Timing Chain Cover Removal and Installation

Timing Chain Cover Removal and Installation
Reference: Timing Chain Cover Components

CAUTION:
^ 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 crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool as shown in figure.

CAUTION:
^ Use special tool to avoid 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





3) Remove crankshaft pulley (1).
If it is hard to remove, use special tools as shown in figure.

Special Tool
(A): 09944-36011
(B): 09926-58010





4) Remove cylinder head cover.
5) Remove oil pan.
6) Remove tensioner pulley and idler pulley.
7) Remove timing chain cover by loosing timing chain cover bolts in numerical order ("1" - "17") evenly and gradually.





8) Remove crankshaft oil seal from timing chain cover using flat-head screwdriver or the like, if necessary.
9) Remove oil seal from timing chain cover if necessary.

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





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





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.)





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





6) Install tensioner pulley and idler pulley.
7) Install cylinder head cover.
8) Install oil pan.
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 Nm (15.3 kg-m, 111.0 lbf-ft)





10) Install engine assembly to vehicle.