Suzuki Aerio, Verona 2002-06

Timing Belt & Sprockets

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Removal & Installation



5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Remove the ignition key.

  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
     
    The front timing belt cover.
     
    The right front wheel
     
    The nut from the cover in the fender liner
     

  4.  
  5. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond
  6.  
  7. Turn the crankshaft a further 1 / 4 turn clockwise and then back again until the markings correspond. The markings are illustrated.
  8.  
  9. Remove the upper timing belt cover.
  10.  
  11. Back off the center bolt of the belt tensioner slightly.
  12.  
  13. Hold the center bolt still. Turn the tensioner eccentric clockwise, using a 6mm Allen key, to 10 o'clock.
  14.  
  15. Remove the timing belt from the tension pulley, camshaft pulley, and water pump.
  16.  
  17. Remove the crankshaft damper, refer to Crankshaft Damper removal and installation.
  18.  
  19. Remove the timing belt.
  20.  
  21. Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 18 ft. lbs. (24 Nm).
  22.  
  23. Spin the tension pulley and listen for noise. Replace if necessary
  24.  
  25. Ensure that the tensioner fork is centered over the cylinder block rib.
  26.  
  27. Ensure that the Allen hole on the eccentric is at "10 o'clock".

    Click image to see an enlarged view

    Fig. Timing mark alignment



    Click image to see an enlarged view

    Fig. Belt tensioner-5-cylinder engine



    Click image to see an enlarged view

    Fig. Timing belt installed



    Click image to see an enlarged view

    Fig. Tension indicator at different temperatures

  28.  

To install:

  1. Install the timing belt over the pulley on the crankshaft.
  2.  
  3. Install the crankshaft damper. Tighten the center nut. Tighten to 133 ft. lbs. (180 Nm).
  4.  
  5. Remove the counterhold and install new bolts. Tighten to 18 ft. lbs. (25 Nm) and angle-tighten 30°.
  6.  
  7. Install or connect the following:
    NOTE
    The following adjustment is carried out on a cold engine. A suitable temperature is approximately 68°F. At higher temperatures, for example with the engine at operating temperature or at higher ambient temperature, the needle is further to the right. The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.



    Crankshaft pulley
     
    The idler pulley
     
    Intake camshaft pulley
     
    Exhaust camshaft pulley
     
    Water pump
     
    Belt tensioner.
     

  8.  
  9. Tension the timing belt as follows:

    Turn the crankshaft clockwise carefully until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley, and the crankshaft
     
    Hold the center bolt on the belt tensioner secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window
     
    Hold the eccentric secure and tighten the center bolt. Tighten to 15 ft. lbs. (20 Nm). Check that the indicator is in the correct position
     

  10.  
  11. To check the alignment:

    Press the belt to check that the indicator on the tensioner moves easily
     
    Install the upper timing belt cover
     
    Turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond
     
    Check that the indicator on the belt tensioner is within the marked area
     

  12.  
  13. Install or connect the following:
    NOTE
    Ensure that the hoses are correctly positioned.



    The front timing belt cover. Tighten to 106 inch lbs. (12 Nm)
     
    The upper timing belt cover
     
    Install the accessory drive belt
     
    The servo reservoir
     
    The expansion tank
     



    The engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm)
     
    Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     
    The cover in the fender liner
     
    The front wheel and tighten the lug nuts to 102 ft. lbs. (138 Nm)
     

  14.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Remove the ignition key.

  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. Remove the accessory drive belt.
  10.  
  11. Remove the upper timing belt cover.
  12.  
  13. Remove the front timing belt cover:
    1. The air duct, cover, surround, and control module box
    2.  
    3. The hose between the thermostat housing and the expansion tank
    4.  
    5. The front timing belt cover
    6.  

  14.  
  15. Lift up the servo reservoir and place it on top of the engine.
    NOTE
    Ensure that the oil does not leak from the ventilation hole in the filler cap.

