SECTION 6A1 SUZUKI JIMNY 2005 3.G Service Owner's Guide

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Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove A/C compressor and/or P/S pump belt (if
equipped).
5) Remove generator belt.
6) Drain engine oil.
7) Drain coolant.
8) Disconnect radiator inlet and outlet hoses from each pipe.
9) Disconnect A/T fluid hoses (2) (vehicle with A/T) and release
its clamps. Place some container under radiator to receive
A/T fluid which will flow out when hose is disconnected.
10) Remove fan shroud upper bolts and install board (1) or the
like. This prevents damage to radiator fins when removing
and installing radiator.
11) Remove radiator with cooling fan referring to Section 6B.
Then remove water pump pulley.
12) With hose connected, detach P/S pump from its bracket (if
equipped) referring to “Power Steering Pump” in Section
3B1.
13) If vehicle equipped with A/C compressor, work of right hand
steering vehicle differs from its of left hand steering vehicle.
Each work is as follows. WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed P/S pump at a place where no damage
will be caused during removal and installation of engine
assembly.

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a) For right hand steering vehicle:
With hose connected, detach A/C compressor from its
bracket.
b) For left hand steering vehicle:
i) Recover refrigerant from refrigeration system using recov-
ery and recycling equipment.
ii) Disconnect magnet clutch lead wire.
iii) Remove suction pipe and disconnect discharge pipe from
A/C compressor.
iv) Remove A/C compressor from its bracket.
When servicing above steps, refer to “Compressor” in Section 1B.
14) Remove air cleaner outlet No.1 and No.2 hoses.
15) Disconnect the following electric lead wires:
TP sensor (1)
MAP sensor (2)
CKP sensor (if equipped) (3)
CMP sensor
ECT sensor
Heated oxygen sensor
EGR valve (if equipped)
IAC valve (4)
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Generator
Starting motor
Oil pressure switch
Ground terminal from intake manifold and cylinder block
Each wire harness clamps
16) Remove intake manifold bracket (7) with main harness from
intake manifold.
17) Remove starting motor referring to “Dismounting” in Section
6G. NOTE:
Suspend removed A/C compressor at a place where no
damage will be caused during removal and installation of
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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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

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Coolant Draining
1) Remove radiator cap (1).
2) Loosen drain plug on radiator to drain coolant.
3) After draining coolant, be sure to tighten drain plug securely.
4) Fill cooling system. Refer to “Coolant” in this section.
Cooling Water Pipes or Hoses
REMOVAL
1) Drain cooling system.
2) To remove water pipes or hoses, loosen screw on each pipe
or hose clip and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
Tighten each clamp bolt securely.
Refill cooling system with proper coolant, referring to
description on “Coolant” and “Cooling System Flush and
Refill” in this section.
Thermostat
REMOVAL
1) Drain cooling system and tighten drain plug.
2) Remove intake manifold, referring to “Throttle Body and
Intake Manifold” in Section 6A1.
3) Disconnect thermostat cap (1) from thermostat case (2).
4) Remove thermostat (3).

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INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clear.
Should this valve be clogged, engine would tend to overheat.
2) Check valve seat for some foreign matters being stuck which
prevent valve from seating tight.
3) Check thermostatic movement of wax pellet as follows:
a) Immerse thermostat (1) in water, and heat water gradually.
b) Check that valve starts to open at specification temp.
c) If valve starts to open at a temperature substantially below
or above, thermostat unit should be replaced with a new
one.
Such a unit, if re-used, will bring about overcooling or over-
heating tendency.
Thermostat functional specification
INSTALLATION
1) When positioning the thermostat (2) on the thermostat case
(1), be sure to align its air breather valve (3) with mark (4).
2) Install thermostat cap (5) to thermostat case with align air
bleed valve and mark.
Then, tighten mounting bolts to specified torque.
Tightening torque
Thermostat cap bolts
(a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Thermostat case bolts
(b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
3) Install intake manifold by referring to “Throttle Body and
Intake Manifold” in Section 6A1.
4) Fill the cooling system.
Temp. at which valve begins
to open80 – 84 °C (176 – 183 °F)
Temp. at which valve
becomes fully open93 – 97 °C (199 – 207 °F)
Valve liftMore than 8 mm at 95 °C
(203 °F)
2. Thermometer
3. Heater

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Vehicle speed sensor (VSS)
INSPECTION
Check vehicle speed sensor referring to step 7 of “DTC P0500
(No.16) Flow Table” in Section 6. If malfunction is found, replace.
Fuel level sensor (GAUGE)
INSPECTION
Refer to “Fuel Meter / Fuel Gauge Unit” in Section 8.
REMOVAL / INSTALLATION
Refer to “Fuel Pump Assembly” in Section 6C.
Knock sensor
INSPECTION
Check knock sensor referring to “DTC P0325 (No.17) Flow Table”
in Section 6. If malfunction is found, replace.
REMOVAL / INSTALLATION
Refer to “Knock Sensor” in Section 6A1.
Main relay, fuel pump relay and A/C condenser fan
control relay
INSPECTION
1) Disconnect negative cable at battery.
2) Remove main relay (1), fuel pump relay (2) and A/C con-
denser fan control relay (3) from vehicle.
3) Check that there is no continuity between terminal “A” and
“B”. If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “C” of relay.
Connect battery negative (–) terminal “D” of relay.
Check continuity between terminal “A” and “B”.
If there is no continuity when relay is connected to the bat-
tery, replace relay.

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On-Vehicle Service
COMPONENTS
Exhaust Manifold
REMOVAL AND INSTALLATION
Refer to “Exhaust Manifold” in Section 6A1 for removal and installation procedures of exhaust manifold.
INSPECTION
Check seals for deterioration or damage.
Exhaust Pipe
REMOVAL AND INSTALLATION
For replacement of exhaust pipe, exhaust center pipe, muffler or any parts used to mount or connect them, be
sure to hoist vehicle and observe WARNING under “Maintenance” and the following.
1. Exhaust pipe (Vehicle without TWC) 6. Gasket 11. Mounting nuts
2. Exhaust pipe (Vehicle with TWC) 7. Spring Tightening torque
3. Exhaust center pipe 8. Mounting Do not reuse.
4. Muffler 9. Oxygen sensor
5. Seal ring 10. Mounting bolts
CAUTION:
Exhaust pipe with three way catalytic converter should not be exposed to any impulse. Do not drop it
or hit it against something.