Timing Chain: Removal and Installation: Installation

1. Install timing chain tensioners (secondary) with stopper pin attached and new O-ring.
2. Install camshaft brackets (No. 1). Refer to [CAMSHAFT: REMOVAL AND INSTALLATION ].

1. Install new O-rings onto cylinder block.
   Fig 2: Identifying Rear Timing Chain Case

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2. Install new O-rings to cylinder head and camshaft bracket (No. 1).
   Fig 3: Identifying Cylinder Head And Camshaft Bracket (No. 1)

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3. Apply liquid gasket using Tool to rear timing chain case back side as shown.

   Use Genuine RTV Silicone Sealant or equivalent.  Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].

   Tool number: WS39930000 ( - ) 

   CAUTION:

   • For (A), completely wipe off liquid gasket covering the area shown.
   • Apply liquid gasket on installation position of water pump and cylinder head very completely.
     Fig 4: Identifying Water Pump Components

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4. Align rear timing chain case with dowel pins (right and left) on cylinder block and install rear timing chain case.
   • Make sure O-rings stay in place during installation to cylinder block, cylinder head and camshaft bracket (No. 1).
5. Tighten bolts in numerical order as shown.
   Fig 5: Identifying Cylinder Head And Camshaft Bracket (No. 1)

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   • There are two type of bolts with different torque specifications. Refer to the following for installing bolts.

     Bolt length Bolt position Torque specification 

     20 mm (0.79 in) 1, 2, 3, 6, 7, 8, 9, 10: 12.7 N.m (1.3 kg-m, 9 ft-lb) 

     16 mm (0.63 in) 4, 5, 11: 12.7 N.m (1.3 kg-m, 9 ft-lb) 

     16 mm (0.63 in) 12 through 26: 15.0 N.m (1.5 kg-m, 11 ft-lb) 

6. After all bolts are tightened, retighten them to the specified torque in numerical order as shown.
   • If liquid gasket protrudes, wipe it off immediately.
7. After installing rear timing chain case, check the surface height difference between following parts on oil pan (upper) mounting surface.
   Fig 6: Checking Surface Height Difference Between Following Parts On Oil Pan Mounting Surface

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   Standard 

   Rear timing chain case to lower cylinder block: 

   -0.24 to 0.14 mm (-0.0094 to 0.0055 in) 

   • If not within the standard, repeat the installation procedure.

Fig 7: Identifying Dowel Pin And Crankshaft Key

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Camshaft dowel pin hole (intake side) 

: At cylinder head upper face side in each bank. 

Camshaft dowel pin (exhaust side) 

: At cylinder head upper face side in each bank. 

Crankshaft key 

: At cylinder head side of right bank. 

1. Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin.
   Fig 8: Identifying Stopper Pin Location

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2. Install timing chains (secondary) (8) and camshaft sprockets [INT (1) and EXH (9)].
   Fig 9: Identifying Timing Chains And Camshaft Sprockets

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   • Left bank mating marks (6)
   • Align the timing chain mating marks (secondary) (2) (blue color link) with the ones on camshaft sprockets (INT and EXH) (4), (5), (7) and (10) (punched), and install them.
     NOTE:

     • Mating marks for camshaft sprocket (INT) are on the back side of camshaft sprocket (secondary).
     • There are two types of mating marks, circle (7), (10) and oval (4), (5) types. They should be used for the right and left banks, respectively.

       Right bank: Use circle type (7) and (10).

       Left bank: Use oval type (4) and (5).

   • Align dowel pin (3) and pin hole on camshafts with the groove (11) and dowel pin on sprockets, and install them.
   • On the intake side, align pin hole on the small diameter side of the camshaft front end with dowel pin (3) on the back side of camshaft sprocket, and install them.
   • On the exhaust side, align dowel pin on camshaft front end with pin groove (11) on camshaft sprocket, and install them.
   • In case that positions of each mating mark and each dowel pin do not fit on mating parts, make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
   • Bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins.
   • It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the top of sprocket teeth and its extended line in advance with paint.
     Fig 10: Identifying Mating Mark On Top Of Sprocket Teeth

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3. After confirming the mating marks are aligned, tighten camshaft sprocket bolts.
   Fig 11: Tightening Camshaft Sprocket Bolts

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   • Secure camshaft using wrench at the hexagonal portion to tighten bolts.
4. Pull stopper pins out from timing chain tensioners (secondary).
   Fig 12: Pulling Stopper Pins Out From Timing Chain Tensioners

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1. Install crankshaft sprocket.
   Fig 13: Installing Crankshaft Sprocket

