Timing belt tension in struction - 2005 Suzuki Forenza

Chain belt? Don't think so. There is a timing chain and a timing belt. Timing chains on automobiles are generally non adjustable and are tensioned by a hydraulic tensioner and require no attention. Some timing belts are also tensioned by a hydraulic tensioner requiring no service. Some timing belts are also tensioned by a cam tensioner that can be adjusted but are rarely in need of servive unless the timing belt is being replaced

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Fig. Fig. 14: Sprocket timing for belt installation-3.0L engines

Fig. Fig. 15: Secure the sprocket when removing or installing the nut-3.0L engines

Fig. Fig. 16: Timing belt tensioner-3.0L engines

Fig. Fig. 17: Positioning the tensioner-3.0L engines
The timing belt can be inspected by removing the upper (front outer) timing cover.

1. Disconnect the negative battery cable.
2. Remove the accessory drive belts.
3. Remove the timing belt covers.
4. Identify the timing belt running direction to avoid reversal during installation.
5. Loosen timing belt tensioner bolt and remove timing belt.
6. Remove the crankshaft sprocket flange.

To install:

1. Rotate the crankshaft sprocket until timing mark on crankshaft sprocket is lined up with the oil pump timing mark at 1 o'clock position.
2. Rotate the (inner) camshaft sprocket until mark on (inner) camshaft sprocket is lined up with the timing mark on alternator bracket.
3. Rotate the (outer) camshaft sprocket (radiator side) until mark on the sprocket is lined up with the timing mark on the timing belt inner cover. Refer to timing belt illustration.
4. Install the timing belt on the crankshaft sprocket while maintaining pressure on the tensioner side.
5. Position the timing belt over the camshaft sprocket (radiator side). Next, position the belt under the water pump pulley, then over the (inner) sprocket and finally over the tensioner.
6. Apply rotating force in the opposite direction to the camshaft sprocket (radiator side) to create tension on the timing belt tension side.
7. Rotate the crankshaft in a clockwise direction and recheck engine timing marks.
8. Install the crankshaft sprocket flange.
9. Loosen the tensioner bolt and allow tensioner spring to tension the belt.
10. Again rotate the crankshaft in a clockwise direction (2) full turns. Recheck the engine timing. Tighten the tensioner bolt to 23 ft. lbs. (31 Nm).
11. Install the timing covers.
12. Install the accessory drive belts.
13. Connect battery negative cable.

.6L (VIN 3) & 2.0L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
   

2. Remove or disconnect the following:
   

   • Negative battery cable
     

   • Engine cover
     

   • Right-hand front wheel
     

   • Right-hand wheel well side cover
     

   • Accessory drive belts
     

   • Water pump pulley
     

   • Timing belt upper cover
     

3. Turn the crankshaft pulley so cylinder No. 1 is at Top Dead Center (TDC). Align the pulley groove with the timing mark "T" of the timing belt cover.
   

4. Remove or disconnect the following:
   

   • Crankshaft pulley
     

   • Crankshaft flange
     

   • Lower timing belt cover
     

   • Timing belt tensioner
     

   • Timing belt To install:Align the timing marks of the camshaft and crankshaft sprockets to ensure the No. 1 cylinder is at TDC.Temporarily install the timing belt tensioner.Install the timing belt over the crankshaft sprocket, then inside the idler pulley, over the camshaft sprocket and then inside the timing belt tensioner.Apply tension to the timing belt by turning the tensioner in the clockwise direction so there is no slack in the belt on the tension side.Tighten the tensioner mounting bolts to 20 ft. lbs. (27 Nm).Check the timing belt tension as follows:
     

1. • 1.6L (VIN 3) engine: Push the tension side of the belt in horizontally with a moderate force, the timing belt cog end is approximately 1/2 of the tensioner mounting bolt head radius away from the bolt head center.
     

   • 2.0L engine: Push the tension side of the belt in horizontally with a moderate force, the timing belt cog end sags approximately 0.16-0.24 inches (4-6 mm).
     

2. Turn the crankshaft two turns in the clockwise direction and realign the crankshaft sprocket and camshaft sprocket timing marks.
   

from autozone.com

Removal & Installation

1.5L, 1.6L (VIN 5) & 1.8L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Remove the accessory drive belts.
4. Remove the alternator.
5. Remove the water pump and crankshaft pulleys.
6. Remove the timing belt guide plate.
7. Remove the upper and lower timing belt covers.
8. Position the crankshaft so that the timing mark is aligned with the timing mark on the engine.
9. Verify that the I and E mark on the camshaft pulley align with the mark on the cylinder head.
   NOTE Do not move the crankshaft or camshaft once the timing marks have been correctly positioned.
   
10. If the timing belt is to be reused, mark the direction of rotation on the timing belt.
11. Remove the timing belt tensioner pulley.
12. Remove the timing belt.
    

