Suzuki Forenza, Reno 2003-06

Timing Belt Rear Cover

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Removal & Installation




NOTE
Tools required. KM-470-B Angular Torque Gauge.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the Manifold Air Temperature (MAT) sensor connector.
  6.  
  7. Disconnect the air cleaner outlet hose from the throttle body.
  8.  
  9. Disconnect the breather tube from the camshaft cover.
  10.  
  11. Remove the air cleaner housing bolts.
  12.  
  13. Remove the air cleaner housing.
  14.  
  15. Remove the right front wheel.
  16.  
  17. Remove the right front wheel well splash shield.
  18.  
  19. Remove the serpentine drive belt.
  20.  
  21. Remove the crankshaft pulley bolts and the crankshaft pulley.
  22.  
  23. Remove the right engine mount bracket.
  24.  
  25. Remove the front timing belt cover bolts.
  26.  
  27. Remove the front timing belt cover.
  28.  
  29. Using the crankshaft gear bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.

    Click image to see an enlarged view

    Fig. Aligning the timing mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.



    Click image to see an enlarged view

    Fig. Aligning the camshaft gears with the notches on the camshaft cover.

  30.  
  31. Align the camshaft gears with the notch on the camshaft cover.
  32.  
  33. Remove the timing belt.
  34.  
  35. Loosen the automatic tensioner bolt. Turn the hex-key tab to relieve belt tension.
  36.  
  37. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  38.  
  39. Remove the intake camshaft gear.
  40.  
  41. Remove the Camshaft Position (CMP) sensor.
  42.  
  43. Remove the water pump.
  44.  
  45. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  46.  
  47. Remove the exhaust camshaft gear.
  48.  
  49. Remove the timing belt automatic tensioner bolt.
  50.  
  51. Remove the timing belt automatic tensioner.
  52.  
  53. Remove the timing belt idler pulley bolt and nut.
  54.  
  55. Remove the timing belt idler pulleys.
  56.  
  57. Remove the engine mount retaining bolts.
  58.  
  59. Remove the engine mount.
  60.  
  61. Remove the crankshaft gear bolt.
  62.  
  63. Remove the crankshaft gear.
  64.  
  65. Remove the rear timing belt cover bolts.
  66.  
  67. Remove the rear timing belt cover.
  68.  

To install:

  1. Install the rear timing belt cover.
  2.  
  3. Install the rear timing belt cover bolts.
  4.  
  5. Tighten the rear timing belt cover bolts to 62 inch lbs. (7 Nm)
  6.  
  7. Install the engine mount and retaining bolts.
  8.  
  9. Tighten the engine mount retaining bolts to 33 ft lbs. (45 Nm)
  10.  
  11. Install the timing belt idler pulleys.
  12.  
  13. Install the timing belt idler pulley bolt and nut.
  14.  
  15. Tighten the timing belt idler pulley bolt to 18 ft lbs. (25 Nm)
  16.  
  17. Tighten the timing belt idler pulley nut to 18 ft lbs. (25 Nm)
  18.  
  19. Install the crankshaft timing belt drive gear and bolt.
  20.  
  21. Tighten the crankshaft gear bolt to 107 ft lbs. (145 Nm) plus 30 degrees and plus 15 degrees using the angular torque gauge KM-470-B.
  22.  
  23. Install the timing belt automatic tensioner and bolt.
  24.  
  25. Install the camshaft gears.
  26.  
  27. Install the timing belt and timing belt cover.
  28.  
  29. Connect the negative battery cable.
  30.  

 
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