Suzuki Esteem, Swift 1994-02

Timing Chain & Sprockets

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Removal & Installation



1.8L Engine
First Timing Chain
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain engine oil.
  6.  
  7. Drain coolant.
  8.  
  9. Remove oil pan.
  10.  
  11. Remove cylinder head cover.
  12.  
  13. Remove timing chain cover.

    Click image to see an enlarged view

    Fig. For reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and lower crankcase match with those on sprockets-1.8L engine

  14.  
  15. For reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and lower crankcase match with those on sprockets as shown in the figure.
  16.  
  17. Remove 2nd timing chain.

    Click image to see an enlarged view

    Fig. Timing chain guide No. 1 (1), timing chain tensioner adjuster No. 1 (2) and timing chain tensioner (3)-1.8L engine

  18.  
  19. Remove timing chain guide No. 1.
  20.  
  21. Remove timing chain tensioner adjuster No. 1.
  22.  
  23. Remove timing chain tensioner.
  24.  
  25. Remove idler sprocket and 1st timing chain.
  26.  
  27. Remove crankshaft timing sprocket.
  28.  

To install:

  1. Check that match mark on crankshaft timing sprocket is in match with timing mark on lower crankcase.
  2.  
  3. Install crankshaft timing sprocket.
  4.  
  5. Apply oil to bush of idler sprocket.
  6.  
  7. Install idler sprocket and sprocket shaft.
  8.  
  9. Install 1st timing chain by aligning dark blue plate of 1st timing chain and match mark on idler sprocket.
  10.  
  11. Bring yellow plate of 1st timing chain into match with match marks on crankshaft timing sprocket.
  12.  
  13. Install timing chain tensioner and tighten the nut to 18 ft. lbs. (25 Nm)

    Click image to see an enlarged view

    Fig. Timing chain tensioner adjuster No. 1 plunger (1), latch (2), adjuster body (3) and stopper (4)-1.8L engine

  14.  
  15. With latch of tensioner adjuster No.1 returned and plunger pushed back into body, insert stopper into latch and body. After inserting it, check to make sure that plunger will not come out.
  16.  
  17. Install timing chain tensioner adjuster No.1 and tighten the bolt to 8 ft. lbs. (11 Nm).
  18.  
  19. Pull out stopper from adjuster No.1.
  20.  
  21. Install timing chain guide No.1 and tighten the timing chain guide No.1 bolt to 7 ft. lbs. (9 Nm).
  22.  
  23. Check that dark blue and yellow plates of 1st timing chain are in match with match marks on sprockets respectively.
  24.  
  25. Install 2nd timing chain.
  26.  
  27. Install timing chain cover.
  28.  
  29. Install cylinder head cover.
  30.  
  31. Install oil pan.
  32.  
  33. Install cooling system and other parts.
  34.  
  35. Refill cooling system with coolant and engine with engine oil.
  36.  
  37. Check to make sure that there is no water leakage and oil leakage at each connection.
  38.  

Second Timing Chain
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain engine oil.
  6.  
  7. Drain coolant.
  8.  
  9. Remove oil pan.
  10.  
  11. Remove cylinder head cover.
  12.  
  13. Remove timing chain cover.

    Click image to see an enlarged view

    Fig. Key on crankshaft (I) (4), arrow mark on idler sprocket (II) (3), marks on sprockets (III) (1) and match with marks on cylinder head (2)-1.8L engine

  14.  
  15. Turn crankshaft to meet the following conditions. Note that this step must be followed for reinstallation of timing chain.

    Key (I) (4) on crankshaft is positioned as shown
     
    Arrow mark on idler sprocket (II) (3) points upward
     
    Marks on sprockets (III) (1), (2) match with marks on cylinder head
     

  16.  
  17. Remove timing chain tensioner adjuster No.2 and gasket. To remove them, slacken 2nd timing chain by turning intake camshaft counterclockwise a little while pushing back pad.
  18.  
  19. Remove intake and exhaust camshaft timing sprocket bolts. To remove them, fit a spanner to hexagonal part at the center of camshaft to hold it stationary.
  20.  
  21. Remove camshaft timing sprockets and 2nd timing chain.
    CAUTION
    After 2nd timing chain is removed, never turn intake camshaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.

  22.  

To install:

  1. Check that match mark on crank timing sprocket is in match with timing mark on lower crankcase as shown in the figure.
  2.  
  3. Check that arrow mark on idler sprocket faces upward.
  4.  
  5. Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head.
  6.  
  7. Install 2nd timing chain by aligning yellow plate of 2nd timing chain and match marks on idler sprocket.
  8.  
  9. Install sprockets to intake and exhaust camshafts by aligning dark blue plate of 2nd timing chain, match marks on intake sprocket and exhaust sprocket respectively.
    CAUTION
    Do not turn more than allowable turning range. If turned excessively, valve and piston may get damaged.


    NOTE
    As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.

  10.  
  11. Install intake and exhaust camshaft timing sprocket bolts and tighten to 58 ft. lbs. (80 Nm). To install it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary.
  12.  
  13. Push back plunger into tensioner body and hold it at the position by inserting stopper into body.
  14.  
  15. Install timing chain tensioner adjuster No. 2 and gasket. Tighten the tensioner adjuster No. 2 bolt to 8 ft. lbs. (11 Nm). Tighten the tensioner adjuster No. 2 nut to 33 ft. lbs. (45 Nm).
  16.  
  17. Pull out stopper from timing chain tensioner adjuster No.2.
  18.  
  19. Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block. Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.
  20.  
  21. Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.
  22.  
  23. Install timing chain cover.
  24.  
  25. Install cylinder head cover.
  26.  
  27. Install oil pan.
  28.  
  29. Install cooling system and other parts.
  30.  
  31. Refill cooling system with coolant and engine with engine oil.
  32.  
  33. Check to make sure that there is no water leakage and oil leakage at each connection.
  34.  

 
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