SUZUKI. TABLE OF CONTENTS Page No. Page No. T.SLENGINE.200000.2.... 30-1 2.0L DOHC ENGINE... 30-9 T.6LENGINE.... 30-6 1.3L Engine TIMING BELT Aer adusent true srw ent 11-14 REPLACE Install the vaive cover. 4. Insta the ar eeoner assembly. Samurai Swift «With the timing belt temoved, avoid turning the camshaft or crankshalt movement is required, exercise extreme SOHC ‘caulionto avold valve damage caused by piston contact. Disconnect and isolate the battery ground cable. Loosen the fan drive belt and remove the bots securing the radiator fan shroud and the cooiing fan Flomove the shroud and fan. Fomove the accassory drive belts and the water purmp pul- ey. Remove the crankshaft puley attaching bots and the pulley, Fig inoltogured foromawe he rane play on tr Femnove tne ting belt cover. Econ ne eniorer nan ot Fl, 2, hen rove he iming bet. Fomove tre valve cover. then loosen al the valve austing Screws al ta way fo alow free camshatt ation. ‘Gn modets bulf before June 1993, rotate the camshalt Sprocket Cocks and align tho ting mark on the cam shal epocel mht V rk on tho Bl iad cov, 9.2. 10 ON models built since June 1983, rotate the camshatt Sprocket clockwtse and align the ing mark Fig, 4. When properly inetalleg, the camshaft pully pin(7) should en- at slot No. 1. The camshatt ible above the “80°C” should align with the V mark on the cylinder head cover. 11, Graifmodel, rae the cama ck ing 217 {im wrench on the crankshaft ming bet puley bolt Fis 8, nd align the punch marken te timing Belt puley wn 6 of ump arow mark, Fig 6. 12. Wital the ding mark aligned, Install the new timing bet comrobal aeutete on foratyeact inte ete? pu ger, Fig. 7. When installing the tie Ing belt, match any arrow on the timing batt with the ro- ing direction of crankshaft. 19. Rotate the crankshat two complete revolutions to allow the bolt 0 be fee of ary slac, thn tighton the tensioner ad tonsloner bot to specications, Fig. 7. 14 Insta tne ting bo cover. 15. Install the cranehaf pulley bolts, Fig. 1 18. Install the water Pum puley and the accessory drive bets, then conreat the batry ground cable. Refer to last page {or proper bell tension, 17, Bajust the vlvo lash as follows: & Remove ho a cleaner assembly, then the valve cover. Ble to fright potion tho canbe andthe rocker arn, Fig. 8. ¢. Measute the clearance at gop (A) using a sutabe feeler Fogo, clearance shouboauindcatedn Fig 6 «@. tine ciearance is not as spectieg, adust by turning the gape eo ita repress ted 1.91 ENGINE ‘With the timing bel removed, avai turning the camsnant or crankshaft. if movement is required, exercise extreme Caution to avoid valve damage caused reontact. Disconnect anc isolate the betery ground cable. On modals fequippes with anaibag, wait 1'2 minvtes after disconnect ing he boty ground cl etre proseedng wih proce 2 Raise and safely support tne vehicle with jackstands 3 Remove te righthand side fender apron extension. Do not ah the center pinin to ar. might fal int the ender. 4 Remove te accessory crve bets and te water pump pul ley. 5 Remove the crankshaft pulley as follows: 8 Lock the crankshaft fo logcen the ankshatt timing bolt ‘Sprocket bol and the crankshaft pulley bolts, Fig. and 10. Remove he crarkehat ming bel puley bat » Romove the crankshait puley bots and the ting belt pulley bolt using a 17 mm socket. 