2005 SUZUKI JIMNY bolts

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Upper half of bearing (1) has an oil groove (2) as shown in
figure.
Install this half with oil groove to cylinder block.
Lower half of bearing does not have an oil groove.
Visual inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and lower halves.
Do not replace either half without replacing the other half.
Main bearing clearance
Check clearance by using gauging plastic according to the follow-
ing procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) the full width of bearing
(parallel to crankshaft) on journal, avoiding oil hole.
4) Tighten bearing cap No.1 bolts (1) – (10) and No.2 bolts (11)
– (20) gradually as follows.
a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft)
according to numerical order in figure.
b) In the same manner as in Step a), tighten them to 50 N·m
(5.0 kg-m, 36.5 lb-ft).
c) In the same manner as in step a), retighten them to 60°.
d) Tighten bolts (11) – (20) to 22 N·m (2.2 kg-m, 16.0 lb-ft)
according to numerical order in figure.
Tightening torque
Crankshaft bearing No.1 bolts (1) – (10) :
50 N·m (5.0 kg-m, 36.5 lb-ft) and extra tightening 60°
Crankshaft bearing No.2 bolts (11) – (20) :
22 N·m (2.2 kg-m, 16.0 lb-ft)
NOTE:
Do not rotate crankshaft while gauging plastic is
installed.

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INSTALLATION
1) Install sensor plate (1) to crankshaft (2) and tighten bolts to
specified torque.
Tightening torque
Sensor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
2) Install main bearings to cylinder block.
Upper half of bearing (1) has an oil groove (2).
Install it to cylinder block (3), and the other half without oil
groove to bearing cap.
Make sure that two halves are painted in the same color.
3) Install thrust bearings (1) to cylinder block between No.2 and
No.3 cylinders. Face oil groove (2) sides to crank webs.
4) Confirm that dowel pins(3) are installed to intake side of
each journal. NOTE:
All parts to be installed must be perfectly clean.
Be sure to oil crankshaft journals, journal bearings,
thrust bearings, crankpins, connecting rod bearings,
pistons, piston rings and cylinder bores.
Journal bearings, bearings caps, connecting rods, rod
bearings, rod bearing caps, pistons and piston rings
are in combination sets. Do not disturb such combina-
tion and make sure that each part goes back to where
it came from, when installing.
NOTE:
When installing sensor plate, align spring pin (3) on
crankshaft and hole of sensor plate.

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5) Install crankshaft to cylinder block.
6) Install bearing cap to cylinder block, making sure to point
arrow mark (on each cap) to crankshaft pulley side. Fit them
sequentially in ascending order, 1, 2, 3, 4 and 5, starting
from pulley side.
After applying engine oil to bearing cap No.1 bolts ((1) –
(10)) and bearing cap No.2 bolts ((11) – (20)), tighten them
gradually as follows.
a) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft)
according to numerical order as shown by using a 12 cor-
ner socket wrenches.
b) In the same manner as in Step a), tighten them to 50 N·m
(5.0 kg-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them to 60°.
d) Tighten bolts (11) – (20) to 22 N·m (2.2 kg-m, 16.0 lb-ft)
according to numerical order as shown.
Tightening torque
Crankshaft bearing cap No.1 bolts (1) – (10)
: 50 N·m (5.0 kg-m, 36.5 lb-ft) and extra tightening 60°
Crankshaft bearing cap No.2 bolts (11) – (20)
: 22 N·m (2.2 kg-m, 16.0 lb-ft)
7) Apply sealant to mating surface of rear oil seal housing (1).
“A” : Sealant 99000-31150
Sealant amount for rear oil seal housing
Width “a” : 3 mm, 0.12 in.
Height “b” : 2 mm, 0.08 in. NOTE:
If bearing cap No.1 bolts are reused, check thread
diameters of them for deformation according to previ-
ous mentioned “Main Bearing Cap No.1 Bolt” and
replace them with new ones if thread diameter exceeds
limit.
NOTE:
After tightening cap bolts, check to be sure that crank-
shaft rotates smoothly when turning it by 12 N·m (1.2 kg-
m, 9.0 lb-ft) torque or below.

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8) Install rear oil seal housing (1) and tighten bolts to specified
torque by using special tool.
Special tool
(A) : 09911-97720
Tightening torque
Rear oil seal housing bolts : 11 N·m (1.1 kg-m, 8.0 lb-ft)
9) Install flywheel (drive plate for A/T).
Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts applied with sealant to specifica-
tion.
“A” : Sealant 1215 99000-31110
Special tool
(A) : 09924-17810
Tightening torque
Flywheel or drive plate bolts
(a) : 70 N·m (7.0 kg-m, 51.0 lb-ft)
10) Install the following parts to engine as previously outlined.
Piston and connecting rod
Cylinder head assembly
Camshaft, tappet and shim
Timing chain guide, chain tensioner adjuster, chain ten-
sioner, timing chain and crankshaft timing sprocket
Timing chain cover
Cylinder head cover
Intake manifold and exhaust manifold
Oil pan and oil pump strainer
11) Install clutch to flywheel (vehicle with M/T) referring to
“Clutch Cover, Clutch Disc, Flywheel and Release Bearing”
in Section 7C.
12) Install engine assembly to vehicle referring to “Engine
Assembly” in this section.
A : Crankshaft side

