Suzuki Vitara, Grand Vitara, XL7 2000-06

 REMOVAL & INSTALLATION

Timing Chain Cover, Chain, Sprockets, & Seal 2
Removal & Installation
2.7L Engine
1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Drain the engine oil.
4. Remove engine assembly from vehicle.
5. Remove or disconnect the following:

Negative battery cable

Intake manifold
Ignition coils
Valve covers
Accessory drive belts
Cooling fan and shroud
Water pump pulley
Radiator
Power steering pump and brackets
Oil pan and pickup tube
Crankshaft pulley
Front crankshaft seal
Crankshaft Position (CKP) sensor
Front cover

Fig. Timing chain alignment marks-2.7L Engine

6. Remove timing chain tensioner adjuster.

7. To remove it, slacken left (No.1) bank 2nd timing chain by turning intake camshaft counterclockwise a little
while pushing back pad.
8. Remove left (No.1) bank intake and exhaust camshaft sprocket bolts.
9. To remove it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary.
10. Remove left (No.1) bank exhaust camshaft sprocket.
11. Remove left (No.1) bank intake camshaft sprocket.
 Fig. Camshaft sprocket removal-2.7L Engine
12. Remove left (No.1) bank 2nd timing chain.
13. Remove or disconnect the following.

Timing chain guide No.1 and No.2

Timing chain tensioner
Timing chain tensioner adjuster
Idler sprocket No.1 and 1st timing chain
Idler sprocket No.2 and sprocket shaft

14. Remove right(No.2) bank 1st timing chain intake camshaft sprocket bolt. To remove it, fit a spanner to
hexagonal part at the center of camshaft to hold it stationary.
15. Remove right (No.2) bank 1st timing chain intake camshaft sprocket.
16. Remove 1st timing chain crankshaft sprocket.

Fig. Right bank 1st camshaft sprocket-2.7L Engine

To install:
1. Prepare the timing chain tensioners for installation by releasing the latches, compressing the tensioner
piston fully into the bore and installing retaining pins.
2. Align the timing chain sprocket matchmarks and colored chain links as shown during assembly.
3. Check timing pulley key of crankshaft is on specified position.
4. Install 1st timing chain crankshaft sprocket to crankshaft.
 Fig. Crankshaft, gear and key-2.7L Engine
5. Check timing mark on right (No.2) bank intake camshaft.

Fig. Right bank (No.2) intake camshaft timing mark-2.7L Engine

6. Install right (No.2) bank 1st timing chain intake camshaft sprocket noting the following points.
A. The sprocket should be set in such way that its timing marks can be seen.
B. Camshaft should be held stationary by using a spanner at its hexagonal parts.

7. Tighten right bank 1st timing chain intake camshaft sprocket bolt to 58 ft. lbs. (80 Nm).
8. Install timing chain tensioner.
9. Tighten timing chain tensioner nut to 18 ft. lbs. (25 Nm).
10. Install 1st timing chain by aligning match marks on right silver plate of 1st timing chain and right (No.2) bank
1st timing chain intake camshaft sprocket.
 Fig. Right (No.2) bank cylinder head-2.7L Engine
11. Apply oil to bush of idler sprocket No.2.
12. Install idler sprocket No.2 and sprocket shaft.
13. Install idler sprocket No.2 by aligning match marks on left silver plate of 1st timing chain.

Fig. Left (No.1) bank cylinder head-2.7L

14. Install crankshaft sprocket by aligning match marks on yellow plate of 1st timing chain and crankshaft timing
sprocket.
15. To install it, fit a spanner to hexagonal part at the center of right (No.2) bank intake camshaft to turn a little.

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

Fig. Crank shaft sprocket aligning mark-2.7L

16. Apply oil to bearing of idler sprocket No.1.
17. Install idler sprocket No.1 and tighten to 40 ft. lbs. (55 Nm).
18. With latch of tensioner adjuster No.1 returned and plunger pushed back into body, insert stopper into latch
and body.
19. After inserting it, check to make sure that plunger will not come out.
20. Install timing chain tensioner adjuster No.1 and tighten to 8 ft. lbs (11Nm).
21. Pull out stopper (3) from adjuster No.1 (1).

Fig. Timing chain tensioner adjuster No.1-2.7L

22. Install timing chain guide No.1 and No.2.
23. Tighten both chain guides to 6 ft. lbs. (9 Nm).

Fig. Chain guides and bolts-2.7L

24. Recheck each aligned timing marks.
25. Install timing chain guide No.4 and tighten to 8 ft. lbs (11 Nm).

Fig. Timing chain guide No.4 and bolts-2.7L

26. Check that knock-pins of intake and exhaust camshafts are aligned with match marks on cylinder head.
 Fig. Intake and exhaust match marks-2.7L
27. Install by aligning match marks on yellow plate of left (No.1) bank 2nd timing chain and idler sprocket No.2.

Fig. Left cylinder head match marks-2.7L

28. Install sprockets to intake and exhaust camshafts by aligning silver plate of left (No.1) bank 2nd timing chain,
match marks on intake sprocket and exhaust sprocket respectively.
29. Install LH (No.1) bank intake and exhaust camshaft timing sprockets.
30. To install it, fit a spanner to hexagonal part at the center of camshaft to hold stationary.
31. Tighten camshaft timing sprocket bolts to 58 ft. lbs. (88 Nm).
32. With latch of tensioner adjuster No.3 returned and plunger pushed back into body, insert stopper (pin) into
set hole.
33. After inserting it, check that plunger will not come out.
34. Install timing chain tensioner adjuster No.3.
35. Tighten Timing chain tensioner adjuster No.3 bolt (c) to 7 ft. lbs. (11 Nm).
36. Tighten Timing chain tensioner adjuster No.3 nut (d) to 32 ft. lbs. (45 Nm).

Fig. Timing chain tensioner adjuster No.3 bolt c-d-2.7L

37. Tightening order for tensioner adjuster bolt and nuts1-2-3
38. Pull out stopper (pin) from set hole.
39. Turn crankshaft two rotations clockwise then align timing pulley key (1) on crankshaft and oil jet on cylinder
block.
40. Recheck all timing marks.
 Fig. All timing marks shown-2.7L(a)

Fig. All timing marks key list-2.7L(b)

41. Apply oil to timing chains, tensioner adjusters sprockets and guides.
42. Install or connect the following:

Front cover. Tighten the bolts to 97 inch lbs. (11 Nm).

CKP sensor
Front crankshaft seal
Crankshaft pulley. Tighten the bolt to 109 ft. lbs. (148 Nm).
Oil pan and pickup tube
Power steering pump and brackets
Radiator
Water pump pulley
Cooling fan and shroud
Accessory drive belts
Valve covers
Ignition coils
Intake manifold
Negative battery cable

43. Install engine assembly

44. Fill the crankcase to the correct level.
45. Fill the cooling system.
46. Start the engine and check for leaks.