Oil and filter SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-7
General Precautions
The WARNING and CAUTION below describe some general precautions that you should observe when servic-
ing a vehicle. These general precautions apply to many of the service procedures described in this manual, and
they will not necessarily be repeated with each procedure to which they apply.
 Before starting any service work, cover fenders, seats
and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g, buttons) may cause damage to the vehicle’s
finish.
 When performing service to electrical parts that does
not require use of battery power, disconnect the nega-
tive cable of the battery. WARNING:
 Whenever raising a vehicle for service, be sure to follow the instructions under “Vehicle Lifting
Points” in this section.
 When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-
matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.
 When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.
 Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-
ant), make sure that the area you work in is well-ventilated.
 To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.
 New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-
mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,
wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing
engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any
clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.
 Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-1
0A 6F1
0B
0B
6G
1A 6H
1B 6K
37A
3A 7A1
3B1 7B1
3C1 7C1
3D 7D
3E 7E
3F 7F
4A2 8A
4B 8B
8C
58D
5A 8E
5B
5C 9
5E
5E1 10
10A
610B
6-1
6A1
6A2
6A4
6B
6C
6E1
6E2
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule .................................. 0B-2
Maintenance Schedule Under Normal
Driving Conditions ........................................ 0B-2
Maintenance Recommended Under Severe
Driving Conditions ........................................ 0B-4
Maintenance Service...................................... 0B-5
Engine .......................................................... 0B-5
Drive Belt .................................................. 0B-5
Valve Lash................................................ 0B-6
Engine Oil and Filter ................................. 0B-6
Engine Coolant ......................................... 0B-8
Exhaust System ....................................... 0B-8
Ignition System ............................................. 0B-9
Spark Plugs .............................................. 0B-9
Fuel System ................................................. 0B-9
Air Cleaner Filter ...................................... 0B-9
Fuel Lines and Connections ................... 0B-10
Fuel Filter ............................................... 0B-10
Fuel Tank ............................................... 0B-10
Emission Control System ........................... 0B-10
Crankcase Ventilation Hoses and
Connections ........................................... 0B-10
PCV (Positive Crankcase Ventilation)
Valve ..................................................... 0B-11Fuel Evaporative Emission Control
System ................................................... 0B-11
Chassis and Body ...................................... 0B-11
Clutch ..................................................... 0B-11
Brake Discs and Pads ............................ 0B-11
Brake Drums and Shoes ........................ 0B-12
Brake Hoses and Pipes.......................... 0B-12
Brake Fluid ............................................. 0B-12
Parking Brake Lever and Cable ............. 0B-13
Tires/Wheels .......................................... 0B-13
Suspension System ............................... 0B-14
Propeller Shafts...................................... 0B-15
Manual Transmission Oil........................ 0B-16
Automatic Transmission Fluid ................ 0B-16
Transfer and Differential Oil ................... 0B-17
Steering System ..................................... 0B-18
Steering Knuckle Seal ............................ 0B-18
Power Steering (P/S) System
(if equipped) ........................................... 0B-19
All Hinges, Latches and Locks ............... 0B-19
Final Inspection............................................ 0B-20
Recommended Fluids and Lubricants ....... 0B-22

