A very good day to replace a leaking cam oil seal on a Suzuki Every/Carry DE51V F6A 660cc engine. And it is always a genius idea by replacing leaking oil seals because oil leaks will cover all the surface of the engine and will build up a sticky gunk and sludge as dirt hardens.
- Open engine bay cover.
- Loosen tire lug nuts while on ground.
- Lift up van by floor jack and support with 2 jack stands on the rear wheel main axle.
- Remove alternator belt cover. Also remove dip stick tube assembly.
- Cover dipstick oil hole to prevent gunk and other foreign materials get into the oil pan.
- An impact driver makes the job done fast and easy. Remove alternator fly wheel pulley using impact driver with a 17mm socket wrench. Squirt a few WD-40 penetrating oil to loosen the bolt up.
- Disassemble and remove timing belt plastic cover.
- You will need a camshaft pulley holding tool to loosen the bolt that holds it. Remember it was torqued to at least 70 Nm (Newton metre) or 52 foot pounds!
- In my case, I welded my own camshaft pulley holder DIY style!
- Next, turn the crankshaft to align TDC (top dead center) to the marker before removing timing belt and pulley.
- Loosen tensioner bolt to release timing belt.
- Degrease and power wash all the plastic and steel covers, bolts and nuts and clean off thoroughly removing gunk grease, oil sludge and dirt.
- After everything is clean, proceed to removing the old leaky camshaft oil seal by driving a screw into it and pull using a long-nose pliers.
- Clean and remove grease cam seal area using cloth and kerosene or acetone.
- Sand and smooth any gouged part of the camshaft using fine sand paper grit.
- Dip the brand new cam seal into a tub of all-purpose engine grease to lubricate the seal in inserting.
- Take time and carefully insert the cam seal flat into the groove. Tap using a hammer and a smooth edge to seat it flat and flush.
- Re-attach the camshaft pulley and torque to manufacturer's specifications.
- Install timing belt and test if the engine will start. If all successfully set back together, the engine will start right.
- Put everything back and we are done!