2nd Timing Chain & Chain Tensioner Installation

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Check that crank timing sprocket key (1) is in match with timing mark (2) on cylinder block as shown in the figure.

Fig 1: Identifying Crankshaft Timing Sprocket Key & Cylinder Block Timing Mark
Courtesy of SUZUKI OF AMERICA CORP.
Check that arrow mark (1) on idler sprocket faces upward as shown in the figure.
Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head as shown in the figure.

Fig 2: Identifying Camshaft Knock Pins & Camshaft Timing Marks
Courtesy of SUZUKI OF AMERICA CORP.
Install 2nd timing chain by aligning yellow plate (1) of 2nd timing chain with arrow mark (2) on idler sprocket.

Fig 3: Identifying 2nd Timing Chain Alignment Position (Idler Sprocket)
Courtesy of SUZUKI OF AMERICA CORP.
Install sprockets to intake and exhaust camshafts by aligning dark blue plate of 2nd timing chain with arrow marks on intake sprocket and exhaust sprocket respectively.
CAUTION: Do not turn camshaft more than allowable turning range.
If turned excessively, valve and piston may get damaged.

NOTE: As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.

Fig 4: Identifying 2nd Timing Chain Alignment Positions (Camshaft Sprockets)
Courtesy of SUZUKI OF AMERICA CORP.
Install intake and exhaust camshaft timing sprocket bolts.
To install it, fit a spanner to hexagonal part at the center of camshaft to hold stationary.

Tightening torque
1. Camshaft timing sprocket bolt (a): 80 N.m (8.0 kg-m, 58.0 lb-ft)
Fig 5: Identifying Camshaft Timing Sprocket Bolts & Spanner Wrench
Courtesy of SUZUKI OF AMERICA CORP.
Push back plunger (1) into tensioner body (2) and hold it with stopper (3) at the position by inserting adapter (3) into body (2).

Fig 6: Setting No.2 Tensioner Adjuster Plunger
Courtesy of SUZUKI OF AMERICA CORP.
Install timing chain tensioner adjuster No.2 (1) with gasket.
Tightening torque
1. Timing chain tensioner adjuster No.2 bolt (a): 11 N.m (1.1 kg-m, 8.0 lb-ft)
2. Timing chain tensioner adjuster No.2 bolt (b): 45 N.m (4.5 kg-m, 33.0 lb-ft)
Pull out stopper (2) from timing chain tensioner adjuster No.2 (1).

Fig 7: Installing Timing Chain Tensioner Adjuster No.2
Courtesy of SUZUKI OF AMERICA CORP.
Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block as shown in the figure.
Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.

Fig 8: Identifying Crankshaft & Camshaft Timing Marks
Courtesy of SUZUKI OF AMERICA CORP.
Apply oil to timing chains, tensioner, tensioner adjusters, sprockets and guides.
Remove timing chain cover. See TIMING CHAIN COVER REMOVAL & INSTALLATION .
Remove cylinder head cover. See CYLINDER HEAD COVER REMOVAL & INSTALLATION .
Remove oil pan and oil pump strainer. See OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION .
Adjust cooling fan belt tension. See COOLING FAN BELT TENSION CHECK & ADJUSTMENT .
Refill cooling system with coolant, front differential with gear oil, engine with engine oil and power steering system with specified fluid.
Verify that there is no coolant leakage, oil leakage, power steering fluid leakage and exhaust gas leakage at each connection.