2005 SUZUKI JIMNY Torque

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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.

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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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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.

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3) Install crankshaft pulley (1). Tighten bolt (2) to specified
torque.
To lock crankshaft pulley, use special tool with it as shown in
figure.
Special tool
(A) : 09917-68221
Tightening torque
Crankshaft pulley bolt (a) : 150 N·m (15.0 kg-m, 108.5 lb-ft)
4) Install P/S pump bracket (1), P/S pump (2) and A/C com-
pressor and/or P/S pump belt tension pulley (3) (if equipped)
referring to “Power Steering Pump” in Section 3B1.
5) Install cylinder head cover referring to “Cylinder Head Cover”
in this section.
6) Install oil pan referring to “Oil Pan and Oil Pump Strainer” in
this section.
7) Install radiator with cooling fan and connect A/T fluid hoses
(vehicle with A/T), radiator inlet and outlet hoses referring to
“Water Pump Belt and Cooling Fan” and “Radiator” in Sec-
tion 6B.
8) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B for adjusting procedure.
9) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1 for adjusting proce-
dure.
10) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
11) Verify that there is no coolant leakage, oil leakage and A/T
fluid leakage (vehicle with A/T) at each connection.

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Oil Pump
REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing chain cover, referring to “Timing Chain
Cover” in this section.
DISASSEMBLY
1) Remove rotor plate (1) by removing its mounting bolts.
[A] : Sealant application
amount4. Timing chain cover 10. Circlip
: Apply sealant 99000-31140 to the mating surface of cylinder and
cylinder head.
: Apply sealant 99000-31150 to mating surface of timing chain cover
referring to the figure of Step 1) in “Timing Chain Cover Installation”.
“a” : 3 mm (0.12 in.) 5. Pin 11. Oil pump mounting bolt
“b” : 2 mm (0.08 in.) 6. Oil seal 12. Timing chain cover mounting bolts
1. Rotor plate 7. Relief valve Tightening torque
2. Outer rotor 8. Spring Do not reuse.
3. Inner rotor 9. Retainer Apply thin coat of engine oil to sliding
surface of each parts.

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ASSEMBLY
1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal
lip portion, and inside surfaces of oil pump case and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Install relief valve component (1) to rotor plate (2).
5) Install rotor plate and tighten all bolts to specified torque.
After installing plate, check to be sure that rotors turn
smoothly by hand (0.3 N·m (0.03 kg-m, 0.25 lb-ft) torque or
below).
Tightening torque
Oil pump rotor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
INSTALLATION
For installation referring to “Timing Chain Cover” in this section.