Timing Chain Cover Removal and Installation: Installation

WARNING: This page is about a different variant/trim than selected.

Clean sealing surface on timing chain cover, cylinder block and cylinder head.
Install new water pump inner gasket (1) to timing chain cover (2).

Fig 1: Identifying Water Pump Inner Gasket And Timing Chain Cover
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool, install new crankshaft oil seal (1) to timing chain cover (2) as shown in figure [A] or [B].
NOTE: Do not apply engine oil and grease to crankshaft oil seal.

Special Tool

(A): 09926-68310

(B): 09913-75821

Fig 2: Installing Crankshaft Oil Seal To Timing Chain Cover
Courtesy of SUZUKI OF AMERICA CORP.

Special Tool

(C): Oil seal installer (J-29184)

Fig 3: Identifying Crankshaft Oil Seal And Timing Chain Cover
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool, install new oil seal (1) to timing chain cover as shown in figure.
Special Tool

(A): 09913-57810

Fig 4: Installing Oil Seal To Timing Chain Cover
Courtesy of SUZUKI OF AMERICA CORP.
Install special tool to cylinder head.
Special Tool

(A): Engine front cover installation guide pins (EN-46109)

Fig 5: Identifying Engine Front Cover Installation Guide Pins
Courtesy of SUZUKI OF AMERICA CORP.
Apply sealant "A" to mating surface of cylinder head (1) and cylinder block (2) as shown in figure.
"A": Sealant 99000-31290 (SUZUKI Bond No. 1217F)

Fig 6: Applying Sealant To Mating Surface Of Cylinder Head And Cylinder Block
Courtesy of SUZUKI OF AMERICA CORP.
Apply sealant "A" to mating surface of timing chain cover (1) as shown in figure.
"A": Sealant 99000-31290 (SUZUKI Bond No. 1217F)

Sealant amount for timing chain cover

Width "a": 3 mm (0.12 in.)

Width "b": 5 mm (0.20 in.)

Height "c": 2.5 mm (0.10 in.)

Fig 7: Applying Sealant To Mating Surface Of Timing Chain Cover
Courtesy of SUZUKI OF AMERICA CORP.
Install timing chain cover and accessory drive belt tensioner as follows.
NOTE: Before installing timing chain cover, check that dowel pin is securely fitted.
1. Tighten timing chain cover bolt to 20 N.m (2.0 kgf-m, 15.0 lbf-ft) in numerical order ("1" - "22") shown in figure evenly and gradually.
2. In the same manner as Step a), retighten them to 60°.
3. Tighten accessory drive belt tensioner bolt ("23") to 25 N.m (2.5 kgf-m, 18.5 lbf-ft).
  Tightening torque
  
  Timing chain cover bolt * (a): 20 N.m → +60° (2.0 kgf-m → +60°, 15 lbf-ft → +60°)
  
  Accessory drive belt tensioner bolt* (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
  
  Fig 8: Identifying Timing Chain Cover Bolt Tightening Sequence
  Courtesy of SUZUKI OF AMERICA CORP.
Remove special tool.
Special Tool

(A): Engine front cover installation guide pins (EN-46109)

Fig 9: Identifying Engine Front Cover Installation Guide Pins
Courtesy of SUZUKI OF AMERICA CORP.
Install new O-ring (3) and new gasket (4).
Install water outlet pipe No. 1 (1) and water outlet pipe No. 2 (2)

Fig 10: Identifying Water Outlet Pipe No. 1 And No. 2
Courtesy of SUZUKI OF AMERICA CORP.
Lock flywheel with special tool as shown in figure.
Special Tool

(A): 09916-97830

Fig 11: Locking Flywheel With Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Apply engine oil between crankshaft pulley and crankshaft.
NOTE: Do not apply engine oil between crankshaft oil seal and crankshaft pulley.

Fig 12: Applying Engine Oil Between Crankshaft Pulley And Crankshaft
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool, install crankshaft pulley (1) to crankshaft as shown in figure.
Special Tool

(A): 09912-37820

Fig 13: Installing Crankshaft Pulley To Crankshaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove special tool, tighten crankshaft pulley bolt as follows.
1. Tighten crankshaft pulley bolt to 120 N.m (12.2 kgf-m, 88.5 lbf-ft).
2. Loosen crankshaft pulley bolt until loosening torque is 0.
3. Tighten crankshaft pulley bolt to 100 N.m (10.2 kgf-m, 74.0 lbf-ft).
4. Retighten crankshaft pulley bolt to 150°.
  Tightening torque
  
  Timing chain cover bolt * (a): 120 N.m → 0 N.m → 100 N.m → +150° (12.2 kgf-m → 0 kgf-m → 10.2 kgf-m → +150°, 88.5 lbf-ft → 0 lbf-ft → 74.0 lbf-ft → +150°)
  
  Fig 14: Identifying Crankshaft Pulley Bolt
  Courtesy of SUZUKI OF AMERICA CORP.
Install belt idler arm to generator bracket. See TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION .
Install OCV. See OCV REMOVAL AND INSTALLATION .
Install P/S pump bracket. See P/S PUMP REMOVAL AND INSTALLATION .
Install water pump pulley. See WATER PUMP REMOVAL AND INSTALLATION .
Install cylinder head cover. See CYLINDER HEAD COVER REMOVAL AND INSTALLATION .
Install accessory drive belt. See ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION .
Install engine assembly to vehicle. See ENGINE ASSEMBLY REMOVAL AND INSTALLATION .