2005 SUZUKI JIMNY Service Workshop Manual

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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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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 by loosening drain plug (1).
5) Remove air cleaner outlet No.1 and No.2 hoses and
breather hose.
6) Remove intake manifold bracket (1) with main harness from
intake manifold.
7) Disconnect the following electric lead wires:
EGR valve (if equipped)
IAC valve (2)
TP sensor (3)
MAP sensor (4)
CMP sensor
ECT sensor
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Heated oxygen sensor
Ground terminal (7) from intake manifold
Each wire harness clamps
8) Remove heated oxygen sensor bracket from cylinder head
and detach heated oxygen sensor coupler from its bracket. 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.

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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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19) Remove exhaust manifold stiffener (1).
20) Loosen cylinder head bolts in such order as indicated in fig-
ure by using a 12 corner socket wrenches and remove them.
21) Check all around cylinder head for any other parts required
to be removed or disconnected and remove or disconnect
whatever necessary.
22) Remove cylinder head with intake manifold and exhaust
manifold. Use lifting device, if necessary.
NOTE:
Don’t forget to remove bolt (M8) (1) as shown in figure.

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DISASSEMBLY
1) For ease in servicing cylinder head, remove intake manifold,
injectors and exhaust manifold from cylinder head.
2) Using special tools (Valve lifter), compress valve spring and
then remove valve cotters (1) by using special tool (For-
ceps).
Special tool
(A) : 09916-14510
(B) : 09916-14521
(C) : 09916-84511
3) Release special tools and remove spring retainer and valve
spring.
4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide and then valve
spring seat (2).
6) Using special tool (valve guide remover), drive valve guide
out from combustion chamber side to valve spring side.
Special tool
(A) : 09916-44910
7) Place disassembled parts except valve stem seal and valve
guide in order so that they can be installed in their original
position.
NOTE:
Do not reuse seal once disassembled. Be sure to use
new seal when assembling.
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.

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INSPECTION
Valve Guides
Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to check stem-to-guide clearance. Be
sure to take reading at more than one place along the length of
each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem-to-guide clearance
Valve stem diameter [A]
Valve guide bore [B]
If bore gauge is not available, check end deflection of valve stem
with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end deflec-
tion.
If deflection exceeds its limit, replace valve stem and valve guide.
Valve stem end deflection limit
In: 0.14 mm (0.006 in.)
Ex: 0.18 mm (0.007 in.)Standard Limit
In0.020 – 0.047 mm
(0.0008 – 0.0019 in.)0.07 mm
(0.0028 in.)
Ex0.045 – 0.072 mm
(0.0018 – 0.0028 in.)0.09 mm
(0.0035 in.)
Standard
In5.465 – 5.480 mm
(0.2152 – 0.2157 in.)
Ex5.440 – 5.455 mm
(0.2142 – 0.2148 in.)
Standard
In and Ex5.485 – 5.510 mm
(0.2159 – 0.2169 in.)

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Valves
Remove all carbon from valves.
Inspect each valve for wear, burn or distortion at its face and
stem end, as necessary, replace it.
Measure thickness “a” of valve head. If measured thickness
exceeds limit, replace valve.
Valve head thickness “a” (In and Ex)
Standard : 1.22 – 1.55 mm (0.048 – 0.061 in.)
Limit : 0.9 mm (0.035 in.)
Inspect valve stem end face for pitting and wear. If pitting or
wear is found there, valve stem end may be resurfaced, but
not too much to grind off its chamber. When it is worn out too
much that its chamber is gone, replace valve.
Check each valve for radial runout with a dial gauge and “V”
block. To check runout, rotate valve slowly. If runout
exceeds its limit, replace valve.
Limit on valve head radial runout
0.08 mm (0.003 in.)
Seating contact width:
Create contact pattern on each valve in the usual manner,
i.e. by giving uniform coat of marking compound to valve
seat and by rotatingly tapping seat with valve head. Valve
lapper (tool used in valve lapping) must be used.
Pattern produced on seating face of valve must be a continu-
ous ring without any break, and the width of pattern must be
within specified range.
Standard seating width “a” revealed by contact pattern on
valve face
In and Ex : 1.1 – 1.3 mm (0.0433 – 0.0512 in.)

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Valve seat repair:
A valve seat not producing a uniform contact with its valve or
showing width of seating contact that is out of specified
range must be repaired by regrinding or by cutting and
regrinding and finished by lapping.
1) EXHAUST VALVE SEAT: Use valve seat cutters (1) to make
two cuts as illustrated in figure. Two cutters must be used:
the first for making 15° angle, and the second for making 45°
angle. The second cut must be made to produce desired
seat width.
Seat width for exhaust valve seat
“a” : 1.1 – 1.3 mm (0.0433 – 0.0512 in.)
2) INTAKE VALVE SEAT: Use valve seat cutters to make three
cuts as illustrated in figure. Three cutters must be used: the
1st for making 15° angle, the 2nd for making 60° angle, and
3rd for making 45° angle. The 3rd cut (45°) must be made to
produce desired seat width.
Seat width for intake valve seat
“b” : 1.1 – 1.3 mm (0.0433 – 0.0512 in.)
3) VALVE LAPPING: Lap valve on seat in two steps, first with
coarse size lapping compound applied to face and the sec-
ond with fine-size compound, each time using valve lapper
according to usual lapping method.
Cylinder Head
Remove all carbon deposits from combustion chambers.
NOTE:
Do not use any sharp-edged tool to scrape off carbon
deposits. Be careful not to scuff or nick metal surfaces
when decarboning. The same applies to valves and valve
seats, too.