6. Remove to rasonater ana tenng bet outer cover 7. Loosen the tensioner bolt ad stud hen push the lnsioner plate fy ward and remove the ting ball rm the Sprockets 8. Prior installaton, ensure the tensioner roles smoothly 8 Inelall he tensioner plate on the tensioner ‘The leneioner ate lug must nthe tensioner hole, 10. Intelfe tensioner assembly. Hand tghion the fensioner bot oniyatthis time. Plate mavementinihe upward rection should Gauge the tensioner to move into same rection 11, On 1986-98 modele, remove te cyinder haad cover, then Completely loosen al tne intake ane exneust vale rocker srmagjusting ecews al locknuts 12 Gnall models, rotate the camshatt sprocket clockwise unt the pully marks sign with he V mark on the bot inside cover Figs’ 3 ond 4 19, Tum the Grakahat ining bet pulley bot clockwise unt the Steele punen marc aig wh fhe of pup cate row +4, Tatil th new ting belt onthe sprockets withthe belt rive Sie ree clany sak and ithe ensonr plate shed i in by finger, Match the arrow mark on the timing belt wi the rotating direction of the crankshaft (clockw this poston, the No.4 plston is at TBC compression st 18. Turn the crankshatt two rotations clockwise after instal the belt to take up the slack of belt Ensure all the sprockoi marks are propery aligned, 16, Tighten the tensioner stud, then the tensioner bot 17, Ensure the seals between the water pump and the ol pump (ase, then instal the Uming bet outside cover. 16. Flomove the crankshaft timing belt pulley boll, then install tho crankshaft pulley Torque the Inner bolt fo 84'ft ths, and the 30-1 aa aaa| 1 Crankshaft pulley 2 Crankshaft pulley bolt 3 Grenk timing belt puley bolt Fig. 1 Crankshaft pulley and retaining bolt outer bolts to 11~131. ibs. 49. Install the water pump pulley and the accessory dive belts Refer to last page for proper belt tension. 20, On 1989-83 models, adjust he valve lash as folows: {Rotate tho crankshatt lo posiion the cam lobe and the fookor am, Fig. '. Measure tie Gearance at gap (A) using a sultable feeler ruennich sould be as noted in Fig 8 «6 Mlthe doarance is not as specified, adjust by turning the adjusting screw untt the proper clearance is obtained, Fig. 6. Aleut tie he sow ceo 1-16 = «Isla the valve cover an torque the bots o 36-42 inch Ibs, {, Install the alr cleaner assembly. 21. On all models, insiall the water ump pulley and the dive bet 22. Install the righthand side tender apron extension, then con- ‘ect the battery ground cable 23 Start the engine and ensure ft operates properly DOHC ° wit the tmifig belt removed, avoid turning the-camshat ‘or etankshaft. W movement is Yequlred, exercise extreme ‘ation to avoid valve damage caused by piston contact, ‘Disconnect ana isolate te batory ground cable. On models ‘equiped wih an airbag, wait 1/2 minutes after clsconnect ing tho batey ground eile boar proceeding wih proce Rlomove the aircleaner assembiy withthe airflow meter and ‘uilet nose, then he ar cleaner bracket Raise and Suppo” the vehicle on lacksiands. Remove the righthand side fender apron exiension, Do not push center the pin in too far. it may fall into the fender. Petove the accessory div bls and tre water pump pur ey. Fbmove the crankshaft pulley as follows 2. Lock the crankshaft fo logsen the crankshat tring belt pulley bltandthe crankshattpulley bots, Figs. 8 and 10. Remove the erenkshait ming belt pulley bok. Remove the srankshar ply bot using &S mm boxa- «Bem ne crankshan ning bt pully bot using a 17 7 Remove the timing belt upper and lower outside covers. It ‘may be required 0 loosen the engine righthand side mount- Ing bot and pushing the ei cleaner bracket to the right. 