Engine Lubrication System: Other Suzuki Vitara I

Oil Pressure Check

Note. Prior to checking oil pressure, check the followings. Oil level in oil pan. If oil level is low, add oil up to Full level hole on oil level gauge. Oil quality. If oil is discolored, or deteriorated, change it. For particular oil to be used. See ENGINE OIL & FILTER CHANGE . Oil leaks. If leak is found, repair it.

Scheme 3

Scheme 4

Scheme 5

1. Remove exhaust manifold cover and then oil pressure switch (1) from cylinder block.
2. Install special tools (Oil pressure gauge) to vacated threaded hole. Special tool (A): 09915-77310 (B): 09915-78211 CAUTION: Be careful not to make special tools touch exhaust manifold when installing because exhaust manifold becomes very hot.
3. Start engine and warm it up to normal operating temperature. NOTE: Be sure to 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.
4. After warming up, raise engine speed to 4000 rpm and measure oil pressure. Oil pressure specification: 390-470 kPa (3.9-4.7 kg/cm 2 , 55.5-66.8 psi) at 4000 rpm
5. After checking oil pressure, stop engine and remove oil pressure gauge.
6. Before reinstalling oil pressure switch, 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) NOTE: If sealing tape edge is bulged out from screw threads of switch, cut it off.
7. Start engine and check oil pressure switch for oil leakage.

Engine Oil & Filter Change

Special Tools Required

Oil filter wrench 09915-47330

1. When replacing engine oil, warm up the engine.
2. Remove the oil drain bolt and drain the engine oil.
3. Reinstall the drain bolt.
4. Tightening Torque: 35 N-m (3.5 kg-m, 25.5 lb-ft)
5. Remove the oil filter with the special tool.
6. Install the oil filter by hand until the filter O-ring contacts the mounting surface.
7. Tighten the oil filter 3/4 of a turn with the oil filter wrench from the mounting surface.
8. Refill with the recommended oil. NOTE: Recommended engine oil: American Petroleum Institute (API) Certified For Gasoline Engines "starburst" symbol. Highly recommended SAE 5W-30 oil. SAE 10W-30 oil is usable at ambient temperatures above -18 °C (0 °F). Engine Oil Capacity 5.0 l (5.3 US qt) at oil change 5.2 l (4.6 US qt) at oil change including filter 5.6 l (5.9 US qt) after engine overhaul
9. Run the engine for more than 3 minutes, then check for oil leakage.

Scheme 6

Scheme 7

Scheme 8

1. Remove oil level gauge.
2. Raise vehicle and remove both front wheels.
3. Remove steering gear box (4) from vehicle. See «POWER STEERING PUMP REMOVAL & INSTALLATION»(ref-179846-S18634312412005071500000) .
4. Remove front differential housing (1) with differential (2) from chassis. See «FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING»(ref-181394-S42487301212005080100000) .
5. Drain engine oil by removing drain plug (3).
6. Remove transmission stiffener if equipped.
7. Remove clutch (torque converter) housing lower plate.
8. Remove oil pan and oil pump strainer (2) from crankcase.

