaft), avoiding oil
hole.
4) Install rod bearing cap (1) to connecting rod.
When installing cap, be sure to point arrow mark (2) on cap
to crankshaft pulley side, as shown in figure. After applying
engine oil to rod bolts and tighten cap nuts (3) gradually as
follows.
a) Tighten all cap nuts to 15 N·m (1.5 kg-m, 11.0 lb-ft).
b) Retighten them to 45°.
c) Repeat step b).
Tightening torque
Connecting rod bearing cap nuts
(a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) and extra tightening 45°
twice
5) Remove cap and using a scale (1) on gauging plastic (2)
envelope, measure gauging plastic width at the widest point
(clearance).
If clearance exceeds its limit, use a new standard size bear-
ing and remeasure clearance.
Connecting rod bearing clearance
Standard : 0.029 – 0.047 mm (0.0011 – 0.0019 in.)
Limit : 0.065 mm (0.0026 in.)
1. Red paint

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6) If clearance can not be brought to within its limit even by
using a new standard size bearing, regrind crankpin to
undersize and use 0.25 mm undersize bearing.
ASSEMBLY
1) Install piston pin to piston (1) and connecting rod (2):
a) After applying engine oil to piston pin and piston pin holes
in piston and connecting rod.
b) Fit connecting rod as shown in figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
2) Install piston rings to piston :
a) As indicated in figure, 1st and 2nd rings have “T” mark
respectively. When installing these piston rings to piston,
direct marked side of each ring toward top of piston.
b) 1st ring (1) differs from 2nd ring (2) in thickness, shape and
color of surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.
c) When installing oil ring (3) install spacer first and then two
rails.
3) After installing three rings (1st, 2nd and oil rings), distribute
their end gaps as shown in figure. NOTE:
After checking the rod bearing clearance, make sure to
check connecting rod bolt diameter.
Refer to “Inspection” of “Connecting Rod”.
NOTE:
Circlip should be installed with its cut part facing as
shown in figure. Install so that circlip end gap comes
within such range as indicated by arrow.
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap

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5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side.
After applying oil to rod bolts and tighten cap nuts (3) gradu-
ally as follows.
a) Tighten all cap nuts to 15 N·m (1.5 kg-m, 11.0 lb-ft).
b) Retighten them to 45°.
c) Repeat Step b).
Tightening torque
Connecting rod bearing cap nuts
(a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) and extra tightening 45°
twice.
6) Reverse removal procedure for installation as previously out-
lined.
7) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
8) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
9) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
10) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
11) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
12) Connect negative cable at battery.
13) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection. NOTE:
Before installing bearing cap, make sure to check con-
necting rod bolt diameter.
Refer to “Inspection” of “Connecting Rod” in this sec-
tion.

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18) Remove heated oxygen sensor bracket from cylinder head
and detach No.1 heated oxygen sensor coupler from its
bracket.
19) Release accelerator cable (1) from clamp (2) (for left hand
steering vehicle only) and disconnect accelerator cable from
throttle body.
20) Remove canister purge hose bracket from intake manifold.
21) Disconnect the following hoses:
Brake booster hose (3) from intake manifold
Canister purge hose (4) from EVAP canister purge valve
Fuel feed and return hoses (5) from each pipe
Heater inlet and outlet hoses from each pipe
Vacuum hose (6) (to check valve)
22) Disconnect exhaust pipe (1) from exhaust manifold.
23) Remove clutch housing (torque converter housing for A/T)
lower plate (1).
24) With drive plate locked by using a proper size rod (1) or the
like, remove torque converter bolts (2) (vehicle with A/T).
25) Support transmission. For A/T vehicle, do not jack under A/T
oil pan to support transmission.

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26) Remove bolts and nuts fastening cylinder block and trans-
mission.
27) Install board (1) or the like on A/C condenser. This prevents
damage to condenser fins when lifting and lowering engine
assembly.
28) Install lifting device.
29) Remove right and left engine mounting bracket bolts (1).
30) Before lifting engine, check to ensure all hoses, electric
wires and cables are disconnected from engine.
31) Remove engine assembly from chassis and transmission by
lifting a little, sliding toward front side, and then carefully
hoist engine assembly.

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Install seal ring and exhaust pipe to exhaust manifold.
Tighten pipe fasteners to specified torque.
Tightening torque
Exhaust pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
6) Reverse disconnected hoses, cables and electric wires for
connection.
7) Install air cleaner outlet hoses.
8) Install radiator with cooling fan and connect A/T fluid hoses
(vehicle with A/T), radiator inlet and outlet hoses referring to
“Water Pump Belt and Cooling Fan” and “Radiator” in Sec-
tion 6B.
9) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
10) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
11) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
12) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
13) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
14) Connect negative cable at battery.
15) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.

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Tighten bearing cap No.1 bolts (1) – (10) and No.2 bolts (11) –
(20) gradually as follows.
1) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft)
according to numerical order in figure.
2) In the same manner as in Step 1), tighten them to 50 N·m
(5.0 kg-m, 36.5 lb-ft).
3) In the same manner as in step 1), retighten them to 60°.
4) Tighten bolts (11) – (20) to 22 N·m (2.2 kg-m, 16.0 lb-ft)
according to numerical order in figure.
Tightening torque
Crankshaft bearing cap No.1 bolts (1) – (10) :
50 N·m (5.0 kg-m, 36.5 lb-ft) and extra tightening 60°
Crankshaft bearing cap No.2 bolts (11) – (20) :
22 N·m (2.2 kg-m, 16.0 lb-ft)
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 : 0.11 – 0.31 mm (0.0043 – 0.0122 in.)
Limit : 0.35 mm (0.0138 in.)
Out-of-round and taper 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 dif-
ference, 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.
Crankshaft out-of-round and taper
Limit : 0.01 mm (0.0004 in.)
Out-of-round : A – B
Taper : a – b
Main Bearings
General information
Service main bearings are available in standard size and
0.25 mm (0.0098 in.) undersize, and each of them has 5
kinds of bearings differing in tolerance.
NOTE:
After checking the thrust play, check for thread deforma-
tion of each bearing cap No.1 bolt according to previous
mentioned “Main Bearing Cap No.1 Bolt” once again.

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Upper half of bearing (1) has an oil groove (2) as shown in
figure.
Install this half with oil groove to cylinder block.
Lower half of bearing does not have an oil groove.
Visual inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Do not replace either half without replacing the other half.
Main bearing clearance
Check clearance by using gauging plastic according to the follow-
ing procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) the full width of bearing
(parallel to crankshaft) on journal, avoiding oil hole.
4) Tighten bearing cap No.1 bolts (1) – (10) and No.2 bolts (11)
– (20) gradually as follows.
a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft)
according to numerical order in figure.
b) In the same manner as in Step a), tighten them to 50 N·m
(5.0 kg-m, 36.5 lb-ft).
c) In the same manner as in step a), retighten them to 60°.
d) Tighten bolts (11) – (20) to 22 N·m (2.2 kg-m, 16.0 lb-ft)
according to numerical order in figure.
Tightening torque
Crankshaft bearing No.1 bolts (1) – (10) :
50 N·m (5.0 kg-m, 36.5 lb-ft) and extra tightening 60°
Crankshaft bearing No.2 bolts (11) – (20) :
22 N·m (2.2 kg-m, 16.0 lb-ft)
NOTE:
Do not rotate crankshaft while gauging plastic is
installed.