Engine drive belt SUZUKI JIMNY 2005 3.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-25
Excessive detonation
(The engine makes
sharp metallic knocks
that change with throt-
tle opening.
Sounds like pop corn
popping.)Engine overheating Refer to “Overheating” of this table.
Faulty spark plug Spark plugs in Section 6F.
Clogged fuel filter and fuel lines Diagnostic Flow Table B-3
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
Poor performance of knock sensor, ECT
sensor or MAP sensorKnock sensor in this section, ECT
sensor or MAP sensor in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Excessive combustion chamber deposits Piston and cylinder head in Section
6A1.
Overheating
Inoperative thermostat Thermostat in Section 6B.
Faulty A/C condenser fan motor or its cir-
cuitA/C condenser fan control system
check in Section 6E.
Loose or slip water pump belt ITEM1-1 Drive belt inspection and
change in Section 0B.
Poor water pump performance Water pump in Section 6B.
Clogged or leaky radiator Radiator in Section 6B.
Improper engine oil grade ITEM1-3 Engine oil and oil filter
change in Section 0B.
Clogged oil filter or oil strainer Oil pressure check in Section 6A1.
Poor oil pump performance Oil pressure check in Section 6A1.
Dragging brakes Diagnosis Table in Section 5.
Slipping clutch Diagnosis Table in Section 7C.
Blown cylinder head gasket Valves and cylinder head in Section
6A1.
Poor gasoline mileage
Faulty ignition coil Ignition coil assembly in Section 6F.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty TP sensor, ECT sensor or MAP
sensorTP sensor, ECT sensor or MAP sen-
sor in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
High idle speed Refer to item “Improper Engine Idle
Speed” previously outlined.
Low compression Previously outlined.
Poor valve seating Valves and cylinder head in Section
6A1.
Dragging brakes Diagnosis Table in Section 5.
Slipping clutch Diagnosis Table in Section 7C.
Thermostat out of order Thermostat in Section 6B.
Improper tire pressure Refer to Section 3F. Condition Possible Cause Reference Item

Downloaded from www.Manualslib.com manuals search engine 6A1-32 ENGINE MECHANICAL (M13 ENGINE)
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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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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6) Install exhaust manifold stiffener and exhaust pipe referring
to “Exhaust Manifold” in this section.
7) Install camshafts, timing chain and chain cover referring to
“Camshaft, Tappet and Shim”, “Timing Chain and Chain
Tensioner” and “Timing Chain Cover” in this section.
8) Install cylinder head cover and oil pan referring to “Cylinder
Head Cover” and “Oil Pan and Oil Pump Strainer” in this sec-
tion.
9) Install intake manifold stiffener and connect each hoses and
electric lead wires securely.
10) Install air cleaner outlet hoses.
11) 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.
12) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
13) 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.
14) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
15) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
16) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
17) Connect negative cable at battery.
18) 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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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.

Downloaded from www.Manualslib.com manuals search engine 6A1-78 ENGINE MECHANICAL (M13 ENGINE)
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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Water Pump Belt and Cooling Fan
REMOVAL
1) Remove radiator shroud securing bolts (1).
2) Remove radiator by referring to “Radiator” in this section.
3) Loosen water pump drive belt tension.
4) Remove cooling fan by removing securing nuts.
Remove power steering and/or compressor drive belt before
removing water pump belt.
5) Remove pump belt.
INSTALLATION
Once cooling fan or water pump belt has been removed, make
sure to tighten bolts and nuts securely in reinstallation and adjust
pump belt tension to specification. For specified tension, refer to
“Water Pump Belt Tension” in this section.
WATER PUMP BELT TENSION INSPECTION
1) Check belt tension. It should be within specification. Refer to
“Water Pump Belt Tension” in this section.
2) If tension is out of specification, adjust it.
For its adjustment, refer to “Water Pump Belt Tension” in this
section.
After adjustment, be sure to tighten bolts.
COOLING FAN CLUTCH INSPECTION
Inspect fluid coupling for oil leakage.
If necessary, replace fan clutch assembly. Do not disassemble
clutch assembly.

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Water Pump
COMPONENTS
REMOVAL
1) Drain cooling system.
Refer to Step 6) of “Cooling System Flush and Refill” in this
section.
2) Remove the radiator shroud.
3) Remove radiator referring to “Radiator” in this section.
4) Loosen water pump drive belt tension.
Then remove water pump pulley (2) with fan clutch (3) and
pump drive belt.
5) Remove water pump assembly (1).
1. Water pump 4. Radiator cooling fan 7. Radiator cooling fan mounting bolt
2. Water pump pulley 5. Water pump mounting bolts Tightening Torque
3. Radiator cooling fan clutch 6. Water pump pulley and fan clutch mounting nuts
1. Drain plug

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INSPECTION
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes an abnormal
noise, replace it.
INSTALLATION
1) Apply sealant to water pump (1).
“A” : Sealant 99000-31150
Sealant quantity for mating surface of water pump
Width “a” : 3mm (0.12 in.)
Height “b” : 2mm (0.08 in.)
2) Install water pump (1) to cylinder block.
Tightening torque
Water pump bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
3) Install water pump pulley (2) with fan clutch (3).
Tightening torque
Water pump pulley nuts (b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Fan clutch bolts (c) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
4) Install water pump drive belt, cooling fan and radiator
shroud.
5) Adjust water pump belt tension.
Refer to “Water Pump Belt Tension” in this section.
6) Connect negative cable at battery.
7) Fill the cooling system.NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-35
Crankshaft position sensor
INSPECTION
Check crankshaft position sensor referring to step 2 and 6 of
“DTC P0335 (No.23) Flow Table” in Section 6. If malfunction is
found, replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Remove generator drive belt, loosen pivot bolt and move
generator outward.
3) Disconnect connector from crankshaft position sensor.
4) Remove crankshaft position sensor (1) from cylinder block.
INSTALLATION
1) Check to make sure that crankshaft position sensor and pul-
ley tooth is free from any metal particles and damage.
2) Install crankshaft position sensor to cylinder block.
3) Connect connector to it securely.
4) Adjust generator belt tension, refer to “Water Pump Belt Ten-
sion” in Section 6B.
5) Connect negative cable to battery.