Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Belts

Print

INSPECTION



See Figures 1, 2, 3, 4, 5, 6 and 7

The 1.3L and 1.6L engines utilize only poly-V belts, whereas the 1.8L engine uses one poly-V belt and one serpentine belt. The 1.8L poly-V belt is referred to as the fan drive belt, and the serpentine belt is referred to as the alternator drive belt, although it also drives most of the other accessories as well.

Inspect the belts for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately. It is best to replace all drive belts at one time, as a preventive maintenance measure, during this service operation.



Click image to see an enlarged view

Fig. Fig. 1: There are typically 3 types of accessory drive belts found on vehicles today



Click image to see an enlarged view

Fig. Fig. 2: An example of a healthy drive belt



Click image to see an enlarged view

Fig. Fig. 3: Deep cracks in this belt will cause flex, building up heat that will eventually lead to belt failure



Click image to see an enlarged view

Fig. Fig. 4: The cover of this belt is worn, exposing the critical reinforcing cords to excessive wear



Click image to see an enlarged view

Fig. Fig. 5: Installing too wide a belt can result in serious belt wear and/or breakage

For poly-V belts, inspect the accessory drive belt tension. The belt should deflect 1 / 4 - 1 / 3 in. (6-9mm) under thumb pressure (approximately 22 lbs. or 10 kg) at the mid-point of the belt. If the belt deflection is not as specified, adjust the belt tension.



Click image to see an enlarged view

Fig. Fig. 6: To inspect the tension of a poly-V belt, use your thumb to depress the belt at the mid-point



Click image to see an enlarged view

Fig. Fig. 7: The serpentine belt tension indicator shows whether or not the belt is properly tensioned-1.8L engine

For the 1.8L engine serpentine belt, tension is indicated by the tension indicator. The serpentine belt tension indicator should point within the proper range (refer to the accompanying illustration). If the indicator does not point in the proper range, the serpentine belt should be replaced.

It may be necessary to use a mirror to read the serpentine belt indicator position.

ADJUSTMENT



1.3L and 1.6L Engines

See Figure 8

Although used drive belts should have a belt deflection of1/4-1/3in. (6-9mm) under thumb pressure (approximately 22 lbs. or 10 kg) at the mid-point of the belt, when adjusting a new drive belt a deflection of 0.16-0.19 in. (4-5mm).

If the accessory drive belt is too tight or loose, adjust it to specification by moving the alternator, A/C compressor or power steering pump (depending on the particular belt).

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: To adjust the tension of the accessory drive belt, loosen the pivot and adjusting bolts, then move the component until the proper tension is reached

  1. Loosen the component's pivot and adjusting bolts until it can be repositioned.
  2.  

On 4WD Sidekick, X-90 and Tracker models, the rear alternator pivot bolt can be difficult to loosen. The best way to loosen and tighten this bolt is to use a stubby combination wrench on the pivot bolt head and a second wrench on the open end of the stubby wrench for leverage.

  1. Using a padded prybar, carefully move the component away from the engine until the belt is properly tensioned, then tighten the adjusting and pivot bolts securely.
  2.  
  3. Connect the negative battery cable.
  4.  

1.8L Engine

FAN DRIVE BELT

See Figure 9

Although used drive belts should have a belt deflection of1/4-1/3in. (6-9mm) under thumb pressure (approximately 22 lbs. or 10 kg) at the mid-point of the belt, when adjusting a new drive belt a deflection of 0.16-0.19 in. (4-5mm).

If the accessory drive belt is too tight or loose, adjust it to specification by moving the fan pulley assembly, as follows:

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: The fan pulley assembly can be moved toward or away from the crankshaft pulley to adjust the fan drive belt tension

  1. Loosen the fan pulley assembly pivot and adjusting bolts until it can be moved.
  2.  
  3. Using a padded prybar, carefully move the fan pulley assembly away from the crankshaft pulley until the belt is properly tensioned, then tighten the adjusting and pivot bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Connect the negative battery cable.
  6.  

ALTERNATOR DRIVE BELT

The serpentine belt utilizes an automatic tensioner assembly, and cannot be manually adjusted. If the belt is out of adjustment, replace it with a new one.

REMOVAL & INSTALLATION



1.3L and 1.6L Engines

See Figures 10 and 11

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the component's pivot and adjusting bolts until it can be repositioned.
  4.  
  5. Push the component toward the engine to release the belt tension, and until the belt can be removed from all applicable pulleys.
  6.  



Click image to see an enlarged view

Fig. Fig. 10: Accessory drive belt routing on models equipped with power steering



Click image to see an enlarged view

Fig. Fig. 11: Accessory drive belt routing for models with air conditioning only (top), and with air conditioning with power steering (bottom)

To install:
  1. Position the accessory drive belt in the pulley grooves, then using a padded prybar, carefully move the component away from the engine until the belt is properly tensioned. Tighten the adjusting and pivot bolts securely.
  2.  

Although used drive belts should have a belt deflection of1/4-1/3in. (6-9mm) under thumb pressure (approximately 22 lbs. or 10 kg) at the mid-point of the belt, when adjusting a new drive belt a deflection of 0.16-0.19 in. (4-5mm).

  1. Connect the negative battery cable.
  2.  

1.8L Engine

FAN DRIVE BELT
  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the fan pulley assembly pivot and adjusting bolts until it can be repositioned.
  4.  
  5. Push the component toward the crankshaft pulley to release the belt tension, and until the belt can be removed from both pulleys.
  6.  

To install:
  1. Position the accessory drive belt in the pulley grooves, then using a padded prybar, carefully move the fan pulley assembly away from the crankshaft pulley until the belt is properly tensioned. Tighten the adjusting and pivot bolts to 37 ft. lbs. (50 Nm).
  2.  

Although used drive belts should have a belt deflection of1/4-1/3in. (6-9mm) under thumb pressure (approximately 22 lbs. or 10 kg) at the mid-point of the belt, when adjusting a new drive belt a deflection of 0.16-0.19 in. (4-5mm).

  1. Connect the negative battery cable.
  2.  

ALTERNATOR DRIVE BELT

See Figure 12

  1. Disconnect the negative battery cable.
  2.  

Before removing the belt, note its routing around all applicable pulleys for ease of installation.

  1. Using a box end wrench on the tensioner pulley center bolt, rotate the tensioner assembly clockwise.
  2.  
  3. While holding the tensioner in this position, remove the alternator drive belt from one or two of the applicable pulleys.
  4.  



Click image to see an enlarged view

Fig. Fig. 12: Use a box end wrench to rotate the tensioner pulley assembly clockwise to relieve serpentine belt tension

  1. Slowly release the tensioner, and remove the box end wrench from the center bolt.
  2.  
  3. Remove the alternator drive belt from the remaining applicable pulleys.
  4.  

To install:

When installing the drive belt on the pulleys, ensure that it is properly seated in all of the pulley grooves.

  1. Using the box end wrench, rotate the tensioner clockwise again, then position the drive belt on all of the pulleys.
  2.  
  3. Slowly release the tensioner until it eliminates all drive belt slack.
  4.  
  5. Inspect the tensioner indicator to be sure that the belt is properly tensioned. If the belt tension is incorrect, the belt should be replaced with a new one, or, if installing a new belt, the belt may not be the correct belt for your vehicle.
  6.  
  7. Connect the negative battery cable, then start the engine. Ensure that the drive belt works properly.
  8.  
  9. Stop the engine, then double-check to ensure that the belt is properly seated on all applicable pulleys.
  10.  

 
label.common.footer.alt.autozoneLogo