2005 SUZUKI JIMNY ATE

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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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8) Install guide hose (1) over threads of rod bolts.
This prevents damage to bearing journal and rod bolt
threads when removing connecting rod.
9) Decarbon top of cylinder bore before removing piston from
cylinder.
10) Push piston and connecting rod assembly out through the
top of cylinder bore.
DISASSEMBLY
1) Using piston ring expander, remove two compression rings
(Top and 2nd) and oil ring from piston.
2) Remove piston pin from connecting rod.
Ease out piston pin circlips (1), as shown.
Force piston pin out.
CLEANING
Decarbon piston head and ring grooves, using a suitable tool.
INSPECTION
Cylinder
Inspect cylinder walls for scratches, roughness or ridges
which indicate excessive wear. If cylinder bore is very rough
or deeply scratched or ridged, rebore cylinder and use over-
size piston.

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Using a cylinder gauge (1), measure cylinder bore in thrust
and axial directions at two positions (“a” and “b”) as shown in
figure.
If any of the following conditions is noted, rebore cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions exceeds taper
limit.
3) Difference between thrust and axial measurements exceeds
out-of-round limit.
Limit on cylinder bore diameter
78.114 mm (3.073 in.)
Limit on taper and out-of-round for cylinder
0.10 mm (0.004 in.)
Pistons
Inspect piston for faults, cracks or other damaged.
Damaged or faulty piston should be replaced.
Piston diameter:
As indicated in figure, piston diameter should be measured
at a position 19.5 mm (0.77 in.) from piston skirt end in the
direction perpendicular to piston pin.
Piston diameter specification NOTE:
If any one of four cylinders has to be rebored, rebore all
four to the same next oversize. This is necessary for the
sake of uniformity and balance.
“a” : 50 mm (1.96 in.)
“b” : 95 mm (3.74 in.)
Standard size77.953 – 77.968 mm
(3.0690 – 3.0696 in.)
Oversize
0.50 mm (0.0196 in.)78.453 – 78.468 mm
(3.0887 – 3.0893 in.)
“a” : 19.5 mm (0.77 in.)

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Connecting rod alignment:
Mount connecting rod on aligner to check it for bow and
twist. If limit is exceeded, replace it.
Connecting rod alignment
Limit on bow : 0.05 mm (0.0020 in.)
Limit on twist : 0.10 mm (0.0039 in.)
Connecting rod bolt diameter (Plastic deformation tightening
bolt)
Measure connecting rod (1) bolt (2) for diameter “A” on 32
mm (1.25 in.) from bolt mounting surface and diameter “B”
on 40 mm (1.57 in.) from bolt mounting surface by using a
micrometer (3).
Calculate difference in diameters (“A” – “B”). If it exceeds
limit, replace connecting rod.
Connecting rod bolt measurement points
“a” : 32 mm (1.25 in.)
“b” : 40 mm (1.57 in.)
Connecting rod bolt diameter difference
Limit (“A” – “B”) : 0.1 mm (0.004 in.)
Crank Pin and Connecting Rod Bearings
Inspect crank pin for uneven wear or damage. Measure
crank pin for out-of-round or taper with a micrometer. If crank
pin is damaged or out-of-round or taper is out of limit,
replace crankshaft or regrind crank pin to undersize and use
undersize bearing.
Crank pin diameter
Out-of-round : A – B
Taper : a – b
Crank pin taper and out-of-round
Limit : 0.01 mm (0.0004 in.)
Connecting rod
bearing sizeCrank pin diameter
Standard41.982 – 42.000 mm
(1.6528 – 1.6535 in.)
0.25 mm (0.0098 in.)
undersize41.732 – 41.750 mm
(1.6430 – 1.6437 in.)

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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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6) If clearance can not be brought to within its limit even by
using a new standard size bearing, regrind crankpin to
undersize and use 0.25 mm undersize bearing.
ASSEMBLY
1) Install piston pin to piston (1) and connecting rod (2):
a) After applying engine oil to piston pin and piston pin holes
in piston and connecting rod.
b) Fit connecting rod as shown in figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
2) Install piston rings to piston :
a) As indicated in figure, 1st and 2nd rings have “T” mark
respectively. When installing these piston rings to piston,
direct marked side of each ring toward top of piston.
b) 1st ring (1) differs from 2nd ring (2) in thickness, shape and
color of surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.
c) When installing oil ring (3) install spacer first and then two
rails.
3) After installing three rings (1st, 2nd and oil rings), distribute
their end gaps as shown in figure. NOTE:
After checking the rod bearing clearance, make sure to
check connecting rod bolt diameter.
Refer to “Inspection” of “Connecting Rod”.
NOTE:
Circlip should be installed with its cut part facing as
shown in figure. Install so that circlip end gap comes
within such range as indicated by arrow.
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap

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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.

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Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove A/C compressor and/or P/S pump belt (if
equipped).
5) Remove generator belt.
6) Drain engine oil.
7) Drain coolant.
8) Disconnect radiator inlet and outlet hoses from each pipe.
9) Disconnect A/T fluid hoses (2) (vehicle with A/T) and release
its clamps. Place some container under radiator to receive
A/T fluid which will flow out when hose is disconnected.
10) Remove fan shroud upper bolts and install board (1) or the
like. This prevents damage to radiator fins when removing
and installing radiator.
11) Remove radiator with cooling fan referring to Section 6B.
Then remove water pump pulley.
12) With hose connected, detach P/S pump from its bracket (if
equipped) referring to “Power Steering Pump” in Section
3B1.
13) If vehicle equipped with A/C compressor, work of right hand
steering vehicle differs from its of left hand steering vehicle.
Each work is as follows. WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed P/S pump at a place where no damage
will be caused during removal and installation of engine
assembly.