Head torque SUZUKI JIMNY 2005 3.G Service User Guide

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Timing Chain Cover
REMOVAL
1) Disconnect negative cable at battery.
2) Remove A/C compressor and/or P/S pump belt (if
equipped).
3) Remove generator belt.
4) Drain engine oil.
[A] : Sealant application
amount3. Oil seal
: Apply engine oil to oil seal lip.8. Cylinder head cover
: Apply sealant 99000-31150 to the sealing
point for timing chain cover mating surface
and cylinder head gasket sealing point.
Refer to “Cylinder Head Cover Installation”.
“a” : 3 mm (0.12 in.) 4. Timing chain cover Tightening torque
: Apply sealant 99000-31140 to the mating surface
of cylinder and cylinder head.
: Apply sealant 99000-31150 to the mating surface
of timing chain cover referring to the figure of Step
1) in INSTALLATION.
“b” : 2 mm (0.08 in.) 5. Pin Do not reuse.
1. Crankshaft pulley bolt 6. Cylinder head cover gasket
2. Crankshaft pulley 7. Timing chain cover mounting bolts

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INSPECTION
Check oil seal (1) lip for fault or other damage.
Replace as necessary.
Special tool
(A) : 09913-75520
INSTALLATION
Reverse removal procedure to install timing chain cover, noting
the following points.
1) Apply sealant “A” to mating surface of cylinder and cylinder
head and “B” to mating surface of timing chain cover as
shown in figure.
“A” : Sealant 99000-31140
“B” : Sealant 99000-31150
Sealant amount for timing chain cover
Width “a” : 3 mm, 0.12 in.
Height “b” : 2 mm, 0.08 in.
2) Apply engine oil to oil seal lip, then install timing chain cover
(1) and water outlet pipe (2).
Tighten bolts and nut to specified torque.
Tightening torque
Timing chain cover bolts and nut
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft) NOTE:
When installing new oil seal, tap it in until its surface is
flash with edge of timing chain cover (2).
To install oil seal, use special tool (Bearing installer).
NOTE:
Before installing timing chain cover, check that pin is
securely fitted.

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3) Install crankshaft pulley (1). Tighten bolt (2) to specified
torque.
To lock crankshaft pulley, use special tool with it as shown in
figure.
Special tool
(A) : 09917-68221
Tightening torque
Crankshaft pulley bolt (a) : 150 N·m (15.0 kg-m, 108.5 lb-ft)
4) Install P/S pump bracket (1), P/S pump (2) and A/C com-
pressor and/or P/S pump belt tension pulley (3) (if equipped)
referring to “Power Steering Pump” in Section 3B1.
5) Install cylinder head cover referring to “Cylinder Head Cover”
in this section.
6) Install oil pan referring to “Oil Pan and Oil Pump Strainer” in
this section.
7) 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.
8) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B for adjusting procedure.
9) 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 for adjusting proce-
dure.
10) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
11) Verify that there is no coolant leakage, oil leakage and A/T
fluid leakage (vehicle with A/T) at each connection.

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Oil Pump
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing chain cover, referring to “Timing Chain
Cover” in this section.
DISASSEMBLY
1) Remove rotor plate (1) by removing its mounting bolts.
[A] : Sealant application
amount4. Timing chain cover 10. Circlip
: Apply sealant 99000-31140 to the mating surface of cylinder and
cylinder head.
: Apply sealant 99000-31150 to mating surface of timing chain cover
referring to the figure of Step 1) in “Timing Chain Cover Installation”.
“a” : 3 mm (0.12 in.) 5. Pin 11. Oil pump mounting bolt
“b” : 2 mm (0.08 in.) 6. Oil seal 12. Timing chain cover mounting bolts
1. Rotor plate 7. Relief valve Tightening torque
2. Outer rotor 8. Spring Do not reuse.
3. Inner rotor 9. Retainer Apply thin coat of engine oil to sliding
surface of each parts.

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Timing Chain and Chain Tensioner
REMOVAL
1) Remove timing chain cover referring to “Timing Chain
Cover”.
2) Align both intake and exhaust camshaft timing sprocket
marks (1) with notches (2) of cylinder head respectively by
turning crankshaft.
3) Remove timing chain tensioner adjuster assembly (3).
4) Remove timing chain tensioner (4).
5) Remove timing chain No.1 guide (5).
6) Remove timing chain (6) with crankshaft timing sprocket (7).
1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly Tightening torque
2. Timing chain 6. Chain tensioner adjuster mounting bolt Apply engine oil to sliding surface.
3. Timing chain No.1 guide 7. Chain tensioner mounting bolt
4. Timing chain tensioner 8. Chain guide mounting bolt
CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than its allowable turning
range described in “INSTALLATION” section.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.
45
6
21
1
3
7

