2005 SUZUKI JIMNY Exhaust system 6k

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-23
3) Install exhaust manifold stiffener (1).
Tighten exhaust manifold stiffener bolts to specified torque.
Tightening torque
Exhaust manifold stiffener bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
4) Install exhaust manifold cover (1).
5) Connect heated oxygen sensor coupler (2) and fit coupler to
bracket securely (if equipped).
6) Connect negative cable at battery.
7) Check exhaust system for exhaust gas leakage.

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6) Install exhaust manifold stiffener and exhaust pipe referring
to “Exhaust Manifold” in this section.
7) Install camshafts, timing chain and chain cover referring to
“Camshaft, Tappet and Shim”, “Timing Chain and Chain
Tensioner” and “Timing Chain Cover” in this section.
8) Install cylinder head cover and oil pan referring to “Cylinder
Head Cover” and “Oil Pan and Oil Pump Strainer” in this sec-
tion.
9) Install intake manifold stiffener and connect each hoses and
electric lead wires securely.
10) Install air cleaner outlet hoses.
11) 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.
12) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
13) 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.
14) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
15) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
16) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
17) Connect negative cable at battery.
18) 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.

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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.

Downloaded from www.Manualslib.com manuals search engine 6A1-78 ENGINE MECHANICAL (M13 ENGINE)
Install seal ring and exhaust pipe to exhaust manifold.
Tighten pipe fasteners to specified torque.
Tightening torque
Exhaust pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
6) Reverse disconnected hoses, cables and electric wires for
connection.
7) Install air cleaner outlet hoses.
8) 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.
9) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
10) 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.
11) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
12) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
13) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
14) Connect negative cable at battery.
15) 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.

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Idle mixture inspection / adjustment (vehicle without
heated oxygen sensor)
All vehicles not equipped with heated oxygen sensor are shipped
with their CO % factory adjusted as follows.
Engine idle mixture (CO %)
0.5 – 1.5 % at specified idle speed
Idle mixture adjustment should never be changed from the origi-
nal factory setting. However, if during diagnosis, the check indi-
cates idle mixture to be the cause of a driver performance
complaint or emission failure, the idle mixture can be adjusted
using the following procedures.
1) Check idle speed according to “Idle Speed / Idle Air Control
(IAC) Duty Inspection” in this section.
2) Using exhaust gas tester, check that idle mixture CO % is
within above specification. If it is out of specification, adjust it
to specification by turning resistor knob.
3) If idle mixture has been adjusted, confirm that idle speed is
within specification. NOTE:
For this inspection and adjustment, exhaust gas tester
(CO meter) and engine tachometer are necessary.
NOTE:
CO adjusting resistor knob to “A” increases CO % (A/F
mixture becomes rich) and turning it to “B” decreases
CO % (A/F mixture becomes lean).
1. CO adjusting resistor

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Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a) : 15 N·m (1.5 kg-m, 11.5 lb-ft)
Connect connector to ECT sensor (1) securely.
Refill coolant referring to “Cooling System Flush and Refill”
in Section 6B.
Heated oxygen sensor (Sensor-1 and sensor-2)
OXYGEN SENSOR HEATER INSPECTION
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals
“V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
Resistance of oxygen sensor heater
HO2S-1 : 5.0 – 6.4
Ω
ΩΩ Ω at 20 °C, 68 °F
HO2S-2 : 11.7 – 14.3
Ω
ΩΩ Ω at 20 °C, 68 °F
3) Connect sensor connector securely.
REMOVAL
NOTE:
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
1. Viewed from terminal side
WARNING:
To avoid danger of being burned, do not touch exhaust
system when system is hot. Oxygen sensor removal
should be performed when system is cool.

Downloaded from www.Manualslib.com manuals search engine 6E-34 ENGINE AND EMISSION CONTROL SYSTEM
1) Disconnect negative cable at battery.
2) For sensor-1, remove exhaust manifold cover (1) and dis-
connect connector of heated oxygen sensor and release its
wire harness from clamps.
3) For sensor-2, disconnect connector of heated oxygen sensor
and release its wire harness from clamp. Hoist vehicle and
then remove exhaust No.1 pipe covers (3).
4) Remove heated oxygen sensor (2) from exhaust manifold or
exhaust No.1 pipe.
INSTALLATION
Reverse removal procedure noting the following.
Tighten heated oxygen sensor (2) to specified torque.
Tightening torque
Heated oxygen sensor (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft)
Connect connector of heated oxygen sensor (2) and clamp
wire harness securely.
After installing heated oxygen sensor (2), start engine and
check that no exhaust gas leakage exists.
Camshaft position sensor
INSPECTION
Check camshaft position sensor referring to “DTC P0340 (No. 15)
Diag. Flow Table” in Section 6. If malfunction is found, replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect connector from camshaft position sensor.
3) Remove camshaft position sensor from cylinder head.
INSTALLATION
1) Check that O-ring is free from damage.
2) Check that camshaft position sensor and signal rotor tooth
are free from any metal particles and damage.
3) Install camshaft position sensor to sensor case.
Tightening torque
Camshaft position sensor bolt
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
4) Connect connector to it securely.
5) Connect negative cable to battery.
[A] : HO2S-1
[B] : HO2S-2

Downloaded from www.Manualslib.com manuals search engine 6H-10 CHARGING SYSTEM
1) Set parking brake and place automatic transmission in
PARK (NEUTRAL on manual transmission). Turn off ignition,
turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line, add dis-
tilled water.
3) Attach end of one jumper cable to positive terminal of
booster battery and the other end of the same cable to posi-
tive terminal of discharged battery. (Use 12-volt battery only
to jump start engine).
4) Attach one end of the remaining negative cable to negative
terminal of booster battery, and the other end to a solid
engine ground (such as exhaust manifold) at least 45 cm (18
in.) away from battery of vehicle being started.
5) Start engine of vehicle with booster battery and turn off elec-
trical accessories. Then start engine of the vehicle with dis-
charged battery.
6) Disconnect jumper cables in the exact reverse order.
WITH CHARGING EQUIPMENT
WARNING:
Departure from these conditions or procedure
described below could result in:
–Serious personal injury (particularly to eyes) or
property damage from such causes as battery explo-
sion, battery acid, or electrical burns.
–Damage to electronic components of either vehicle.
Remove rings, watches, and other jewelry. Wear
approved eye protection.
Be careful so that metal tools or jumper cables do not
contact positive battery terminal (or metal in contact
with it) and any other metal on vehicle, because a short
circuit could occur.
WARNING:
Do not connect negative cable directly to negative termi-
nal of dead battery.
CAUTION:
When jump starting engine with charging equipment, be
sure equipment used is 12-volt and negative ground. Do
not use 24-volt charging equipment. Using such equip-
ment can cause serious damage to electrical system or
electronic parts.