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Timing Chain Installation

WARNING: This page is about a different car, the 2004 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.
  1. Installation should follow the removal procedure in the reverse order.
  2. Install the timing chain after aligning both the mark on the camshaft sprocket and on the timing chain using camshaft sprocket holder DW110-150.
    3. Fig 1: Installing Timing Chain After Aligning Both Mark On Camshaft Sprocket
    G01985678Courtesy of SUZUKI OF AMERICA CORP.
  3. Align both the timing mark on the crankshaft sprocket and on the timing chain.
  4. Adjust the crankshaft using the crankshaft adjuster DW110-190.
    5. Fig 2: Adjusting Crankshaft Using Crankshaft Adjuster
    G01985679Courtesy of SUZUKI OF AMERICA CORP.
  5. Make sure the three timing marks on the timing chain are exactly aligned with the marks on the exhaust camshaft sprocket, intake camshaft sprocket, and crankshaft sprocket respectively.
    6. Fig 3: Aligning Timing Marks On Timing Chain
    G01985680Courtesy of SUZUKI OF AMERICA CORP.
  6. Install the fixed timing chain guide.

    Tighten 

    1. Tighten the fixed timing chain guide bolts to 18-22 N.m (13-16 lb-ft).
    7. Fig 4: Installing Fixed Timing Chain Guide
    G01985681Courtesy of SUZUKI OF AMERICA CORP.
  7. Install the timing chain lever.

    Tighten 

    1. Tighten the timing chain lever bolt to 18-22 N.m (13-16 lb-ft).
    8. Fig 5: Installing Timing Chain Lever
    G01985682Courtesy of SUZUKI OF AMERICA CORP.
  8. Install the timing chain tensioner.

    Tighten 

    1. Tighten the timing chain tensioner bolt to 18-22 N.m (13-16 lb-ft).
    9. Fig 6: Installing Timing Chain Tensioner
    G01985683Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the top chain guide.

    Tighten 

    1. Tighten the top chain guide bolt to 9-11 N.m (80-97 lb-in).
    10. Fig 7: Installing Top Chain Guide
    G01985684Courtesy of SUZUKI OF AMERICA CORP.
  10. Install two dowel rings.
  11. Apply the liquid gasket (Loctite® 5900-M8585) on the timing chain cover.
    12. Fig 8: Applying Liquid Gasket On Timing Chain Cover
    G01985685Courtesy of SUZUKI OF AMERICA CORP.
  12. Install the timing chain cover install guide pin DW110-140 and position the timing chain cover.
    CAUTION: Be sure the applied liquid gasket is not damaged when installing the timing chain cover.
    13. Fig 9: Installing Timing Chain Cover Install Guide Pin
    G01985686Courtesy of SUZUKI OF AMERICA CORP.
  13. Install the timing chain cover.

    Tighten 

    1. Tighten the timing chain cover bolt (Center) to 18-22 N.m (13-16 lb-ft).
    2. Tighten the timing chain cover bolts to 6-10 N.m (53-89 lb-in)).
    14. Fig 10: Installing Timing Chain Cover
    G01985687Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the drive belt automatic tensioner.

    Tighten 

    1. Tighten the drive belt automatic tensioner retaining bolt to 20-30 N.m (15-22 lb-ft).
    15. Fig 11: Installing Drive Belt Automatic Tensioner
    G01985688Courtesy of SUZUKI OF AMERICA CORP.
  15. Install the water pump pulley.

    Tighten 

    1. Tighten the water pump pulley bolts to 8-12 N.m (71-106 lb-in).
    16. Fig 12: Installing Water Pump Pulley
    G01985689Courtesy of SUZUKI OF AMERICA CORP.
  16. Install the engine mount bracket support.

    Tighten 

    1. Tighten the engine mount bracket support bolts to 25-31 N.m (18-23 lb-ft).
    17. Fig 13: Installing Engine Mount Bracket Support
    G01985690Courtesy of SUZUKI OF AMERICA CORP.
  17. Install the crankshaft pulley. Tighten the crankshaft pulley bolt using the crankshaft pulley holder DW110-130-01 and the crankshaft pulley installer/remover DW110-130-02.
    CAUTION: Very high torque is required to remove or to install the crankshaft pulley. Never remove the crankshaft pulley when the vehicle is hung on the lift.

    Tighten 

    1. Tighten the crankshaft pulley bolt to 500-600 N.m (369-443 lb-ft).
    18. Fig 14: Installing Crankshaft Pulley
    G01985691Courtesy of SUZUKI OF AMERICA CORP.
  18. Install the oil pan. Refer to Oil Pan / Oil Pump Installation  .
    19. Fig 15: Installing Oil Pan
    G01985692Courtesy of SUZUKI OF AMERICA CORP.
  19. Install the cylinder head cover. Refer to Cylinder Head Cover Installation  .
    20. Fig 16: Installing Cylinder Head Cover
    G01985693Courtesy of SUZUKI OF AMERICA CORP.
  20. Install the intake manifold. Refer to Intake Manifold Installation  .
    21. Fig 17: Installing Intake Manifold
    G01985694Courtesy of SUZUKI OF AMERICA CORP.
  21. Install the flexible plate.

    Tighten 

    1. Tighten the flexible plate bolts to 70-80 N.m (52-59 lb-ft).
    22. Fig 18: Installing Flexible Plate
    G01985695Courtesy of SUZUKI OF AMERICA CORP.
  22. Install the transaxle to the engine assembly.
  23. Install the engine and transaxle assembly. Refer to Engine Assembly Installation  .
Fig 19: Installing Engine & Transaxle Assembly
G01985696Courtesy of SUZUKI OF AMERICA CORP.
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