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Required Service Material
Tightening Torque Specification
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant SUZUKI BOND NO. 1207C
(99000-31150)To apply to mating surface of cylinder block and oil
pan.
To apply to mating surface of cylinder block and
timing chain cover.
To apply to sealing surface of cylinder head cover.
To apply to mating surface to rear oil seal housing.
SUZUKI BOND NO. 1207B
(99000-31140)To apply to mating surface of cylinder block, cylin-
der head and timing chain cover.
SUZUKI BOND NO. 1215
(99000-31110)To flywheel (M/T) or drive plate (A/T) bolts.
Fastening partTightening torque
Nm kg-m lb-ft
Oil pressure switch 14.0 1.4 10.5
Camshaft housing bolts
(for replacement of shim)8.0 0.8 6.0
Camshaft housing bolts 11.0 1.1 8.0
Cylinder head cover bolts 8.0 0.8 6.0
Intake manifold bolts and nuts 25.0 2.5 18.0
Exhaust manifold bolts and nuts 55.0 5.5 40.0
Exhaust pipe bolts 50.0 5.0 36.5
Exhaust manifold stiffener bolts 50.0 5.0 36.5
Oil pump strainer bolt 11.0 1.1 8.0
Oil pump strainer bracket bolt 11.0 1.1 8.0
Oil pan bolts and nuts 11.0 1.1 8.0
Oil pan drain plug 50.0 5.0 36.5
Timing chain cover bolts and nut 23.0 2.3 17.0
Crankshaft pulley bolt 150.0 15.0 108.5
Oil pump rotor plate bolts 11.0 1.1 8.0
Timing chain No.1 guide bolts 9.0 0.9 6.5
Timing chain tensioner adjuster bolts 11.0 1.1 8.0
Venturi plug 5.0 0.5 3.5
Cylinder head bolt for M8 22.0 2.2 16.0
Cylinder head bolts for M10 a) Tighten 40 N·m
b) Turn 60°
c) Turn 60°a) Tighten 4.0 kg-m
b) Turn 60°
c) Turn 60°a) Tighten 29.0 lb-ft
b) Turn 60°
c) Turn 60°
Connecting rod bearing cap nuts a) Tighten 15 N·m
b) Turn 45°
c) Turn 45°a) Tighten 1.5 kg-m
b) Turn 45°
c) Turn 45°a) Tighten 11.0 lb-ft
b) Turn 45°
c) Turn 45°
Engine mounting bolts 50.0 5.0 36.5

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Special Tool
Crankshaft bearing cap No.1 bolts
(for inspection of crankshaft thrust play)50.0 5.0 36.5
Crankshaft bearing cap No.2 bolts 22.0 2.2 16.0
Sensor plate bolts 11.0 1.1 8.0
Crankshaft bearing cap No.1 bolts a) Tighten 50 N·m
b) Turn 60°a) Tighten 5.0 kg-m
b) Turn 60°a) Tighten 36.5 lb-ft
b) Turn 60°
Rear oil seal housing bolts 11.0 1.1 8.0
Flywheel or drive plate bolts 70.0 7.0 51.0
Torque converter bolts 20.0 2.0 14.5
Timing chain tensioner bolt 22.0 2.2 16.0
Knock sensor 23.0 2.3 16.5
Cylinder block and transmission fasten-
ing bolts and nuts (vehicle with M/T)94.0 9.4 68.0
Cylinder block and transmission fasten-
ing bolts and nuts (vehicle with A/T)80.0 8.0 58.0 Fastening partTightening torque
Nm kg-m lb-ft
09911-97720 09911-97820 09913-75520 09915-47330
Oil seal guide Oil seal installer Bearing installer Oil filter wrench
09915-64510-001 09915-64510-002 09915-64530 09915-67010
Compression gauge Connector Hose Attachment

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-9
9) Run engine, with radiator cap removed, until radiator upper
hose is hot.
10) With engine idling, add coolant to radiator until level reaches
the bottom of filler neck. Install radiator cap, making sure
that the ear of cap lines up with reservoir hose.
Water Pump Belt Tension
1) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If it is necessary to replace belt, refer to “Water Pump
Belt and Cooling Fan” in this section.
2) Check belt for tension. Belt is in proper tension when it
deflects 4.5 to 5.5 mm (0.18 – 0.22 in.) under thumb pres-
sure (about 10 kg or 22 lb.).
Water pump belt tension
“a” : 4.5 – 5.5 mm (0.18 – 0.22 in.) as deflection / 10 kg (22
lbs)
3) If belt is too tight or too loose, adjust it to proper tension by
displacing generator position.
4) Tighten generator adjusting bolt and pivot bolts as specified
torque.
Tightening torque
Generator adjusting bolt (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Generator pivot bolts (b) : 50 N·m (5.0 kg-m, 36.0 lb-ft)
5) Connect negative cable at battery terminal.WARNING:
Disconnect negative cable at battery before checking and
adjusting belt tension.
NOTE:
When replacing belt with a new one, adjust belt tension
to 3 – 4 mm (0.12 – 0.16 in.).

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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