AutoZone 2006 Chevrolet Truck Silverado 1500HD 2WD 6.0L SFI 8cyl | Repair Guides | Engine & Engine Overhaul | Engine Mechanical | Timing Chain Cover And Seal | AutoZone.com

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    Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

    Timing Chain Cover and Seal

    Print

    REMOVAL & INSTALLATION



    1.8L Engine

    See Figures 1, 2, 3, 4 and 5

    It is a good idea to keep your ignition keys with the new oil containers so that you do not accidentally start the engine before filling it with oil.

    1. Disconnect the negative battery cable.
    2.  


    CAUTION
    The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

    1. Drain the engine oil.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of timing chain cover and crankshaft pulley mounting



    Click image to see an enlarged view

    Fig. Fig. 2: A steering wheel puller will be necessary to draw the accessory drive belt pulley off of the end of the crankshaft


    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

    1. Drain the engine coolant.
    2.  
    3. Remove the oil pan and oil pump pick-up.
    4.  
    5. Remove the rocker arm cover.
    6.  
    7. Remove the water bypass pipe and bypass hose No. 2.
    8.  
    9. Remove the cooling fan, pulley and accessory drive belt.
    10.  
    11. Remove the alternator drive belt.
    12.  
    13. Remove the water pump pulley.
    14.  
    15. Remove the alternator drive belt tensioner and idler pulley.
    16.  
    17. Detach the upper radiator hose from the thermostat housing.
    18.  
    19. If equipped, without disconnecting the A/C hoses, separate the A/C compressor from the compressor mounting bracket. Position the compressor aside and secure it with strong cord or wire.
    20.  
    21. If equipped, remove the A/C compressor mounting bracket from the engine.
    22.  
    23. Using a long breaker bar and socket, remove the crankshaft pulley bolt. To secure the crankshaft from rotating, install a pulley holding tool (such as Suzuki Tool 09917-68221). Use M8, P1.25 bolts with a strength rating of at least 7T to attach the holding tool to the pulley.
    24.  
    25. Once the bolt is removed, install a steering wheel puller on the crankshaft drive belt pulley, then draw the pulley off of the end of the crankshaft.
    26.  
    27. Remove the timing chain cover retaining fasteners, then pull the cover off of the engine and cylinder head.
    28.  
    29. Clean the gasket mating surfaces on the timing chain cover, engine block, and cylinder head of all oil, dirt and old sealant material.
    30.  


    WARNING
    Take care not to damage the oil seal bore during removal, otherwise oil leakage may occur.

    1. Remove the crankshaft oil seal from the cover by using a seal prytool, or by driving it out of the cover with a drift and hammer.
    2.  

    To install:

    The new oil seal must be installed so that the side of the seal where the seal spring is visible is installed inward (toward the engine block).

    1. Use a seal installation tool should be used to install a new crankshaft oil seal in the timing chain cover. If the driving tool is not available, a large socket and hammer can be used. The socket diameter should be the same as the metal part of the oil seal. Drive the seal into the cover bore until the outer surface of the seal is flush with the timing chain cover.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 3: Use a seal installer (A) and hammer to drive the new oil seal into the cover bore until the outer edge of the seal is flush with the cover surface



    Click image to see an enlarged view

    Fig. Fig. 4: Prior to installing the timing chain cover on the engine block and cylinder head, apply silicone sealant to the cover as indicated (areas marked A)

    1. Apply silicone sealant, such as Suzuki sealant 99000-31150, to the timing chain cover on the cover-to-engine mating surface. Refer to the accompanying illustration for sealant application.
    2.  
    3. Ensure that the timing chain cover locating dowel is installed in the engine block. Apply a thin coat of clean engine oil to the crankshaft oil seal lip, then install the cover. Tighten the cover retaining bolts to 97 inch lbs. (11 Nm).
    4.  
    5. Slide the crankshaft pulley onto the end of the crankshaft and install the center bolt. Install the crankshaft holding tool, then tighten the center bolt to 109 ft. lbs. (150 Nm). The center bolt will draw the pulley onto the crankshaft when tightened to the specified torque value.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 5: Use a spanner tool (A) to hold the crankshaft pulley steady while tightening the center bolt to 109 ft. lbs. (150 Nm)

