1D
Timing Chain Cover Removal and Installation
CAUTION:
• Keep working table, tools and hands clean while over hauling.
• Use special care to handle aluminium parts so as not to damage them.
• Do not expose removed parts to dust. Keep them always clean.
Without VVT
Reference: Timing Chain Cover Components:M13A
Removal
1) Disconnect negative cable at battery.
2) Remove A/C compressor and/or P/S pump belt (if equipped).
3) Remove generator belt.
4) Drain engine oil.
5) Drain coolant.
WARNING:
To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
6) Disconnect radiator inlet and outlet hoses from each pipe.
7) Disconnect A/T fluid hoses (1) (vehicle with A/T) and release its clamps. Place some container under radiator to receive A/T fluid which will flow out when hose is disconnected.
8) Remove fan shroud upper bolts and install board (1) or the like. This prevents damage to radiator fins when removing and installing radiator.
9) Remove radiator with cooling fan. Then remove water pump pulley. Refer to Radiator Removal and Installation:M13A and Water Pump Removal and Installation:M13A .
10) Remove A/C compressor and/or P/S pump belt tension pulley (1) (if equipped).
11) With hose connected, detach P/S pump from its bracket and then remove P/S pump bracket (2) (if equipped) referring to P/S Pump Removal and Installation .
NOTE:
Suspend removed P/S pump at a place where no damage will be caused during removal and installation of timing chain cover.
12) Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool with it as shown in the figure.
Special Tool
(A) : 09917–68221
13) Remove crankshaft pulley (1).
If it is hard to remove, use special tools as shown in the figure. If bolts of special tool are too long, replace them with those of suitable length.
Special Tool
(A) : 09944–36011
(B) : 09926–58010
14) Remove oil pan referring to Oil Pan and Oil Pump Strainer Removal and Installation:M13A .
15) Remove cylinder head cover referring to Cylinder Head Cover Removal and Installation:M13A .
16) Disconnect CMP sensor coupler (1) and release its harness clamps.
17) Remove water outlet pipe (2).
18) Remove timing chain cover (3).
Installation
Reference: Timing Chain Cover Inspection:M13A
Reverse removal procedure to install timing chain cover, noting the following points.
1) Apply sealant “A” to mating surface of cylinder and cylinder head and “B” to mating surface of timing chain cover as shown in the figure.
“A” : Water tight sealant 99000–31140 ( SUZUKI Bond No.1207B )
“A” : Sealant 99000–31250 ( SUZUKI Bond No.1207F )
Sealant amount for timing chain cover
Width “a”: 3 mm, 0.12 in.
Height “b”: 2 mm, 0.08 in.
2) Apply engine oil to oil seal lip, then install timing chain cover (1) and water outlet pipe (2).
Tighten bolts and nut to specified torque.
NOTE:
Before installing timing chain cover, check that pin is securely fitted.
Tightening torque
Timing chain cover bolts and nut ( a ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
3) Install crankshaft pulley (1). Tighten bolt (2) to specified torque.
To lock crankshaft pulley, use special tool with it as shown in the figure.
Special Tool
(A) : 09917–68221
Tightening torque
Crankshaft pulley bolt ( a ): 150 N·m ( 15.0 kg-m, 108.5 lb-ft)
4) Install P/S pump bracket (1), P/S pump (2) and A/C compressor and/or P/S pump belt tension pulley (3) (if equipped) referring to P/S Pump Removal and Installation .
5) Install cylinder head cover referring to Cylinder Head Cover Removal and Installation:M13A .
6) Install oil pan referring to Oil Pan and Oil Pump Strainer Removal and Installation:M13A .
7) Install radiator with cooling fan and connect A/T fluid hoses (vehicle with A/T), radiator inlet and outlet hoses referring to Water Pump Removal and Installation:M13A and Radiator Removal and Installation:M13A .
8) Adjust generator belt tension referring to Water Pump Belt Tension Inspection and Adjustment:M13A .
9) Adjust A/C compressor and/or P/S pump belt tension (if equipped) referring to Compressor Drive Belt Inspection and Adjustment (M13A Model) or P/S Pump Drive Belt Inspection and Adjustment for adjusting procedure.
10) Refill cooling system with coolant, engine with engine oil and A/T with specified A/T fluid (vehicle with A/T).
11) Verify that there is no coolant leakage, oil leakage and A/T fluid leakage (vehicle with A/T) at each connection.
With VVT
Reference: Timing Chain Cover Components:M13A
Removal
1) Disconnect negative cable at battery.
2) Remove A/C compressor and/or P/S pump belt (if equipped).
3) Remove generator belt.
4) Drain engine oil.
5) Drain coolant.
WARNING:
To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
6) Disconnect radiator inlet and outlet hoses from each pipe.
7) Disconnect A/T fluid hoses (1) (vehicle with A/T) and release its clamps. Place some container under radiator to receive A/T fluid which will flow out when hose is disconnected.
8) Remove fan shroud upper bolts and install board (1) or the like. This prevents damage to radiator fins when removing and installing radiator.
9) Remove radiator with cooling fan. Then remove water pump pulley. Refer to Radiator Removal and Installation:M13A and Water Pump Removal and Installation:M13A .
10) Remove A/C compressor and/or P/S pump belt tension pulley (1) (if equipped).