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

Downloaded from www.Manualslib.com manuals search engine 0B-2 MAINTENANCE AND LUBRICATION
Maintenance Schedule
Maintenance Schedule Under Normal Driving Conditions
NOTE:
 This interval should be judged by odometer reading or months, whichever comes first.
 This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.
IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 1827364554
Months 12 24 36 48 60 72
ENGINE
Drive belt V-belt I R I R I R
V-rib belt (Flat type)––I––R
Valve lash (clearance) –I–I–I
Engine oil and oil filter R R R R R R
Engine coolant––R––R
Exhaust system–I–I–I
IGNITION SYSTEM
✱Spark plugs When
unleaded
fuel is usedVehicle without
HO2SNickel spark
plug–R–R–R
Iridium spark
plug––R––R
Vehicle with
HO2SNickel spark
plug––R––R
Iridium spark
plug–––R––
When leaded fuel is used, refer to “Maintenance Recommended Under Severe Driving Condi-
tions” in this section.
FUEL SYSTEM
Air cleaner filter I I R I I R
Fuel lines and connections–I–I–I
Fuel filter Replace every 210,000 km (126,000 miles).
Fuel tank––I––I
EMISSION CONTROL SYSTEM
Crankcase ventilation hoses and connections
(Vehicle without HO2S)––I––I
✱PCV valve Vehicle without HO2S––I––I
Vehicle with HO2S–––––I
✱Fuel evaporative emission
control systemVehicle without HO2S–I–I–I
Vehicle with HO2S–––––I
NOTE:
“R”: Replace or change
“I”: Inspect and correct, replace or lubricate if necessary
 For Sweden, items with
✱
✱✱ ✱ (asterisk) should be performed by odometer reading only.
 For spark plugs, replace every 50,000 km if the local law requires.
 Nickel spark plug: BKR6E-11 (NGK) or K20PR-U11 (DENSO)
 Iridium spark plug: IFR5E11 (NGK) or SK16PR-A11 (DENSO)

Downloaded from www.Manualslib.com manuals search engine 0B-4 MAINTENANCE AND LUBRICATION
Maintenance Recommended Under Severe Driving Conditions
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as shown in the fol-
lowing table.
Severe condition code
A : Repeated short trips
B : Driving on rough and/or muddy roads
C : Driving on dusty roads
D : Driving in extremely cold weather and/or salted roads
E : Repeated short trips in extremely cold weather
F : Leaded fuel use
G : – – – – –
H : Trailer towing (if admitted)
Severe
Condition CodeMaintenanceMaintenance
OperationMaintenance Interval
– B C D – – – –Drive belt (V-rib belt)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
A – C D E F – H Engine oil and oil filter R Every 5,000 km (3,000 miles) or 4 months
– B – – – – – –Exhaust pipe mountings IEvery 15,000 km
(9,000 miles) or 12 months
– – C – – – – –Air cleaner filter ✱1I Every 2,500 km (1,500 miles)
REvery 30,000 km
(18,000 miles) or 24 months
A B C – E F – H Spark plugsNickel spark plug R Every 10,000 km (6,000 miles) or 8 months
Iridium spark plug
REvery 30,000 km
(18,000 miles) or 24 months
– B C D – – – H Wheel bearing IEvery 15,000 km
(9,000 miles) or 12 months
– B – – – – – –Suspension bolts and nuts TEvery 15,000 km
(9,000 miles) or 12 months
– B – D E – – H Propeller shafts IEvery 15,000 km
(9,000 miles) or 12 months
– B – – E – – HManual transmission,
transfer and differential oilRFirst time only:
15,000 km (9,000 miles) or 12 months
Second time and after: Every 30,000 km
(18,000 miles) or 24 months reckoning from
0 km (0 mile) or 0 month
– B – – E – – H Automatic transmission fluid REvery 30,000 km
(18,000 miles) or 24 months
– B C D – – – –Steering knuckle seal IEvery 15,000 km
(9,000 miles) or 12 months
NOTE:
 “I”: Inspect and correct, replace or lubricate if necessary
 “R”: Replace or change
 “T”: Tighten to the specified torque

