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.
^ Take special care when handling aluminum parts so as not to damage them.
^ Do not expose removed parts to dust. Always keep them clean.

Removal
1) Remove engine assembly from vehicle.
2) Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool as shown in the following 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
(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.
5) Remove oil pan.
6) Remove tensioner pulley and idler pulley.
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-end screwdriver or the like, if necessary.
9) Remove oil control valve from timing chain cover if necessary.

Installation
Reference: Timing Chain Cover Inspection

1) Install oil control valve if removed.
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 kg-m, 18.5 lbf-ft)
Timing chain cover bolt* (M10 bolt) (b): 55 Nm (5.6 kg-m, 40.5 lbf-ft)





7) Install tensioner pulley and idler pulley.
8) Install cylinder head cover.
9) Install oil pan.
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
(A): 09917-68221
Tightening torque
Crankshaft pulley bolt (a): 150 Nm (15.3 kg-m, 111.0 lbf-ft)





11) Install engine assembly to vehicle.