Timing Chain Installation

WARNING: This page is about a different car, the 2006 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.

Installation should follow the removal procedure in the reverse order.
Install the timing chain after aligning both the mark on the camshaft sprocket and on the timing chain using camshaft sprocket holder DW110-150.

Fig 1: Installing Timing Chain Using Camshaft Sprocket Holder (DW110-150)
Courtesy of SUZUKI OF AMERICA CORP.
Align both the timing mark on the crankshaft sprocket and on the timing chain.
Adjust the crankshaft using the crankshaft adjuster DW110-190.

Fig 2: Adjusting Crankshaft Using Crankshaft Adjuster (DW110-190)
Courtesy of SUZUKI OF AMERICA CORP.
Make sure the 3 timing marks on the timing chain are exactly aligned with the marks on the exhaust camshaft sprocket, intake camshaft sprocket, and crankshaft sprocket respectively.

Fig 3: Identifying Timing Marks On Timing Chain And Exhaust Camshaft Sprocket
Courtesy of SUZUKI OF AMERICA CORP.
Install the fixed timing chain guide.
Tighten:

Tighten the fixed timing chain guide bolts to 18 - 22 N.m (13 - 16 lb-ft).

Fig 4: Identifying Fixed Timing Chain Guide Retaining Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the timing chain lever.
Tighten:

Tighten the timing chain lever bolt to 18 - 22 N.m (13 - 16 lb-ft).

Fig 5: Identifying Timing Chain Lever Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Install the timing chain tensioner.
Tighten:

Tighten the timing chain tensioner bolt to 18 - 22 N.m (13 - 16 lb-ft).

Fig 6: Identifying Timing Chain Tensioner Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the top chain guide.
Tighten:

Tighten the top chain guide bolt to 9 - 11 N.m (80 - 97 lb-in.).

Fig 7: Identifying Top Chain Guide Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install 2 dowel rings.
Apply the liquid gasket (Loctite® 5900-M8585) on the timing chain cover.

Fig 8: Identifying Areas To Apply Liquid Gasket (Loctite® 5900-M8585) On Timing Chain Cover
Courtesy of SUZUKI OF AMERICA CORP.
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.

Fig 9: Identifying Guide Pin (DW110-140)
Courtesy of SUZUKI OF AMERICA CORP.
Install the timing chain cover.
Tighten:
- Tighten the timing chain cover bolt (Center) to 18 - 22 N.m (13 - 16 lb-ft).
- Tighten the timing chain cover bolts to 6 - 10 N.m (53 - 89 lb-in.).
  
  Fig 10: Identifying Timing Chain Cover And Retaining Bolts
  Courtesy of SUZUKI OF AMERICA CORP.
Install the drive belt automatic tensioner.
Tighten:

Tighten the drive belt automatic tensioner retaining bolt to 20 - 30 N.m (15 - 22 lb-ft).

Fig 11: Identifying Drive Belt Automatic Tensioner And Retaining Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the water pump pulley.
Tighten:

Tighten the water pump pulley bolts to 8 - 12 N.m (71 - 106 lb-in.).

Fig 12: Identifying Water Pump Pulley And Retaining Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the engine mount bracket support.
Tighten:

Tighten the engine mount bracket support bolts to 25 - 31 N.m (18 - 23 lb-ft).

Fig 13: Identifying Engine Mount Bracket Support And Retaining Bolts
Courtesy of SUZUKI OF AMERICA CORP.
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:

Tighten the crankshaft pulley bolt to 500 - 600 N.m (369 - 443 lb-ft).

Fig 14: Installing Crankshaft Pulley Bolt Using Crankshaft Pulley Holder (DW110-130-01) And The Crankshaft Pulley Installer/Remover (DW110-130-02)
Courtesy of SUZUKI OF AMERICA CORP.
Install the oil pan. Refer to OIL PAN / OIL PUMP INSTALLATION .

Fig 15: Identifying Oil Pan And Retaining Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the cylinder head cover. Refer to Cylinder Head Cover Installation .

Fig 16: Identifying Cylinder Head Cover And Retaining Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the intake manifold. Refer to Intake Manifold Installation .

Fig 17: Removing/Installing Intake Manifold And Retaining Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the flexible plate.
Tighten:

Tighten the flexible plate bolts to 70 - 80 N.m (52 - 59 lb-ft).

Fig 18: Identifying Flexible Plate And Retaining Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the transaxle to the engine assembly.
Install the engine and transaxle assembly. Refer to Engine Assembly Installation .

Fig 19: Identifying Engine And Transaxle Assembly On Power Pack Stand (DW010-010)
Courtesy of SUZUKI OF AMERICA CORP.