Timing Chain Cover Removal and Installation

Timing Chain Cover Removal and Installation

Timing Chain Cover Components

NOTE:

If the crankshaft pulley bolt is loosened and tightened without crankshaft locked using the special tool, the timing chain, sprocket and their related parts may receive undue forces, which could cause damage to these components.

When loosening and tightening the crankshaft pulley bolt, be sure to use the special tool, which should be securely installed to the crankshaft pulley using a bolt of the following specifications:

Bolt size: M8

Pitch: 1.25 mm

Length: 25 mm (0.98 in.)

Strength: 7T

Removal

1) Remove engine assembly from vehicle. Removal and Replacement
2) Remove crankshaft pulley bolt.

To lock crankshaft pulley (1), use special tool as shown in the following figure.
Special Tool

(A): 09917-68221





3) Remove crankshaft pulley (1).

Use special tools as shown in figure if it is hard to remove.
Special Tool

(A): 09944-36011

(B): 09926-58010





4) Remove cylinder head cover. Cylinder Head Cover Removal and Installation
5) Remove oil pan. Oil Pan and Oil Pump Strainer Removal and Installation
6) Remove tensioner pulley and idler pulley. Tensioner and Idler Pulley Removal and Installation
7) Remove timing chain cover bolts, then remove timing chain cover with engine hook.
8) Remove crankshaft oil seal from timing chain cover using flat-bladed screwdriver or the like, if necessary.
9) Remove oil control valve from timing chain cover if necessary. OCV Removal and Installation

Installation

Timing Chain Cover Inspection
1) Install oil control valve if removed. 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

(A): 09913-75510





4) Install dowel pins (1) to cylinder block.





5) Apply sealant "A" as follows:
a) Fill sealant "A" to mating clearance of cylinder block and cylinder head.
b) 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.)





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 Nm (2.5 kgf-m, 18.5 lbf-ft)
Timing chain cover bolt* (M10 bolt) (b): 55 Nm (5.6 kgf-m, 40.5 lbf-ft)





7) Install tensioner pulley and idler pulley. Tensioner and Idler Pulley Removal and Installation
8) Install cylinder head cover. Cylinder Head Cover Removal and Installation
9) Install oil pan. 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.
Special Tool

(A): 09917-68221

Tightening torque
Crankshaft pulley bolt (a): 150 Nm (15.3 kgf-m, 111.0 lbf-ft)





11) Install engine assembly to vehicle. Removal and Replacement