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Home >> Suzuki >> 2002 >> XL-7 Plus >> Repair and Diagnosis >> External Pages >> Different car >> Section 153 (Engine Mechanical) >> Repair Instructions >> Timing Chain Cover Removal and Installation >> Removal
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Timing Chain Cover Removal and Installation: Removal

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative cable at battery.
  2. Drain engine oil.
  3. Drain coolant referring to "COOLANT DRAINING ".
  4. Remove throttle body and intake manifold. Refer to "THROTTLE BODY AND INTAKE MANIFOLD REMOVAL: ".
  5. Remove cylinder head covers. Refer to "CYLINDER HEAD COVERS REMOVAL AND INSTALLATION: ".
  6. Remove cooling fan, fan clutch and water pump pulley. Refer to "COOLING FAN AND FAN CLUTCH REMOVAL AND INSTALLATION ".
  7. Remove radiator. Refer to "RADIATOR REMOVAL AND INSTALLATION ".
  8. Remove thermostat cap. Refer to "THERMOSTAT REMOVAL AND INSTALLATION ".
  9. Remove P/S pump (A/C compressor) drive belt. Refer to "COOLING FAN / GENERATOR BELT REMOVAL AND INSTALLATION ".
  10. Remove water pump drive belt. Refer to "COOLING FAN / GENERATOR BELT REMOVAL AND INSTALLATION .
  11. Remove P/S pump and P/S pump bracket. Refer to "POWER STEERING PUMP REMOVAL AND INSTALLATION ".
  12. Raise vehicle.
  13. Remove oil pan. Refer to "OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION ".
  14. Remove crankshaft pulley bolt (1). To lock crankshaft pulley, use special tool (camshaft pulley holder) as shown in figure.

    Special tool 

    (A): 09917-68221 

    Fig 1: Removing Crankshaft Pulley Bolt
    G02256705Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Be sure to use the following bolt for fixing special tool to crankshaft pulley.
    Bolt size: M8, P1.25 L = 45 mm (1.77 in.)
    Strength: 7T
    Fig 2: Measuring Bolt Length
    G02256706Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove crankshaft pulley (1).

    If it is hard to remove, use special tools (Steering wheel remover, Bearing puller attachment) as shown in figure.

    If bolts of steering wheel remover are too long, replace them with those of suitable length.

    Special tool 

    (B): 09944-36011 

    (C): 09926-58010 

    Fig 3: Removing Crankshaft Pulley
    G02256707Courtesy of SUZUKI OF AMERICA CORP.
  16. Disconnect CKP sensor connector and remove CKP sensor if necessary.
  17. Remove timing chain cover.
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