Timing Chain Removal

Tools Required: 

DW110-060 Engine Assembly Lift Support 

DW010-010 Power Pack Stand 

DW110-030 Engine Overhaul Stand 

DW110-130-01 Crankshaft Pulley Holder 

DW110-130-02 Crankshaft Pulley Installer/Remover 

DW110-150 Camshaft Sprocket Holder 

DW110-190 Crankshaft Adjuster 

DW110-140 Timing Chain Cover Install Guide Pin 

1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to DRAINING AND REFILLING THE COOLING SYSTEM .
5. Drain the engine oil.
6. Drain the transaxle oil.
   Fig 1: Identifying Fuel Pump Fuse

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7. Drain the power steering oil.
8. Recover the refrigerant.
9. Remove the engine assembly. Refer to Engine Assembly Removal .
   Fig 2: Identifying Engine Assembly On Power Pack Stand DW010-010

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10. Remove the flexible plate bolts and the flexible plate.
11. Support the engine assembly with the engine overhaul stand DW110-030.
    Fig 3: Removing/Installing Flexible Plate Bolts

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12. Remove the intake manifold. Refer to Intake Manifold Removal .
    Fig 4: Removing/Installing Intake Manifold And Retaining Bolts

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13. Remove the cylinder head cover. Refer to Cylinder Head Cover Removal .
    Fig 5: Removing/Installing Cylinder Head Cover Retaining Bolts

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14. Remove the drive belt.
    Fig 6: Removing/Installing Drive Belt

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15. Remove the oil pan. Refer to OIL PAN / OIL PUMP REMOVAL .
    Fig 7: Removing/Installing Oil Pan Retaining Bolts

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16. Install the crankshaft pulley holder DW110-130-01 to the crankshaft pulley bolt.
    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.
    Fig 8: Removing/Installing Crankshaft Pulley Holder (DW110-130-01) To Crankshaft Pulley Bolt

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17. Remove the crankshaft pulley bolt using the crankshaft pulley installer/remover DW110-130-02.
    Fig 9: Removing/Installing Crankshaft Pulley Bolt Using Crankshaft Pulley Installer/Remover (DW110-130-02)

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18. Remove the engine mount bracket support.
    Fig 10: Removing/Installing Engine Mount Bracket Support Retaining Bolts

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19. Remove the water pump pulley.
    Fig 11: Removing/Installing Water Pump Pulley Retaining Bolts

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20. Remove the drive belt automatic tensioner retaining bolts and the tensioner.
    Fig 12: Removing/Installing Drive Belt Automatic Tensioner Retaining Bolts

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21. Remove the timing chain cover.
22. Remove 2 dowel rings for timing cover.
    Fig 13: Removing/Installing Timing Chain Cover Retaining Bolts

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23. Remove the timing chain tensioner.
    Fig 14: Removing/Installing Timing Chain Tensioner Retaining Bolts

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24. Remove the fixed timing chain guide.
    Fig 15: Removing/Installing Fixed Timing Chain Guide Retaining Bolts

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25. Remove the timing chain lever.
    Fig 16: Removing/Installing Timing Chain Lever Retaining Bolt

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26. Remove the top chain guide.
27. Remove the timing chain.
28. Remove the crankshaft sprocket and the woodruff key.
    Fig 17: Removing/Installing Top Chain Guide Retaining Bolts

    Courtesy of SUZUKI OF AMERICA CORP.