2005 SUZUKI JIMNY Engine Mechanical

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Engine Lubrication
The oil pump is of a trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump
strainer and passed through the pump to the oil filter.
The filtered oil flows into 2 paths in cylinder block.
In one path, oil reaches the crankshaft journal bearings. Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting passages drilled in the crankshaft, and then injected from
the big end of connecting rod to lubricate piston, rings, and cylinder wall.
In other path oil goes up to the cylinder head and lubricates valves and camshafts, etc., after passing through
the internal oilway of camshafts.
An oil relief valve is provided on the oil pump. This valve starts relieving oil pressure when the pressure exceeds
about 400 kPa (4.0 kg/cm
2, 56.9 psi).

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Diagnosis
Diagnosis Table
Refer to “Engine Diagnosis Table” in Section 6.
Compression Check
Check compression pressure on all 4 cylinders as follows:
1) Warm up engine.
2) Stop engine after warming up.
3) Disconnect accelerator cable (1) from clamp (2) (For left
hand steering vehicle only).
4) Remove cylinder head upper cover (3).
5) Disconnect ignition coil couplers (1).
6) Remove ignition coil assemblies (2) with high-tension cord
(3).
7) Remove all spark plugs.
8) Disconnect fuel injector wires (4) at the coupler.
9) Install special tools (Compression gauge) into spark plug
hole.
Special tool
(A) : 09915-64510-001
(B) : 09915-64510-002
(C) : 09915-64530
(D) : 09915-67010 NOTE:
After warming up engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
model), and set parking brake and block drive wheels.

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10) Disengage clutch (1) (to lighten starting load on engine) for
M/T vehicle, and depress accelerator pedal (2) all the way to
make throttle fully open.
11) Crank engine with fully charged battery, and read the highest
pressure on compression gauge.
Compression pressure specification
12) Carry out Steps 9) through 11) on each cylinder to obtain 4
readings.
13) After checking, install spark plugs and ignition coil assem-
blies (1) with high-tension cord (2).
14) Connect ignition coil couplers (3).
15) Connect fuel injector wires (4) at the coupler.
16) Check cylinder head upper cover gasket for deterioration and
then install it into groove of cylinder head upper cover (1)
securely.
17) Install cylinder head upper cover with gasket on to cylinder
head cover.
18) Connect accelerator cable (2) to clamp (3) (For left hand
steering vehicle only).
NOTE:
For measuring compression pressure, crank engine at
least 250 rpm by using fully charged battery.
If check results are below the limit valve, check instal-
lation condition for special tool.
Standard1400 kPa
(14.0 kg/cm
2, 199.0 psi)
Limit1100 kPa
(11.0 kg/cm
2, 156.0 psi)
Max. difference between
any two cylinders100 kPa
(1.0 kg/cm
2, 14.2 psi)

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Engine Vacuum Check
The engine vacuum that develops in the intake line is a good indi-
cator of the condition of the engine. The vacuum checking proce-
dure is as follows:
1) Warm up engine to normal operating temperature.
2) Stop engine and turn off the all electric switches.
3) Remove cap (1) from intake manifold.
4) Connect special tool (Vacuum gauge) to intake manifold.
Special tool
(A) : 09915-67310
5) Run engine at specified idle speed and read vacuum gauge.
Vacuum should be within specification.
Vacuum specification (at sea level)
59 – 73 kPa (45 – 55 cm Hg, 17.7 – 21.6 in. Hg)
at specified idle speed
6) After checking, disconnect special tool (Vacuum gauge) from
intake manifold.
7) Install cap to intake manifold.NOTE:
After warming up engine, be sure to place transmission
gear shift lever in “Neutral” (shift selector lever to “P”
range for A/T model), and set parking brake and block
drive wheels.

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Oil Pressure Check
Oil level in oil pan.
If oil level is low, add oil up to Full level mark (hole) (1) on oil
level gauge.
Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in Section 0B.
Oil leaks.
If leak is found, repair it.
1) Disconnect oil pressure switch coupler (1) and remove oil
pressure switch (2) from cylinder block.
2) Install special tools (Oil pressure gauge) to vacated threaded
hole.
Special tool
(A) : 09915-77310
(B) : 09915-78211
3) Start engine and warm it up to normal operating tempera-
ture.
4) After warming up, raise engine speed to 4,000 rpm and mea-
sure oil pressure.
Oil pressure specification
280 – 430 kPa (2.8 – 4.3 kg/cm
2, 39.8 – 61.1 psi) at 4,000
rpm
5) Stop engine and remove oil pressure gauge and attachment.NOTE:
Prior to checking oil pressure, check the following items.
2. Low level mark (hole)
NOTE:
Be sure to place transmission gear shift lever in “Neu-
tral” (shift selector lever to “P” range for A/T model), and
set parking brake and block drive wheels.

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6) Before reinstalling oil pressure switch (2), be sure to wrap its
screw threads with sealing tape (1) and tighten switch to
specified torque.
Tightening torque
Oil pressure switch (a) : 14 N.m (1.4 kg-m, 10.5 lb-ft)
7) Start engine and check oil pressure switch for oil leakage.
If oil leakage is found, repair it.
8) Connect oil pressure switch coupler (1).NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.

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Valve Lash (Clearance)
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder Head
Cover” in this section.
3) Using 17 mm wrench, turn crankshaft pulley (1) clockwise
until cam lobes (2) become perpendicular to shim faces (3)
at valves “1” and “7” as shown in figure.
4) Check valve lashes with thickness gauge (4) according to
the following procedure.
If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90° (by turning crankshaft with wrench).
c) Make sure that cam lobes are perpendicular to shim faces
at valves to be checked (in this case, “3” and “8”), if not,
adjust it by turning crankshaft. Check valve lashes.
d) In the same manner as b) – c), check valve lashes at valves
“4” and “6”.
e) In the same manner as b) – c) again, check valve lashes at
valves “2” and “5”.
Valve clearance specification
REPLACEMENT OF SHIM
1) Close the valve whose shim (2) is to be replaced by turning
crankshaft, then turn tappet (3) till its cut section (1) faces
inside as shown in figure.When cold
(Coolant temperature
is 15 – 25°C or
59 –77°F)When hot
(Coolant temperature
is 60 – 68°C or
140 – 154°F)
Intake0.18 – 0.22 mm
(0.007 – 0.009 in.)0.21 – 0.27 mm
(0.008 – 0.011 in.)
Exhaust0.28 – 0.32 mm
(0.011 – 0.013 in.)0.30 – 0.36 mm
(0.012 – 0.014 in.)

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2) Lift valve by turning crankshaft and then remove camshaft
housing bolts (1) where the shim to be replaced.
3) Install special tool with camshaft housing bolts as shown in
figure.
Special tool
(A) : 09916-67020
Tightening torque
Camshaft housing bolts (for tightening of special tool)
(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
Special tool selection table
4) Turn camshaft by approximately 90° clockwise and remove
shim (3).
2. Plug hole
NOTE:
Check the special tools carved seal as shown, and
then install special tool in accordance with the location
of each camshaft housing.
If special tool is holding down the shim, adjust special
tool position so as not to hold down the shim by loos-
ening camshaft housing bolt.
No. on camshaft housingEmbossed mark
on special tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345
A: I : Intake side or E : Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
WARNING:
Never put in the hand between camshaft and tappet.
1. Special tool
2. Magnet