Front Timing Chain Case: Removal and Installation: Installation

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

Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.

Fig 1: Identifying Hammer Dowel Pins Into Front Timing Chain Case
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Be sure to place dowel pins in the original holes in front timing chain case.
Install new front oil seal on the front timing chain case.
- 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 2: Installing Front Oil Seal On Front Timing Chain Case
  Courtesy of SUZUKI OF AMERICA CORP.
- 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 3: Pressing Oil Seal
  Courtesy of SUZUKI OF AMERICA CORP.
- Make sure the garter spring is in position and seal lip is not inverted.
Install water pump cover and chain tensioner cover to front timing chain case, if removed.
- Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown.
  
  Fig 4: Identifying Water Pump Cover And Chain Tensioner Cover
  Courtesy of SUZUKI OF AMERICA CORP.
  
  Use Genuine RTV Silicone Sealant or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].
  
  Tool number: WS39930000 (-)
Install idler pulley, if removed.
Install front timing chain case as follows:
1. Apply a continuous bead of liquid gasket using Tool to front timing chain case back side as shown.
  
  Fig 5: Identifying Front Timing Chain Case
  Courtesy of SUZUKI OF AMERICA CORP.
  
  Use Genuine RTV Silicone Sealant or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].
  
  Tool number : WS39930000 (-)
2. Install new O-rings on rear timing chain case.
  
  Fig 6: Identifying O-Rings On Rear Timing Chain Case
  Courtesy of SUZUKI OF AMERICA CORP.
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 7: Identifying Front Timing Chain Case And Cylinder Block
    Courtesy of SUZUKI OF AMERICA CORP.
  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 8: Identifying Front Timing Chain Case
    Courtesy of SUZUKI OF AMERICA CORP.
  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 9: Front Timing Chain Case Bolts Tighten Sequence
  Courtesy of SUZUKI OF AMERICA CORP.
5. After all bolts are tightened, retighten them to the specified torque in numerical order as shown.
  - There are four type of bolts.
    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)
Install two bolts in front of oil pan (upper) in numerical order as shown.

Fig 10: Oil Pan Bolts Tightening Sequence
Courtesy of SUZUKI OF AMERICA CORP.

Front oil pan bolt torque: 22.0 N.m (2.2 kg-m, 16 ft-lb)
Install right and left intake valve timing control covers as follows:
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 11: Identifying Intake Valve Timing Control Covers
  Courtesy of SUZUKI OF AMERICA CORP.
  
  Use Genuine RTV Silicone Sealant or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].
  
  Tool number: WS39930000 (-)
3. Install new collared O-rings in front timing chain case oil hole (left and right sides).
  
  Fig 12: Identifying O-Rings In Front Timing Chain Case Oil Hole
  Courtesy of SUZUKI OF AMERICA CORP.
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 13: Dowel Pin Hole Location And Bolt Tightening Sequence
  Courtesy of SUZUKI OF AMERICA CORP.
Install crankshaft pulley as follows:
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 to release the ring gear and install the rear cover plate. Refer to [OIL PAN AND OIL STRAINER: EXPLODED VIEW ].
  Tool number: - (J-48761)
Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
Installation of the remaining components is in the reverse order of removal.