Engine Lubrication System: Other Suzuki Forenza I

Finding the Leak

1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc.
2. Identify where the fluid is leaking from. After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. Wait a few minutes. Find the approximate location of the leak by the drippings on the paper.
3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach.
4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam, or spray solvent. Thoroughly clean the area. Dry the area. Operate the vehicle for several miles at normal operating temperature and varying speeds. After operating the vehicle, visually check the suspected component. If you still cannot locate the leak, try using the powder or black light and dye method.

Powder Method

1. Clean the suspected area.
2. Apply an aerosol-type powder, (such as foot powder), to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. Trace the leak path over the white powder surface to the source.

Black Light and Dye Method

A dye and light kit is available for finding leaks. Refer to the manufacturer's directions when using the kit.

1. Pour the specified amount of dye into the engine oil fill tube.
2. Operate the vehicle under normal operating conditions as directed in the kit.
3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.

Repairing the Leak

Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined in order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak.

Gaskets

1. The fluid level/pressure is too high.
2. The crankcase ventilation system is malfunctioning.
3. The fasteners are improperly tightened or the threads are dirty or damaged.
4. The flanges or the sealing surface is warped.
5. There are scratches, burrs or other damage to the sealing surface.
6. The gasket is damaged or worn.
7. There is cracking or porosity of the component.
8. An improper seal was used, (where applicable).

Seals

1. The fluid level/pressure is too high.
2. The crankcase ventilation system is malfunctioning.
3. The seal bore is damaged, scratched, burred or nicked.
4. The seal is damaged or worn.
5. Improper installation is evident.
6. There are cracks in the component.
7. The shaft surface is scratched, nicked or damaged.
8. A loose or worn bearing is causing excess seal wear.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Disconnect the negative battery cable.
2. Drain the engine oil from the engine crankcase.
3. Remove the exhaust front pipe. Refer to «MUFFLER - FRONT REMOVAL AND INSTALLATION»(ref-257079-S16342677372007062900000) .
4. Remove the oil pan flange-to-transaxle retaining bolts.
5. Remove the transaxle-to-oil pan flange retaining bolt.
6. Remove the transaxle rear mount bracket.
7. Remove the lower reaction rod.
8. Remove the oil pan retaining bolts.
9. Remove the oil pan from the engine block with pushing the engine assy forward.

Scheme 9

1. Coat the new oil pan gasket with sealant.
2. Install the oil pan to the engine block.
3. Install the oil pan retaining bolts. Tighten: Tighten the oil pan retaining bolts to 10 N.m (89 lb-in).
4. Install the oil pan flange-to-transaxle retaining bolts. Tighten: Tighten the oil pan flange-to-transaxle bolts to 40 N.m (30 lb-ft).
5. Install the transaxle-to-oil pan flange retaining bolt. Tighten: Tighten the transaxle-to-oil pan bolt to 40 N.m (30 lb-ft).
6. Install the transaxle rear mount bracket. Refer to «TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION»(ref-257095-S30102914772007062900000) .
7. Install the lower reaction rod.
8. Install the lower reaction rod bolts. Tighten: Tighten the lower reaction rod bolt to 69 N.m (49 lb-ft).
9. Install the exhaust flex pipe.
10. Install the exhaust flex pipe retaining nuts to the exhaust manifold. Tighten: Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 N.m (26 lb-ft).
11. Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe. Tighten: Tighten the exhaust flex pipe-to-catalytic converter or connecting pipe retaining nuts to 35 N.m (26 lb-ft).
12. Connect the negative battery cable.
13. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 35 N.m (26 lb-ft).
14. Refill the engine crankcase with engine oil.

Scheme 10

1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes in the engine block.
5. Clean the oil pan scraper.

Scheme 11

Scheme 12

1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to «TIMING BELT REMOVAL AND INSTALLATION»(ref-257073-S15577769162007062900000) .
3. Remove the rear timing belt cover. Refer to «REAR TIMING BELT COVER REMOVAL AND INSTALLATION»(ref-257073-S41486984562007062900000) .
4. Disconnect the oil pressure switch connector.
5. Remove the oil pan. Refer to «Oil Pan Removal and Installation»(ref-257075-S07273442882007062900000) .
6. Remove the oil suction pipe and support bracket bolts.
7. Remove the oil suction pipe.
8. Remove the oil pump retaining bolts.
9. Carefully separate the oil pump and gasket from the engine block and oil pan.
10. Remove the oil pump.

Scheme 13

1. Apply Loctite® 242 to the oil pump bolts and Room Temperature Vulcanizing (RTV) sealant to the new oil pump gasket.
2. Install the gasket to the oil pump and install the oil pump to the engine block with the bolts. Tighten: Tighten the oil pump retaining bolts to 10 N.m (89 lb-in).
3. Install a new oil pump-to-crankshaft seal. Coat the lip of the seal with a thin coat of grease.
4. Coat the threads of the oil suction pipe and support bracket bolts with Loctite® 242.
5. Install the oil suction pipe and the bolts. Tighten: Tighten the oil suction pipe bolts to 10 N.m (89 lb-in) and support bracket bolts to 6 N.m (53 lb-in).
6. Install the oil pan. Refer to «Oil Pan Removal and Installation»(ref-257075-S07273442882007062900000) .
7. Connect the oil pressure switch connector.
8. Install the rear timing belt cover. Refer to «REAR TIMING BELT COVER REMOVAL AND INSTALLATION»(ref-257073-S41486984562007062900000) .
9. Install the timing belt. Refer to «TIMING BELT REMOVAL AND INSTALLATION»(ref-257073-S15577769162007062900000) .
10. Connect the negative battery cable.

Scheme 14

1. Clean the oil pump and the engine block gasket mating surface areas.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.
5. Remove the oil pump rear cover bolts.
6. Remove the rear cover.
7. Clean the oil pump housing and all the oil pump parts.
8. Inspect all the oil pump parts for signs of wear. Refer to «System Specifications»(ref-257075-S06858596822007062900000) . Replace the worn oil pump parts.
9. Coat all the oil pump parts with clean engine oil. Install the oil pump parts.
10. Apply Loctite® 242 to the oil pump rear cover bolts and install the cover and bolts. Tighten: Tighten the oil pump rear cover bolts to 6 N.m (53 lb-in).
11. Install the safety relief valve, spring, washer and bolt. Tighten: Tighten the safety relief valve bolt to 30 N.m (22 lb-ft).