Removal and Replacement
Oil Pan and Oil Pump Strainer Removal and InstallationRemoval
1. Remove oil level gauge.
2. Raise vehicle.
3. Remove engine under cover.
4. Remove exhaust No. 1 pipe.
5. Remove transfer.
6. Remove clutch housing plate (1).
7. Drain engine oil by removing drain plug (1).
8. Cut sealant at hatched part shown in the figure using special tool and hammer (1).
Special Tool (A):09921-96510
NOTE: Be careful not to damage stud bolt (4) between oil pan and crankcase when cutting sealant.
9. Remove oil pan (2), oil pump strainer (3) and O-rings (5) from lower crankcase.
Installation
1. Install new O-rings (2) to oil pump strainer (1) securely as shown in figure. Tighten strainer bolts to specified torque.
Tightening torque
Oil pump strainer bolt a: 11 Nm (1.1 kgf-m, 8.0 ft. lbs.)
2. Apply sealant to oil pan (1) mating surface continuously as shown in figure.
"A": Sealant 99000-31260SUZUKI Bond No.1217G
Sealant amount for oil pan
Width "a": 2 mm (0.08 in.)
Height "b": 2 mm (0.08 in.)
3. After fitting oil pan (1) 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 bolt and nut a: 11 Nm (1.1 kgf-m, 8.0 ft. lbs.)
Transmission case No.1 bolt b: 55 Nm (5.5 kgf-m, 40.0 ft. lbs.)
4. Install new gasket and drain plug (2) to oil pan after applying engine oil. Tighten drain plug to specified torque.
Tightening torque
Oil drain plug c: 35 Nm (3.5 kgf-m, 25.5 ft. lbs.)
5. Install clutch housing plate (1).
Tighten upper bolt first, then tighten lower bolt to specified torque.
Tightening torque
Clutch housing plate upper bolt a: 30 Nm (3.0 kgf-m 22.0 ft. lbs.)
Clutch housing plate lower bolt b: 11 Nm (1.1 kgf-m, 8.0 ft. lbs.)
6. Install transfer.
7. Install exhaust No. 1 pipe.
8. Install engine under cover.
9. Install oil level gauge. 10) Refill engine with engine oil.