09100-08222 Suzuki Bolt

1. Remove tube assemblies (1) and access covers (2) from each side of the engine. 2. Remove electronic control module (3). See the topic "Remove & Install Electronic Control Module (ECM)."3. Remove covers (4) from each side of the front engine housing. 4. Push valve lifters (5) up away from the camshaft into the cylinder head assemblies, and hold the lifters in position. An O-ring seal can be used to hold the valve lifters up. 5. Remove the covers over the camshaft drive gears from the flywheel housing.6. Remove the bolt and plate (7) that fastens gear (8) to the camshaft. 7. Put the three washers from tooling (B) beneath plate (7) and install the bolt and plate (7).
Do not apply more than 51675 kPa (7500 psi) pressure to 1P820 Hydraulic Puller. 8B7559 adapters are rated at 6 1/2 ton each and 1P820 Hydraulic Puller is rated at 17 ton at 68,900 kPa (10000 psi). If to much pressure is applied, the gear may be damaged.
8. Install tooling (B) on camshaft drive gear (8). Apply 51,675 kPa (7500 psi) to the puller and hit the screw part of the puller with a hammer until the gear is free of the camshaft taper. Remove tooling (B) and gear (8). 9. Remove bolts (9) and thrust washers (10) that fasten the right hand camshaft in the engine block. 10. Remove timing ring (6) from the left hand camshaft.11. Repeat Step 6 through Step 9 for the left hand camshaft gear and cam thrust washers.
Typical Example12. Install tooling (C) on each end of the camshaft. Tooling (D) can be installed on the flywheel housing to remove the camshafts from the rear of the engine, or it can be installed on the front drive housing to remove the camshafts from the front of the engine.13. Install tooling (D) on the flywheel housing.14. Install tooling (E) on one end of tooling (C).15. Pull the camshaft out while rotating it using tooling (E). Pull the camshaft out of the engine until a hoist can be fastened to it. Remove front camshaft (11) and rear camshaft (12) as a unit from the engine. The weight of the 3512 Engine camshaft assembly is approximately 63 Kg (139 lb.). The weight of the 3516 Engine camshaft assembly is approximately 82 Kg (181 lb.). 16. Remove bolts (13). Separate the camshafts, and remove spacer (14).17. If necessary, remove the dowel from the end of the front camshaft.18. Repeat Step 12 through 17 for the remaining camshaft on the other side of the engine.Install Camshafts
Typical Example1. Position tooling (A) on the flywheel housing. Install the bolts that hold it. Do not tighten the bolts at this time.2. Install tool (B) on the end of front camshaft (11).3. Be sure the camshaft and camshaft bearings are thoroughly clean. Put clean engine oil on the lobes and journals of the camshaft. Put a thin coat of clean engine oil on the camshaft bearings.4. Position front camshaft (11) in the engine until tool (B) is located in the first camshaft bearing.5. Rotate the camshaft and tighten the bolts that hold tooling (A) to the flywheel housing.6. Rotate the camshaft and install it until the end of the camshaft is just out of tooling (A).
Typical Example
Typical Example7. If the dowel was removed from the front camshaft, install the dowel in the front camshaft. Install the dowel until the end of the dowel is 22.0 0.5 mm (.87 .02 in.) from the end surface of the camshaft. Make sure the camshafts are installed respective to the marks (rear L.H., rear R.H.) on the ends of the camshafts.8. Fasten a hoist to rear camshaft (12). Install spacer (14) and rear camshaft (12) onto front camshaft (11). Install bolts (13) and tighten by hand to