30-2 Timing belt Tensioner plate Tensioner bolt Tensioner stud Fig. 2. Releasing timing belt tensioner £8, For installation ofthe timing belt, ensure that the camshaft timing belt sprocket and the crarkshafl timing be sprockat are properly aligned, Fig. 1, 9, Flemove the timing belt as follows: fa. Loosen the tensioner stud and bolt 5. Remove the tansioner spring and damper, then the timing belt, Once the timing belt Is removed, never turn the amanatts () or, the erankshat (2) Independenty more than, Fig. 12, of intemal engine damage may 40. Prior 10. installation, ensure that the tensioner rotates roar th 11, Eh the lg ofthe tensioner plats fis in the hoe of te tensioner 12. Han tgtten the tensioner bolt ony tts tine Pte more rent ne upward drecion shout cause he fester fhoveln te sme drecton 1s, Ensure thatthe ease tring bet sprocket punch mars ign vine mar onthe cyioorreas’ Do matt each pulley beyond the range, specified In Fig. 12,1 the Sprodkets do ot stopinplace dueto counterirce ofthe tive sping, baa Th sprockets pce ng oh et 14, Eire thatthe cranks ming bet sprocket punch mak Signs he atfow mark one lpump case bonot ure the sprockel beyond renge spectted in Fig. 18 45, Insa ne tng bolton fe sorcsets wth te oie sie of {feboltee fon any sack latch any arrow mark on the 1 2 3 4 mang bi wan he oatingcrectan of ho ranks Clockwise) 18 {iturin Wesioner sping and te sping damper. Hand tighten the tonsioner stua. 17 Tum the erankshaf two rotations clockwise afte instaling the beltto take up tne slack ofthe beh Ensure althe sprock elmarie are propery aligned 118, Torque the tensioner stud to 84108 inch Ibs. Torque the to loner bolt to 18-22 ft. bs. 18, Eneute thatthe seal is betwoon the water pump and the ol pump case, then instal the timing belt outside covers Torque the cover bolts and nuts to 84—108 inch bs. 20, Remove the cranksheft pulley bolt, then install the oranke shat pley Torq the nos bot io 84H Tbs Torque te outer bolts to 11-15 ft. Ibs. 21, Install the water pump pulley and the accessory ave bets ofer to last page for proper belt tension. Install the air cleaner bracket, then the ar cleaner assem Install the righthand side fender apron extension, then com rect the battery ground cable. BB 19 ENGINE| Fig.3. Camshaft sprocket timin engi silt before ine, Models bui Fig. 4 Camshaft sprocket timing mark. 43 engine. Models built since June 1993 | Fig. 5 Crankshaft pulley timing mark. 1.3L SOHC engineSUZUKI enn j : Wpentcla | Water os tfiam «| comet | sete oe, 2et0Nn oe tere oe ae Be re ene weg wah a Hee ee Wee! Taam [018-027 wm | 023-077 mn 2 jeation —_ {0.0051 - 0.0087 in}| (0.009-0.011 inj a casa, 948-020 mm | 028-030 xhaust | (90063 - 0.0079 in! (0.0102 -G.0118 in) Serew lock nut 15 —19Nm (5 = 189m. 110~135%6%) Aajusting sro 1 Tensioner stud ® 2. Tensioner batt 3 Tensioner pete er torque specifications, 1.3L Valve ster SOHC engine Fig. 8 Valve lash adjustment. 1994 & earlier 1.3. SOHC engine 1. Clutch housing 2. Square hole 3. Siotted serewctrivor 4 Oilpen 5. Exhaust No. 1 pipe Fig. 9. Positioning screwdriver through clutch housing bore. Manual transaxle 4. Timing bott 5, Punch mark by “I” 2. Camshte timing belt (intake side) pulleys 6. Punch mark by "E" 3. Crankshaft timing belt {exhaust side) pulley 7. Mark on oil pump cast 4. Marks on eylinder 8. Key on crankshaft 1. Drive plate head cover 2. Slotted screwdriver coon eee Fig. 11. Camshaft & crankshaft sprocket timing Fig. 10 Locking flexplate in position. Automatic marks. 1.3L DOHC engine ‘transaxle 30-4 1 9 ENGINE ea na a ee «Cl™ SUZUKI Fe 4 x int by L Fig. 12. Sprocket movement limits. 4.3L DOHC ‘engine Fig. 13 Holding camshaft sprockets in position. 