    1. If equipped, install the A/C compressor mounting bracket. Tighten the bolts to 40 ft. lbs. (55 Nm).
    2.  
    3. Install the alternator drive belt idler pulley. Tighten the retaining nut to 33 ft. lbs. (45 Nm).
    4.  
    5. Reattach the upper radiator hose to the thermostat housing.
    6.  
    7. Install the alternator drive belt tensioner. Tighten the tensioner mounting bolts to 19 ft. lbs. (25 Nm).
    8.  
    9. Install the cooling fan belt, pulley and fan.
    10.  
    11. Install the water pump pulley.
    12.  
    13. Install the alternator drive belt.
    14.  
    15. Install the water bypass pipe and bypass hose No. 2. Tighten the bolts to 203 inch lbs. (23 Nm).
    16.  
    17. Install the rocker arm cover.
    18.  
    19. Install the oil pump pick-up and the oil pan.
    20.  
    21. Adjust the cooling fan drive belt tension, as described in General Information & Maintenance .
    22.  
    23. Refill the cooling system with the proper amount and type of coolant.
    24.  
    25. Refill the front differential (if applicable) with the proper amount and type of lubricant.
    26.  


    WARNING
    Operating the engine without the proper amount and type of engine oil can result in severe engine damage.

    1. Refill the engine with the proper amount and type of clean engine oil.
    2.  
    3. Start the engine and check for coolant, oil and exhaust leaks.
    4.  
    5. Have your front wheel alignment inspected.
    6.  

    OIL SEAL REPLACEMENT



    Oil seal replacement is covered in the cover removal and installation procedure. However, if the oil seal needs to be replaced but the cover does not need to removed, use the following procedure.

    1. Disconnect the negative battery cable.
    2.  
    3. If extra clearance is necessary for crankshaft drive belt pulley removal is necessary, remove the cooling fan, pulley and accessory drive belt.
    4.  
    5. Remove the alternator drive belt.
    6.  
    7. Using a long breaker bar and socket, remove the crankshaft pulley bolt. To secure the crankshaft from rotating, install a pulley holding tool (such as Suzuki Tool 09917-68221). Use M8, P1.25 bolts with a strength rating of at least 7T to attach the holding tool to the pulley.
    8.  
    9. Once the bolt is removed, install a steering wheel puller on the crankshaft drive belt pulley, then draw the pulley off of the end of the crankshaft.
    10.  


    WARNING
    Take care not to damage the oil seal bore during removal, otherwise oil leakage may occur.

    1. Using a small prytool, carefully pry the old oil seal out of the cover bore. Take care not to scratch the oil pump housing bore, otherwise oil leakage may occur. Wrapping a piece of tape around the end of the prytool may help reduce the change of scoring the bore by covering any sharp corners on the tool.
    2.  
    3. Clean the oil seal bore and the crankshaft.
    4.  
    5. If the oil seal is being removed because of oil leakage, inspect the crankshaft surface where the oil seal contacts it. If there is a wear groove on the crankshaft, a new oil seal will probably not cure the oil leak. Before removing the crankshaft and replacing it, explore the possibility of repairing it by installing a metal sleeve, designed just for this problem, over the crankshaft end. The crankshaft sleeve will present a new, flat surface, with which the new oil seal can make contact. Crankshaft sleeves are usually available from automotive parts stores.
    6.  

    To install:
    1. Apply a thin coat of clean engine oil to the oil seal lip, then slide the oil seal over the crankshaft and into position against the timing chain cover. Use a deep socket, which is the same diameter as the oil seal, and a hammer to drive the oil seal into the housing. Drive the new seal into the housing only until the outer seal edge is flush with the cover surface.
    2.  

    The new oil seal must be installed so that the side of the seal where the seal spring is visible is installed inward (toward the engine block).

    1. Slide the crankshaft pulley onto the end of the crankshaft and install the center bolt. Install the crankshaft holding tool, then tighten the center bolt to 109 ft. lbs. (150 Nm). The center bolt will draw the pulley onto the crankshaft when tightened to the specified torque value.
    2.  
    3. Install the cooling fan belt, pulley and fan.
    4.  
    5. Install the alternator drive belt.
    6.  
    7. Adjust the cooling fan drive belt tension, as described in General Information & Maintenance .
    8.  
    9. Start the engine and check oil leakage from the new oil seal.
    10.  

     
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