2005 SUZUKI JIMNY valve

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-59
6) Install valve to valve guide
Before installing valve to valve guide, apply engine oil to
stem seal, valve guide bore and valve stem.
7) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end (1)) and bot-
tom end (small-pitch end (2)). Be sure to position spring in
place with its bottom end (small-pitch end) facing the bottom
(valve spring seat side).
8) Using special tools (Valve lifter), compress valve spring and
fit two valve cotters (1) into groove in valve stem.
Special tool
(A) : 09916-14510
(B) : 09916-14521
(C) : 09916-84511
9) Install intake manifold, injectors and exhaust manifold to cyl-
inder head.
INSTALLATION
1) Clean mating surface of cylinder head and cylinder block.
Remove oil, old gasket and dust from mating surface.
2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.“TOP”
mark provided on gasket comes to crankshaft pulley side,
facing up (toward cylinder head side).
A : Valve spring retainer side
B : Valve spring seat side
NOTE:
When compressing the valve spring, do not damage
inside face of tappet installing hole.

Downloaded from www.Manualslib.com manuals search engine 6A1-62 ENGINE MECHANICAL (M13 ENGINE)
Pistons, Piston Rings, Connecting Rods and Cylinders
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.
5) Remove cylinder head referring to “Valves and Cylinder
Head” in this section.
6) Mark cylinder number on all pistons, connecting rods and
connecting rod caps using silver pencil or quick drying paint.
7) Remove rod bearing caps.
1. Top ring8. Piston pin
2. 2nd ring9. Piston pin circlip
3. Oil ring10. Bearing cap nut
1) Tighten all nuts to 15 N·m (1.5 kg-m)
2) Turn all nuts to 45°
3) Then, turn all nuts to 45° once again
4. PistonTightening torque
5. Connecting rod
: Apply engine oil to sliding surface except inner surface of big end, and rod bolts.
Make sure rod bolt diameter when reuse it due to plastic deformation tightening.
Refer to “Inspection” of “Connecting Rod”.Apply engine oil to sliding surface of each
parts.
6. Connecting rod bearing cap
: Point arrow mark on cap to crankshaft pulley side.Do not reuse.
7. Connecting rod bearing

Downloaded from www.Manualslib.com manuals search engine 6A1-74 ENGINE MECHANICAL (M13 ENGINE)
a) For right hand steering vehicle:
With hose connected, detach A/C compressor from its
bracket.
b) For left hand steering vehicle:
i) Recover refrigerant from refrigeration system using recov-
ery and recycling equipment.
ii) Disconnect magnet clutch lead wire.
iii) Remove suction pipe and disconnect discharge pipe from
A/C compressor.
iv) Remove A/C compressor from its bracket.
When servicing above steps, refer to “Compressor” in Section 1B.
14) Remove air cleaner outlet No.1 and No.2 hoses.
15) Disconnect the following electric lead wires:
TP sensor (1)
MAP sensor (2)
CKP sensor (if equipped) (3)
CMP sensor
ECT sensor
Heated oxygen sensor
EGR valve (if equipped)
IAC valve (4)
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Generator
Starting motor
Oil pressure switch
Ground terminal from intake manifold and cylinder block
Each wire harness clamps
16) Remove intake manifold bracket (7) with main harness from
intake manifold.
17) Remove starting motor referring to “Dismounting” in Section
6G. NOTE:
Suspend removed A/C compressor at a place where no
damage will be caused during removal and installation of
engine assembly.

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-75
18) Remove heated oxygen sensor bracket from cylinder head
and detach No.1 heated oxygen sensor coupler from its
bracket.
19) Release accelerator cable (1) from clamp (2) (for left hand
steering vehicle only) and disconnect accelerator cable from
throttle body.
20) Remove canister purge hose bracket from intake manifold.
21) Disconnect the following hoses:
Brake booster hose (3) from intake manifold
Canister purge hose (4) from EVAP canister purge valve
Fuel feed and return hoses (5) from each pipe
Heater inlet and outlet hoses from each pipe
Vacuum hose (6) (to check valve)
22) Disconnect exhaust pipe (1) from exhaust manifold.
23) Remove clutch housing (torque converter housing for A/T)
lower plate (1).
24) With drive plate locked by using a proper size rod (1) or the
like, remove torque converter bolts (2) (vehicle with A/T).
25) Support transmission. For A/T vehicle, do not jack under A/T
oil pan to support transmission.

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 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.

Downloaded from www.Manualslib.com manuals search engine 6B-4 ENGINE COOLING
Water Pump
The centrifugal type water pump is used in the cooling system.
The pump impeller is supported by a totally sealed bearing.
The water pump can not be disassembled.
Thermostat
A wax pellet type thermostat is used in the cooling system.
The temperature at which the valve begins to open is stamped on
thermostat.
In the top portion of the thermostat, an air bleed valve (1) is pro-
vided; this valve is for venting out the gas or air, if any, that is
accumulated in the circuit.
Cooling Fan Clutch
Fluid is enclosed in the cooling fan clutch (2) and at its center
front, there is a bimetal (3) whose thermal reaction and the engine
speed control the cooling fan speed.
Coolant (Water) Temperature Gauge
A water temp. gauge is located at intake manifold.
This gauge activates a temp. meter in the instrument cluster.
When installing, wind sealing tape on gauge thread and tighten it.
NOTE:
Do not disassemble clutch assembly.
WARNING:
Keep hands, tools, and clothing away from engine cool-
ing fan (1) to help prevent personal injury.

Downloaded from www.Manualslib.com manuals search engine 6B-12 ENGINE COOLING
INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clear.
Should this valve be clogged, engine would tend to overheat.
2) Check valve seat for some foreign matters being stuck which
prevent valve from seating tight.
3) Check thermostatic movement of wax pellet as follows:
a) Immerse thermostat (1) in water, and heat water gradually.
b) Check that valve starts to open at specification temp.
c) If valve starts to open at a temperature substantially below
or above, thermostat unit should be replaced with a new
one.
Such a unit, if re-used, will bring about overcooling or over-
heating tendency.
Thermostat functional specification
INSTALLATION
1) When positioning the thermostat (2) on the thermostat case
(1), be sure to align its air breather valve (3) with mark (4).
2) Install thermostat cap (5) to thermostat case with align air
bleed valve and mark.
Then, tighten mounting bolts to specified torque.
Tightening torque
Thermostat cap bolts
(a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Thermostat case bolts
(b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
3) Install intake manifold by referring to “Throttle Body and
Intake Manifold” in Section 6A1.
4) Fill the cooling system.
Temp. at which valve begins
to open80 – 84 °C (176 – 183 °F)
Temp. at which valve
becomes fully open93 – 97 °C (199 – 207 °F)
Valve liftMore than 8 mm at 95 °C
(203 °F)
2. Thermometer
3. Heater