2005 SUZUKI JIMNY oil

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Diagnosis
Diagnosis Table
Refer to “Engine Diagnosis Table” in Section 6.
Compression Check
Check compression pressure on all 4 cylinders as follows:
1) Warm up engine.
2) Stop engine after warming up.
3) Disconnect accelerator cable (1) from clamp (2) (For left
hand steering vehicle only).
4) Remove cylinder head upper cover (3).
5) Disconnect ignition coil couplers (1).
6) Remove ignition coil assemblies (2) with high-tension cord
(3).
7) Remove all spark plugs.
8) Disconnect fuel injector wires (4) at the coupler.
9) Install special tools (Compression gauge) into spark plug
hole.
Special tool
(A) : 09915-64510-001
(B) : 09915-64510-002
(C) : 09915-64530
(D) : 09915-67010 NOTE:
After warming up engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
model), and set parking brake and block drive wheels.

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10) Disengage clutch (1) (to lighten starting load on engine) for
M/T vehicle, and depress accelerator pedal (2) all the way to
make throttle fully open.
11) Crank engine with fully charged battery, and read the highest
pressure on compression gauge.
Compression pressure specification
12) Carry out Steps 9) through 11) on each cylinder to obtain 4
readings.
13) After checking, install spark plugs and ignition coil assem-
blies (1) with high-tension cord (2).
14) Connect ignition coil couplers (3).
15) Connect fuel injector wires (4) at the coupler.
16) Check cylinder head upper cover gasket for deterioration and
then install it into groove of cylinder head upper cover (1)
securely.
17) Install cylinder head upper cover with gasket on to cylinder
head cover.
18) Connect accelerator cable (2) to clamp (3) (For left hand
steering vehicle only).
NOTE:
For measuring compression pressure, crank engine at
least 250 rpm by using fully charged battery.
If check results are below the limit valve, check instal-
lation condition for special tool.
Standard1400 kPa
(14.0 kg/cm
2, 199.0 psi)
Limit1100 kPa
(11.0 kg/cm
2, 156.0 psi)
Max. difference between
any two cylinders100 kPa
(1.0 kg/cm
2, 14.2 psi)

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Oil Pressure Check
Oil level in oil pan.
If oil level is low, add oil up to Full level mark (hole) (1) on oil
level gauge.
Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in Section 0B.
Oil leaks.
If leak is found, repair it.
1) Disconnect oil pressure switch coupler (1) and remove oil
pressure switch (2) from cylinder block.
2) Install special tools (Oil pressure gauge) to vacated threaded
hole.
Special tool
(A) : 09915-77310
(B) : 09915-78211
3) Start engine and warm it up to normal operating tempera-
ture.
4) After warming up, raise engine speed to 4,000 rpm and mea-
sure oil pressure.
Oil pressure specification
280 – 430 kPa (2.8 – 4.3 kg/cm
2, 39.8 – 61.1 psi) at 4,000
rpm
5) Stop engine and remove oil pressure gauge and attachment.NOTE:
Prior to checking oil pressure, check the following items.
2. Low level mark (hole)
NOTE:
Be sure to place transmission gear shift lever in “Neu-
tral” (shift selector lever to “P” range for A/T model), and
set parking brake and block drive wheels.

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6) Before reinstalling oil pressure switch (2), be sure to wrap its
screw threads with sealing tape (1) and tighten switch to
specified torque.
Tightening torque
Oil pressure switch (a) : 14 N.m (1.4 kg-m, 10.5 lb-ft)
7) Start engine and check oil pressure switch for oil leakage.
If oil leakage is found, repair it.
8) Connect oil pressure switch coupler (1).NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.

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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.

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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.