Timing Chain Cover Removal and Installation: Installation

Reference: TIMING CHAIN COVER CLEANING AND INSPECTION 

1. Clean sealing surfaces on timing chain cover, cylinder block and cylinder head.

   Remove oil, old sealant and dust from sealing surface.

2. Install new oil seal (2) to timing chain cover using special tool, if removed.
   NOTE: When installing new oil seal (2), drive it until its surface is flash with edge of timing chain cover (1).

   Special Tool 

   (A): 09913-75510 

   Fig 1: Installing Timing Chain Cover Oil Seal

   Courtesy of SUZUKI OF AMERICA CORP.
3. Apply sealant "A" and "B" to specific area as shown in Fig 2.

   "A": Sealant 99000-31260SUZUKI Bond No. 1217G 

   "B": Water tight sealant 99000-31140SUZUKI Bond No. 1207B 

   Sealant amount for timing chain cover 

   "a": 3 mm (0.12 in.) 

   "b": 2 mm (0.08 in.) 

   "c": 4 mm (0.16 in.) 

   "d": 16 mm (0.63 in.) 

   "e": 14 mm (0.55 in.) 

   "f": 65 mm (2.56 in.) 

   "g": 73 mm (2.87 in.) 

   Fig 2: Identifying Area For Applying Sealant

   Courtesy of SUZUKI OF AMERICA CORP.
4. Apply engine oil to oil seal lip, then install timing chain cover (1). Tighten bolts and nut to specified torque.
   NOTE: Before installing timing chain cover, check that pin is securely fitted.

   Tightening torque 

   Timing chain cover bolt and nut a: 11 N.m (1.1 kg-m, 8.0 lb-ft) 

   Fig 3: Identifying Timing Chain Cover Bolts & Nut

   Courtesy of SUZUKI OF AMERICA CORP.
5. Install belt idler pulley (1). Tighten nut to specified torque.

   Tightening torque 

   Idler pulley nut a: 42 N.m (4.2 kg-m, 30.5 lb-ft) 

6. Install belt tensioner (2). Tighten bolts to specified torque.

   Tightening torque 

   Generator belt tensioner bolt b: 25 N.m (2.5 kg-m, 18.5 lb-ft) 

7. Install water pump pulley (3).
   Fig 4: Identifying Water Pump Pulley & Belt Tensioner Bolts

   Courtesy of SUZUKI OF AMERICA CORP.
8. Install cylinder head cover, referring to INSTALLATION .
9. Install oil pan. Refer to INSTALLATION .
10. Install crankshaft pulley. To lock crankshaft pulley (1), use special tool (camshaft pulley holder) as shown in Fig 5.

    Special Tool 

    (A): 09917-68221 

    NOTE: Be sure to use the following bolts instead of pins in order to fix crank pulley by special tool.
    Bolt size: M8, P1.25 L = 25 mm (0.98 in.)
    Strength: 7T

    Tightening torque 

    Crankshaft pulley bolt a: 150 N.m (15.0 kg-m, 108.5 lb-ft) 

    Fig 5: Locking Crankshaft Pulley Bolt

    Courtesy of SUZUKI OF AMERICA CORP.
11. Install engine assembly to vehicle, referring to INSTALLATION .