09206-11004 Suzuki PIN

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
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06561826
Attach a suitable lifting device to rear half of the camshaft. The weight of one-half of the camshaft for the 3512E Engine is approximately 45 kg (99 lb). Install spacer (28) and the rear half of the camshaft onto the front half of the camshaft. Install bolts (29) and tighten to a torque of 55 7 N m (41 5 lb ft).Note: Ensure that the camshafts are assembled according to the marks on the ends of the camshafts. If the dowel was removed from the front half of the camshaft, install the dowel. Install the dowel to 12.0 0.5 mm (0.47 0.02 inch) from the surface of the camshaft.
Illustration 2 g06561910
Example of the camshaft assembly installed in the front housing.
Illustration 3 g06561033
Example of the camshaft assembly installed in the flywheel housing.
Install Tooling (C) on the front housing or the flywheel housing. Do not tighten the bolts on Tooling (C).Note: Tooling (C) can be installed on the flywheel housing to install camshaft assembly (26) from the rear of the engine.
Install Tooling (B) on the ends of camshaft assembly (26). Install Tooling (D) on Tooling (B) which is installed on the front of the camshaft assembly.
Ensure that camshaft assembly (26) and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft assembly. Also place clean engine oil on the camshaft bearings.
Rotate camshaft assembly (26) and insert the camshaft into the engine. Position the camshaft assembly in the engine until Tooling (B) is in the front camshaft bearing. Rotate the camshaft to align Tooling (C) and the camshaft bores. Tighten the bolts for Tooling (C).
Rotate camshaft assembly (26) 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 4 g06561719
Install thrust washers (25) and bolts (24).
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 5 g06562352
Remove the timing pin from the storage position under the rear camshaft cover as shown in the removal procedure.
Turn the camshaft until timing pin (15) can be installed through the cylinder block and into groove (32) that is in the camshaft. Refer to Testing and Adjusting, "Camshaft Timing" for more information.
Illustration 6 g06562278
Remove bolts (34), cover (33), and plug (35) from the flywheel housing.
Illustration 7 g06562391
Install one bolt (34) into the flywheel housing through the hole for plug (35). Use Tooling (E) and a ratchet to turn the flywheel until bolt (34) can be installed through the hole and into the flywheel. Doing so 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 8 g06562615
Use the following procedure to install camshaft drive gear (23) and camshaft drive gear (20).
Clean the taper of the camshaft and the tapered