timing chain SUZUKI JIMNY 2005 3.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-61
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.

Downloaded from www.Manualslib.com manuals search engine 6A1-80 ENGINE MECHANICAL (M13 ENGINE)
REMOVAL
1) Remove engine assembly from vehicle as previously out-
lined.
2) Remove clutch cover, clutch disc and flywheel (drive plate
for A/T) by using special tool.
Special tool
(A) : 09924-17810
3) Remove the following parts from engine as previously out-
lined.
Oil pan and oil pump strainer
Intake manifold and exhaust manifold
Cylinder head cover
Timing chain cover
Timing chain guide, chain tensioner adjuster, chain ten-
sioner, timing chain and crankshaft timing sprocket
Camshaft, tappet and shim
Cylinder head assembly
Piston and connecting rod
4) Remove rear oil seal housing (1).
5) Loosen bearing cap No.1 and No.2 bolts in such order as
indicated in figure and remove them.
6) Remove crankshaft from cylinder block.

Downloaded from www.Manualslib.com manuals search engine 6A1-92 ENGINE MECHANICAL (M13 ENGINE)
8) Install rear oil seal housing (1) and tighten bolts to specified
torque by using special tool.
Special tool
(A) : 09911-97720
Tightening torque
Rear oil seal housing bolts : 11 N·m (1.1 kg-m, 8.0 lb-ft)
9) Install flywheel (drive plate for A/T).
Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts applied with sealant to specifica-
tion.
“A” : Sealant 1215 99000-31110
Special tool
(A) : 09924-17810
Tightening torque
Flywheel or drive plate bolts
(a) : 70 N·m (7.0 kg-m, 51.0 lb-ft)
10) Install the following parts to engine as previously outlined.
Piston and connecting rod
Cylinder head assembly
Camshaft, tappet and shim
Timing chain guide, chain tensioner adjuster, chain ten-
sioner, timing chain and crankshaft timing sprocket
Timing chain cover
Cylinder head cover
Intake manifold and exhaust manifold
Oil pan and oil pump strainer
11) Install clutch to flywheel (vehicle with M/T) referring to
“Clutch Cover, Clutch Disc, Flywheel and Release Bearing”
in Section 7C.
12) Install engine assembly to vehicle referring to “Engine
Assembly” in this section.
A : Crankshaft side

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-93
Required Service Material
Tightening Torque Specification
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant SUZUKI BOND NO. 1207C
(99000-31150)To apply to mating surface of cylinder block and oil
pan.
To apply to mating surface of cylinder block and
timing chain cover.
To apply to sealing surface of cylinder head cover.
To apply to mating surface to rear oil seal housing.
SUZUKI BOND NO. 1207B
(99000-31140)To apply to mating surface of cylinder block, cylin-
der head and timing chain cover.
SUZUKI BOND NO. 1215
(99000-31110)To flywheel (M/T) or drive plate (A/T) bolts.
Fastening partTightening torque
Nm kg-m lb-ft
Oil pressure switch 14.0 1.4 10.5
Camshaft housing bolts
(for replacement of shim)8.0 0.8 6.0
Camshaft housing bolts 11.0 1.1 8.0
Cylinder head cover bolts 8.0 0.8 6.0
Intake manifold bolts and nuts 25.0 2.5 18.0
Exhaust manifold bolts and nuts 55.0 5.5 40.0
Exhaust pipe bolts 50.0 5.0 36.5
Exhaust manifold stiffener bolts 50.0 5.0 36.5
Oil pump strainer bolt 11.0 1.1 8.0
Oil pump strainer bracket bolt 11.0 1.1 8.0
Oil pan bolts and nuts 11.0 1.1 8.0
Oil pan drain plug 50.0 5.0 36.5
Timing chain cover bolts and nut 23.0 2.3 17.0
Crankshaft pulley bolt 150.0 15.0 108.5
Oil pump rotor plate bolts 11.0 1.1 8.0
Timing chain No.1 guide bolts 9.0 0.9 6.5
Timing chain tensioner adjuster bolts 11.0 1.1 8.0
Venturi plug 5.0 0.5 3.5
Cylinder head bolt for M8 22.0 2.2 16.0
Cylinder head bolts for M10 a) Tighten 40 N·m
b) Turn 60°
c) Turn 60°a) Tighten 4.0 kg-m
b) Turn 60°
c) Turn 60°a) Tighten 29.0 lb-ft
b) Turn 60°
c) Turn 60°
Connecting rod bearing cap nuts a) Tighten 15 N·m
b) Turn 45°
c) Turn 45°a) Tighten 1.5 kg-m
b) Turn 45°
c) Turn 45°a) Tighten 11.0 lb-ft
b) Turn 45°
c) Turn 45°
Engine mounting bolts 50.0 5.0 36.5

Downloaded from www.Manualslib.com manuals search engine 6A1-94 ENGINE MECHANICAL (M13 ENGINE)
Special Tool
Crankshaft bearing cap No.1 bolts
(for inspection of crankshaft thrust play)50.0 5.0 36.5
Crankshaft bearing cap No.2 bolts 22.0 2.2 16.0
Sensor plate bolts 11.0 1.1 8.0
Crankshaft bearing cap No.1 bolts a) Tighten 50 N·m
b) Turn 60°a) Tighten 5.0 kg-m
b) Turn 60°a) Tighten 36.5 lb-ft
b) Turn 60°
Rear oil seal housing bolts 11.0 1.1 8.0
Flywheel or drive plate bolts 70.0 7.0 51.0
Torque converter bolts 20.0 2.0 14.5
Timing chain tensioner bolt 22.0 2.2 16.0
Knock sensor 23.0 2.3 16.5
Cylinder block and transmission fasten-
ing bolts and nuts (vehicle with M/T)94.0 9.4 68.0
Cylinder block and transmission fasten-
ing bolts and nuts (vehicle with A/T)80.0 8.0 58.0 Fastening partTightening torque
Nm kg-m lb-ft
09911-97720 09911-97820 09913-75520 09915-47330
Oil seal guide Oil seal installer Bearing installer Oil filter wrench
09915-64510-001 09915-64510-002 09915-64530 09915-67010
Compression gauge Connector Hose Attachment

Downloaded from www.Manualslib.com manuals search engine IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-9
5) Fix ignition timing to initial one as follows.
a) When using SUZUKI scan tool:
Select “MISC” mode on SUZUKI scan tool and fix ignition
timing to initial one.
b) Without using SUZUKI scan tool: (vehicle without immobi-
lizer indicator lamp)
Disconnect scan tool from DLC, and connect D and E ter-
minals of monitor connector (1) or E to body ground by
using service wire so that ignition timing is fixed on initial
one.
6) Using timing light (1), check that ignition timing is within
specification.
Initial ignition timing (test switch terminal grounded or
fixed with SUZUKI scan tool)
5
± 3° BTDC at idle speed
Ignition order
1-3-4-2
7) If ignition timing is out of specification, check the followings:
CKP sensor
CKP sensor plate
TP sensor
Test switch signal circuit
VSS
Timing chain cover installation
8) After checking Initial Ignition Timing, release ignition timing
fixation by using SUZUKI scan tool or disconnect service
wire from monitor connector.
9) With engine idling (test switch terminal ungrounded, throttle
opening at closed position and car stopped), check that igni-
tion timing is about 7°–17° BTDC. (Constant variation within
a few degrees from 7°–17° indicates no abnormality but
proves operation of electronic timing control system.) Also,
check that increasing engine speed advances ignition timing.
If above check results are not satisfactory, check CKP sen-
sor, test switch terminal circuit and ECM.