Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION



1.3L Engine

See Figures 1 through 10

  1. If added undervehicle clearance is needed, apply the parking brake and block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  2.  
  3. If equipped, remove the undervehicle skid plate.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Drain the engine oil into a large catch pan.
  2.  
  3. Remove the clutch or torque converter inspection cover.
  4.  


WARNING
Do not use a prytool between the oil pan and engine block mating surfaces to separate the two components, otherwise the gasket surface may be damaged.

  1. Remove the oil pan mounting bolts and lower the oil pan from the engine. Remove the oil pick-up tube retaining bolts, then remove the tube and oil pan from the engine together.
  2.  
  3. Thoroughly clean the engine block mating surface, the oil pan and the pick-up tube of all oil, grime and old silicone sealer. Remove the old seal from the pick-up tube mounting hole.
  4.  

To install:
  1. Apply a continuous bead of silicone sealant to the oil pan gasket surface.
  2.  
  3. Install a new pick-up seal into the tube mounting hole.
  4.  
  5. Raise the oil pan and oil pump pick-up into position. Install the pick-up tube, and tighten the retaining bolts to 80-106 inch lbs. (9-12 Nm).
  6.  
  7. Position the oil pan against the engine block and install all of the mounting bolts finger-tight.
  8.  
  9. Tighten the oil pan mounting bolts to 80-106 inch lbs. (9-12 Nm) by starting at the center of the oil pan and working your way toward both ends.
  10.  
  11. Install the oil pan drain plug, along with a new washer. Tighten the drain plug to 22-28 ft. lbs. (30-40 Nm).
  12.  
  13. Install the lower clutch or torque converter inspection cover.
  14.  
  15. If applicable, install the undervehicle skid plate, and lower the vehicle.
  16.  


WARNING
Wait at least 30 minutes after tightening the oil pan mounting bolts before adding oil to the engine. This time period will allow the silicone sealant to set properly.

  1. Fill the engine with the proper amount and type of engine oil. Refer to General Information & Maintenance for details.
  2.  
  3. Start the engine and check for oil leaks from the oil pan perimeter.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of oil pan and pick-up mounting-1.3L and 1.6L engines



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Fig. Fig. 2: To remove the oil pan, loosen the lower inspection plate retaining bolts ...



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Fig. Fig. 3: ... then remove the inspection plate from the transmission



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Fig. Fig. 4: On 1.3L engines, lower the oil pan and allow it to rest on the crossmember, then detach the pick-up tube from the oil pump-remove both components together from the vehicle



Click image to see an enlarged view

Fig. Fig. 5: On 1.6L engines, loosen all of the oil pan retaining bolts ...



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Fig. Fig. 6: ... then remove the oil pan from the engine



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Fig. Fig. 7: Once the oil pan is lowered, the two pick-up mounting bolts (arrows) can be accessed



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Fig. Fig. 8: Remove the two bolts ...



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Fig. Fig. 9: ... and detach the pick-up and screen from the oil pump



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Fig. Fig. 10: On 1.3L and 1.6L engines, apply a continuous bead of silicone sealant to the oil pan mating flange to properly seal the engine block-to-oil pan joint

1.6L Engine

See Figures 11 and 12

  1. Apply the parking brake and block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  2.  
  3. On 4-wheel drive models, remove the front differential from the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: On 4-wheel drive models, remove the front differential from the vehicle for oil pan removal



Click image to see an enlarged view

Fig. Fig. 12: On 1.6L MFI engines mated to automatic transmissions, the left-hand side transmission brace must be removed before the torque converter inspection plate

  1. On MFI engines, remove the Crankshaft Position (CKP) sensor.
  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Drain the engine oil into a large catch pan.
  2.  
  3. On MFI engines equipped with automatic transmissions, remove the left-hand side transmission brace.
  4.  
  5. Remove the clutch or torque converter inspection cover.
  6.  


WARNING
Do not use a prytool between the oil pan and engine block mating surfaces to separate the two components, otherwise the gasket surface may be damaged.

  1. Remove the oil pan mounting bolts and lower the oil pan from the engine. Remove the oil pick-up tube retaining bolt(s), then remove the tube from the engine.
  2.  

If removing the oil pan with the oil pick-up still attached to the oil pump is difficult, lower the oil pan as far as possible, detach the pick-up attaching bolts, then remove the pan with the pick-up from the vehicle.

  1. Thoroughly clean the engine block gasket surface, the oil pan and the pick-up tube of all oil, grime and old silicone sealant. Remove the old seal from the pick-up tube mounting hole.
  2.  

