2005 SUZUKI JIMNY crank

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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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6) Install valve to valve guide
Before installing valve to valve guide, apply engine oil to
stem seal, valve guide bore and valve stem.
7) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end (1)) and bot-
tom end (small-pitch end (2)). Be sure to position spring in
place with its bottom end (small-pitch end) facing the bottom
(valve spring seat side).
8) Using special tools (Valve lifter), compress valve spring and
fit two valve cotters (1) into groove in valve stem.
Special tool
(A) : 09916-14510
(B) : 09916-14521
(C) : 09916-84511
9) Install intake manifold, injectors and exhaust manifold to cyl-
inder head.
INSTALLATION
1) Clean mating surface of cylinder head and cylinder block.
Remove oil, old gasket and dust from mating surface.
2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.“TOP”
mark provided on gasket comes to crankshaft pulley side,
facing up (toward cylinder head side).
A : Valve spring retainer side
B : Valve spring seat side
NOTE:
When compressing the valve spring, do not damage
inside face of tappet installing hole.

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Pistons, Piston Rings, Connecting Rods and Cylinders
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.
5) Remove cylinder head referring to “Valves and Cylinder
Head” in this section.
6) Mark cylinder number on all pistons, connecting rods and
connecting rod caps using silver pencil or quick drying paint.
7) Remove rod bearing caps.
1. Top ring8. Piston pin
2. 2nd ring9. Piston pin circlip
3. Oil ring10. Bearing cap nut
1) Tighten all nuts to 15 N·m (1.5 kg-m)
2) Turn all nuts to 45°
3) Then, turn all nuts to 45° once again
4. PistonTightening torque
5. Connecting rod
: Apply engine oil to sliding surface except inner surface of big end, and rod bolts.
Make sure rod bolt diameter when reuse it due to plastic deformation tightening.
Refer to “Inspection” of “Connecting Rod”.Apply engine oil to sliding surface of each
parts.
6. Connecting rod bearing cap
: Point arrow mark on cap to crankshaft pulley side.Do not reuse.
7. Connecting rod bearing

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Piston pin clearance:
Check piston pin clearance in small end and piston. Replace
connecting rod and/or piston if its small end is badly worn or
damaged or if measured clearance exceeds limit.
Piston pin clearance in connecting rod small end
0.003 – 0.014 mm (0.0001 – 0.0006 in.)
Piston pin clearance in piston
0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Small-end bore for connecting rod
20.003 – 20.011 mm (0.7875 – 0.7878 in.)
Piston pin diameter
19.997 – 20.000 mm (0.7873 – 0.7874 in.)
Piston bore
20.006 – 20.014 mm (0.7876 – 0.7880 in.)
Piston Rings
To measure end gap, insert piston ring (1) into cylinder bore and
then measure the gap by using thickness gauge (2).
If measured gap is out of specification, replace ring.
Piston ring end gap
Connecting Rod
Big-end side clearance:
Check big-end of connecting rod for side clearance, with rod
fitted and connected to its crank pin in the normal manner. If
measured clearance is found to exceed its limit, replace con-
necting rod.
Side clearance for connecting rod big-end
Standard : 0.25 – 0.40 mm (0.0098 – 0.0157 in.)
Limit : 0.55 mm (0.0217 in.)
NOTE:
Decarbon and clean top of cylinder bore before inserting
piston ring.
Item Standard Limit
Top ring0.20 – 0.35 mm
(0.0079 – 0.0138 in.)0.7 mm
(0.0276 in.)
2nd ring0.30 – 0.45 mm
(0.0118 – 0.0177 in.)1.0 mm
(0.0039 in.)
Oil ring0.20 – 0.70 mm
(0.0079 – 0.0276 in.)1.5 mm
(0.059 in.)
“a” : 120 mm (4.72 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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INSTALLATION
1) Apply engine oil to pistons, rings, cylinder walls, connecting
rod bearings and crankpins.
2) Install guide hoses (1) over connecting rod bolts.
These guide hoses protect crank pin and threads of rod bolt
from damage during installation of connecting rod and piston
assembly.
3) When installing piston and connecting rod assembly into cyl-
inder bore, point front mark on piston head to crankshaft pul-
ley side.
4) Install piston and connecting rod assembly into cylinder
bore. Use special tool (Piston ring compressor) to compress
rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until
all piston rings have entered cylinder bore.
Special tool
(A) : 09916-77310 NOTE:
Do not apply oil between connecting rod and bearing or
between bearing cap and bearing.
A : Crankshaft pulley side
B : Flywheel side