Camshaft: Removal and Installation: Installation

Install valve lifters.
- Install them in the original positions.
Install camshafts.

Fig 1: Identifying Camshafts
Courtesy of SUZUKI OF AMERICA CORP.
- Distinction between intake and exhaust camshafts is performed with the different shapes of rear end.
  Intake: Signal plate shape for camshaft position sensor (PHASE)
  
  Exhaust: Cone end shape
- Install camshafts so that camshaft dowel pins on the front side are positioned as shown.
  
  Fig 2: Camshaft Installation Position
  Courtesy of SUZUKI OF AMERICA CORP.
Install camshaft brackets with the following procedure:
1. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face.
2. Install camshaft brackets (No. 2 to 5) aligning the identification marks on upper surface as shown.
  
  Fig 3: Aligning Identification Marks On Upper Surface
  Courtesy of SUZUKI OF AMERICA CORP.
  
  NOTE: Install so that identification mark can be correctly read when viewed from the exhaust side.
3. Install camshaft bracket (No. 1) with the following procedure:
  1. Apply liquid gasket to camshaft bracket (No. 1) as shown.
    
    Fig 4: Identifying Liquid Gasket Applying Specification On Camshaft Bracket (No. 1)
    Courtesy of SUZUKI OF AMERICA CORP.
    
    Use Genuine RTV Silicone Sealant or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].
    
    CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part (A).
  2. Apply liquid gasket to camshaft bracket (No. 1) contact surface on the front cover backside.
    
    Fig 5: Identifying Liquid Gasket Applying Specification On Camshaft Bracket (No. 1)
    Courtesy of SUZUKI OF AMERICA CORP.
    
    Use Genuine RTV Silicone Sealant or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].
    - Apply liquid gasket to the outside of bolt hole on front cover.
  3. Locate camshaft bracket (No. 1) near installation position, and install it without disturbing the liquid gasket applied to the surfaces.
    
    Fig 6: Identifying Liquid Gasket Application Face
    Courtesy of SUZUKI OF AMERICA CORP.
Tighten bolts of camshaft brackets in the following steps, in numerical order as shown.
Step 1 (bolts 9 - 11): 2.0 N.m (0.2 kg-m, 17 in-lb)

Step 2 (bolts 1 - 8): 2.0 N.m (0.2 kg-m, 17 in-lb)

Step 3 (bolts 1 - 11): 5.9 N.m (0.6 kg-m, 52 in-lb)

Step 4 (bolts 1 - 11): 10.4 N.m (1.1 kg-m, 92 in-lb)

Fig 7: Tightening Order Of Camshaft Brackets Bolt

Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: After tightening bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the parts.

Install camshaft position sensor (PHASE).
Install camshaft sprockets.
- Install them by aligning the mating marks on each camshaft sprocket with the paint marks on the timing chain link plates during removal.
  
  Fig 8: Identifying Mating Marks On Camshaft Sprocket
  Courtesy of SUZUKI OF AMERICA CORP.
  CAUTION:
  - Aligned mating marks could slip. Therefore, after matching them, hold the timing chain in place by hand.
  - Before and after installing chain tensioner, make sure again that mating marks have not slipped.
  NOTE: Before installation of chain tensioner, it is possible to re-match the marks on timing chain with the ones on each sprocket.
Install chain tensioner.
CAUTION: After installation, pull the stopper pin off completely, and make sure that chain tensioner plunger is released.
Install chain guide.
Install O-rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control cover.
Install O-ring to front cover.
Apply liquid gasket using Tool to intake valve timing control cover as shown.

Fig 9: Identifying Liquid Gasket Applying Specifications On Intake Valve Timing Control Cover
Courtesy of SUZUKI OF AMERICA CORP.

Tool number: WS39930000 (-)

Use Genuine RTV Silicone Sealant or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ].
Tighten bolts in numerical order as shown.

Fig 10: Tightening Order Of Intake Valve Timing Control Cover
Courtesy of SUZUKI OF AMERICA CORP.
Install intake valve timing control solenoid valve to intake valve timing control cover if removed.
Connect ground cables, and install harness clip.
Check and adjust valve clearance. Refer to [SERVICE DATA AND SPECIFICATIONS ].
Installation is in the reverse order of removal after this step.
NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after the engine start. However, this is normal. Noise will stop after hydraulic pressure rises.