7.3L DOHC engine ° e 19 ENGIVE 30-58 Valve Engine 1 Disconnect and isolate the battory ground cable. On models ‘equipped with an airbag, walt 172 minutos after disconnect- ing the battery ground cable before proceoding with proce- ute 2 Remove the coolant reservoir tank, cooling fan and fan ‘shroud, 3, On models equipped with AVC, recover the AIC system frigerant intg an approved container, then remove the com- pressor flexbie suction hase from the suction pipe. 4, Onall models, remove the accessory drive balls. ‘5. Remove the water pump and crankshaft pulleys, then the timing belt outer cover, 16. Rleomave the timing belt tensioner spring and stud, then loos ‘anthe tensioner bolt. 7. Remove the ming beltby pushing up the tensioner pulley by hand. Rlemve the tensioner and tensioner plate 9. Prior toinstallation, inspect tne tensioner for smooth rotation, {hon nsort the tensioner plteock ab into te tensioner lock tab slot 10. Install the tonsioner assembly. Hand tighten the tensioner boitonly atts tme. Pate movementin ho upward drection should éausa he tancioner tomave in same direction 11 Remove the oyindor Road cover, then fooson all th valve lash adjusting sorowe and locxnuts 12. Tumis eanehatt pulyclockwse and align toting mask ‘nthe eamshalt sprookel withthe Vimar on th inno bolt cover Fig. 1 413, Tuli erankshaf clockwise and align the punch mark on the crankshaft wih the arrow on of pump, Fig 2. 14, Install the new lining belt so there's no slack onthe dive Sie ofthe bel Fg. 3, With the Installation ofthe timing belt ensure that the arrow mark onthe belt matches the rotation ofthe crankshaft At this point, No. 4pistonisat ‘TDC of the compression stroke. 15. Hook tne tensioner spring to the tensioner plate and bot, then hand tohten the fonsioner stud 16. Remove the slack inthe bing belly turning the crankshaft {Wo lu rotatons clockwise ater bet Irstatiaton. 17, Toru the tensioner stud to 84108 inch Ibs. ad the bolt to iezen bs. 18. Install he ting belt outer cover 19. thstll the crankshaft puley Torque the bolts to 12 bs. 20 tra ho asa tvoue, wate ump py asait cot ing an and te AC compressor flexible suction hose 21, natal the accessory drve belts. Refer to last page for proper belt tension. 22, Rdjustine vave ash as flows: 2° Tim the crankshaft so tho V mark on the pulley aligns with tha 0 mark calibrated on the tning bok cover b, Romovathe distioutor cap to onaurethatrotoris pointing to the No. 1 oyinder fring postion, Fig. 4. No.1 piston should be at TOG of compracsion sloke. the rtoris aut of plaes rotate the crankshaft clockerse onco, With pix tonal TO0,measurethevalvelashol 1,2, Band valves, Figs. 5 and. Ith valve lash is out of specication, Fig. 5, adjust by tuning te adjustment scraws, then Folding the Screw, {orgus tha ocknut to 11-148 Ibs, 4. Rotate the crankshaft one fll tua, then adjust the valve lashofvaive Nos. 34,8 and and repost stop c © ter inspecting all ine valvos and adjusting, ropiace tho ‘ave cover, dtrbulr can and te clear. 23. On models eGulpped with A/G, evacuate and charge tho Re ayatem Pet a 30-6 1. Timing pulley 2. Timing mark 3 "Vv" mark 4. Bolt inside cover Fig. 1 Camshatt timing mark. 8 valve engine 24, On all models, connect the battery ground cable, then spect the coolant level 16 Valve Engine With the timing tet removed, avoid turning the camshatt ‘or crankshaft it movement Is 'required, exercise extreme auton to avoid vaive damage caused by plston contact 4 Disconnect and isolate ths balerygreundasle Onmosels quipped with an airbag, wal minus