cam SUZUKI JIMNY 2005 3.G Service Owner's Guide

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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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7) Remove tappets (1) with shims (2).
INSPECTION
Cam Wear
Using a micrometer, measure cam height “a”. If measured height
is below its limit, replace camshaft.
Cam height “a” of camshaft
Camshaft Runout
Set camshaft between two “V” blocks, and measure its runout by
using a dial gauge.
If measured runout exceeds below limit, replace camshaft.
Camshaft runout limit
0.10 mm (0.0039 in.)
Camshaft Journal Wear
Check camshaft journals and camshaft housings for pitting,
scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head
with housing. Never replace cylinder head without replacing
housings.
Standard Limit
Intake cam 44.919 – 45.079 mm
(1.768 – 1.775 in.)44.80 mm
(1.764 in.)
Exhaust cam 44.399 – 44.559 mm
(1.748 – 1.754 in.)44.28 mm
(1.743 in.)

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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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INSTALLATION
1) Install tappets and shims to cylinder head.
Apply engine oil around tappet and then install it to cylinder
head.
2) Install camshafts (1).
Apply engine oil to sliding surface of each camshaft and
camshaft journal then install them as shown in figure.
3) Install camshaft housing pins (1) as shown in figure.
4) Check position of camshaft housings.
Embossed marks are provided on each camshaft housing,
indicating position and direction for installation. Install hous-
ings as indicated by these marks. NOTE:
When installing shim, make sure to direct shim No. side
toward tappet.
NOTE:
Before installing camshafts, turn crankshaft until key
position faces upward. Refer to “Timing Chain and Chain
Tensioner”.
A. I : Intake side or E : Exhaust side
B. Position from timing chain side
C. Pointing to timing chain side

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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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9) Disconnect accelerator cable (1) from throttle body.
10) Disconnect the following hoses:
Brake booster hose (2) from intake manifold
Canister purge hose (3) from EVAP canister purge valve
Fuel feed and return hoses (4) from each pipe
Water hose from thermostat case (5)
Heater inlet hose from its pipe
Vacuum hose (to check valve) (6)
11) Remove canister purge hose bracket from intake manifold.
12) Remove intake manifold stiffener (1).
13) Remove oil pan referring to “Oil Pan and Oil Pump Strainer”
in this section.
14) Remove cylinder head cover referring to “Cylinder Head
Cover” in this section.
15) Remove timing chain cover referring to “Timing Chain Cover”
in this section.
16) Remove timing chain referring to “Timing Chain and Chain
Tensioner” in this section.
17) Remove intake and exhaust camshafts referring to “Cam-
shaft, Tappet and Shim” in this section.
18) Disconnect exhaust pipe (1) from exhaust manifold.

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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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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.

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INSTALLATION
1) Install sensor plate (1) to crankshaft (2) and tighten bolts to
specified torque.
Tightening torque
Sensor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
2) Install main bearings to cylinder block.
Upper half of bearing (1) has an oil groove (2).
Install it to cylinder block (3), and the other half without oil
groove to bearing cap.
Make sure that two halves are painted in the same color.
3) Install thrust bearings (1) to cylinder block between No.2 and
No.3 cylinders. Face oil groove (2) sides to crank webs.
4) Confirm that dowel pins(3) are installed to intake side of
each journal. NOTE:
All parts to be installed must be perfectly clean.
Be sure to oil crankshaft journals, journal bearings,
thrust bearings, crankpins, connecting rod bearings,
pistons, piston rings and cylinder bores.
Journal bearings, bearings caps, connecting rods, rod
bearings, rod bearing caps, pistons and piston rings
are in combination sets. Do not disturb such combina-
tion and make sure that each part goes back to where
it came from, when installing.
NOTE:
When installing sensor plate, align spring pin (3) on
crankshaft and hole of sensor plate.

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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