11) With hose connected, detach P/S pump from its bracket and then remove P/S pump bracket (2) (if equipped) referring to P/S Pump Removal and Installation .
NOTE:
Suspend removed P/S pump at a place where no damage will be caused during removal and installation of timing chain cover.
12) Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool with it as shown in the figure.
Special Tool
(A) : 09917–68221
13) Remove crankshaft pulley (1).
If it is hard to remove, use special tools as shown in the figure.
If bolts of special tool are too long, replace them with those of suitable length.
Special Tool
(A) : 09944–36011
(B) : 09926–58010
14) Remove oil pan referring to Oil Pan and Oil Pump Strainer Removal and Installation:M13A .
15) Remove cylinder head cover referring to Cylinder Head Cover Removal and Installation:M13A .
16) Remove water pump pulley.
17) Remove oil gallery pipes No.2 (1) and No.3 (2).
18) Remove water pipe (1) from timing chain cover (2).
19) Remove timing chain cover.
20) Remove oil gallery pipe No.1 (1) and oil control valve (2) from timing chain cover (3).
21) Remove oil seal from timing chain cover, if necessary.
Installation
1) Clean sealing surface on timing chain cover, cylinder block and cylinder head.
Remove oil, old sealant and dust from sealing surface.
2) Install new oil seal (1) to timing chain cover (2), if removed.
NOTE:
When installing new oil seal, press fit to timing chain cover (2) by using special tool (Bearing installer) as shown in figure.
Special Tool
(A) : 09913–75810
Drive in dimension
“a”: 1.5 mm (0.06 in.)
3) Install new O-ring (1) to oil control valve (2).
4) Install oil control valve to timing chain cover (3).
Tighten nuts to specification.
Tightening torque
Oil control valve mounting nuts ( a ): 11 N·m ( 1.1 kg-m, 8.0 lb-ft)
5) Install oil gallery pipe No.1 (4) with new copper washers (5) to timing chain cover.
Tighten bolts to specification.
Tightening torque
Oil gallery pipe No.1 bolts ( b ): 30 N·m ( 3.0 kg-m, 21.5 lb-ft)
6) Apply sealant “A” to mating surface of cylinder and cylinder head and “B” to mating surface of timing chain cover as shown in figure.
“A” : Water tight sealant 99000–31140 ( SUZUKI Bond No.1207B )
“B” : Sealant 99000–31260 ( SUZUKI Bond No.1217G )
Sealant amount for timing chain cover
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
[A]: View A 3. Cylinder head gasket
1. Cylinder head 4. Rub into
2. Cylinder block 5. Jig
7) Apply engine oil to oil seal lip, then install timing chain cover (1).
Tighten bolts and nut to specified torque.
NOTE:
Before installing timing chain cover, check that pin is securely fitted.
Tightening torque
Timing chain cover bolts ( a ): 25 N·m ( 2.5 kg-m, 18.0 lb-ft)
Timing chain cover nut ( b ): 25 N·m ( 2.5 kg-m, 18.0 lb-ft)
8) Apply engine oil to new O-rings (2) and install them to water pipe (3).
9) Install water pipe (3) to timing chain cover (1).
Tighten bolts to specified torque.
Tightening torque
Water pipe bolts ( c ): 25 N·m ( 2.5 kg-m, 18.0 lb-ft)
10) Install new O-ring (1) to oil gallery pipes No.2 (2) and No.3 (3).
11) Install oil gallery pipes No.2 and No.3 to cylinder head (4) and timing chain cover (5).
Tighten bolts to specified torque.
Tightening torque
Oil gallery pipes No.2 and No.3 bolts ( a ): 11 N·m ( 1.1 kg-m, 8.0 lb-ft)
12) Install water pump pulley.
13) Install crankshaft pulley (1). Tighten bolt (2) to specified torque.
To lock crankshaft pulley, use special tool with it as shown in figure.
Special Tool
(A) : 09917–68221
Tightening torque
Crankshaft pulley bolt ( a ): 150 N·m ( 15.0 kg-m, 108.5 lb-ft)
14) Install P/S pump bracket (1), P/S pump (2) and A/C compressor and/or P/S pump belt tension pulley (3) (if equipped) referring to P/S Pump Removal and Installation .
15) Install cylinder head cover referring to Cylinder Head Cover Removal and Installation:M13A .
16) Install oil pan referring to Oil Pan and Oil Pump Strainer Removal and Installation:M13A .
17) Install radiator with cooling fan and connect A/T fluid hoses (vehicle with A/T), radiator inlet and outlet hoses referring to Cooling Water Pipes or Hoses Removal and Installation:M13A and Radiator Removal and Installation:M13A .
18) Adjust generator belt tension referring to Water Pump Belt Tension Inspection and Adjustment:M13A .
19) Adjust A/C compressor and/or P/S pump belt tension (if equipped) referring to Compressor Drive Belt Inspection and Adjustment (M13A Model) or P/S Pump Drive Belt Inspection and Adjustment .
20) Refill cooling system with coolant, engine with engine oil and A/T with specified A/T fluid (vehicle with A/T).
21) Verify that there is no coolant leakage, oil leakage and A/T fluid leakage (vehicle with A/T) at each connection.