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. To facilitate and ensure installation of oil pan, increase clearance between engine and vehicle body according to the following procedure. Disconnect exhaust pipe from exhaust manifold. Remove engine mounting nuts (Right and Left). Using engine support jack, hoist engine 2-3 cm (about 1 in.). CAUTION: Do not hoist engine more than instructed above. That may cause trouble to engine or transmission.
2. Apply sealant continuously to oil pan (1) mating surface as shown in the figure. "A": Sealant 99000-31250
3. Install O-rings (2) in the position as shown in the figure and install oil pump strainer (3) to oil pump (1). Tighten strainer bolts first and then bracket bolt 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)
4. After fitting oil pan (4) 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 bolt and nut (c): 11 N.m (1.1 kg-m, 8.0 lb-ft)
5. Lower engine and tighten engine mounting nuts to specified torque. See «ENGINE ASSEMBLY REMOVAL & INSTALLATION»(ref-180378-S15837203732005072500000) .
6. Install gasket and drain plug (2) to oil pan (1). Tighten drain plug to specified torque. Tightening torque Engine oil drain plug (a): 35 N.m (3.5 kg-m, 25.5 lb-ft)
7. Install clutch (torque converter) housing lower plate.
8. Connect exhaust pipe to exhaust manifold. See «EXHAUST MANIFOLD REMOVAL AND INSTALLATION»(ref-181392-S42318371162005080100000) .
9. Install transmission stiffener to transmission and cylinder block if equipped.
10. Install front differential housing. See «FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING»(ref-181394-S42487301212005080100000) .
11. Refill front differential housing with gear oil. See «FRONT DIFFERENTIAL GEAR OIL INSPECTION AND CHANGE»(ref-181394-S33631820442005080100000) .
12. Install steering gear box to vehicle. See «POWER STEERING PUMP REMOVAL & INSTALLATION»(ref-179846-S18634312412005071500000) .
13. Install oil level gauge.
14. Refill engine with engine oil. See «ENGINE OIL & FILTER CHANGE»(ref-181380-S22991404612005080200000) .
15. Refill power steering system with specified fluid.
16. Verify that there is no engine oil leakage, differential oil leakage and power steering fluid leakage at each connection.

Scheme 13

Scheme 14

1. Inside of oil pan and oil pump strainer screen.
2. Clean sealing surface on oil pan and crankcase. Remove oil, old sealant, and dust from sealing surface.

Scheme 15

Scheme 16

Scheme 17

1. Disconnect negative cable at battery.
2. Drain engine oil.
3. Remove oil pan and oil pump strainer. See «OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION»(ref-181380-S23709522132005080100000) .
4. Remove oil pump sprocket cover (1).
5. Remove oil pump (2) from lower crankcase (1). CAUTION: Don't remove sprocket out of oil pump. Or damage of oil pump center shaft and abnormal operation of oil pump could result.

Scheme 18

Scheme 19

1. Install oil pump (2) to lower crankcase (1) and tighten bolts to specified torque. NOTE: When installing oil pump, be careful not to allow pins to fall off. Tightening torque Oil pump mounting bolt (a): 27 N.m (2.7 kg-m, 19.5 lb-ft)
2. Install oil pump sprocket cover (1) and tighten bolts to specified torque. Tightening torque Oil pump sprocket cover bolt (a): 11 N.m (1.1 kg-m, 8.0 lb-ft)
3. Install oil pan and oil pump strainer. See «OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION»(ref-181380-S23709522132005080100000) .
4. Refill engine with engine oil. See «ENGINE OIL & FILTER CHANGE»(ref-181380-S22991404612005080200000) .
5. Connect negative cable at battery.
6. After completing installation, check oil pressure by running engine. See «OIL PRESSURE CHECK»(ref-181380-S01098294892005080100000) .

Scheme 20

1. Disassemble oil pump as shown in the figure.

Scheme 21

Scheme 22

1. Wash, clean and then dry all disassembled parts.
2. Apply thin coat of engine oil to inner and outer rotors, and inside surfaces of oil pump case.
3. Install outer rotor to pump case No. 1.
4. Install relief valve (3), relief spring (2) and retainer (1) to oil pump case No.2 (4). Tighten retainer to specified torque. Tightening torque Oil pump retainer (a): 29 N.m (2.9 kg-m, 21.0 lb-ft)
5. Install oil pump case pins (5) to oil pump case No.2 (4).
6. Assemble oil pump. After assembling oil pump check to be sure that rotor turns smoothly by hand. Tightening torque Oil pump bolt (a): 12 N.m (1.2 kg-m, 9.0 lb-ft)

Radial clearance

Check radial clearance between outer rotor (2) and oil pump case (1), using thickness gauge (3). If clearance exceeds its limit, replace outer rotor or case.

1. Radial clearance between outer rotor and oil pump case
2. Limit: 0.15 mm (0.0059 in.)

Scheme 23

Side clearance

Using straightedge (5) and thickness gauge (4), measure side clearance.

Oil pump side clearance

1. Limit: 0.11 mm (0.0043 in.)

Scheme 24

Scheme 25

Scheme 26

Scheme 27