2005 SUZUKI JIMNY crank pulley

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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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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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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.

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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.

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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

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Rod bearing :
Inspect bearing shells for signs of fusion, pitting, burn or flak-
ing and observe contact pattern. Bearing shells found in
defective condition must be replaced.
Two kinds of rod bearing are available; standard size bear-
ing and 0.25 mm (0.0098 in.) undersize bearing. For identifi-
cation of undersize bearing, it is painted red at the position
as indicated in figure, undersize bearing thickness is 1.605 –
1.615 mm (0.0632 – 0.0635 in.) at the center of it.
Rod bearing clearance:
1) Before checking bearing clearance, clean bearing and crank
pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gauging plastic (1) to full width of crank pin
as contacted by bearing (parallel to crankshaft), avoiding oil
hole.
4) Install rod bearing cap (1) to connecting rod.
When installing cap, be sure to point arrow mark (2) on cap
to crankshaft pulley side, as shown in figure. After applying
engine oil to rod bolts and tighten cap nuts (3) gradually as
follows.
a) Tighten all cap nuts to 15 N·m (1.5 kg-m, 11.0 lb-ft).
b) Retighten them to 45°.
c) Repeat step b).
Tightening torque
Connecting rod bearing cap nuts
(a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) and extra tightening 45°
twice
5) Remove cap and using a scale (1) on gauging plastic (2)
envelope, measure gauging plastic width at the widest point
(clearance).
If clearance exceeds its limit, use a new standard size bear-
ing and remeasure clearance.
Connecting rod bearing clearance
Standard : 0.029 – 0.047 mm (0.0011 – 0.0019 in.)
Limit : 0.065 mm (0.0026 in.)
1. Red paint

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INSTALLATION
1) Apply engine oil to pistons, rings, cylinder walls, connecting
rod bearings and crankpins.
2) Install guide hoses (1) over connecting rod bolts.
These guide hoses protect crank pin and threads of rod bolt
from damage during installation of connecting rod and piston
assembly.
3) When installing piston and connecting rod assembly into cyl-
inder bore, point front mark on piston head to crankshaft pul-
ley side.
4) Install piston and connecting rod assembly into cylinder
bore. Use special tool (Piston ring compressor) to compress
rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until
all piston rings have entered cylinder bore.
Special tool
(A) : 09916-77310 NOTE:
Do not apply oil between connecting rod and bearing or
between bearing cap and bearing.
A : Crankshaft pulley side
B : Flywheel side

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5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side.
After applying oil to rod bolts and tighten cap nuts (3) gradu-
ally as follows.
a) Tighten all cap nuts to 15 N·m (1.5 kg-m, 11.0 lb-ft).
b) Retighten them to 45°.
c) Repeat Step b).
Tightening torque
Connecting rod bearing cap nuts
(a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) and extra tightening 45°
twice.
6) Reverse removal procedure for installation as previously out-
lined.
7) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
8) 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.
9) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
10) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
11) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
12) Connect negative cable at battery.
13) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection. NOTE:
Before installing bearing cap, make sure to check con-
necting rod bolt diameter.
Refer to “Inspection” of “Connecting Rod” in this sec-
tion.