1st Timing Chain and Chain Tensioner Installation

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Check timing mark on crankshaft as shown in the figure.

Fig 1: Checking Timing Mark On Crankshaft
Courtesy of SUZUKI OF AMERICA CORP.
Install 1st timing chain crankshaft sprocket as shown in the figure.
Confirm that tooth for CKP sensor are free from metal particles and damage.

Fig 2: Installing 1st Timing Chain Crankshaft Sprocket
Courtesy of SUZUKI OF AMERICA CORP.
Check timing mark on RH bank intake camshaft as shown in the figure.

Fig 3: Checking Timing Mark On RH Bank Intake Camshaft
Courtesy of SUZUKI OF AMERICA CORP.
Install RH bank 1st timing chain intake camshaft sprocket (1) noting the following points.
- The sprocket should be set in such way that its RH mark (4) can be seen.
- Camshaft (2) should be held stationary by using a spanner at its hexagonal parts (3) as shown in the figure.
Tightening torque

RH bank 1st timing chain intake camshaft sprocket bolt (a): 80 N.m (8.0 kg-m, 58.0 lb-ft)

Fig 4: Installing RH Bank 1st Timing Chain Intake Camshaft Sprocket
Courtesy of SUZUKI OF AMERICA CORP.
Install timing chain tensioner (1) as shown in the figure.
Tightening torque

Timing chain tensioner nut (b): 25 N.m (2.5 kg-m, 18.0 lb-ft)

Fig 5: Installing Timing Chain Tensioner
Courtesy of SUZUKI OF AMERICA CORP.
Install 1st timing chain by aligning match marks (2) on RH silver plate (1) of 1st timing chain and RH bank 1st timing chain intake camshaft sprocket.

Fig 6: Installing 1st Timing Chain By Aligning Match Marks On RH Silver Plate
Courtesy of SUZUKI OF AMERICA CORP.
Apply oil to bush of idler sprocket No. 2.
Install idler sprocket No. 2 and sprocket shaft.
Install idler sprocket No. 2 by aligning match marks (2) on LH silver plate (1) of 1st timing chain.

Fig 7: Installing Idler Sprocket No. 2 Aligning Match Marks On LH Silver Plate
Courtesy of SUZUKI OF AMERICA CORP.
Install crankshaft sprocket by aligning match marks (2) on gold or yellow plate (1) of 1st timing chain and crankshaft timing sprocket.
To install it, fit a spanner to hexagonal part at the center of RH bank intake camshaft to turn a little.

CAUTION: Do not turn camshaft more than necessary. If turned excessively, valve and piston may get damaged.

Fig 8: Installing Crankshaft Sprocket By Aligning Match Marks On Gold Or Yellow Plate
Courtesy of SUZUKI OF AMERICA CORP.
Apply oil to bearing of idler sprocket No. 1.
Install idler sprocket No. 1.
Tightening torque

Idler sprocket No. 1 bolt (c): 55 N.m (5.5 kg-m, 40.0 lb-ft)

Fig 9: Installing Idler Sprocket No. 1
Courtesy of SUZUKI OF AMERICA CORP.
With latch of tensioner adjuster No. 1 returned and plunger (1) pushed back into body, insert stopper (3) into latch (2) and body.
After inserting it, check to make sure that plunger (1) will not come out.

Fig 10: Checking Plunger
Courtesy of SUZUKI OF AMERICA CORP.
Install timing chain tensioner adjuster No. 1 (1).
Tightening torque

Timing chain tensioner adjuster No. 1 bolt (d): 11 N.m (1.1 kg-m, 8.0 lb-ft)
Pull out stopper (3) from adjuster No. 1 (1).

Fig 11: Installing Timing Chain Tensioner Adjuster
Courtesy of SUZUKI OF AMERICA CORP.
Install timing chain guide No. 1 (2) and No. 2 (1).
Tightening torque

Timing chain guide No. 1 and No. 2 bolt (e): 9 N.m (0.9 kg-m, 6.5 lb-ft)

Fig 12: Installing Timing Chain Guide No. 1 & No. 2
Courtesy of SUZUKI OF AMERICA CORP.
Check each aligned timing marks as shown in the figure.

Fig 13: Checking Each Aligned Timing Marks
Courtesy of SUZUKI OF AMERICA CORP.
Install LH bank 2nd timing chain. Refer to "LH (NO. 1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
Install timing chain cover. Refer to "TIMING CHAIN COVER REMOVAL AND INSTALLATION ".
Install oil pan referring to "OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION ".
Install front differential housing referring to "FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING ".
Install P/S system referring to "POWER STEERING PUMP REMOVAL AND INSTALLATION ".
Install cooling system referring to "COOLING FAN AND FAN CLUTCH REMOVAL AND INSTALLATION ".
Install intake manifold with throttle body referring to "THROTTLE BODY AND INTAKE MANIFOLD INSTALLATION ".
Refill cooling system with coolant, front differential with gear oil, P/S system with specified fluid and engine with engine oil.
Check wheel alignment referring to "WHEEL ALIGNMENT SPECIFICATIONS ".
Verify that there is no fuel leakage, water leakage and oil leakage at each connection.