Timing Chain Cover Removal & Installation: Installation

WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Reverse removal sequence to install timing chain cover noting the following points.

Clean sealing surface on timing chain cover, crankcase, cylinder block and cylinder heads. Remove oil, old sealant, and dust from sealing surface.

Fig 1: Cleaning Sealing Surface On Timing Chain Cover, Crankcase, Cylinder Block & Cylinder Heads
Courtesy of SUZUKI OF AMERICA CORP.
Apply sealant "A" to timing chain cover sealing surface area as shown in the figure.
"A": Water tight sealant 99000-31250

Fig 2: Applying Sealant To Timing Chain Cover Sealing Surface Area
Courtesy of SUZUKI OF AMERICA CORP.
Apply sealant "B" to mating surfaces of cylinder head and cylinder block as shown.
"B": Water tight sealant 99000-31140

Fig 3: Applying Sealant To Mating Surfaces Of Cylinder Head & Cylinder Block
Courtesy of SUZUKI OF AMERICA CORP.
Apply engine oil to new oil seal lip and water pump O-ring. Using special tool (bearing installer), install new oil seal (2) with its surface is flash with edge of timing chain cover (1).
Special tool

(D): 09913-75510

Fig 4: Installing New Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Install timing chain cover.
Tightening torque

Timing chain cover bolt: 11 N.m (1.1 kg-m, 8.0 lb-ft)
Apply engine oil to O-ring of CKP sensor and install CKP sensor (4) to timing chain cover.
Tightening torque

CKP sensor bolt (b): 6 N.m (0.6 kg-m, 4.5 lb-ft)
Install crankshaft pulley (1).
To lock crankshaft pulley, use special tool (camshaft pulley holder) with it at shown in the figure.

Special tool

(A): 09917-68221

Tightening torque

Crankshaft pulley bolt (a): 150 N.m (15 kg-m, 108.5 lb-ft)

Fig 5: Installing Crankshaft Pulley
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Be sure to use the following bolt for fixing special tool to crank pulley.
Bolt size: M8, P1.25 L = 45 mm
Strength: 7T

Fig 6: Identifying Bolt For Fixing Special Tool To Crankshaft Pulley
Courtesy of SUZUKI OF AMERICA CORP.