2005 SUZUKI JIMNY cam

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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

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8) Lift valve by turning crankshaft counterclockwise (in opposite
direction against above Step 4) and remove special tool.
Special tool
(A) : 09916-67020
9) Install camshaft housing (1) and tighten them to specified
torque.
Tightening torque
Camshaft housing bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
10) Check valve clearance again.
11) Install cylinder head cover, referring to “Cylinder Head
Cover” in this section.
1. Tappet
2. Camshaft

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Timing Chain and Chain Tensioner
REMOVAL
1) Remove timing chain cover referring to “Timing Chain
Cover”.
2) Align both intake and exhaust camshaft timing sprocket
marks (1) with notches (2) of cylinder head respectively by
turning crankshaft.
3) Remove timing chain tensioner adjuster assembly (3).
4) Remove timing chain tensioner (4).
5) Remove timing chain No.1 guide (5).
6) Remove timing chain (6) with crankshaft timing sprocket (7).
1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly Tightening torque
2. Timing chain 6. Chain tensioner adjuster mounting bolt Apply engine oil to sliding surface.
3. Timing chain No.1 guide 7. Chain tensioner mounting bolt
4. Timing chain tensioner 8. Chain guide mounting bolt
CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than its allowable turning
range described in “INSTALLATION” section.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.
45
6
21
1
3
7

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INSTALLATION
1) Check that match marks (1) on intake and exhaust camshaft
timing sprockets are in match with notches (2) on cylinder
head as shown in figure.
2) Set key (3) and turn crankshaft to position key on upside of
crankshaft.
3) Install timing chain by aligning dark blue plate (1) of timing
chain and mark (2) on camshaft timing sprocket and then
aligning dark blue plate (3) and triangle mark (4) as shown in
figure.
4) Fit crankshaft timing sprocket to timing chain by aligning gold
plate (5) of timing chain and mark (6) on crankshaft timing
sprocket. Then install crankshaft timing sprocket fitted with
chain to crankshaft.
5) Apply engine oil to sliding surface of timing chain No.1 guide
(1) and install it as shown in figure.
Tighten guide bolts to specified torque.
Tightening torque
Timing chain No.1 guide bolts
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft) CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than such an extent (“a”,
“b”) as shown in figure.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.
“a” :90°5. Crankshaft allowable turning range.
By key on crankshaft, within 90° from top on both right and left.
“b” :15°4. Camshaft (IN and EX) allowable turning range.
By marks on camshaft timing sprocket within 15° from notches on
cylinder head on both right and left.

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6) Apply engine oil to sliding surface of chain tensioner (1) and
install chain tensioner and spacer.
Tighten tensioner bolt to specified torque
Tightening torque
Timing chain tensioner bolt
(a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
7) Check that match marks (1) on intake and exhaust camshaft
timing sprockets are in match with dark blue plates (2) of tim-
ing chain and match mark (3) on crankshaft timing sprocket
is in match with gold plate (4) of timing chain.
8) Screw in plunger (1) by turning timing chain tensioner
adjuster (2) in arrow direction and install a retainer (3) (wire)
to hold plunger in place.
9) Install timing chain tensioner adjuster assembly (1) with a
retainer (2).
Tighten adjuster bolts to specified torque and then remove a
retainer from chain tensioner adjuster assembly.
Tightening torque
Timing chain tensioner adjuster bolts
(a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
221
3
4

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10) Apply engine oil to timing chain and then turn crankshaft
clockwise by 2 revolutions and check that match marks (1)
on intake and exhaust camshaft timing sprockets are in
match with notches (2) on cylinder head and key (3) is on
upside of crankshaft as shown in figure.
If each mark of timing chain and each match mark are no
matches, adjust each sprocket and timing chain.
11) Install timing chain cover referring to “Timing Chain Cover” in
this section.
12) Perform Steps 3) to 8) of “INSTALLATION” of “Timing Chain
Cover” in this section.
21
1
3

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Camshaft, Tappet and Shim
REMOVAL
1) Remove cylinder head cover and oil pan referring to “Cylin-
der Head Cover” and “Oil Pan and Oil Pump Strainer” in this
section.
2) Remove timing chain cover referring to “Timing Chain Cover”
in this section.
3) Remove timing chain referring to “Timing Chain and Chain
Tensioner” in this section.
4) Loosen camshaft housing bolts in such order as indicated in
figure and remove them.
5) Remove camshaft housings.
6) Remove intake and exhaust camshafts.
1. Intake camshaft 4. Tappet Tightening torque
2. Exhaust camshaft 5. Camshaft housing Apply engine oil to sliding surface of each part.
3. Shim
: Shim No. on it faces tappet side.6. Camshaft housing bolt

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7) Remove tappets (1) with shims (2).
INSPECTION
Cam Wear
Using a micrometer, measure cam height “a”. If measured height
is below its limit, replace camshaft.
Cam height “a” of camshaft
Camshaft Runout
Set camshaft between two “V” blocks, and measure its runout by
using a dial gauge.
If measured runout exceeds below limit, replace camshaft.
Camshaft runout limit
0.10 mm (0.0039 in.)
Camshaft Journal Wear
Check camshaft journals and camshaft housings for pitting,
scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head
with housing. Never replace cylinder head without replacing
housings.
Standard Limit
Intake cam 44.919 – 45.079 mm
(1.768 – 1.775 in.)44.80 mm
(1.764 in.)
Exhaust cam 44.399 – 44.559 mm
(1.748 – 1.754 in.)44.28 mm
(1.743 in.)