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INSTALLATION
1) Check that match marks (1) on intake and exhaust camshaft
timing sprockets are in match with notches (2) on cylinder
head as shown in figure.
2) Set key (3) and turn crankshaft to position key on upside of
crankshaft.
3) Install timing chain by aligning dark blue plate (1) of timing
chain and mark (2) on camshaft timing sprocket and then
aligning dark blue plate (3) and triangle mark (4) as shown in
figure.
4) Fit crankshaft timing sprocket to timing chain by aligning gold
plate (5) of timing chain and mark (6) on crankshaft timing
sprocket. Then install crankshaft timing sprocket fitted with
chain to crankshaft.
5) Apply engine oil to sliding surface of timing chain No.1 guide
(1) and install it as shown in figure.
Tighten guide bolts to specified torque.
Tightening torque
Timing chain No.1 guide bolts
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft) CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than such an extent (“a”,
“b”) as shown in figure.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.
“a” :90°5. Crankshaft allowable turning range.
By key on crankshaft, within 90° from top on both right and left.
“b” :15°4. Camshaft (IN and EX) allowable turning range.
By marks on camshaft timing sprocket within 15° from notches on
cylinder head on both right and left.

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Camshaft, Tappet and Shim
REMOVAL
1) Remove cylinder head cover and oil pan referring to “Cylin-
der Head Cover” and “Oil Pan and Oil Pump Strainer” in this
section.
2) Remove timing chain cover referring to “Timing Chain Cover”
in this section.
3) Remove timing chain referring to “Timing Chain and Chain
Tensioner” in this section.
4) Loosen camshaft housing bolts in such order as indicated in
figure and remove them.
5) Remove camshaft housings.
6) Remove intake and exhaust camshafts.
1. Intake camshaft 4. Tappet Tightening torque
2. Exhaust camshaft 5. Camshaft housing Apply engine oil to sliding surface of each part.
3. Shim
: Shim No. on it faces tappet side.6. Camshaft housing bolt

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Check clearance by using gauging plastic. Checking procedure is
as follows.
1) Clean housings and camshaft journals.
2) Remove all tappets with shims.
3) Install camshafts to cylinder head.
4) Place a piece of gauging plastic to full width of journal of
camshaft (parallel to camshaft).
5) Install camshaft housing.
6) Tighten camshaft housing bolts in such order as indicated in
figure a little at a time till they are tightened to specified
torque.
Tightening torque
Camshaft housing bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
7) Remove housing, and using scale (2) on gauging plastic (1)
envelop, measure gauging plastic width at its widest point.
Camshaft journal clearance
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 dif-
ference from specification is greater.
Camshaft journal outside diameter [A]
Camshaft journal bore diameter [B] NOTE:
Do not rotate camshaft while gauging plastic is installed.
Standard Limit
0.045 – 0.087 mm
(0.0018 – 0.0034 in.)0.12 mm
(0.0047 in.)
Item Standard
No.126.934 – 26.955 mm
(1.0604 – 1.0612 in.)
Other22.934 – 22.955 mm
(0.9029 – 0.9037 in.)
Item Standard
No.127.000 – 27.021 mm
(1.0630 – 1.0638 in.)
Other23.000 – 23.021 mm
(0.9055 – 0.9063 in.)

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5) After applying engine oil to housing bolts, tighten them tem-
porarily first. Then tighten them by the following numerical
order in figure. Tighten a little at a time and evenly among
bolts and repeat tightening sequence two or three times
before they are tightened to specified torque.
Tightening torque
Camshaft housing bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
6) Install timing chain with crankshaft sprocket referring to
“Timing Chain and Chain Tensioner” in this section.
7) Install timing chain cover referring to “Timing Chain Cover” in
this section.
8) Check valve lashes referring to “Valve Lash” in this section.
9) Install cylinder head cover and oil pan referring to “Cylinder
Head Cover” and “Oil Pan and Oil Pump Strainer” in this sec-
tion.
10) 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.
11) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
12) 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.
13) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
14) Verify that there is no coolant leakage, oil leakage and A/T
fluid leakage (vehicle with A/T) at each connection.

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Valves and Cylinder Head
1. Valve cotters 6. Intake valve 11. Cylinder head gasket
: “TOP” mark provided on gasket comes to
crankshaft pulley side, facing up.
2. Valve spring retainer 7. Exhaust valve 12. Knock pin
3. Valve spring 8. Valve guide Tightening torque
4. Valve stem seal 9. Cylinder head bolt
1) Tighten all bolts at 40 N·m (4.0 kg-m)
2) Turn all bolts to 60°
3) Then, turn all bolts to 60° once againDo not reuse.
5. Valve spring seat 10. Cylinder head
Apply engine oil to sliding surface of each
part.