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Installation 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.
Fig 1: Identifying Guide
G04841497Courtesy of SUZUKI OF AMERICA CORP.
  1. Install the 8 mm (0.315 in) guide from the EN 46109 into the cylinder block positions as shown in Fig 1.
    Fig 2: Identifying Cylinder Block Seal
    G04841498Courtesy of SUZUKI OF AMERICA CORP.
  2. Install the engine front cover to cylinder block seal.
    Fig 3: Placing Bead Of RTV Sealant On Engine Front Cover
    G04841499Courtesy of SUZUKI OF AMERICA CORP.
  3. Place a 3 mm (0.118 in) bead of RTV sealant, GM P/N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover as shown in Fig 3 (1).
    Fig 4: Identifying Engine Front Cover
    G04841500Courtesy of SUZUKI OF AMERICA CORP.
  4. Place the engine front cover onto the EN 46109 and slide into position.
  5. Remove the EN 46109 from the cylinder block.
    Fig 5: Identifying Front Cover Bolts
    G04841501Courtesy of SUZUKI OF AMERICA CORP.
  6. Hand start all the front cover bolts.
    Fig 6: Tightening Engine Front Cover Bolts In Sequence
    G04841502Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Refer to FASTENER NOTICE .
  7. Tighten the engine front cover bolts in the sequence shown in Fig 6.

    Tightening torque 

    Tighten the engine front cover bolts in sequence to 23 N.m (17 lb ft)  .

  8. Install the engine oil pan. Refer to INSTALLATION PROCEDURE .
  9. Install the camshaft position actuator solenoid valves from the front cover. Refer to INSTALLATION PROCEDURE , INSTALLATION PROCEDURE , INSTALLATION PROCEDURE and INSTALLATION PROCEDURE .
  10. Install the camshaft position actuator valves from the front cover. Refer to INSTALLATION PROCEDURE , INSTALLATION PROCEDURE , INSTALLATION PROCEDURE and INSTALLATION PROCEDURE .
  11. Install the crankshaft balancer. Refer to INSTALLATION PROCEDURE .
  12. Install the power steering pump and position aside. Refer to INSTALLATION PROCEDURE .
  13. Install the water pump. Refer to INSTALLATION PROCEDURE .
  14. Install the water outlet housing assembly. Refer to INSTALLATION PROCEDURE .
  15. Install the drive belt tensioner. Refer to INSTALLATION PROCEDURE .
  16. Install the camshaft covers. Refer to INSTALLATION PROCEDURE  and INSTALLATION PROCEDURE .
  17. Install the lower intake manifold. Refer to INSTALLATION PROCEDURE .
  18. Refill the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL) and DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL) .
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