To install:
  1. Apply a continuous bead of silicone sealant (such as Suzuki Sealant 99000-31150) to the oil pan gasket surface.
  2.  
  3. Install a new pick-up seal into the tube mounting hole.
  4.  
  5. Raise the oil pan and oil pump pick-up into position. Install the pick-up tube, and tighten the retaining bolts to 80-106 inch lbs. (9-12 Nm).
  6.  
  7. Position the oil pan against the engine block and install all of the mounting bolts finger-tight.
  8.  
  9. Tighten the oil pan mounting bolts to 80-106 inch lbs. (9-12 Nm) by starting at the center of the oil pan and working your way toward both ends.
  10.  
  11. Install the oil pan drain plug, along with a new washer. Tighten the drain plug to 22-28 ft. lbs. (30-40 Nm).
  12.  
  13. Install the lower clutch or torque converter inspection cover.
  14.  
  15. If applicable, install the left-hand side transmission brace, and tighten the mounting bolts to 36 ft. lbs. (50 Nm).
  16.  
  17. If applicable, install the front differential assembly.
  18.  
  19. Refill the front differential with the proper type and amount of lubricant. Refer to General Information & Maintenance for details.
  20.  
  21. If equipped, install the CKP sensor.
  22.  
  23. Lower the vehicle.
  24.  


WARNING
Wait at least 30 minutes after tightening the oil pan mounting bolts before adding oil to the engine. This time period will allow the silicone sealant to set properly.

  1. Fill the engine with the proper amount and type of engine oil. Refer to General Information & Maintenance for details.
  2.  
  3. Start the engine and check for oil leaks from the oil pan perimeter.
  4.  

1.8L Engine

See Figures 13, 14 and 15

  1. Break loose the lug nuts on both front wheels.
  2.  
  3. Apply the parking brake and block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the engine oil dipstick and tube from the engine.
  6.  
  7. Remove the front wheels, then remove the differential from the vehicle.
  8.  
  9. Remove the tie rods, center link and idler arm from the vehicle, as described in Suspension & Steering .
  10.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Drain the engine oil into a large catch pan.
  2.  
  3. Remove the clutch or torque converter inspection cover.
  4.  



Click image to see an enlarged view

Fig. Fig. 13: Exploded view of the oil pan and oil pump pick-up and screen mounting



Click image to see an enlarged view

Fig. Fig. 14: The tie rods, center link and idler arm must be removed for oil pan removal-detach the steering components at the points indicated (black arrows)


WARNING
Do not use a prytool between the oil pan and engine block mating surfaces to separate the two components, otherwise the gasket surface may be damaged.

  1. Remove the oil pan mounting bolts and lower the oil pan from the engine; temporarily support it on the vehicle crossmember. Using an open end wrench inserted between the lowered oil pan and the engine block, remove the oil pick-up tube retaining bolt(s). Separate the pick-up tube from the oil pump, then remove the tube and oil pan from the vehicle together.
  2.  
  3. Thoroughly clean the engine block gasket surface, the oil pan and the pick-up tube of all oil, grime and old silicone sealant. Remove the old seal from the pick-up tube mounting hole.
  4.  

To install:
  1. Apply a continuous bead of silicone sealant (such as Suzuki Sealant 99000-31150) to the oil pan mating surface.
  2.  
  3. Install a new pick-up seal into the tube mounting hole.
  4.  
  5. Raise the oil pan and oil pump pick-up into position. Install the pick-up tube, and tighten the retaining bolts to 80-106 inch lbs. (9-12 Nm).
  6.  
  7. Position the oil pan against the engine block and install all of the mounting bolts finger-tight.
  8.  
  9. Tighten the oil pan mounting bolts to 80-106 inch lbs. (9-12 Nm) by starting at the center of the oil pan and working your way toward both ends.
  10.  
  11. Install the oil pan drain plug, along with a new washer. Tighten the drain plug to 22-28 ft. lbs. (30-40 Nm).
  12.  



Click image to see an enlarged view

Fig. Fig. 15: Be sure to apply a continuous bead of silicone sealant to the oil pan mating flange prior to installation, otherwise oil leakage may occur

  1. Install the lower clutch or torque converter inspection cover.
  2.  
  3. Install the tie rods, center link and idler arm.
  4.  
  5. Install the front differential assembly.
  6.  
  7. Refill the front differential with the proper type and amount of lubricant. Refer to General Information & Maintenance for details.
  8.  
  9. Install the engine oil level dipstick and tube.
  10.  
  11. Lower the vehicle.
  12.  


WARNING
Wait at least 30 minutes after tightening the oil pan mounting bolts before adding oil to the engine. This time period will allow the silicone sealant to set properly.

  1. Fill the engine with the proper amount and type of engine oil. Refer to General Information & Maintenance for details.
  2.  
  3. Start the engine and check for oil leaks from the oil pan perimeter.
  4.  

 
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