SUZUKI JIMNY 2005 3.G Service Workshop Manual

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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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INSPECTION
Main bearing cap No.1 bolt
Measure each thread diameter of bearing cap No.1 bolts (1) at
“A” on 60 mm (2.36 in.) from seat side of flange bolt and “B” on 90
mm (3.54 in.) from seat side of flange bolt by using a micrometer
(2).
Calculate difference in diameters (“A” – “B”).
If it exceeds limit, replace with new one.
Bearing cap No.1 bolt diameter measurement points
“a” : 60 mm (2.36 in.)
“b” : 90 mm (3.54 in.)
Bearing cap No.1 bolt diameter difference
Limit (“A” – “B”) : 0.2 mm (0.008 in.)
Crankshaft
Crankshaft runout
Using a dial gauge, measure runout at center journal. Rotate
crankshaft slowly. If runout exceeds its limit, replace crankshaft.
Crankshaft runout
Limit : 0.04 mm (0.0016 in.)
Crankshaft thrust play
Measure this play with crankshaft set in cylinder block in the nor-
mal manner, that is with thrust bearing (1) and journal bearing
caps installed.
Thickness of crankshaft thrust bearing
Standard : 2.500 mm (0.0984 in.)
Oversize (0.125 mm (0.0049 in.)) : 2.563 mm (0.1009 in.)

“A”
“a”
“b”“B”

1
1
2

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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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Upper half of bearing (1) has an oil groove (2) as shown in
figure.
Install this half with oil groove to cylinder block.
Lower half of bearing does not have an oil groove.
Visual inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Do not replace either half without replacing the other half.
Main bearing clearance
Check clearance by using gauging plastic according to the follow-
ing procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) the full width of bearing
(parallel to crankshaft) on journal, avoiding oil hole.
4) Tighten bearing cap No.1 bolts (1) – (10) and No.2 bolts (11)
– (20) gradually as follows.
a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft)
according to numerical order in figure.
b) In the same manner as in Step a), tighten them to 50 N·m
(5.0 kg-m, 36.5 lb-ft).
c) In the same manner as in step a), retighten them to 60°.
d) 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 No.1 bolts (1) – (10) :
50 N·m (5.0 kg-m, 36.5 lb-ft) and extra tightening 60°
Crankshaft bearing No.2 bolts (11) – (20) :
22 N·m (2.2 kg-m, 16.0 lb-ft)
NOTE:
Do not rotate crankshaft while gauging plastic is
installed.

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5) Remove bearing caps and using scale (1) on gauging plastic
(2) envelop, measure gauging plastic width at its widest
point. If clearance exceeds its limit, replace bearing. Always
replace both upper and lower inserts as a unit.
A new standard bearing may produce proper clearance. If
not, it will be necessary to regrind crankshaft journal for use
of 0.25 mm undersize bearing.
After selecting new bearing, recheck clearance.
Main bearing clearance
Standard : 0.025 – 0.045 mm (0.0010 – 0.0018 in.)
Limit : 0.065 mm (0.0026 in.)
Selection of main bearings
STANDARD BEARING:
If bearing is in malcondition, or bearing clearance is out of specifi-
cation, select a new standard bearing according to the following
procedure and install it.
1) First check journal diameter. As shown in figure, crank web
No.2 has stamped numbers.
Three kinds of numbers (“1”, “2” and “3”) represent the fol-
lowing journal diameters.
Stamped numbers on crank web No.2 represent journal
diameters marked with an arrow in figure respectively.
For example, stamped number “1” indicates that correspond-
ing journal diameter is 44.994 – 45.000 mm (1.7714 –
1.7717 in.).
Crankshaft journal diameter NOTE:
After checking the bearing clearance, check for thread
deformation of each bearing cap No.1 bolt according to
previous mentioned Step 4) once again.
Stamped numbers Journal diameter
144.994 – 45.000 mm
(1.7714 – 1.7717 in.)
244.988 – 44.994 mm
(1.7712 – 1.7714 in.)
344.982 – 44.988 mm
(1.7709 – 1.7712 in.)

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2) Next, check bearing cap bore diameter without bearing. On
mating surface of cylinder block, five alphabets are stamped
as shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) represent the fol-
lowing cap bore diameters.
Stamped alphabets on cylinder block represent bearing cap
bore diameter marked with an arrow in figure respectively.
For example, stamped “A” indicates that corresponding
bearing cap bore diameter is 49.000 – 49.006 mm (1.9291 –
1.9294 in.).
Crankshaft bearing cap bore
3) There are five kinds of standard bearings differing in thick-
ness. To distinguish them, they are painted in the following
colors at the center of bearings.
Each color indicates the following thickness.
Standard size of crankshaft main bearingStamped alphabetBearing cap bore diameter
(without bearing)
A49.000 – 49.006 mm
(1.9291 – 1.9294 in.)
B49.006 – 49.012 mm
(1.9294 – 1.9296 in.)
C49.012 – 49.018 mm
(1.9296 – 1.9298 in.)
Color painted Bearing thickness
Pink1.990 – 1.994 mm
(0.0783 – 0.0785 in.)
Purple1.993 – 1.997 mm
(0.0785 – 0.0786 in.)
Brown1.996 – 2.000 mm
(0.0786 – 0.0787 in.)
Green1.999 – 2.003 mm
(0.0787 – 0.0789 in.)
Black2.002 – 2.006 mm
(0.0788 – 0.0790 in.)
1. Paint