ator ciscomect. ing the batory ground cable belore proceeding ith proce- ure 2 OnEsteom and Vitara models, proceeds follows: 2 "famove he ihand ste olf engre unre 8. Remove the Ale compressor, power steering pump and iove bets wih the noses sifatacnes ¢- Suppor the engine by using sutabeliting device, then rermove the a deaner case withthe ar Sloane cet hove. 4. Remove the engine righthand mourting racket andi ener Fig. 2. Romans ne water pump pul and ave belt 2. On Sidekick models, praceed a3 follows 2" Hamave tre AG compressor and power steering pump sive bot », Homovelineensine coin fan, water pump pute and ivobe «¢. Remove ine fan shroud, i may be required to discon- fect the upper radiator hose to fectitate the fan Shroud removal Onall modes, remove the crankshaft pully attachingbots, thenthe eansshatt pute. Remove ie ining Set outer cover. ‘ign te crankahet sprocket ana camshaft sprocket ining marks, Fig. 8 belt tensioner tensioner plate andsoring. Remove the ting bel, Eneure the crankshaft and camshaft sprocket timing marks. axe prone aligned, Fig. B ith the tming marks signed, ‘he No.4 cyinder sat the TOC positon, The camshaft and crankshaft should never be moved beyond 20° in either di- fection rom the TDC position wih the timing belt removed. 10, Install the ensioner and the tensioner plate Position tha ten- sioner in the released postion and hand tighton the bol 11, Install the new timing belt over the orankshan anc camshaft ‘Sprockets and the tensioner pulley. Ensure the tension side (of the timing belt Is free of slack during installation. 12. Install the tensioner spring, tnan loosen tha tensioner bolt and alow te tensioner spring io tension tho timing bet After & Z 16. ENGINE tis' SUZUKI Teor , \ Timing belt pulley, SA 2 Punch mark 3. Arrow mark on oil pump case Fig. 2. Crankshaft timing mark. 8 valve engine the bott nas tensioned, hand tighten the tensioner stud nut 13 Turn the crankshaft wo revolutions clockwise. Ensure the timing belts free of slack. Torque the tensioner stud rutto 96 inch Ibs. Torque the tensioner bolt 18 Ibs. 14 Ensure the crankshaft and camshaft sprocket timing marks are properiy aligned, Fig. 8. 16, Insal the ting bel cover, Torque the atacing bots to 96 inc 16. On 1995 Esteem modols, install the crankshaft pulley by aligning the key into its slot on the crankshaft sprocket ‘Torque the attaching bois to 12°. (bs 17. On 1996-2002 Esteem and Vitara models, install the crankshaft pulley by aligning the dowel pin into the hole on the crankshaft sprocket Toraue te attaching bolts i 12 bs, 18. On Sidekick models, proceed as follows: fa Insta the fan shroud. Connect the upper radiator hose and adjust the coolant fevel as required 'b Intall tho water purnp pulley, engine cooling fan and tho ive belt Refer to last page for proper belt tension. Install the. steering pump and A/C compressor ive bell. Refer to last page for proper belt tension. 19 On Esteem & Vitara models, proceed as follows: 4 nea te water pump pully and torque the bots to 98 inch bs. Install he drive bolt Refor to last page for proper belt tension ‘6 Installthe engine righthand mounting bracket and stifen- fe, then torque the bolts 0 40 ft. Ibs, 4. Insiallthe air cleaner case with the air cleaner outer pipe, then remove th lifting device, . Install the AIC compressor and power steering pump. Refer to last page for proper belt tension. 