2005 SUZUKI JIMNY valve

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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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2) Remove outer rotor (1) and inner rotor (2).
3) Remove relief valve (1), spring (2) and retainer (3) by remov-
ing circlip (4).
INSPECTION
Check oil seal lip for fault or other damage. Replace as nec-
essary.
Special tool
(A) : 09913-75520
NOTE:
When installing new oil seal (1), press-fit it till its end face
is flush with oil pump case (2) end face.

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Check outer (1) and inner rotors (2), rotor plate, and oil pump
case for excessive wear or damage.
Check relief valve (1) for excessive wear or damage and
operates smoothly.
MEASUREMENT
Radial clearance
Check radial clearance between outer rotor (1) and case (2),
using thickness gauge (3).
If clearance exceeds its limit, replace outer rotor or case.
Limit on radial clearance between outer rotor and case for
oil pump
0.310 mm (0.0122 in.)
Side clearance
Using straight edge (1) and thickness gauge (2), measure side
clearance.
Limit on side clearance for oil pump inner rotor
0.15 mm (0.0059 in.)

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ASSEMBLY
1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal
lip portion, and inside surfaces of oil pump case and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Install relief valve component (1) to rotor plate (2).
5) Install rotor plate and tighten all bolts to specified torque.
After installing plate, check to be sure that rotors turn
smoothly by hand (0.3 N·m (0.03 kg-m, 0.25 lb-ft) torque or
below).
Tightening torque
Oil pump rotor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
INSTALLATION
For installation referring to “Timing Chain Cover” in this section.

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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
1
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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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.