09100-06122 Suzuki BOLT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-3029 Camshaft Support 1
1U-6311 Plate 1
B - Loctite Graphite-50 Anti-Seize -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The correct relationship of the camshaft segments must be observed at the time of assembly. If the camshaft segments are not properly timed, serious engine damage will occur.
Illustration 1 g01529537
This Illustration shows the location of the dowels on the camshaft bearing journal. (X) Location of the single dowel in the face of the camshaft bearing journal. (Y) Location of the variable dowel in the face of the camshaft bearing journal. (Z) Locating groove.
Illustration 2 g00575985Note: The position of the single dowel in relation to the variable dowel determines the letter designation of the cam journals. The single dowel is located on the same end as the locating groove. The variable dowel is located on the end that is opposite of the locating groove.Each journal has several dowel holes on the side opposite the locating groove. There is only one dowel hole on the side of the locating groove. The letter designation of each journal gives the dowel location of that journal for the side opposite the locating groove.
Illustration 3 g01301752
This Illustration shows the letter designation of G3606 camshaft journals.
Illustration 4 g01301753
This Illustration shows the letter designation of G3608 camshaft journals.
Before assembly, check the location of the dowel and the height of each camshaft journal. The assembled height of each dowel must be 15.0 0.5 mm (0.59 0.02 inch). Note: Install the camshaft journals with the locating groove toward the front of the engine for both standard rotation engines and reverse rotation engines.Install the camshaft segments with the groove toward the rear of the engine for standard rotation engines.Install the camshaft segments with the groove toward the front of the engine for reverse rotation engines.
Illustration 5 g03864023
Install the spacer in camshaft journal (18).
Apply clean engine oil to camshaft journal (18). Install the camshaft journal (18) in the camshaft bearing with the groove toward the front of the engine.
Install the bolts that hold camshaft journal (18) to the camshaft segment. Tighten the bolts hand tight.
Put the spacers in position on the camshaft journals.
Install Tooling (A) on the side of the cylinder block. Note: Ensure that the groove on the camshaft segment is in the correct position for the rotation of the engine.
Attach a suitable lifting device to camshaft segment (19). The weight of camshaft segment (19) is approximately 31 kg (69 lb). Put camshaft segment (19) into position on Tooling (A).
Roll camshaft segment (19) into position on Tooling (A). Align the dowels at each end of camshaft segment (19). Install bolts (17). Tighten the bolts (17) hand tight.
Tighten the camshaft journal bolts.
Apply clean engine oil on the rear camshaft bearing.
Illustration 6 g03864399
Apply Tooling (B) on the threads of bolt (33).
Attach a suitable lifting device to camshaft drive gear (31). The weight of camshaft (31) is approximately 41 kg (90 lb).
Install camshaft drive gear (31), plate (35), bolts (32), washer (34), and bolt (33).
Tighten bolt (33) to a torque of 2000 275 N m (1475 203 lb ft). Strike on plate (35) to seat the gear taper on the camshaft. Retighten bolt (33) to a torque of 2000 275 N m (1475 203 lb ft). Repeat until torque does not change.
Illustration 7 g03865097
Install bolts (30) and timing and speed drive (29).
With the camshaft pinned, assemble camshaft drive gear (31) with one of the 1/2-13 threaded holes at the 12 O'clock position such that the floor 1/2-13 threaded holes form a diamond pattern.
Assemble the spacer and timing and speed drive (29) to camshaft drive gear (31) with the extra tooth on timing and speed drive (29) close to primary sensor. Leave bolts (30) loose so timing and speed drive (29) can be rotated.