✱
✱✱ ✱1: Inspect or replace more frequently if necessary

Downloaded from www.Manualslib.com manuals search engine 0B-6 MAINTENANCE AND LUBRICATION
3) Check belt for tension.
Power steering pump and/or A/C compressor drive belt
tension
“a”: 6 – 9 mm (0.24 – 0.35 in.) deflection under 100 N
(10 kg, 22 lb) pressure.
4) If belt tension is out of above specification, adjust it referring
to “Compressor Drive Belt” in Section 1B or “Power Steering
Belt Check” in Section 3B1.
5) Connect negative cable to battery.
REPLACEMENT
Replace belt with new one referring to “Compressor Drive Belt” in
Section 1B or “Power Steering Belt Check” in Section 3B1.
Valve Lash
INSPECTION
1) Inspect intake and exhaust valve lash and adjust as neces-
sary.
Refer to “Valve Lash (Clearance)” in Section 6A1 for valve
lash inspection and adjustment procedure.
Engine Oil and Filter
CHANGE
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.
1. P/S pump pulley
2. Camshaft pulley
3. A/C compressor pulley (if equipped)
4. Belt tension pulley
1. Camshaft
2. Thickness gauge
WARNING:
 New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
 Step 1) – 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-7
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug,
and tighten it securely as specified below.
Tightening torque
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
3) Loosen oil filter by using oil filter wrench (special tool).
Special tool
(A) : 09915-47330
4) Screw new filter on oil filter stand by hand until the filter
O-ring contacts the mounting surface.
5) Tighten the filter (1) 3/4 turn from the point of contact with
the mounting surface using an oil filter wrench (2).
Tightening torque
(b) : 14 N·m (1.4 kg-m, 10.5 lb-ft) (for reference)
NOTE:
Before fitting new oil filter, be sure to oil its O-ring. Use
engine oil for this purpose.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which filter O-ring first contacts
the mounting surface.

Downloaded from www.Manualslib.com manuals search engine 0B-8 MAINTENANCE AND LUBRICATION
6) Replenish oil until oil level is brought to FULL level mark on
dipstick. (oil pan and oil filter capacity). The filler inlet is at
the top of the cylinder head cover.
It is recommended to use engine oil of SE, SF, SG, SH, SJ or
SL grade.
Select the appropriate oil viscosity according to the proper
engine oil viscosity chart [A].
Engine oil specification
7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for three minutes. Stop it and wait five
minutes before checking oil level. Add oil, as necessary, to
bring oil level to FULL level mark on dipstick.
Engine Coolant
CHANGE
Change engine coolant referring to “Cooling System Flush and
Refill” in Section 6B.
Exhaust System
INSPECTION
Oil pan capacity About 3.8 liters (8.0/6.7 US/lmp pt.)
Oil filter capacity About 0.2 liters (0.4/0.3 US/lmp pt.)
Others About 0.3 liters (0.6/0.5 US/lmp pt.)
Total About 4.3 liters (9.1/7.6 US/lmp pt.)
NOTE:
Engine oil capacity is specified. However, note that the
amount of oil required when actually changing oil may
somewhat differ from the data in the table depending on
various conditions (temperature, viscosity, etc.)
1. Full level mark (hole)
2. Low level mark (hole)
WARNING:
To avoid danger of being burned, do not touch exhaust
system when it is still hot. Any service on exhaust sys-
tem should be performed when it is cool.

Downloaded from www.Manualslib.com manuals search engine 0B-22 MAINTENANCE AND LUBRICATION
Recommended Fluids and Lubricants
Engine oilSE, SF, SG, SH, SJ or SL
(Refer to “Engine Oil and Oil Filter” in this section for engine oil viscos-
ity.)
Engine coolant
(Ethylene glycol base coolant)“Antifreeze/Anticorrosion coolant”
Brake fluid DOT 3
Manual transmission oil Refer to “Maintenance Service” in Section 7A.
Transfer oil Refer to “Oil Change” in Section 7D.
Differential oil (front & rear) Refer to “Oil Change” in Section 7E and 7F.
Automatic transmission fluid
An equivalent of DEXRON
®-IIE or DEXRON®-III
Power steering fluid
An equivalent of DEXRON
®-II, DEXRON®-IIE or DEXRON®-III
Clutch linkage pivot points
Water resistance chassis grease
(SUZUKI SUPER GREASE A 99000-25010)
Steering knuckle seal
Door hinges
Engine oil or water resistance chassis grease
Hood latch assembly
Key lock cylinder Spray lubricant

