Timing Chain: Removal and Installation: Installation

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

Fig 1: Identifying Timing Chain Components

Courtesy of SUZUKI OF AMERICA CORP.

NOTE: The figure above shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.

Make sure that dowel pin hole, dowel pin of camshaft and crankshaft key are located as shown. (No. 1 cylinder at compression TDC).

Fig 2: Identifying Dowel Pin And Crankshaft Key
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Though camshaft does not stop at the position as shown, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.

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.

CAUTION: Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore big dia. side).
Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION: Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions repeatedly during the installation process.
1. Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin.
  
  Fig 3: Identifying Stopper Pin Location
  Courtesy of SUZUKI OF AMERICA CORP.
  - Use stopper pin included with Tool J-50246.
2. Before installing timing chains (secondary) and camshaft sprockets, confirm mating marks are visible. If necessary, use paint or equivalent to re-mark the camshaft sprockets at each mating mark.
  
  Fig 4: Identifying Mating Mark On Top Of Sprocket Teeth
  Courtesy of SUZUKI OF AMERICA CORP.
3. Install timing chains (secondary) (8) and camshaft sprockets [INT (1) and EXH (9)].
  
  Fig 5: Identifying Timing Chains And Camshaft Sprockets
  Courtesy of SUZUKI OF AMERICA CORP.
  - 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 by slightly turning camshaft(s).
  - Bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins.
4. Confirm the mating marks are aligned, then finger tighten camshaft sprocket bolts. Final tightening will be done with all timing chains installed.
5. Remove stopper pins out from timing chain tensioners (secondary).
  
  Fig 6: Pulling Stopper Pins Out From Timing Chain Tensioners
  Courtesy of SUZUKI OF AMERICA CORP.
Install timing chain (primary) as follows:
1. Install crankshaft sprocket.
  
  Fig 7: Installing Crankshaft Sprocket
  Courtesy of SUZUKI OF AMERICA CORP.
  - Make sure the mating marks on crankshaft sprocket face the front of engine.
2. Install the primary timing chain.
  
  Fig 8: Identifying Primary Timing Chain
  Courtesy of SUZUKI OF AMERICA CORP.
  - 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.
Install internal chain guide.

Fig 9: Identifying Internal Chain Guide, Slack Guide And Timing Chain Tensioner
Courtesy of SUZUKI OF AMERICA CORP.
Remove stopper pin from primary timing chain tensioner.
Make sure again that the mating marks on camshaft sprockets and timing chain have not slipped out of alignment.
Tighten camshaft sprocket bolts to specification with all timing chains installed and Tool holding the crankshaft.
Tool number : - (J-48761)
Install front timing chain case. Refer to Front Timing Chain Case: Removal and Installation