09125-06069 Suzuki Bolt

Table 1
Required Tools
Tool Part Number Part Description Qty
B 125-0200 Camshaft Pilot As 2
C 125-0201 Camshaft Guide As 1
D 8T-3169 Crank Assembly 1
E 238-9586 Camshaft Drive Group 1
F 5P-3931 Anti-Seize Compound -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The following procedure is for installing the camshaft in the left-hand side of the engine.
Illustration 1 g01123198
Install Tooling (C) on the front housing. Do not tighten the bolts on Tooling (C). Note: Tooling (C) can be installed on the flywheel housing in order to install the camshaft from the rear of the engine.
Install Tooling (B) on the ends of the camshaft. Install Tooling (D) on Tooling (B) which is installed on the front of the camshaft.
Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings.
Rotate the camshaft and insert the camshaft into the engine. Position the camshaft in the engine until Tooling (B) is in the front camshaft bearing. Rotate the camshaft in order to align Tooling (C) and the camshaft bores. Tighten the bolts for Tooling (C).
Rotate the camshaft and insert the camshaft into the engine. Remove Tooling (D) from Tooling (B). Remove Tooling (B) from the camshaft. Remove Tooling (C) from the front housing.
Illustration 2 g01122334
Install thrust washer (10) and bolts (11).
Install bolts (12).
If the camshaft is out of time more than 18 degrees (approximately 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, "Camshaft Timing" for more information.
Illustration 3 g01122583
Remove timing plate (15) from the storage position under the rear camshaft cover.
Turn the camshaft until the timing pin can be installed through the cylinder block and into the groove that is in the camshaft. Refer to Testing and Adjusting, "Camshaft Timing" for more information.
Illustration 4 g01123337
Remove bolts (17), cover (16), and plug (18) from flywheel housing (19).
Install one bolt (17) into the flywheel housing through the hole for plug (18). Use Tooling (E) and a ratchet to turn the flywheel until bolt (17) can be installed through the hole and into the flywheel. Turning the flywheel will position the No. 1 cylinder at the top center. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston" for more information.
Illustration 5 g01123380
Use the following procedure in order to install camshaft drive gear (8).
Clean camshaft taper and clean the tapered bore of the camshaft gear with a lint free cloth with a solvent to remove excess oil. Clean the parts again with a lint free alcohol wipe in order to remove any residue. If the alcohol wipe is dirty after cleaning the parts, clean the parts again with a lint free alcohol wipe. Clean the parts until no residue is left on the alcohol wipe. Note: The camshaft taper and the tapered bore of the camshaft gear are clean, dry, and free of residue before assembly.
Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.
Place camshaft drive gear (8) in position. Remove the backlash by rotating the gears in the opposite direction of engine rotation. Note: For "Standard Rotation" engines, turn the camshaft drive gears CLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE.
Install bolt (6) and ring (7). Ensure that the hole in the ring is properly seated on the locating pin.
Tighten the bolt to a torque of 360 N m (265 lb ft).
Place a Mark on the bolt.
Place a driver against the retaining plate of the camshaft gear. Strike the driver solidly with a hammer 3 to 4 times.
Tighten the bolt again to a torque of 360 N m (265 lb ft).
Repeat Steps 12.g and 12.h until the Mark has turned at least 90 degrees.
Remove the timing pin from the camshaft. Install the timing pin in the storage position under the rear camshaft cover.
Illustration 6 g01122151
Install the O-ring seal on engine speed/timing sensor (5). Extend the sliphead of the speed/timing sensor to a minimum distance of 4.0 mm (0.16 inch) prior to installation.
Apply Tooling (F) to the threads of engine speed/timing sensor (5). Install the engine speed/timing sensor in the flywheel housing and tighten to a torque of 40 5 N m (30 4 lb ft).
Install cover (4) on the flywheel housi