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-25
Excessive detonation
(The engine makes
sharp metallic knocks
that change with throt-
tle opening.
Sounds like pop corn
popping.)Engine overheating Refer to “Overheating” of this table.
Faulty spark plug Spark plugs in Section 6F.
Clogged fuel filter and fuel lines Diagnostic Flow Table B-3
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
Poor performance of knock sensor, ECT
sensor or MAP sensorKnock sensor in this section, ECT
sensor or MAP sensor in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Excessive combustion chamber deposits Piston and cylinder head in Section
6A1.
Overheating
Inoperative thermostat Thermostat in Section 6B.
Faulty A/C condenser fan motor or its cir-
cuitA/C condenser fan control system
check in Section 6E.
Loose or slip water pump belt ITEM1-1 Drive belt inspection and
change in Section 0B.
Poor water pump performance Water pump in Section 6B.
Clogged or leaky radiator Radiator in Section 6B.
Improper engine oil grade ITEM1-3 Engine oil and oil filter
change in Section 0B.
Clogged oil filter or oil strainer Oil pressure check in Section 6A1.
Poor oil pump performance Oil pressure check in Section 6A1.
Dragging brakes Diagnosis Table in Section 5.
Slipping clutch Diagnosis Table in Section 7C.
Blown cylinder head gasket Valves and cylinder head in Section
6A1.
Poor gasoline mileage
Faulty ignition coil Ignition coil assembly in Section 6F.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty TP sensor, ECT sensor or MAP
sensorTP sensor, ECT sensor or MAP sen-
sor in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
High idle speed Refer to item “Improper Engine Idle
Speed” previously outlined.
Low compression Previously outlined.
Poor valve seating Valves and cylinder head in Section
6A1.
Dragging brakes Diagnosis Table in Section 5.
Slipping clutch Diagnosis Table in Section 7C.
Thermostat out of order Thermostat in Section 6B.
Improper tire pressure Refer to Section 3F. Condition Possible Cause Reference Item

Downloaded from www.Manualslib.com manuals search engine 6-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Excessive engine oil
consumptionSticky piston ring Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn piston and cylinder Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn piston ring groove and ring Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Improper location of piston ring gap Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn or damaged valve stem seal Valves and cylinder head in Section
6A1.
Worn valve stem Valves and cylinder head in Section
6A1.
Low oil pressure
Improper oil viscosity ITEM1-3 Engine oil and oil filter
change in Section 0B.
Malfunctioning oil pressure switch Oil pressure switch in Section 8.
Clogged oil strainer Oil pan and oil pump strainer in Sec-
tion 6A1.
Functional deterioration of oil pump Oil pump in Section 6A1.
Worn oil pump relief valve Oil pump in Section 6A1.
Excessive clearance in various sliding
partsRefer to Section 6A1.
Engine noise
See NOTE below.Improper valve lash Valve lash in Section 6A1.
Worn valve stem and guide Valves and cylinder head in Section
6A1.
Weak or broken valve spring Valve springs in Section 6A1.
Warped or bent valve Valves and cylinder head in Section
6A1.
Loose camshaft housing bolts Camshaft in Section 6A1.
Worn piston, ring and cylinder bore Pistons and cylinders in Section 6A1.
Worn crankpin bearing Crankpin and connecting rod bearing
in Section 6A1.
Worn crankpin Crankpin and connecting rod bearing
in Section 6A1.
Loose connecting rod nuts Connecting rod in Section 6A1.
Low oil pressure Previously outlined.
Worn crankshaft journal bearing Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Worn crankshaft journal Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Loose lower crankcase (bearing cap) bolts Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Excessive crankshaft thrust play Main bearings, Crankshaft and cylin-
der block in Section 6A1. Condition Possible Cause Reference Item
NOTE:
Before checking the mechanical noise, make sure that :
Ignition timing is properly adjusted.
Specified spark plug is used.
Specified fuel is used.