Timing Chain Cover Removal & Installation: Installation

Reverse removal sequence to install timing chain cover noting the following points.

1. Clean sealing surface on timing chain cover, crankcase, cylinder block and cylinder head. Remove oil, old sealant, and dust from sealing surface.
2. Apply sealant "A" and "B" to area as shown in the figure.
   1. "A":  Sealant 99000-31250
   2. "B":  Sealant 99000-31140
   Fig 1: Identifying Timing Cover Fasteners & Sealant Application Area

   Courtesy of SUZUKI OF AMERICA CORP.
3. Apply engine oil to oil seal lip, then install timing chain cover (1). Tighten bolts (3) and nut (2) to specified torque.
   NOTE: Before installing timing chain cover, check that pin is securely fitted.

   Tightening torque 

   1. Timing chain cover bolt and nut (a):  11 N.m (1.1 kg-m, 8.0 lb-ft)
   Fig 2: Identifying Timing Chain Cover Fasteners

   Courtesy of SUZUKI OF AMERICA CORP.
4. Install crankshaft pulley.

   To lock crankshaft pulley (1), use special tool (camshaft pulley holder) with it at shown in the figure.

   Special tool 

   1. (A):  09917-68221

      Tightening torque 

   1. Crankshaft pulley bolt (a):  150 N.m (15 kg-m, 108.5 lb-ft)
   Fig 3: Installing Crankshaft Pulley Bolt

   Courtesy of SUZUKI OF AMERICA CORP.
   CAUTION: Be sure to use the following bolt for fixing special tool to crankshaft pulley.
   Bolt size: M8, P 1.25, L = 45 mm
   Strength: 7T
   Fig 4: Identifying Bolt Length

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5. Install A/C compressor bracket (2), if equipped. Tighten bracket bolts to specified torque.

   Tightening torque 

   1. A/C compressor bracket bolt (a):  55 N.m (5.5 kg-m, 40.0 lb-ft)
6. Install generator belt idler pulley (1). Tighten nut to specified torque.

   Tightening torque 

   1. Generator belt idler pulley bolt (b):  45 N.m (4.5 kg-m, 33.0 lb-ft)
7. Connect radiator outlet hose (3) to thermostat cap.
   Fig 5: Identifying Radiator Outlet Hose, Generator Belt Idler Pulley & A/C Compressor Bracket

   Courtesy of SUZUKI OF AMERICA CORP.
8. Install generator belt tensioner (4). Tighten bolts to specified torque.

   Tightening torque 

   1. Generator belt tensioner bolt (a):  25 N.m (2.5 kg-m, 18.5 lb-ft)
9. Install water pump pulley (3).
10. Install generator belt by turning generator belt tensioner center bolt clockwise to loosen tension of generator belt.
11. Install cooling fan belt, fan pulley, cooling fan and shroud.
12. Install bypass pipe (1) and water bypass hose No.2 (2).
    Fig 6: Identifying Water Pump Pulley, Cooling Fan Pulley & Generator Belt Tensioner

    Courtesy of SUZUKI OF AMERICA CORP.
13. Install cylinder head cover. See CYLINDER HEAD COVER REMOVAL & INSTALLATION .
14. Install oil pan and oil pump strainer. See OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION .
15. Adjust cooling fan belt tension. See COOLING FAN BELT TENSION CHECK & ADJUSTMENT .
16. Refill cooling system with coolant, front differential with gear oil, engine with engine oil and power steering system with specified fluid.
17. Verify that there is no coolant leakage, oil leakage, power steering fluid leakage and exhaust gas leakage at each connection.