Timing Chain Cover Removal and Installation: Installation

Reference: TIMING CHAIN COVER INSPECTION 

1. Install oil control valve if removed, see OCV Removal and Installation .
2. Clean mating surface of timing chain cover, cylinder block and cylinder head by removing old sealant and oil.
3. Check oil seal (1) for any damage.

   Replace oil seal if any abnormalities are found.

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

   Special Tool 

   1. 09913-75510 
   Fig 1: Identifying Oil Seal With Special Tool

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

   Courtesy of SUZUKI OF AMERICA CORP.
5. Apply sealant "A" as follows:
   1. Fill sealant "A" to mating clearance of cylinder block and cylinder head.
   2. Apply sealant "A" to mating surface of timing chain cover as specified.
      NOTE:

      • Before applying sealant, make sure mating surfaces are clean and dry.
      • Install timing chain cover within 2 minutes after applying sealant.
      • Wipe off excessive sealant of upper and lower end of the cover.

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

      Sealant bead size for timing chain cover 

      Width "a": 3 mm (0.11 in.) 

      Height "b": 2 mm (0.07 in.) 

      Fig 3: Identifying Sealant Applying Area

      Courtesy of SUZUKI OF AMERICA CORP.
6. Apply engine oil to oil seal lip, and then install timing chain cover with engine hook. 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 Tightening Sequence

   Courtesy of SUZUKI OF AMERICA CORP.
7. Install tensioner pulley and idler pulley, see TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION .
8. Install cylinder head cover, see CYLINDER HEAD COVER REMOVAL AND INSTALLATION .
9. Install oil pan, see OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION .
10. 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 prevent unnecessary load on 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 (0.0492 in.)

      Length: 25 mm (0.98 in.)

      Strength: 7T

    Special Tool 

    1. 09917-68221 

    Tightening torque 

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

    Fig 5: Removing Crankshaft Pulley Bolt

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