Timing Chain Cover Removal and Installation: Installation

Reference: TIMING CHAIN COVER INSPECTION 

1. Clean mating surface of timing chain cover, cylinder block and cylinder head.

   Remove oil, old sealant and dust from mating surface.

2. Check oil seal (1) for any damage.

   If abnormality is found, replace oil seal.

   NOTE: When installing new oil seal, press it into timing chain cover (2) using special tool as shown in figure.

   Special Tool 

   (A): 09913-75510 

   Fig 1: Pressing Oil Seal Into Timing Chain Cover Using Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
3. Install dowel pins (1) to cylinder block.
   Fig 2: Identifying Dowel Pins To Cylinder Block

   Courtesy of SUZUKI OF AMERICA CORP.
4. Apply sealant "A" to mating surface of cylinder, cylinder head and timing chain cover as shown in figure.

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

   Sealant bead size for timing chain cover 

   Width "a": 3 mm (0.12 in.) 

   Height "b": 2 mm (0.08 in.) 

   Fig 3: Applying Sealant "A" To Mating Surface Of Cylinder, Cylinder Head And Timing Chain Cover

   Courtesy of SUZUKI OF AMERICA CORP.
5. Apply engine oil to oil seal lip, then install timing chain cover. Tighten timing chain cover bolts to specified torque in numerical order ("1" - "17") evenly and gradually.
   NOTE: Before installing timing chain cover, check that dowel pins are securely fitted.

   Tightening torque 

   Timing chain cover bolt* (M8 bolt) (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft) 

   Timing chain cover bolt* (M10 bolt) (b): 55 N.m (5.6 kg-m, 40.5 lbf-ft) 

   Fig 4: Identifying Timing Chain Cover Bolt

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install tensioner pulley and idler pulley, see ACCESSORY DRIVE BELT TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION .
7. Install cylinder head cover, see Cylinder Head Cover Removal and Installation .
8. Install oil pan, see OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION .
9. Install crankshaft pulley (1) and tighten crankshaft pulley bolt to specified torque.

   To lock crankshaft pulley, use special tool as shown in figure.

   CAUTION:

   • Use special tool to avoid being applying unnecessary load to timing chain, sprockets and any other related parts.
   • Use specified bolts (2) to install special tool to crankshaft pulley.

     Bolt size: M8

     Pitch: 1.25 mm

     Length: 25 mm (0.98 in.)

     Strength: 7T

   Special Tool 

   (A): 09917-68221 

   Tightening torque 

   Crankshaft pulley bolt (a): 150 N.m (15.3 kg-m, 111.0 lbf-ft) 

   Fig 5: Identifying Crankshaft Pulley Bolt

   Courtesy of SUZUKI OF AMERICA CORP.
10. Install engine assembly to vehicle, see Engine Assembly Removal and Installation .