Suzuki Aerio, Verona 2002-06

Timing Belt Front Cover

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Removal & Installation



5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The cross stay between the suspension turrets
     
    The servo reservoir and the expansion tank. Lift up and place on top of the engine.
     
    The accessory drive belt, refer to Accessory Drive Belts removal and installation
     
    The upper timing belt cover
     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    Ensure that the hoses are correctly positioned.



    Front timing belt cover. Tighten to 106 inch lbs. (12 Nm).
     
    Upper timing belt cover
     
    Accessory drive belt
     
    Servo reservoir
     
    Expansion tank
     



    Cross stay brace and tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm)
     
    Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     
    Fender liner cover
     
    Front wheel and tighten the lug nuts to 102 ft. lbs. (138 Nm).
     

  2.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove:

    The bolt holding the engine stabilizer brace to the bracket on the engine
     
    The bolts holding the engine stabilizer brace to the suspension turrets
     
    The engine stabilizer brace.
     

  4.  
  5. Remove the plastic pipes between the turbocharger and charge air cooler and between the air cleaner and turbocharger. Put them to one side.
  6.  
  7. Remove the clamp from the intake manifold for the turbocharger for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the firewall.
  8.  
  9. Relieve the load from the belt tensioner and remove the accessory drive belt.
  10.  
  11. Remove the upper timing belt cover.
  12.  
  13. Remove front timing belt cover.
  14.  

To install:

  1. Install or connect the following:

    Front timing belt cover. Tighten to 106 inch lbs. (12 Nm)
     
    Upper timing belt cover
     
    Accessory drive belt
     
    Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp.
     
    Install the plastic hoses between the turbocharger and charge air cooler and between the air cleaner and turbocharger.
     
    Tighten the hose clamps.
     

  2.  
  3. Install:

    Engine stabilizer brace and tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm)
     
    Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     

  4.  

 
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