2005 SUZUKI JIMNY Cylinder

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12) Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool with it as
shown in figure.
Special tool
(A) : 09917-68221
13) Remove crankshaft pulley (1).
If it is hard to remove, use special tools as shown in figure.
If bolts of special tool are too long, replace them with those
of suitable length.
Special tool
(A) : 09944-36011
(B) : 09926-58010
14) Remove oil pan referring to “Oil Pan and Oil Pump Strainer”
in this section.
15) Remove cylinder head cover referring to “Cylinder Head
Cover” in this section.
16) Disconnect CMP sensor coupler (1) and release its harness
clamps.
17) Remove water outlet pipe (2).
18) Remove timing chain cover (3).
CLEANING
Clean sealing surface on timing chain cover, cylinder block
and cylinder head.
Remove oil, old sealant and dust from sealing surface.

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INSPECTION
Check oil seal (1) lip for fault or other damage.
Replace as necessary.
Special tool
(A) : 09913-75520
INSTALLATION
Reverse removal procedure to install timing chain cover, noting
the following points.
1) Apply sealant “A” to mating surface of cylinder and cylinder
head and “B” to mating surface of timing chain cover as
shown in figure.
“A” : Sealant 99000-31140
“B” : Sealant 99000-31150
Sealant amount for timing chain cover
Width “a” : 3 mm, 0.12 in.
Height “b” : 2 mm, 0.08 in.
2) Apply engine oil to oil seal lip, then install timing chain cover
(1) and water outlet pipe (2).
Tighten bolts and nut to specified torque.
Tightening torque
Timing chain cover bolts and nut
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft) NOTE:
When installing new oil seal, tap it in until its surface is
flash with edge of timing chain cover (2).
To install oil seal, use special tool (Bearing installer).
NOTE:
Before installing timing chain cover, check that pin is
securely fitted.

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3) Install crankshaft pulley (1). Tighten bolt (2) to specified
torque.
To lock crankshaft pulley, use special tool with it as shown in
figure.
Special tool
(A) : 09917-68221
Tightening torque
Crankshaft pulley bolt (a) : 150 N·m (15.0 kg-m, 108.5 lb-ft)
4) Install P/S pump bracket (1), P/S pump (2) and A/C com-
pressor and/or P/S pump belt tension pulley (3) (if equipped)
referring to “Power Steering Pump” in Section 3B1.
5) Install cylinder head cover referring to “Cylinder Head Cover”
in this section.
6) Install oil pan referring to “Oil Pan and Oil Pump Strainer” in
this section.
7) 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.
8) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B for adjusting procedure.
9) 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 for adjusting proce-
dure.
10) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
11) 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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Oil Pump
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing chain cover, referring to “Timing Chain
Cover” in this section.
DISASSEMBLY
1) Remove rotor plate (1) by removing its mounting bolts.
[A] : Sealant application
amount4. Timing chain cover 10. Circlip
: Apply sealant 99000-31140 to the mating surface of cylinder and
cylinder head.
: Apply sealant 99000-31150 to mating surface of timing chain cover
referring to the figure of Step 1) in “Timing Chain Cover Installation”.
“a” : 3 mm (0.12 in.) 5. Pin 11. Oil pump mounting bolt
“b” : 2 mm (0.08 in.) 6. Oil seal 12. Timing chain cover mounting bolts
1. Rotor plate 7. Relief valve Tightening torque
2. Outer rotor 8. Spring Do not reuse.
3. Inner rotor 9. Retainer Apply thin coat of engine oil to sliding
surface of each parts.

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Timing Chain and Chain Tensioner
REMOVAL
1) Remove timing chain cover referring to “Timing Chain
Cover”.
2) Align both intake and exhaust camshaft timing sprocket
marks (1) with notches (2) of cylinder head respectively by
turning crankshaft.
3) Remove timing chain tensioner adjuster assembly (3).
4) Remove timing chain tensioner (4).
5) Remove timing chain No.1 guide (5).
6) Remove timing chain (6) with crankshaft timing sprocket (7).
1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly Tightening torque
2. Timing chain 6. Chain tensioner adjuster mounting bolt Apply engine oil to sliding surface.
3. Timing chain No.1 guide 7. Chain tensioner mounting bolt
4. Timing chain tensioner 8. Chain guide mounting bolt
CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than its allowable turning
range described in “INSTALLATION” section.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.
45
6
21
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3
7

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INSTALLATION
1) Check that match marks (1) on intake and exhaust camshaft
timing sprockets are in match with notches (2) on cylinder
head as shown in figure.
2) Set key (3) and turn crankshaft to position key on upside of
crankshaft.
3) Install timing chain by aligning dark blue plate (1) of timing
chain and mark (2) on camshaft timing sprocket and then
aligning dark blue plate (3) and triangle mark (4) as shown in
figure.
4) Fit crankshaft timing sprocket to timing chain by aligning gold
plate (5) of timing chain and mark (6) on crankshaft timing
sprocket. Then install crankshaft timing sprocket fitted with
chain to crankshaft.
5) Apply engine oil to sliding surface of timing chain No.1 guide
(1) and install it as shown in figure.
Tighten guide bolts to specified torque.
Tightening torque
Timing chain No.1 guide bolts
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft) CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than such an extent (“a”,
“b”) as shown in figure.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.
“a” :90°5. Crankshaft allowable turning range.
By key on crankshaft, within 90° from top on both right and left.
“b” :15°4. Camshaft (IN and EX) allowable turning range.
By marks on camshaft timing sprocket within 15° from notches on
cylinder head on both right and left.

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10) Apply engine oil to timing chain and then turn crankshaft
clockwise by 2 revolutions and check that match marks (1)
on intake and exhaust camshaft timing sprockets are in
match with notches (2) on cylinder head and key (3) is on
upside of crankshaft as shown in figure.
If each mark of timing chain and each match mark are no
matches, adjust each sprocket and timing chain.
11) Install timing chain cover referring to “Timing Chain Cover” in
this section.
12) Perform Steps 3) to 8) of “INSTALLATION” of “Timing Chain
Cover” in this section.
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3

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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