engine SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 6A1-90 ENGINE MECHANICAL (M13 ENGINE)
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.

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-91
5) Install crankshaft to cylinder block.
6) Install bearing cap to cylinder block, making sure to point
arrow mark (on each cap) to crankshaft pulley side. Fit them
sequentially in ascending order, 1, 2, 3, 4 and 5, starting
from pulley side.
After applying engine oil to bearing cap No.1 bolts ((1) –
(10)) and bearing cap No.2 bolts ((11) – (20)), tighten them
gradually as follows.
a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft)
according to numerical order as shown by using a 12 cor-
ner socket wrenches.
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 as shown.
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)
7) Apply sealant to mating surface of rear oil seal housing (1).
“A” : Sealant 99000-31150
Sealant amount for rear oil seal housing
Width “a” : 3 mm, 0.12 in.
Height “b” : 2 mm, 0.08 in. NOTE:
If bearing cap No.1 bolts are reused, check thread
diameters of them for deformation according to previ-
ous mentioned “Main Bearing Cap No.1 Bolt” and
replace them with new ones if thread diameter exceeds
limit.
NOTE:
After tightening cap bolts, check to be sure that crank-
shaft rotates smoothly when turning it by 12 N·m (1.2 kg-
m, 9.0 lb-ft) torque or below.

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 ENGINE MECHANICAL (M13 ENGINE) 6A1-95
09915-67310 09915-77310 09915-78211 09916-14510
Vacuum gauge Oil pressure gauge Oil pressure gauge
attachmentValve lifter
09916-14521 09916-34542 09916-34550 09916-37320
Valve lifter attachment Reamer handle Reamer (5.5 mm) Reamer (10.5 mm)
09916-44910 09916-56011 09916-58210 09916-67020
Valve guide remover Valve guide installer
attachmentValve guide installer han-
dleTappet holder
09916-77310 09916-84511 09917-68221 09917-98221
Piston ring compressor Forceps Camshaft lock holder Valve stem seal installer

Downloaded from www.Manualslib.com manuals search engine 6A1-96 ENGINE MECHANICAL (M13 ENGINE)
09924-17810 09926-58010 09944-36011
Flywheel holder Bearing puller attachment Steering wheel remover

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-1
6B
SECTION 6B
ENGINE COOLING
CONTENTS
General Description ........................................6B-2
Cooling System Circulation ........................... 6B-2
Radiator Cap ................................................. 6B-3
Coolant Reservoir ......................................... 6B-3
Water Pump .................................................. 6B-4
Thermostat .................................................... 6B-4
Cooling Fan Clutch ........................................ 6B-4
Coolant (Water) Temperature Gauge............ 6B-4
Diagnosis .........................................................6B-5
Maintenance ....................................................6B-6
Coolant .......................................................... 6B-6
Coolant Level ................................................ 6B-7
Cooling System Service ................................ 6B-7Cooling System Flush and Refill ................... 6B-8
Water Pump Belt Tension ............................. 6B-9
On-Vehicle Service ....................................... 6B-10
Cooling System Component ....................... 6B-10
Coolant Draining ......................................... 6B-11
Cooling Water Pipes or Hoses .................... 6B-11
Thermostat .................................................. 6B-11
Water Pump Belt and Cooling Fan ............. 6B-13
Radiator ...................................................... 6B-14
Water Pump ................................................ 6B-15
Required Service Material ............................ 6B-17
Tightening Torque Specification ................. 6B-17

Downloaded from www.Manualslib.com manuals search engine 6B-2 ENGINE COOLING
General Description
The cooling system consists of the radiator cap, radiator, reservoir, hoses, water pump, cooling fan & clutch,
thermostat. The radiator is of tube-and-fin type.
Cooling System Circulation
1. Radiator inlet hose 5. Water pump 9. Heater outlet hose
2. Radiator outlet hose 6. Fast idle control plunger of throttle body 10. Radiator
3. Water inlet pipe 7. Cylinder block/cylinder head
4. Thermostat 8. Heater inlet hose

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-3
Radiator Cap
A pressure-vent cap is used on the radiator. The cap contains a
pressure valve (1) and ventilation valve (2).
The cap has its face marked 1.1, which means that its pressure
valve opens at 1.1 kg/cm
2 (15.6 psi, 110 kPa).
Coolant Reservoir
A “see-through” plastic reservoir (1) is connected to the radiator
by a hose.
Coolant level should be between “FULL” level mark (2) and
“LOW” level mark (3) on the reservoir.
Coolant should be added only to the reservoir as necessary.NOTE:
Do not remove radiator cap to check engine coolant
level; check coolant visually at the see-through coolant
reservoir.
Coolant should be added only to reservoir as necessary.
WARNING:
As long as there is pressure in the cooling system, the
temperature can be considerably higher than the boiling
temperature of the solution in the radiator without caus-
ing the solution to boil. Removal of the radiator cap while
engine is hot and pressure is high will cause the solution
to boil instantaneously and possibly with explosive force,
spewing the solution over engine, fenders and person
removing cap. If the solution contains flammable anti-
freeze such as alcohol (not recommended for use at any
time), there is also the possibility or causing a serious
fire.
[A]: At air bleed 3. From reservoir
[B]: At valves closed 4. To reservoir
[C]: At pressure relief 5. Pressure in radiator
[D]: At vacuum relief
NOTE:
When installing reservoir cap, set arrow marks (4) on the
reservoir and cap as the figure.