Timing Chain: Removal and Installation: Removal

Remove engine under cover. Refer to FRONT BUMPER: REMOVAL AND INSTALLATION .
Release the fuel pressure. Refer to [FUEL PRESSURE CHECK: QR25DE ].
Remove the air cleaner and air duct assembly. Refer to [AIR CLEANER AND AIR DUCT: REMOVAL AND INSTALLATION ].
Remove the spark plugs. Refer to [SPARK PLUG: REMOVAL AND INSTALLATION ]
Remove the rocker cover. Refer to [ROCKER COVER: REMOVAL AND INSTALLATION [QR25DE] ].
Remove the coolant overflow reservoir tank.
Remove the drive belt auto-tensioner. Refer to [DRIVE BELT AUTO TENSIONER AND IDLER PULLEY: REMOVAL AND INSTALLATION ].
Remove the generator. Refer to [GENERATOR: REMOVAL AND INSTALLATION - QR25DE MODELS ]
Remove the strut tower brace. Refer to [FRONT SUSPENSION ASSEMBLY: COMPONENT ]
Dismount and position aside the A/C compressor with the piping attached.
Dismount and position aside the power steering pump and reservoir tank with the piping attached.
Remove the oil pan, and oil strainer. Refer to [OIL PAN: REMOVAL AND INSTALLATION ]
Remove IVT control cover bolts in the order as shown.

Fig 1: IVT Control Cover Bolts Removing Order
Courtesy of SUZUKI OF AMERICA CORP.
Remove the IVT control cover by cutting the sealant using Tool.
Tool number: KV10111100 (J-37228)
Pull chain guide between camshaft sprockets out through front cover.
Set the No. 1 cylinder at TDC on the compression stroke with the following procedure:

Fig 2: Identifying TDC Mark And Timing Indicator
Courtesy of SUZUKI OF AMERICA CORP.
1. Rotate the crankshaft pulley clockwise and align the mating marks to the timing indicator on the front cover.
2. At the same time, make sure that the mating marks on the camshaft sprockets are lined up as shown.
  
  Fig 3: Identifying Mating Marks On Camshaft Sprockets
  Courtesy of SUZUKI OF AMERICA CORP.

If not lined up, rotate the crankshaft pulley one more turn to line up the mating marks to the positions as shown.

Remove crankshaft pulley with the following procedure:

Fig 4: Removing Crankshaft Pulley
Courtesy of SUZUKI OF AMERICA CORP.
1. Hold the crankshaft pulley with a suitable tool, then loosen the crankshaft pulley bolt, and pull the pulley out about 10 mm (0.39 in). Remove the crankshaft pulley bolt.
2. Attach a pulley puller in the M6 (0.24 in diameter) thread hole on crankshaft pulley, and remove crankshaft pulley.
  
  Fig 5: Removing Crankshaft Pulley
  Courtesy of SUZUKI OF AMERICA CORP.
If the front oil seal needs to be replaced, remove it using a suitable tool.

Fig 6: Removing Front Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Remove the front cover as follows:

Fig 7: Front Cover Bolt Loosening Sequence
Courtesy of SUZUKI OF AMERICA CORP.
1. Loosen the front cover bolts in the order as shown, and remove them.
2. Remove the front cover.
  CAUTION:
  - Be careful not to damage the mating surface.
Remove timing chain with the following procedure:
1. Push in chain tensioner plunger. Insert a stopper pin into hole on chain tensioner body to secure chain tensioner plunger and remove chain tensioner.
  NOTE: Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin.
  
  Fig 8: Removing Chain Tensioner
  Courtesy of SUZUKI OF AMERICA CORP.
2. Remove timing chain.
  CAUTION: Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston.
Remove camshaft sprockets. Refer to Camshaft: Removal and Installation .
Remove timing chain slack guide, timing chain tension guide and spacer.
Remove balancer unit timing chain tensioner with the following procedure:
1. Lift lever up, and release ratchet claw for return proof.
  
  Fig 9: Removing Balancer Unit Timing Chain Tensioner
  Courtesy of SUZUKI OF AMERICA CORP.
2. Push tensioner sleeve in, and hold it.
3. Matching the hole on lever with the one on body, insert a stopper pin to secure tensioner sleeve.
  NOTE: Use approximately 1 mm (0.04 in) dia. hard metal pin as a stopper pin.
4. Remove balancer unit timing chain tensioner.
Secure the hexagonal portion of the balancer shaft using a suitable tool. Loosen the balancer unit sprocket bolt.
Remove balancer unit timing chain, balancer unit sprocket and crankshaft sprocket.
NOTE: When removing balancer unit timing chain, remove crankshaft sprocket and balancer unit sprocket at the same time.

Loosen bolts in reverse order as shown, and remove balancer unit.

Fig 10: Tightening Order Of Balancer Unit Bolts
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not disassemble balancer unit.

NOTE: Use TORX socket (size E14) for bolts No. 1 to 4.