Timing Chain and Chain Tensioner Removal and Installation: Installation

Reference: TIMING CHAIN AND CHAIN TENSIONER INSPECTION 

1. Turn crankshaft position key slot (1) within specified range (30 - 90°) (2) in counterclockwise direction from top as shown in figure.
2. Align timing mark (3) on CMP actuator with match marks (4) on camshaft housing No. 1.
3. Align timing mark (5) on exhaust camshaft timing sprocket with match marks (4) on camshaft housing No. 1.
4. Install key (6) to key slot (1) of crankshaft.
   1. Align key slot of crankshaft timing sprocket (7) with key, and then Install crankshaft timing sprocket to crankshaft.
   2. Align timing mark (8) on crankshaft timing sprocket with match mark (9) on lower crank case.
      Fig 1: Aligning Timing Mark On Crankshaft Timing Sprocket With Match Mark On Lower Crank Case

      Courtesy of SUZUKI OF AMERICA CORP.
5. Install timing chain while aligning two blue plates (2) with timing marks (1) on CMP actuator and exhaust camshaft timing sprockets.
   Fig 2: Installing Timing Chain While Aligning Two Blue Plates With Timing Marks

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install timing chain while aligning blue plate (2) with timing mark (1) on crankshaft timing sprocket.
   Fig 3: Aligning Blue Plate With Timing Mark On Crankshaft Timing Sprocket

   Courtesy of SUZUKI OF AMERICA CORP.
7. Install timing chain guide (1) and tighten timing chain guide bolts (2) to specified torque.

   Tightening torque 

   Timing chain guide bolt (a): 9 N.m (0.92 kg-m, 7.0 lbf-ft) 

8. Apply engine oil to sliding surface of timing chain guide.
9. Attach spacer (4) to timing chain tensioner (3).
10. Install timing chain tensioner (3) and tighten timing chain tensioner bolt (5) to specified torque.

    Tightening torque 

    Timing chain tensioner bolt (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft) 

11. Apply engine oil to sliding surface of timing chain tensioner.
12. Make sure that all blue plated (6) are aligned with timing marks (7) on corresponding timing sprockets.
    Fig 4: Identifying Timing Marks On Corresponding Timing Sprockets

    Courtesy of SUZUKI OF AMERICA CORP.
13. Screw in plunger (2) of timing chain tensioner adjuster (1) clockwise and install a retainer (3) (1.4 mm-diameter wire or the like) to hold plunger in place.
    Fig 5: Identifying Plunger Of Timing Chain Tensioner Adjuster

    Courtesy of SUZUKI OF AMERICA CORP.
14. Install timing chain tensioner adjuster (1) with a retainer.

    Tighten timing chain tensioner adjuster bolts (2) to specified torque, and then remove a retainer from timing chain tensioner adjuster.

    Tightening torque 

    Timing chain tensioner adjuster bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft) 

15. Apply engine oil to timing chain, and then turn crankshaft clockwise fully twice, and make sure the following items.
    • Timing mark (4) on CMP actuator is aligned with match mark (3) on camshaft housing No. 1.
    • Timing mark (5) on exhaust camshaft timing sprocket is aligned with match mark (3) on camshaft housing No. 1.
    • Timing mark (6) on crankshaft timing sprocket is aligned with match mark (7) on lower crank case.
      NOTE:

      • Be sure to turn crankshaft fully twice. If it is once, timing marks on CMP actuator and exhaust camshaft timing sprocket do not meet match marks on camshaft housing No. 1.
      • After turning crankshaft twice, the discrimination links of timing chain are not aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but it is normal.
        Fig 6: Identifying Discrimination Links Of Timing Chain

        Courtesy of SUZUKI OF AMERICA CORP.
16. Install timing chain cover, see Timing Chain Cover Removal and Installation .
17. Install cylinder head cover, see Cylinder Head Cover Removal and Installation .
18. Install oil pan, see OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION .
19. Install engine assembly, see Engine Assembly Removal and Installation .