2005 SUZUKI JIMNY camshaft

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INSTALLATION
1) Install tappets and shims to cylinder head.
Apply engine oil around tappet and then install it to cylinder
head.
2) Install camshafts (1).
Apply engine oil to sliding surface of each camshaft and
camshaft journal then install them as shown in figure.
3) Install camshaft housing pins (1) as shown in figure.
4) Check position of camshaft housings.
Embossed marks are provided on each camshaft housing,
indicating position and direction for installation. Install hous-
ings as indicated by these marks. NOTE:
When installing shim, make sure to direct shim No. side
toward tappet.
NOTE:
Before installing camshafts, turn crankshaft until key
position faces upward. Refer to “Timing Chain and Chain
Tensioner”.
A. I : Intake side or E : Exhaust side
B. Position from timing chain side
C. Pointing to timing chain side

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5) After applying engine oil to housing bolts, tighten them tem-
porarily first. Then tighten them by the following numerical
order in figure. Tighten a little at a time and evenly among
bolts and repeat tightening sequence two or three times
before they are tightened to specified torque.
Tightening torque
Camshaft housing bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
6) Install timing chain with crankshaft sprocket referring to
“Timing Chain and Chain Tensioner” in this section.
7) Install timing chain cover referring to “Timing Chain Cover” in
this section.
8) Check valve lashes referring to “Valve Lash” in this section.
9) Install cylinder head cover and oil pan referring to “Cylinder
Head Cover” and “Oil Pan and Oil Pump Strainer” in this sec-
tion.
10) 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.
11) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
12) 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.
13) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
14) 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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9) Disconnect accelerator cable (1) from throttle body.
10) Disconnect the following hoses:
Brake booster hose (2) from intake manifold
Canister purge hose (3) from EVAP canister purge valve
Fuel feed and return hoses (4) from each pipe
Water hose from thermostat case (5)
Heater inlet hose from its pipe
Vacuum hose (to check valve) (6)
11) Remove canister purge hose bracket from intake manifold.
12) Remove intake manifold stiffener (1).
13) Remove oil pan referring to “Oil Pan and Oil Pump Strainer”
in this section.
14) Remove cylinder head cover referring to “Cylinder Head
Cover” in this section.
15) Remove timing chain cover referring to “Timing Chain Cover”
in this section.
16) Remove timing chain referring to “Timing Chain and Chain
Tensioner” in this section.
17) Remove intake and exhaust camshafts referring to “Cam-
shaft, Tappet and Shim” in this section.
18) Disconnect exhaust pipe (1) from exhaust manifold.

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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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REMOVAL
1) Remove engine assembly from vehicle as previously out-
lined.
2) Remove clutch cover, clutch disc and flywheel (drive plate
for A/T) by using special tool.
Special tool
(A) : 09924-17810
3) Remove the following parts from engine as previously out-
lined.
Oil pan and oil pump strainer
Intake manifold and exhaust manifold
Cylinder head cover
Timing chain cover
Timing chain guide, chain tensioner adjuster, chain ten-
sioner, timing chain and crankshaft timing sprocket
Camshaft, tappet and shim
Cylinder head assembly
Piston and connecting rod
4) Remove rear oil seal housing (1).
5) Loosen bearing cap No.1 and No.2 bolts in such order as
indicated in figure and remove them.
6) Remove crankshaft from cylinder block.

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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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09915-67310 09915-77310 09915-78211 09916-14510
Vacuum gauge Oil pressure gauge Oil pressure gauge
attachmentValve lifter
09916-14521 09916-34542 09916-34550 09916-37320
Valve lifter attachment Reamer handle Reamer (5.5 mm) Reamer (10.5 mm)
09916-44910 09916-56011 09916-58210 09916-67020
Valve guide remover Valve guide installer
attachmentValve guide installer han-
dleTappet holder
09916-77310 09916-84511 09917-68221 09917-98221
Piston ring compressor Forceps Camshaft lock holder Valve stem seal installer