Oil Pan and Oil Pump Strainer Removal and Installation

Oil Pan and Oil Pump Strainer Removal and Installation

Oil Pan and Oil Pump Strainer Components

Removal

1) Remove left and right side engine undercovers.
2) Drain engine oil. Service and Repair
3) Remove exhaust pipe No.1. Exhaust System Components
4) For 4WD model, remove transfer. Removal and Replacement
5) Remove oil level gauge (1) and oil level gauge guide (2).





6) Remove transaxle bolts (1), then remove drive plate cover (2) for CVT model, or clutch housing lower plate (2) for M/T model.





7) Remove oil pan bolts from oil pan (1).
8) Remove oil pan (1) from lower crank case by using special tool and hammer (2).
Special Tool

(A): 09921-96510





9) Remove oil pump strainer from oil pump assembly.
10) Remove oil pan baffle plate from lower crank case.

Installation

1) Install oil pan baffle plate (1).

Tightening torque
Oil pan baffle plate bolt (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)

2) Apply engine oil to new O-rings (2) and install them to oil strainer (3).
3) Install oil strainer (3) to oil pump (4).

Tightening torque
Oil strainer bolt (b): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)





4) Install dowel pins (1) to oil pan.






5) Apply sealant to oil pan mating surface as shown in figure.

NOTE:
- Before applying sealant, make sure mating surfaces are clean and dry.
- Install oil pan within 2 minutes after applying sealant.

"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)

Sealant amount for oil pan
Width "a": 3 mm (0.12 in.)
Height "b": 2 mm (0.08 in.)





6) Install oil pan according to the following procedure.

NOTE:
The oil pan bolt No.2 is pre-coated with adhesive. If the bolt is reused, it may work loose.

Be sure to replace the oil pan bolt No.2 with new one whenever it is removed.

a) Fit oil pan to lower crank case.
b) Tighten oil pan bolts to 15 Nm (1.5 kgf-m, 11.0 lbf-ft) in numerical order ("1" - "17") evenly and gradually.
c) In the same manner as Step b), retighten them to 25 Nm (2.5 kgf-m, 18.5 lbf-ft).

Tightening torque
Oil pan bolt* (a): (15 Nm -> 25 Nm (1.5 kgf-m -> 2.5 kgf-m, 11.0 lbf-ft -> 18.5 lbf-ft))





7) Install transaxle bolts (1) and then drive plate cover (2) for CVT model, or clutch housing lower plate (2) for M/T model.

Tightening torque
Transaxle bolt (a): 80 Nm (8.2 kgf-m, 59.0 lbf-ft) ((CVT model))
Transaxle bolt (a): 85 Nm (8.7 kgf-m, 63.0 lbf-ft) ((M/T model))
Drive plate cover bolt (b): 11 Nm (1.1 kgf-m, 8.5 lbf-ft) ((CVT model))
Clutch housing lower plate bolt (b): 11 Nm (1.1 kgf-m, 8.5 lbf-ft) ((M/T model))





8) Apply engine oil to new O-ring (1) and install it to oil pan.
9) Install oil level gauge guide (2) and oil level gauge (3).

Tightening torque
Oil level gauge guide bolt (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)





10) For 4WD model, install transfer. Removal and Replacement
11) Install exhaust pipe No.1. Exhaust System Components
12) Install drain plug and refill engine with engine oil. Service and Repair
13) Run the engine and check for engine oil leaks.
14) Install left and right side engine undercovers.