LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 1991 >> Samurai JS >> Repair and Diagnosis >> External Pages >> Different car >> Section 40 (Engine Mechanical) >> Repair Instructions >> Engine Front Cover Replacement >> Removal Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removal Procedure

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the lower intake manifold. Refer to REMOVAL PROCEDURE .
  2. Remove the camshaft covers. Refer to REMOVAL PROCEDURE  and REMOVAL PROCEDURE .
  3. Drain the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL) and DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL) .
  4. Remove the water outlet housing assembly. Refer to REMOVAL PROCEDURE .
  5. Remove the drive belt tensioner. Refer to REMOVAL PROCEDURE .
  6. Remove the water pump. Refer to REMOVAL PROCEDURE .
  7. Remove the power steering pump and position aside. Refer to REMOVAL PROCEDURE .
  8. Remove the crankshaft balancer. Refer to REMOVAL PROCEDURE .
  9. Remove the camshaft position actuator valves from the front cover. Refer to REMOVAL PROCEDURE , REMOVAL PROCEDURE , REMOVAL PROCEDURE and REMOVAL PROCEDURE .
  10. Remove the camshaft position actuator solenoid valves from the front cover. Refer to REMOVAL PROCEDURE , REMOVAL PROCEDURE , REMOVAL PROCEDURE and REMOVAL PROCEDURE .
  11. Remove the engine oil pan. Refer to REMOVAL PROCEDURE .
    Fig 1: Identifying Engine Front Cover Bolts
    G04841491Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove the engine front cover bolts.
    Fig 2: Identifying "Jackscrew" Hole
    G04841492Courtesy of SUZUKI OF AMERICA CORP.
  13. Loosely install a 10 x 1.5 mm bolt in the "jackscrew" hole (1).
  14. Using the pry points (2) located at the edge of the front cover and the "jackscrew", shear the RTV sealant.
    Fig 3: Identifying Engine Front Cover
    G04841493Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove the engine front cover.
    Fig 4: Identifying Special Tool (EN 46111)
    G04841494Courtesy of SUZUKI OF AMERICA CORP.
  16. Using the EN 46111, rotate the crankshaft until the left cylinder head camshafts align with the EN 46105-2 and the right cylinder head camshafts align with the EN 46105-1.
    Fig 5: Identifying EN 46105-1 On Right Camshafts
    G04841495Courtesy of SUZUKI OF AMERICA CORP.
  17. Install the EN 46105-1 to the right camshafts.
    Fig 6: Identifying EN 46105-2 On Left Camshafts
    G04841496Courtesy of SUZUKI OF AMERICA CORP.
  18. Install the EN 46105-2 to the left camshafts.
scientia non olet · About LEMON Manuals