  16.  
  17. Seal the hose between the expansion tank and the radiator. Disconnect the hose at the tank.
  18.  
  19. Lift up the expansion tank and place it on top of engine.
  20.  
  21. Raise the car.
  22.  
  23. Remove:

    The right front wheel
     
    The plastic nuts on the cover in the fender liner.
     

  24.  
  25. Install the upper timing belt cover.
  26.  
  27. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.
  28.  
  29. Turn the crankshaft a further 1 / 4 turn clockwise.
  30.  
  31. Then turn back counter-clockwise until the markings correspond.
  32.  
  33. Remove the upper timing belt cover.
  34.  
  35. Remove the 4 crankshaft damper bolts. Counterhold the crankshaft center nut.
  36.  
  37. Remove:

    The crankshaft damper
     
    The accessory drive belt
     
    The belt cover behind the crankshaft pulley for the accessory drive belt
     

  38.  
  39. Spray universal oil or similar around the rubber sleeve on the underside of the oil pump.
  40.  
  41. Remove the rubber sleeve.
  42.  
  43. Slacken off the center bolt for the belt tensioner slightly.
  44.  
  45. Hold the center bolt still. Turn the tensioner eccentric counter-clockwise using a 6mm Allen key. Turn to 10 o'clock.
  46.  
  47. Unhook and remove the timing belt.
    CAUTION
    Do not turn the camshafts or the crankshaft when the timing belt has been removed.

  48.  
  49. Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 17 ft. lbs. (24 Nm).
  50.  
  51. Spin the tension pulley and listen for noise. Replace if necessary.
  52.  

To install:

  1. Ensure that the tensioner fork is centered over the cylinder block rib bracket.
  2.  
  3. Ensure that the Allen hole on the eccentric is at 10 o'clock.
  4.  
  5. Install the timing belt in this order:
    NOTE
    Belt tension adjustment is carried out on a cold engine. A suitable temperature is approximately 68°F (20°C).



    Crankshaft
     
    Idler pulley
     
    Intake cam
     
    Exhaust cam
     
    Water pump
     
    Tension pulley
     

  6.  
  7. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
  8.  
  9. The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
  10.  
  11. Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be in tension between the intake camshaft pulley, the idler pulley, and the crankshaft.
  12.  
  13. Hold the belt tensioner center bolt secure. Turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position.
  14.  
  15. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
  16.  
  17. Hold the eccentric secure. Tighten the center bolt to 18 ft. lbs. (25 Nm).
  18.  
  19. Check that the indicator is in the correct position.
  20.  
  21. Press the belt to check that the indicator on the tensioner moves easily.
  22.  
  23. Install the upper timing belt cover.
  24.  
  25. Turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond.
  26.  
  27. Check that the indicator on the belt tensioner is within the marked area.
  28.  
  29. Install the accessory drive belt around the pulley on the crankshaft.
  30.  
  31. Install:

    The rubber sleeve on the underside of the oil pump
     
    The crankshaft damper. Use new bolts. Tighten to 133 ft. lbs. (180 Nm).
     
    The plastic nuts for the cover in the right-hand fender liner
     
    The right front wheel. Tighten lug nuts to 102 ft. lbs. (138 Nm)
     

  32.  
  33. Lower the car.
  34.  
  35. Remove the front timing belt cover.
  36.  
  37. Tension the accessory drive belt.
  38.  
  39. Install the front cover:
    1. The front timing belt cover
    2.  
    3. The hose between the thermostat housing and the expansion tank
    4.  
    5. The surround, cover and air ducts for the control module box
    6.  

  40.  
  41. Install:

    The expansion tank
     
    The hose between the expansion tank and the radiator
     
    The servo reservoir
     
    The upper timing belt cover
     

  42.  
  43. Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp.
  44.  
  45. Install the plastic hoses between the turbocharger and charge air cooler and between the air cleaner and turbocharger.
  46.  
  47. Tighten the hose clamps.
  48.  
  49. Install:

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

  50.  
  51. Check:

    Coolant level
     
    The servo fluid level
     

  52.  

 
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