Timing Chain Cover Removal and Installation
Timing Chain Cover Removal and InstallationCAUTION:
^ Keep working table, tools and hands clean while overhauling.
^ Use special care to handle aluminum parts so as not to damage them.
^ Do not expose removed parts to dust. Keep them always clean.
Removal
1) Remove engine assembly from vehicle.
2) Remove accessory drive belt.
3) Remove cylinder head cover.
4) Remove water pump pulley.
5) Remove P/S pump bracket.
6) Remove OCV.
7) Remove belt idler arm from generator bracket.
8) Remove water outlet pipe No.1 (1), water outlet pipe No.2 (2), O-ring (3) and gasket (4).
9) Lock flywheel with special tool as shown in figure.
Special Tool
(A): 09916-97830
10) Remove crankshaft pulley bolt (1).
11) Using special tools, remove crankshaft pulley (1) as shown in figure.
Special Tool
(A): 09910-97810
(B): 09912-37830
12) Remove accessory drive belt tensioner (1) from timing chain cover.
13) Remove timing chain cover.
14) Remove water pump inner gasket (1) from timing chain cover (2).
15) Remove oil seal (1) from timing chain cover (2).
16) Using special tool, remove crankshaft oil seal (1) from timing chain cover (2) as shown in figure.
Special Tool
(A): 09913-57830
17) If necessary, remove water pump from timing chain cover.
18) If necessary, remove CMP sensor from timing chain cover.
Installation
1) Clean sealing surface on timing chain cover, cylinder block and cylinder head.
2) Install new water pump inner gasket (1) to timing chain cover (2).
3) Using special tool, install new crankshaft oil seal (1) to timing chain cover (2) as shown in figure [A] or [B].
NOTE:
Do not apply engine oil and grease to crankshaft oil seal.
Special Tool
(A): 09926-68310
(B): 09913-75821
Special Tool
(C): Oil seal installer (J-29184)
4) Using special tool, install new oil seal (1) to timing chain cover as shown in figure.
Special Tool
(A): 09913-57810
5) Install special tool to cylinder head.
Special Tool
(A): Engine front cover installation guide pins (EN-46109)
6) Apply sealant "A" to mating surface of cylinder head (1) and cylinder block (2) as shown in figure.
"A": Sealant 99000-31290 (SUZUKI Bond No.1217F)
7) Apply sealant "A" to mating surface of timing chain cover (1) as shown in figure.
"A": Sealant 99000-31290 (SUZUKI Bond No.1217F)
Sealant amount for timing chain cover
Width "a": 3 mm (0.12 in.)
Width "b": 5 mm (0.20 in.)
Height "c": 2.5 mm (0.10 in.)
8) Install timing chain cover and accessory drive belt tensioner as follows.
NOTE:
Before installing timing chain cover, check that dowel pin is securely fitted.
a) Tighten timing chain cover bolt to 20 Nm (2.0 kgf-m, 15.0 lbf-ft) in numerical order ("1" - "22") shown in figure evenly and gradually.
b) In the same manner as Step ), retighten them to 60 degrees.
c) Tighten accessory drive belt tensioner bolt ("23") to 25 Nm (2.5 kgf-m, 18.5 lbf-ft).
Tightening torque
Timing chain cover bolt * (a): 20 Nm -> +60 degrees (2.0 kgf-m -> +60 degrees, 15 lbf-ft -> +60 degrees)
Accessory drive belt tensioner bolt* (b): 25 Nm (2.5 kg-m, 18.5 lbf-ft)
9) Remove special tool.
Special Tool
(A): Engine front cover installation guide pins (EN-46109)
10) Install new O-ring (3) and new gasket (4).
11) Install water outlet pipe No.1 (1) and water outlet pipe No.2 (2)
12) Lock flywheel with special tool as shown in figure.
Special Tool
(A): 09916-97830
13) Apply engine oil between crankshaft pulley and crankshaft.
NOTE:
Do not apply engine oil between crankshaft oil seal and crankshaft pulley.
14) Using special tool, install crankshaft pulley (1) to crankshaft as shown in figure.
Special Tool
(A): 09912-37820
15) Remove special tool, tighten crankshaft pulley bolt as follows.
a) Tighten crankshaft pulley bolt to 120 Nm (12.2 kgf-m, 88.5 lbf-ft).
b) Loosen crankshaft pulley bolt until loosening torque is 0.
c) Tighten crankshaft pulley bolt to 100 Nm (10.2 kgf-m, 74.0 lbf-ft).
d) Retighten crankshaft pulley bolt to 150 degrees.
Tightening torque
Timing chain cover bolt * (a): 120 Nm -> 0 Nm -> 100 Nm -> +150 degrees (12.2 kgf-m -> 0 kgf-m -> 10.2 kgf-m -> +150 degrees, 88.5 lbf-ft 0 lbf-ft -> 74.0 lbf-ft -> +150 degrees)
16) Install belt idler arm to generator bracket.
17) Install OCV.
18) Install P/S pump bracket.
19) Install water pump pulley.
20) Install cylinder head cover.
21) Install accessory drive belt.
22) Install engine assembly from vehicle.