Suzuki Esteem, Swift 1994-02

Timing Belt

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General Information



Timing belts are typically only used on overhead camshaft engines. Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain will normally last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to operate the valvetrain of an overhead camshaft engine.

Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage:



Does the owner know if, or when the belt was replaced-
 
If the vehicle purchased is used, or the condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect, replace or at least inform the owner that the vehicle is equipped with a timing belt.
 
Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km).
 

Interference Engines

Engines, chain-or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing were disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time.

An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

Inspection




NOTE
For manufacturers recommended service interval, refer to the maintenance interval chart located in this manual.

The average replacement interval for a timing belt is approximately 60,000 miles (96,000km). If, however, the timing belt is inspected earlier or more frequently than suggested, and shows signs of wear or defects, the belt should be replaced at that time.


WARNING
Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.



Click image to see an enlarged view

Fig. Never bend or twist a timing belt excessively, and do not allow solvents, antifreeze, gasoline, acid or oil to come into contact with the belt

Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist:



Hardening of the rubber-back side is glossy without resilience and leaves no indentation when pressed with a fingernail
 
Cracks on the rubber backing
 
Cracks or peeling of the canvas backing
 
Cracks on rib root
 
Cracks on belt sides
 
Missing teeth or chunks of teeth
 
Abnormal wear of belt sides-the sides are normal if they are sharp, as if cut by a knife
 

If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval.


WARNING
On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails.



Click image to see an enlarged view

Fig. Broken tooth may be due to a damaged pulley



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Fig. Back surface worn or cracked from a possible overheated engine or interference with the belt cover



Click image to see an enlarged view

Fig. Side wear from improper installation



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Fig. Worn teeth from excessive belt tension, camshaft or distributor not turning properly, or fluid leaking on the belt

Removal & Installation




NOTE
The radio may have a coded theft protection circuit. Obtain the code before disconnecting the battery, removing the radio fuse, or removing the radio.


CAUTION
Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for timing belts is 60,000 miles.


CAUTION
On models with an air bag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

1.3L Engines
  1. Remove all necessary components for access to the upper and lower timing belt outside covers, then remove the covers.
  2.  
  3. Align the camshaft timing belt pulley with its timing marks. The crankshaft and camshaft marks are straight up.
  4.  
  5. Remove the resonator and the timing belt outside cover.
  6.  
  7. Remove the tensioner stud and loosen the tensioner bolt.
  8.  
  9. Remove the tensioner spring and damper, then remove the timing belt.
    WARNING
    After the timing belt is removed never turn the camshaft or the crankshaft. Interference may occur between the pistons and the valves causing component damage.

  10.  
  11. Remove the tensioner and the tensioner plate.
  12.  

To install:

  1. Install the timing belt tensioner plate and tensioner. Only hand-tighten the tensioner bolt.
    NOTE
    Be sure that the lug on the tensioner plate is inserted into the hole on the tensioner.

  2.  
  3. Be sure the tensioner plate and the tensioner move uniformly. If they do not move together remove the tensioner and the tensioner plate and reinsert the plate lug into the tensioner hole.
  4.  
  5. Check the camshaft sprocket to verify that it has not moved.
  6.  
  7. Check the crankshaft alignment by verifying that the punch mark on the timing belt pulley is aligned with the arrow on the oil pump case.
  8.  
  9. Remove the cylinder head cover.
    NOTE
    This is to permit the free rotation of the camshaft. When installing the timing belt on the pulleys, the tensioner spring force should correctly tension the belt. If the camshaft does not rotate freely the belt will not be correctly tensioned.

  10.  
  11. With the timing marks aligned, hold the tensioner plate up by hand and install the timing belt on the pulleys so there is no slack on the drive side of the belt.
  12.  
  13. Turn the crankshaft 2 rotations clockwise. Confirm that the timing marks are still properly aligned.
  14.  
  15. If the belt is free of slack and the alignment marks are correct tighten the tensioner stud to 84-96 inch lbs. (9-12 Nm). Tighten the tensioner bolt to 17-21 ft. lbs. (24-30 Nm).
  16.  
  17. Install the timing belt upper and lower outside covers. Tighten the timing cover bolts to 84-96 inch lbs. (9-12 Nm).
  18.  
  19. Install all remaining components in the reverse order of the removal procedure.

    Click image to see an enlarged view

    Fig. View of the timing belt and timing marks-Suzuki 1.0L engine



    Click image to see an enlarged view

    Fig. Match the -V- notch to the -E- mark on the camshaft, and the punch and arrow on the crankshaft to properly position the engine for belt service-Suzuki 1.3L and 1.6L engines

  20.  

1.6L Engine
  1. Remove all necessary components for access to the timing belt covers, then remove the covers.
  2.  
  3. Loosen but do not remove the tensioner bolt.
    CAUTION
    After the timing belt is removed, never turn the camshaft and crankshaft independently. This engine is an interference engine and if the camshaft or crankshaft is turned beyond a certain point, damage to the valves could occur.

  4.  
  5. Loosen the timing belt tensioner adjusting bolt and pivot nut. Apply pressure to the tensioner to loosen the timing belt, and remove the timing belt from the camshaft and crankshaft sprockets.
  6.  
  7. Remove the timing belt tensioner, tensioner plate and tensioner spring.
  8.  

To install:

  1. Install the timing belt tensioner, plate and spring. Hand-tighten the tensioner bolt and stud only at this time.
  2.  
  3. Turn the camshaft sprocket clockwise and align the timing marks.
  4.  
  5. Turn the crankshaft clockwise, using a 17mm wrench to crank the timing belt sprocket bolt.
  6.  
  7. Align the punch mark on the timing belt sprocket with the arrow mark on the oil pump.
  8.  
  9. With the timing marks aligned, remove any slack from the drive side of the belt. Tighten the tensioner bolt to 16-20 ft. lbs. (22-28 Nm).
  10.  
  11. To allow the belt to be free of any slack, turn the crankshaft clockwise 2 full rotations. Confirm that the timing marks are aligned.
  12.  
  13. Install the timing cover and tighten the bolts to 84-96 inch lbs. (9-12 Nm).
  14.  
  15. Install all remaining components in the reverse order of the removal procedure.
  16.  

 
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