6a1 SUZUKI JIMNY 2005 3.G Service Repair Manual

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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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Wear of Tappet and Shim
Check tappet and shim for pitting, scratches or damage.
If any malcondition is found, replace.
Measure cylinder head bore and tappet outside diameter to deter-
mine cylinder head-to-tappet clearance. If clearance exceeds
limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard : 0.025 – 0.066 mm (0.0010 – 0.0026 in.)
Limit : 0.15 mm (0.0059 in.)
Tappet outside diameter [A]
Standard : 30.959 – 30.975 mm (1.2189 – 1.2195 in.)
Cylinder head tappet bore [B]
Standard : 31.000 – 31.025 mm (1.2205 – 1.2215 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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Valves and Cylinder Head
1. Valve cotters 6. Intake valve 11. Cylinder head gasket
: “TOP” mark provided on gasket comes to
crankshaft pulley side, facing up.
2. Valve spring retainer 7. Exhaust valve 12. Knock pin
3. Valve spring 8. Valve guide Tightening torque
4. Valve stem seal 9. Cylinder head bolt
1) Tighten all bolts at 40 N·m (4.0 kg-m)
2) Turn all bolts to 60°
3) Then, turn all bolts to 60° once againDo not reuse.
5. Valve spring seat 10. Cylinder head
Apply engine oil to sliding surface of each
part.

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REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Drain engine oil.
4) Drain coolant by loosening drain plug (1).
5) Remove air cleaner outlet No.1 and No.2 hoses and
breather hose.
6) Remove intake manifold bracket (1) with main harness from
intake manifold.
7) Disconnect the following electric lead wires:
EGR valve (if equipped)
IAC valve (2)
TP sensor (3)
MAP sensor (4)
CMP sensor
ECT sensor
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Heated oxygen sensor
Ground terminal (7) from intake manifold
Each wire harness clamps
8) Remove heated oxygen sensor bracket from cylinder head
and detach heated oxygen sensor coupler from its bracket. 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.

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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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19) Remove exhaust manifold stiffener (1).
20) Loosen cylinder head bolts in such order as indicated in fig-
ure by using a 12 corner socket wrenches and remove them.
21) Check all around cylinder head for any other parts required
to be removed or disconnected and remove or disconnect
whatever necessary.
22) Remove cylinder head with intake manifold and exhaust
manifold. Use lifting device, if necessary.
NOTE:
Don’t forget to remove bolt (M8) (1) as shown in figure.

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DISASSEMBLY
1) For ease in servicing cylinder head, remove intake manifold,
injectors and exhaust manifold from cylinder head.
2) Using special tools (Valve lifter), compress valve spring and
then remove valve cotters (1) by using special tool (For-
ceps).
Special tool
(A) : 09916-14510
(B) : 09916-14521
(C) : 09916-84511
3) Release special tools and remove spring retainer and valve
spring.
4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide and then valve
spring seat (2).
6) Using special tool (valve guide remover), drive valve guide
out from combustion chamber side to valve spring side.
Special tool
(A) : 09916-44910
7) Place disassembled parts except valve stem seal and valve
guide in order so that they can be installed in their original
position.
NOTE:
Do not reuse seal once disassembled. Be sure to use
new seal when assembling.
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.