engine oil SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-15
Cylinder Head Cover
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect accelerator cable (1) from clamp (2) (For left
hand steering vehicle only).
3) Remove cylinder head upper cover (3).
4) Disconnect ignition coil couplers (1).
5) Remove ignition coil assemblies (2) with high-tension cord
(3).
6) Remove oil level gauge (1).
7) Disconnect breather hose (2) from cylinder head cover (3)
and PCV hose (4) from PCV valve (5).
8) Remove cylinder head cover mounting bolts in such order as
indicated in figure.
9) Remove cylinder head cover (1) with cylinder head cover
gasket (2) and spark plug hole gasket (3).

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INSTALLATION
1) Install new spark plug hole gaskets (1) and new cylinder
head cover gasket (2) to cylinder head cover (3) as shown in
figure.
2) Remove oil, old sealant, and dust from sealing surface on
cylinder head and cover. After cleaning, apply sealant “A” to
the following point.
Cylinder head gasket (1) sealing surface area (2) as shown.
“A” : Sealant 99000-31150
Timing chain cover (1) and cylinder head (2) matching sur-
face as shown.
“A” : Sealant 99000-31150 NOTE:
Be sure to check each of these parts for deterioration or
any damage before installation and replace if found
defective.

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3) Install cylinder head cover to cylinder head.
4) Tighten bolts in such order as indicated in figure a little at a
time till they are tightened to specified torque.
Tightening torque
Cylinder head cover bolts (a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
5) Connect breather hose (1) and PCV hose (2).
6) Install oil level gauge (3).
7) Install ignition coil assemblies with high-tension cord.
8) Connect ignition coil couplers.
9) Install cylinder head upper cover.
10) Connect accelerator cable to clamp (For left hand steering
vehicle only).
11) Connect negative cable at battery.NOTE:
When installing cylinder head cover, use care so that cyl-
inder head cover gasket or spark plug hole gaskets will
not get out of place or fall off.

Downloaded from www.Manualslib.com manuals search engine 6A1-24 ENGINE MECHANICAL (M13 ENGINE)
Oil Pan and Oil Pump Strainer
REMOVAL
1) Remove oil level gauge.
2) Remove air cleaner outlet No.1 (1) and No.2 (2) hoses and
breather hose (3).
3) To facilitate and ensure removal of oil pan, increase clear-
ance between engine and vehicle body according to the fol-
lowing procedure.
a) Install support device (1).
b) Loosen engine mounting bracket bolts (2), but do not
remove them.
c) Hoist engine 10 – 15 mm (0.4 – 0.6 in.).
[A] : Sealant application amount 3. O-ring 8. Oil pan nut
“a” : 3 mm (0.12 in.) 4. Gasket 9. Oil pan bolt
“b” : 2 mm (0.08 in.) 5. Drain plug Tightening torque
1. Oil pan
: Apply sealant 99000-31150 to mating surface.6. Strainer bolt Do not reuse.
2. Strainer 7. Bracket bolt
CAUTION:
Do not hoist engine more than instructed above. That
may cause trouble to engine or transmission.

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4) Drain engine oil by removing drain plug.
5) Remove clutch housing (torque converter housing for A/T
vehicle) lower plate (1).
6) Remove oil pan and then oil pump strainer (1) from cylinder
block.
CLEAN
Inside of oil pan and oil pump strainer screen.
Clean sealing surface on oil pan and cylinder block.
Remove oil, old sealant and dust from sealing surface.

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INSTALLATION
1) Apply sealant continuously to oil pan mating surface as
shown in figure.
“A” sealant : 99000-31150
Sealant amount for oil pan
Width “a” : 3 mm, 0.12 in.
Height “b” : 2 mm, 0.08 in.
2) Install new O-rings (1) in the position as shown in figure and
install oil pump strainer (2).
Tighten strainer bolt (3) first and then bracket bolt (4) to
specified torque.
Tightening torque
Oil pump strainer bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Oil pump strainer bracket bolt
(b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
3) After fitting oil pan to cylinder block, run in securing bolts and
start tightening at the center:
move wrench outward, tightening one bolt at a time. Tighten
bolts and nuts to specified torque.
Tightening torque
Oil pan bolts and nuts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
4) Install new gasket and drain plug to oil pan.
Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
5) Install clutch housing (torque converter housing for A/T vehi-
cle) lower plate (1).

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6) Lower engine and tighten engine mounting bracket bolts to
specified torque.
Tightening torque
Engine mounting bracket bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
7) Install oil level gauge.
8) Refill engine with engine oil referring to “Engine Oil and Filter
Change” in Section 0B.
9) Verify that there is no engine oil leakage at each connection.

Downloaded from www.Manualslib.com manuals search engine 6A1-28 ENGINE MECHANICAL (M13 ENGINE)
Timing Chain Cover
REMOVAL
1) Disconnect negative cable at battery.
2) Remove A/C compressor and/or P/S pump belt (if
equipped).
3) Remove generator belt.
4) Drain engine oil.
[A] : Sealant application
amount3. Oil seal
: Apply engine oil to oil seal lip.8. Cylinder head cover
: Apply sealant 99000-31150 to the sealing
point for timing chain cover mating surface
and cylinder head gasket sealing point.
Refer to “Cylinder Head Cover Installation”.
“a” : 3 mm (0.12 in.) 4. Timing chain cover Tightening torque
: Apply sealant 99000-31140 to the mating surface
of cylinder and cylinder head.
: Apply sealant 99000-31150 to the mating surface
of timing chain cover referring to the figure of Step
1) in INSTALLATION.
“b” : 2 mm (0.08 in.) 5. Pin Do not reuse.
1. Crankshaft pulley bolt 6. Cylinder head cover gasket
2. Crankshaft pulley 7. Timing chain cover mounting bolts

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12) Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool with it as
shown in figure.
Special tool
(A) : 09917-68221
13) Remove crankshaft pulley (1).
If it is hard to remove, use special tools as shown in figure.
If bolts of special tool are too long, replace them with those
of suitable length.
Special tool
(A) : 09944-36011
(B) : 09926-58010
14) Remove oil pan referring to “Oil Pan and Oil Pump Strainer”
in this section.
15) Remove cylinder head cover referring to “Cylinder Head
Cover” in this section.
16) Disconnect CMP sensor coupler (1) and release its harness
clamps.
17) Remove water outlet pipe (2).
18) Remove timing chain cover (3).
CLEANING
Clean sealing surface on timing chain cover, cylinder block
and cylinder head.
Remove oil, old sealant and dust from sealing surface.

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INSPECTION
Check oil seal (1) lip for fault or other damage.
Replace as necessary.
Special tool
(A) : 09913-75520
INSTALLATION
Reverse removal procedure to install timing chain cover, noting
the following points.
1) Apply sealant “A” to mating surface of cylinder and cylinder
head and “B” to mating surface of timing chain cover as
shown in figure.
“A” : Sealant 99000-31140
“B” : Sealant 99000-31150
Sealant amount for timing chain cover
Width “a” : 3 mm, 0.12 in.
Height “b” : 2 mm, 0.08 in.
2) Apply engine oil to oil seal lip, then install timing chain cover
(1) and water outlet pipe (2).
Tighten bolts and nut to specified torque.
Tightening torque
Timing chain cover bolts and nut
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft) NOTE:
When installing new oil seal, tap it in until its surface is
flash with edge of timing chain cover (2).
To install oil seal, use special tool (Bearing installer).
NOTE:
Before installing timing chain cover, check that pin is
securely fitted.