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4) From number stamped on crank web No.2 and alphabets
stamped on cylinder block, determine new standard bearing
to be installed to journal, by referring to table shown below.
For example, if number stamped on crank web No.2 is “1”
and alphabet stamped on cylinder block is “B”, install a new
standard bearing painted in “Purple” to its journal.
Specification of standard crankshaft main bearing
5) Using scale (1) on gauging plastic (2), check bearing clear-
ance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing
and recheck clearance.
6) When replacing crankshaft or cylinder block due to any rea-
son, select new standard bearings to be installed by referring
to number stamped on new crankshaft or alphabets stamped
on new cylinder block.
UNDERSIZE BEARING (0.25 mm):
0.25 mm undersize bearing is available, in five kinds varying
in thickness.
To distinguish them, each bearing is painted in the following
colors at the center of bearing.
Each color represents the following thickness.
Undersize of crankshaft main bearingNumber stamped on crank web
No.2 (Journal diameter)
123
Alphabet
stamped on
cylinder block
(Cap bore dia.)APink Purple Brown
B Purple Brown Green
C Brown Green Black
New standard bearing to be
installed.
Color painted Bearing thickness
Red and Pink2.115 – 2.119 mm
(0.0833 – 0.0834 in.)
Red and Purple2.118 – 2.122 mm
(0.0834 – 0.0835 in.)
Red and Brown2.121 – 2.125 mm
(0.0835 – 0.0837 in.)
Red and Green2.124 – 2.128 mm
(0.0836 – 0.0838 in.)
Red and Black2.127 – 2.131 mm
(0.0837 – 0.0839 in.)
1. Paint

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If necessary, regrind crankshaft journal and select undersize
bearing to use with it as follows.
a) Regrind journal to the following finished diameter.
Finished diameter
44.732 – 44.750 mm (1.7611 – 1.7618 in.)
1) Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicu-
lar to each other in order to check for out-of-round.
2) Using journal diameter measured above and alphabets
stamped on cylinder block, select an undersize bearing by
referring to table given below.
Check bearing clearance with newly selected undersize
bearing.
Specification of undersize crankshaft main bearing
Rear Oil Seal
Carefully inspect oil seal (1) for wear or damage.
If its lip is worn or damaged, replace it.
For oil seal installation, press-fit rear oil seal (1) to oil seal hous-
ing (2) by using special tool as shown in the figure.
Special tool
(A) : 09911-97820
Crank rear oil seal installing position
“a” : 3 mm (0.12 in.)
Measured journal diameter
44.744 – 44.750 mm
(1.7616 – 1.7618 in.)44.738 – 44.744 mm
(1.7613 – 1.7616 in.)44.732 – 44.738 mm
(1.7611 – 1.7613 in.)
Alphabets stamped
on cylinder blockA Red and Pink Red and Purple Red and Brown
B Red and Purple Red and Brown Red and Green
C Red and Brown Red and Green Red and Black
Undersize bearing to be installed

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Flywheel
If ring gear is damaged, cracked or worn, replace flywheel.
If the surface contacting clutch disc is damaged, or exces-
sively worn, replace flywheel.
Check flywheel for face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel runout
Limit : 0.2 mm (0.0079 in.)
Sensor Plate
Check sensor plate for crack or damage. If malcondition is
found, replace it.
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed
surface for distortion and, if flatness exceeds its limit, correct
it.
Cylinder block flatness
Limit : 0.05 mm (0.0020 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must
also be rebored at the same time.
2) Select oversized piston according to amount of cylinder
wear.
Oversize piston diameter
Size Piston diameter
Oversize 0.5078.453 – 78.468 mm
(3.0887 – 3.0893 in.)

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3) Using micrometer, measure piston diameter.
Measurement position for piston diameter
“a” : 19.5 mm (0.77 in.)
4) Calculate cylinder bore diameter to be rebored as follows.
D = A + B – C
D : Cylinder bore diameter to be rebored.
A : Piston diameter as measured.
B : Piston clearance = 0.02 –0.04 mm (0.0008 – 0.0016 in.)
C : Allowance for honing = 0.02 mm (0.0008 in.)
5) Rebore and hone cylinder to calculated dimension.
6) Measure piston clearance after honing.
NOTE:
Before reboring, install all main bearing caps in place
and tighten to specification to avoid distortion of bearing
bores.