2005 SUZUKI JIMNY drain bolt

Downloaded from www.Manualslib.com manuals search engine 6A1-24 ENGINE MECHANICAL (M13 ENGINE)
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.

Downloaded from www.Manualslib.com manuals search engine 6A1-26 ENGINE MECHANICAL (M13 ENGINE)
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).

Downloaded from www.Manualslib.com manuals search engine 6A1-28 ENGINE MECHANICAL (M13 ENGINE)
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

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-29
5) Drain coolant.
6) Disconnect radiator inlet and outlet hoses from each pipe.
7) Disconnect A/T fluid hoses (1) (vehicle with A/T) and release
its clamps. Place some container under radiator to receive
A/T fluid which will flow out when hose is disconnected.
8) Remove fan shroud upper bolts and install board (1) or the
like. This prevents damage to radiator fins when removing
and installing radiator.
9) Remove radiator with cooling fan. Then remove water pump
pulley. Refer to “Radiator” and “Water Pump Belt and Cool-
ing Fan” in Section 6B.
10) Remove A/C compressor and/or P/S pump belt tension pul-
ley (1) (if equipped).
11) With hose connected, detach P/S pump from its bracket and
then remove P/S pump bracket (2) (if equipped) referring to
“Power Steering Pump” in Section 3B1. WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed P/S pump at a place where no damage
will be caused during removal and installation of timing
chain cover.

Downloaded from www.Manualslib.com manuals search engine 6A1-62 ENGINE MECHANICAL (M13 ENGINE)
Pistons, Piston Rings, Connecting Rods and Cylinders
REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Drain engine oil.
4) Drain coolant.
5) Remove cylinder head referring to “Valves and Cylinder
Head” in this section.
6) Mark cylinder number on all pistons, connecting rods and
connecting rod caps using silver pencil or quick drying paint.
7) Remove rod bearing caps.
1. Top ring8. Piston pin
2. 2nd ring9. Piston pin circlip
3. Oil ring10. Bearing cap nut
1) Tighten all nuts to 15 N·m (1.5 kg-m)
2) Turn all nuts to 45°
3) Then, turn all nuts to 45° once again
4. PistonTightening torque
5. Connecting rod
: Apply engine oil to sliding surface except inner surface of big end, and rod bolts.
Make sure rod bolt diameter when reuse it due to plastic deformation tightening.
Refer to “Inspection” of “Connecting Rod”.Apply engine oil to sliding surface of each
parts.
6. Connecting rod bearing cap
: Point arrow mark on cap to crankshaft pulley side.Do not reuse.
7. Connecting rod bearing

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-73
Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove A/C compressor and/or P/S pump belt (if
equipped).
5) Remove generator belt.
6) Drain engine oil.
7) Drain coolant.
8) Disconnect radiator inlet and outlet hoses from each pipe.
9) Disconnect A/T fluid hoses (2) (vehicle with A/T) and release
its clamps. Place some container under radiator to receive
A/T fluid which will flow out when hose is disconnected.
10) Remove fan shroud upper bolts and install board (1) or the
like. This prevents damage to radiator fins when removing
and installing radiator.
11) Remove radiator with cooling fan referring to Section 6B.
Then remove water pump pulley.
12) With hose connected, detach P/S pump from its bracket (if
equipped) referring to “Power Steering Pump” in Section
3B1.
13) If vehicle equipped with A/C compressor, work of right hand
steering vehicle differs from its of left hand steering vehicle.
Each work is as follows. WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed P/S pump at a place where no damage
will be caused during removal and installation of engine
assembly.

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-93
Required Service Material
Tightening Torque Specification
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant SUZUKI BOND NO. 1207C
(99000-31150)To apply to mating surface of cylinder block and oil
pan.
To apply to mating surface of cylinder block and
timing chain cover.
To apply to sealing surface of cylinder head cover.
To apply to mating surface to rear oil seal housing.
SUZUKI BOND NO. 1207B
(99000-31140)To apply to mating surface of cylinder block, cylin-
der head and timing chain cover.
SUZUKI BOND NO. 1215
(99000-31110)To flywheel (M/T) or drive plate (A/T) bolts.
Fastening partTightening torque
Nm kg-m lb-ft
Oil pressure switch 14.0 1.4 10.5
Camshaft housing bolts
(for replacement of shim)8.0 0.8 6.0
Camshaft housing bolts 11.0 1.1 8.0
Cylinder head cover bolts 8.0 0.8 6.0
Intake manifold bolts and nuts 25.0 2.5 18.0
Exhaust manifold bolts and nuts 55.0 5.5 40.0
Exhaust pipe bolts 50.0 5.0 36.5
Exhaust manifold stiffener bolts 50.0 5.0 36.5
Oil pump strainer bolt 11.0 1.1 8.0
Oil pump strainer bracket bolt 11.0 1.1 8.0
Oil pan bolts and nuts 11.0 1.1 8.0
Oil pan drain plug 50.0 5.0 36.5
Timing chain cover bolts and nut 23.0 2.3 17.0
Crankshaft pulley bolt 150.0 15.0 108.5
Oil pump rotor plate bolts 11.0 1.1 8.0
Timing chain No.1 guide bolts 9.0 0.9 6.5
Timing chain tensioner adjuster bolts 11.0 1.1 8.0
Venturi plug 5.0 0.5 3.5
Cylinder head bolt for M8 22.0 2.2 16.0
Cylinder head bolts for M10 a) Tighten 40 N·m
b) Turn 60°
c) Turn 60°a) Tighten 4.0 kg-m
b) Turn 60°
c) Turn 60°a) Tighten 29.0 lb-ft
b) Turn 60°
c) Turn 60°
Connecting rod bearing cap nuts a) Tighten 15 N·m
b) Turn 45°
c) Turn 45°a) Tighten 1.5 kg-m
b) Turn 45°
c) Turn 45°a) Tighten 11.0 lb-ft
b) Turn 45°
c) Turn 45°
Engine mounting bolts 50.0 5.0 36.5

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-11
Coolant Draining
1) Remove radiator cap (1).
2) Loosen drain plug on radiator to drain coolant.
3) After draining coolant, be sure to tighten drain plug securely.
4) Fill cooling system. Refer to “Coolant” in this section.
Cooling Water Pipes or Hoses
REMOVAL
1) Drain cooling system.
2) To remove water pipes or hoses, loosen screw on each pipe
or hose clip and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
Tighten each clamp bolt securely.
Refill cooling system with proper coolant, referring to
description on “Coolant” and “Cooling System Flush and
Refill” in this section.
Thermostat
REMOVAL
1) Drain cooling system and tighten drain plug.
2) Remove intake manifold, referring to “Throttle Body and
Intake Manifold” in Section 6A1.
3) Disconnect thermostat cap (1) from thermostat case (2).
4) Remove thermostat (3).