1 Adjust the power steering pumo belt tension or A/C com pressor bl tension Refer to last page for proper belt tension, 20 Onall models, connect the battery ground cable 21. Inspect and adjust the ignition timing as required 181 ENGINE Dive side of belt Tentione pate Soving Tencloner sua Washer Bott Direction of crankshaft Fig. 3. Timing belt installation. 8 valve engine Fig. 4 Distributor rotor position. 8 valve engine 30-7(cootane wr yawe eauresreo i ‘oriad = 154) Perf [naka 035 ~ 0.77 mm Stor (B.000-001T im lexan 9.25 —0.28 mm lodio2a0108 i 1. Auten eerew 2. uring sor 3 Valve stm Fig. 5 Valve lash adjustment. 8 valve engine 2 Timing mark 1. Engine right mounting bracket 2. Engine right mounting bracket stiffener Fig. 7 Engine mounting bracket & stiffener removal. Esteem & Vitara 4 Arrow mark 2. Punch mark Fig. 8 Crankshaft sprocket & camshaft sprocket ‘timing marks. 16 valve engine 30-8 161 ENGINE& 2.0L DOHC Engine TIMING BELT ‘REPLACE «ith the ting bet removed, avoid turning the camshaft lor crankshatt. 1 movement is required, exercise extreme ‘caution to avoid valve damage caused by piston contact. Disconnect and isolate the battery ground cable Disconnect the MAT sensor electicl connector Disconnect the air outlet hose from the throtle body. Disconnect the breather tube from the valve cover lemove the air cleaner housing bots, then the housing [Loosen the righthand front whee! lugnuts False and safely support tne vehicle with jackstands, Remove the righthand front tire and wheel Remove the righthand front wheelwell splash shield Remove the engine serpentine drive bolt Remove the crankshaft pulley center and outer bots, then the pulley Install Suzuki engine support fixture tool No, J-28487-B, or equivalent 13, Remove the engine righthand mount bracket retaining bots, then the bracket 14 Remove the timing belt front cover retaining bolts, then the 15. Instalthe crankshaft pulley center bolt 16. Rotate the crankshaft clockwise until the sprocket timing mark aligns with the timing belt lower rear cover natch, Fig. 1. 17, Allgn the camshaft sprocket marks with the valve cover notches, Fig. 2. 18. Loosen the automatic tensioner bolt and rotete the hex key tab to eliave the timing bell tension 48, Remove the timing belt 20. Ensure the crankshaft and camshalt sprocket timing marks are all stil propery aligned. 21, Note any running direction marks, then installthe new timing bolt 22, Rotate the automatic tensioner hex key ab clockwise to ten- sion the timing belt. Gontinue rotating until the pointer aligns with the notch, Fig. 3. 28 Install the tensioner bot. Torque to 18 ft. Ibs. 2A Rotate the crankshaft clockwise two full ums and ensure the automatic tensioner pointer tas property aligned. 25, Insta ie timing bet ont over: Torque the Bos to 9 inch 26. Install the righthand engine mount bracket. Torque the bolts fo4t fos 27. Rlemove the engine suppor fixture 28 Install the crankshaft pulley bolls Torque to 15 bs 29 Install the engine serpentine drive belt, 30. Install the splash shield 31. Inetall the tre and wheel, thon lower the vohiclo 52. Torque the lugnuts to 74 Ibs. 233. Inetall the icfiter housing. Torque the bolts to 89 inch Ibe. 34. Connect the air intake tube tothe throttle body & Conrect ine beater ube tothe valve cover ar 38 Connect the MAT sensor electical connector ‘Connect the battery ground cabio Start the engine and ensure it operates property 20L DOHC ENGINE 1 Crankshaft sprocket mark alignment Fig. 2 Camshaft sprocket mark alignment 30-9 jessica cunceoauasasenai a dceSuAtAcnG A nGSOMLCUSRUMAAIOEOMSULLISSERSNAEEFig. 3 Automatic tensioner pointer & notch ‘alignment 30-10 . 2.0L DOHC ENGINE AD AD AD AD woe sol wl me oc mmf wit