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   • Make sure the mating marks on crankshaft sprocket face the front of engine.
2. Install the primary timing chain.
   Fig 14: Identifying Primary Timing Chain

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   • Water pump (G).
   • Install primary timing chain so the mating mark punched (B) on camshaft sprocket is aligned with the blue link (A) on the timing chain, while the mating mark notched (E) on the crankshaft sprocket (D) is aligned with the copper link (F) on the timing chain, as shown.
   • When it is difficult to align mating marks (A) with (B) and (E) with (F) of the primary timing chain with each sprocket, gradually turn the camshaft using a wrench on the hexagonal portion to align it with the mating marks.
   • During alignment, be careful to prevent dislocation of mating mark alignments of the secondary timing chains.

Fig 15: Identifying Internal Chain Guide, Slack Guide And Timing Chain Tensioner

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Fig 16: Identifying Slack Guide, Mounting Bolt And Cylinder Block

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• When installing timing chain tensioner (primary), push in plunger and keep it pressed in with stopper pin.
• Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary).
• After installation, pull out stopper pin.

• Apply new engine oil to both oil seal lip and dust seal lip.
• Install it so that each seal lip is oriented as shown.
  Fig 18: Installing Front Oil Seal On Front Timing Chain Case

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• Press-fit oil seal until it becomes flush with front timing chain case end face using suitable drift [outer diameter: 60 mm (2.36 in)].
  Fig 19: Pressing Oil Seal

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• Make sure the garter spring is in position and seal lip is not inverted.

• Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown.
  Fig 20: Applying Continuous Bead Of Liquid Gasket To Front Timing Chain Case

  Courtesy of SUZUKI OF AMERICA CORP.

  Tool number: WS39930000 ( - ) 

  Use Genuine RTV Silicone Sealant or equivalent.  Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].

1. Apply a continuous bead of liquid gasket using Tool to front timing chain case back side as shown.
   Fig 21: Applying Continuous Bead Of Liquid Gasket To Front Timing Chain Case Back Side

   Courtesy of SUZUKI OF AMERICA CORP.

   Tool number: WS39930000 ( - ) 

   Use Genuine RTV Silicone Sealant or equivalent.  Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].

2. Install new O-rings on rear timing chain case.
   Fig 22: Identifying O-rings On Rear Timing Chain Case

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3. Assemble front timing chain case as follows:
   1. Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely.
      Fig 23: Identifying Front Timing Chain Case And Cylinder Block

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   2. Since front timing chain case is offset for difference of bolt holes, tighten bolts temporarily while holding front timing chain case from front and top as shown.
      Fig 24: Identifying Front Timing Chain Case

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   3. Same as the previous step, insert dowel pin while holding front timing chain case from front and top completely.
4. Tighten bolts to the specified torque in numerical order as shown.
   Fig 25: Identifying Front Timing Chain Case Bolts Tighten Sequence

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5. After all bolts tightened, retighten them to the specified torque in numerical order as shown.

   Bolt position Bolt diameter 

   1 - 5: 10 mm (0.39 in) 

   6 - 25: 6 mm (0.24 in) 

   Bolt position Tightening specification 

   1 - 5: 55.0 N.m (5.6 kg-m, 41 ft-lb) 

   6 - 25: 12.7 N.m (1.3 kg-m, 9 ft-lb) 

Fig 26: Identifying Oil Pan Bolts

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Front oil pan bolt torque: 22.0 N.m (2.2 kg-m, 16 ft-lb) 

1. Install new seal rings in shaft grooves.
2. Apply a continuous bead of liquid gasket using Tool to intake valve timing control covers as shown.
   Fig 27: Identifying Intake Valve Timing Control Covers

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   Tool number: WS39930000 ( - ) 

   Use Genuine RTV Silicone Sealant or equivalent.  Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].

3. Install new collared O-rings in front timing chain case oil hole (left and right sides).
   Fig 28: Identifying O-rings In Front Timing Chain Case Oil Hole

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4. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with the holes to install intake valve timing control covers.
5. Tighten bolts in numerical order as shown.
   Fig 29: Identifying Intake Valve Timing Control Covers Bolts

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1. Install crankshaft pulley, taking care not to damage front oil seal.
   • When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).
2. Tighten crankshaft pulley bolt in two steps.

   Step 1: 44.1 N.m (4.5 kg-m, 33 ft-lb) 

   Step 2: 84° - 90° degrees clockwise 

3. Remove Tool.
   Fig 30: Identifying Transmission And Oil Pan

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   Tool number: - (J-48761)