09106-12001 Suzuki BOLT

Hot engine oil and components can cause personal injury. Do not allow hot engine oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
1. Drain the engine oil from the oil pan in a suitable container for storage or disposal. The capacity of the engine oil pan is 125 liters (33 U.S. gal). 2. Disconnect hose assembly (1) from the backside of the oil change connector. 3. Remove two nuts (3) and the washers. Loosen, but do not remove the bolt, the nut and clamp assembly (4) that secures dipstick tube assembly (2) to the bracket. Repeat on the remaining clamp assembly (not shown).4. Lift dipstick tube assembly (2) from the front oil pan, and set aside. 5. Remove tube assembly (5) from front oil pan assembly (6). 6. Remove two bolts (8) and the washers, and set valve (7) aside. 7. Mark and identify two wire harnesses (9) for installation purposes. Disconnect two wire harnesses (9) at the electrical connections.8. Mark and identify six bolts (12) for installation purposes. Remove six bolts (12) and the washers from oil pump inlet elbow (11). Remove the two bolts that secure pump inlet elbow (10). Remove pump inlet elbow (10) and oil pump inlet elbow (11). Remove the three seals. 9. Remove four bolts (13) and the washers, and remove bracket (14) from the rear oil pan. 10. Remove eight bolts (19) and the washers that fasten center oil pan (18) to the front oil pan assembly.11. Remove eight bolts (16) and the washers that fasten rear oil pan (15) to center oil pan (18).12. Mark and identify 11 twelve point head bolts (21) for installation purposes. Remove 13 twelve point head bolts (21) and the washers, and remove rear oil pan (15). Remove sealant (17) from the mating surfaces of rear oil pan (15) and center oil pan (18).13. Remove 12 bolts (20) and the washers that secure center oil pan (18). Remove sealant (17) from the mating surfaces of center oil pan (15) and the front oil pan assembly. 14. Mark and identify 17 twelve point head bolts (22) for installation purposes. Using two people, support front oil pan assembly (6). Remove 17 twelve point head bolts (22) and the washers. Remove front oil pan assembly (6) from the engine. The weight of front oil pan assembly (6) is 39 kg (85 lb).15. If necessary, remove the filter screen and the suction bell from front oil pan assembly (6). The following steps are for installation of the oil pan.
Check the condition of all O-ring seals and gaskets and replace with new if needed. Remove all traces of sealant and gasket material from all mating surfaces of the oil pans and the engine block. Failure to clean the surfaces could result in leakage of engine oil. Apply 3S-6252 Silicone Sealant to all contact surfaces of gaskets and gasket joints when reassembling.
16. Apply 8T-9014 RTV Silicone Sealant or 7M-7260 Liquid Gasket as required to the engine block where the flywheel housing and the front drive cover meet. Put a new gasket in position on the engine block and apply 3S-6252 RTV Silicone Sealant or 7M-7260 Liquid Gasket to each gasket joint. 17. Using two people, put front oil pan assembly (6) in position on the bottom of the engine block. Install 17 twelve point head bolts (22) and the washers. The eight 1/2 in - 13 NC bolts require 7M-7260 Liquid Sealant on the threads prior to assembly. 18. Apply 8T-9014 RTV Silicone Sealant or 7M-7260 Liquid Gasket (17) as required to the mating surfaces between center oil pan (18) and the front oil pan assembly.19. Put center oil pan in position on the engine block, and install 12 bolts (20) and the washers. Install eight bolts (19) that fasten center oil pan (18) to the front oil pan.20. Apply 8T-9014 RTV Silicone Sealant or 7M-7260 Liquid Gasket (17) to the mating surfaces between center oil pan (18) and rear oil pan (15).21. Position rear oil pan (15) on the engine block. Install 11 twelve point head bolts (21) and the washers. The two 1/2 in - 13 NC bolts require 7M-7260 Liquid Sealant on the threads prior to assembly.22. Install eight bolts (16) that fasten center oil pan (18) to rear oil pan (15). 23. The two bolts that secure bracket (14) to the rear oil pan require 7M-7260 Liquid Sealant on the threads prior to assembly. Put bracket (14) in position. Install four bolts (13) and the washers. 24. Check the seals for wear or damage, and replace if necessary. Lubricate the seals with clean engine oil prior to installation. Put the seals in position on elbows (10) and (11).25. Put pump inlet elbow (10) in position in oil pump inlet elbow (11).26. Put pump inlet elbow (10) and oil pump inlet elbow (11) in position on the front oil pan assembly. Install six bolts (12) and the washers. Install the two bolts and the washers that secure pump inlet elbow (10).27. Connect two wire harnesses (9) at the electrical connections. 28. Put valve (7) in position. Install two bolts (8) and the washers. 27. Connect tube assembly (5) to front oil pan assembly (6). 28. Put dipstick tube assembly (2) and a new gasket in position. Install two nuts (3) and the washers.29. Tighten the bolt and the nut on clamp assembly (4) that secures dipstick tube assembly (2) to the bracket. Repeat for the remaining clamp assembly. 30. Connect hose assembly (1).31. Tighten the drain plug on the front oil pan assembly to a torque of 110 15 N m (81 11 lb ft). Tighten the bolt on the bottom of the rear oil pan to a torque of 55 7 N m (41 5 lb ft).32. Fill the engine with engine oil to the correct