Timing Chain: Removal and Installation: Removal

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

Set No. 1 cylinder to TDC.

Fig 1: Setting No. 1 Cylinder To TDC
Courtesy of SUZUKI OF AMERICA CORP.
- Rotate crankshaft pulley clockwise to align timing mark (A) (grooved line without color) with timing indicator (B).
Remove front timing chain case. Refer to FRONT TIMING CHAIN CASE: REMOVAL AND INSTALLATION
Check timing chain markings to confirm No. 1 cylinder is at TDC of its compression stroke.
- If not, remove Tool and turn crankshaft clockwise 360° (one revolution).
- Re-install Tool.
  Tool number : - (J-48761)
- If the original timing chain markings are not legible, use paint or equivalent to mark the timing chains to the sprockets.
If removing the secondary timing chains, loosen camshaft sprocket bolts.
Compress the primary timing chain tensioner.

Fig 2: Locating Timing Chain Tensioner
Courtesy of SUZUKI OF AMERICA CORP.
1. Loosen clip of primary timing chain tensioner, and release plunger stopper (1).
2. Depress plunger into tensioner body by pressing slack guide (2).
3. Keep slack guide pressed and insert stopper pin through the tensioner body hole and plunger groove (3) to hold plunger in.
Remove internal chain guide, tension guide and slack guide.

Fig 3: Removing Internal Chain Guide, Tension Guide And Slack Guide
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Tension guide can be removed after removing timing chain (primary).
Remove timing chain (primary) and crankshaft sprocket.
CAUTION: After removing timing chain (primary), do not turn crankshaft and camshaft separately, or valves will strike the piston heads.
Remove crankshaft sprocket, if necessary.
Remove timing chain (secondary) and camshaft sprockets as follows:
1. Attach suitable stopper pin to the right and left timing chain tensioners (secondary).
  
  Fig 4: Identifying Right/Left Timing Chain Tensioners
  Courtesy of SUZUKI OF AMERICA CORP.
  NOTE:
  - Use stopper pin included with Tool J-50246.
2. Remove camshaft sprocket (INT and EXH) bolts.
3. Remove timing chain (secondary) together with camshaft sprockets.
  - Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
  - Insert 0.5 mm (0.020 in)-thick metal or resin plate between timing chain and timing chain tensioner plunger (guide). Remove timing chain (secondary) together with camshaft sprockets with timing chain loose from guide groove.
    
    Fig 5: Identifying Timing Chain Tensioner And Plunger
    Courtesy of SUZUKI OF AMERICA CORP.
    
    CAUTION: Be careful of plunger coming off when removing timing chain (secondary).
    
    NOTE: Camshaft sprocket (INT) is a one piece integrated design sprockets for timing chain (primary) and for timing chain (secondary).
  - When handling camshaft sprocket (INT), be careful of the following:
    
    Fig 6: Identifying Camshaft Sprocket Bolts
    Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION:
    Handle carefully to avoid any shock to camshaft sprocket.
    
    Do not disassemble. (Do not loosen bolts (A) as shown).
    NOTE: For removal of timing chain tensioner (secondary), refer to [Secondary Timing Chain Tensioner Removal and Installation ]. [Removing camshaft bracket (No. 1) is required.]