cooling SUZUKI JIMNY 2005 3.G Service Repair Manual

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Water Pump
COMPONENTS
REMOVAL
1) Drain cooling system.
Refer to Step 6) of “Cooling System Flush and Refill” in this
section.
2) Remove the radiator shroud.
3) Remove radiator referring to “Radiator” in this section.
4) Loosen water pump drive belt tension.
Then remove water pump pulley (2) with fan clutch (3) and
pump drive belt.
5) Remove water pump assembly (1).
1. Water pump 4. Radiator cooling fan 7. Radiator cooling fan mounting bolt
2. Water pump pulley 5. Water pump mounting bolts Tightening Torque
3. Radiator cooling fan clutch 6. Water pump pulley and fan clutch mounting nuts
1. Drain plug

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INSPECTION
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes an abnormal
noise, replace it.
INSTALLATION
1) Apply sealant to water pump (1).
“A” : Sealant 99000-31150
Sealant quantity for mating surface of water pump
Width “a” : 3mm (0.12 in.)
Height “b” : 2mm (0.08 in.)
2) Install water pump (1) to cylinder block.
Tightening torque
Water pump bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
3) Install water pump pulley (2) with fan clutch (3).
Tightening torque
Water pump pulley nuts (b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Fan clutch bolts (c) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
4) Install water pump drive belt, cooling fan and radiator
shroud.
5) Adjust water pump belt tension.
Refer to “Water Pump Belt Tension” in this section.
6) Connect negative cable at battery.
7) Fill the cooling system.NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.

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Required Service Material
Tightening Torque Specification
MaterialRecommended SUZUKI product
(Part Number)Use
Ethylene glycol base
coolant (Anti-freeze /
Anti-corrosion coolant)–Additive to engine cooling system for improving
cooling efficiency and for protection against
rusting.
SealantSUZUKI BOND NO.1207C
(99000 – 31150)To apply to water pump mating surface.
Fastening partTightening torque
Nm kg-m lb-ft
Water pump bolt 23 2.3 17.0
Thermostat cap bolt 11 1.1 8.0
Thermostat case bolt 25 2.5 18.0
Fun clutch bolt 11 1.1 8.0

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Air Intake System
Throttle body
ON-VEHICLE INSPECTION
Check that throttle valve lever (1) moves smoothly.
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Disconnect accelerator cable (1) from throttle valve lever.
1. Throttle body 4. Gasket 7. TP sensor screws
2. Throttle body gasket 5. Idle air control valve Tightening torque
3. TP sensor 6. IAC valve screws Do not reuse

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INSTALLATION
1) Clean mating surfaces and install throttle body gasket to
intake manifold.
Use new gasket.
2) Connect engine coolant hoses.
3) Install throttle body (1) to intake manifold.
4) Connect connectors to TP sensor (2) and IAC valve (3)
securely.
5) Install air cleaner outlet No.2 hose (1) and pipe.
6) Connect accelerator cable and adjust cable play to specifica-
tion.
7) Refill cooling system.
8) Connect negative cable at battery.

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Engine coolant temperature sensor (ECT sensor)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Drain coolant referring to Step 6) of “Cooling System Flush
and Refill” in Section 6B.
3) Disconnect connector from ECT sensor.
4) Remove ECT sensor (1) from water outlet cap.
INSPECTION
Immerse temperature sensing part of ECT sensor (1) in water (or
ice) and measure resistance between terminal “A” and “B” while
heating water gradually.
If measured resistance doesn’t show such characteristic as
shown in left figure, replace ECT sensor (1).
INSTALLATION
Reverse removal procedure noting the following:
Clean mating surfaces of ECT sensor (1) and water outlet
cap.
Check O-ring for damage and replace if necessary. WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.

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Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a) : 15 N·m (1.5 kg-m, 11.5 lb-ft)
Connect connector to ECT sensor (1) securely.
Refill coolant referring to “Cooling System Flush and Refill”
in Section 6B.
Heated oxygen sensor (Sensor-1 and sensor-2)
OXYGEN SENSOR HEATER INSPECTION
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals
“V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
Resistance of oxygen sensor heater
HO2S-1 : 5.0 – 6.4
Ω
ΩΩ Ω at 20 °C, 68 °F
HO2S-2 : 11.7 – 14.3
Ω
ΩΩ Ω at 20 °C, 68 °F
3) Connect sensor connector securely.
REMOVAL
NOTE:
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
1. Viewed from terminal side
WARNING:
To avoid danger of being burned, do not touch exhaust
system when system is hot. Oxygen sensor removal
should be performed when system is cool.

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-11
Dismounting
1) Disconnect negative cable (3).
2) Disconnect positive cable (2).
3) Remove retainer (5).
4) Remove battery (1).

Handling
When handling battery, following safety precautions should be
followed:
Hydrogen gas is produced by battery. A flame or spark near
battery may cause the gas to ignite.
Battery fluid is highly acidic. Avoid spilling on clothing or
other fabric. Any spilled electrolyte should be flushed with
large quantity of water and cleaned immediately.
Remounting
1) Reverse removal procedure.
2) Torque battery cables to specification.
Tightening torque
Body ground bolt (a) : 8.0 N·m (0.8 kg-m, 6.0 lb-ft)
Generator
Generator belt
Refer to “Water Pump Belt and Cooling Fan” in Section 6B.
4. Body ground bolt
NOTE:
Check to be sure that ground cable has enough clear-
ance to hood panel by terminal.

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Unit Repair Overhaul
Generator
Dismounting
1) Disconnect negative (–) cable (2) at battery (1).
2) Remove bolts (2) and then canister (1) together with its
bracket.
3) Disconnect “B” terminal wire (3) and coupler (2) from gener-
ator (1).
4) Remove generator belt. Refer to “Water Pump Belt and
Cooling Fan” in Section 6B.
5) Remove generator.
1. Generator adjusting bolt
2. Generator pivot bolt
3.“B” terminal