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Camshafts Removal and Installation: Installation

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Take extreme care to prevent any scratches, nicks or damage to the camshafts.
  1. Lubricate the camshaft journals and the camshaft caps with engine oil.
  2. Install the intake camshaft.
  3. Install the intake camshaft caps in their original positions.
  4. Install the intake camshaft cap bolts.
  5. Install the exhaust camshaft.
  6. Install the exhaust camshaft caps in their original positions.
  7. Install the exhaust camshaft cap bolts.
  8. Tighten the camshaft cap bolts gradually and in the sequence shown in illustration for each camshaft cap.

    Tighten 

    Tighten the camshaft bearing cap bolts to 8 N.m (71 lb-in).

    Fig 1: Installing Exhaust Camshaft Cap Bolts
    G04102677Courtesy of SUZUKI OF AMERICA CORP.
  9. Measure the intake camshaft end play and the exhaust camshaft end play. Refer to "ENGINE SPECIFICATIONS :".
  10. Install the intake camshaft gear.
  11. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

    Tighten 

    Tighten the intake camshaft gear bolt to 50 N.m (37 lb-ft) plus 60 degrees and 15 degrees using the angular torque gauge KM-470-B.

    Fig 2: Installing Intake Camshaft Gear
    G04102678Courtesy of SUZUKI OF AMERICA CORP.
  12. Install the exhaust camshaft gear.
  13. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

    Tighten 

    Tighten the exhaust camshaft gear bolt to 50 N.m (37 lb-ft) plus 60 degrees and 15 degrees using the angular torque gauge KM-470-B.

    Fig 3: Installing Exhaust Camshaft Gear
    G04102679Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the camshaft cover and the camshaft cover gasket.
  15. Install the camshaft cover washers.
  16. Install the camshaft cover bolts.

    Tighten 

    Tighten the camshaft cover bolts to 8 N.m (71 lb-in).

    Fig 4: Installing Camshaft Cover And Camshaft Cover Gasket
    G04102680Courtesy of SUZUKI OF AMERICA CORP.
  17. Connect the ignition wires to the spark plugs.
  18. Install the spark plug cover.
  19. Install the spark plug cover bolts.

    Tighten 

    Tighten the spark plug cover bolts to 8 N.m (71 lb-in).

  20. Connect the breather tube to the camshaft cover.
  21. Connect the engine ventilation hose to the camshaft cover.
  22. Install the timing belt. Refer to "TIMING BELT REMOVAL AND INSTALLATION :".
    Fig 5: Connecting Breather Tube To Camshaft Cover
    G04102681Courtesy of SUZUKI OF AMERICA CORP.
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