To install:

1. Install the timing belt tensioner pulley, move the tensioner to its furthest point and tighten the lockbolt.
2. Install the timing belt onto the pulleys, as follows, crankshaft pulley first, then the idler pulley, exhaust camshaft pulley, intake camshaft pulley, and the tensioner pulley.
3. Loosen the tensioner pulley and allow the tensioner spring to apply tension on the belt, then tighten the lockbolt to 28-38 ft. lbs. (38-51 Nm).
4. Rotate the crankshaft clockwise 2 turns and be sure all marks are still correctly aligned.
5. Install the remaining components in the revere order of the removal noting the following torque specifications:
   
   Crankshaft pulley: 9-13 ft. lbs. (12-17 Nm) Water pump pulley: 9-13 ft. lbs. (12-17 Nm)
   
6. Connect the negative battery cable.

1.6L (VIN 3) & 2.0L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   Negative battery cable Engine cover Right-hand front wheel Right-hand wheel well side cover Accessory drive belts Water pump pulley Timing belt upper cover
   
3. Turn the crankshaft pulley so cylinder No. 1 is at Top Dead Center (TDC). Align the pulley groove with the timing mark T of the timing belt cover.
4. Remove or disconnect the following:
   NOTE If the timing belt is to be reused, mark the belt to indicate its turning direction.
   
   
   Crankshaft pulley Crankshaft flange Lower timing belt cover Timing belt tensioner Timing belt
   

To install:

1. Align the timing marks of the camshaft and crankshaft sprockets to ensure the No. 1 cylinder is at TDC.
2. Temporarily install the timing belt tensioner.
3. Install the timing belt over the crankshaft sprocket, then inside the idler pulley, over the camshaft sprocket and then inside the timing belt tensioner.
4. Apply tension to the timing belt by turning the tensioner in the clockwise direction so there is no slack in the belt on the tension side.
5. Tighten the tensioner mounting bolts to 20 ft. lbs. (27 Nm).
6. Check the timing belt tension as follows:
   1. 1.6L (VIN 3) engine: Push the tension side of the belt in horizontally with a moderate force, the timing belt cog end is approximately 1 / 2 of the tensioner mounting bolt head radius away from the bolt head center.
   2. 2.0L engine: Push the tension side of the belt in horizontally with a moderate force, the timing belt cog end sags approximately 0.16-0.24 inches (4-6 mm).
   
   
7. Turn the crankshaft two turns in the clockwise direction and realign the crankshaft sprocket and camshaft sprocket timing marks.
8. Install or connect the following:
   
   Lower timing belt cover. Tighten bolts to 6-7 ft. lbs. (8-10 Nm). Crankshaft flange Crankshaft pulley. Tighten bolt to 101-109 ft. lbs. (138-147 Nm) for 1.6L (VIN 3) engine and 123-130 ft. lbs. (168-177 Nm) for 2.0L engine. Upper timing belt cover. Tighten bolts to 6-7 ft. lbs. (8-10 Nm). Water pump pulley Accessory drive belts Right-hand wheel well side cover Right-hand front wheel Engine cover Negative battery cable

Did you compress the timing belt tensioner?

There should be a small hole in the upper part of the timing belt tensioner housing and also on the end of the timing belt tensioner plunger, and the plunger must be compressed back into the tensioner housing until you can place a small allen wrench or something similar through the holes in the tensioner housing and the plunger to hold the plunger down and from putting tension on the timing belt until the timing belt has been installed.

Once you are sure that the timing belt is installed properly then you can pull out what you have holding the tensioner plunger and allow the timing belt to be tensioned.

If you are unsure of the procedure to compress the tensioner, or of the condition of the timing belt tensioner, then just replace the tensioner, it will come already compressed with a pin through it holding the plunger, and do not remove the holding pin until the timing belt is properly installed with all of the timing marks in their correct places.

Timing belt “B” (balancer belt) and related components—2004–2005 Galant and 2004–2005 Lancer 2.4L engine

1. Disconnect the negative battery cable. Remove the engine under cover.
   
2. Remove the crankshaft damper pulley.
   
3. Disconnect the control wiring harness connector, battery wiring harness connector and connector bracket to engine mounting insulator.
   
4. Remove the harness bracket. Remove the upper timing belt cover. Remove the water pump pulley. Remove the idler pulley.
   
5. Remove the auto tensioner. Remove the lower timing belt cover.
   
6. Turn the crankshaft clockwise and align each timing mark to set the number one piston to TDC of its compression stroke.
   
7. Remove the timing belt under cover rubber plug and then install special tool MD998738. Screw the special tool until it contacts the timing belt tensioner arm.
   
   NOTE The special tool must be screwed in gradually at the rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the tool may bend.
   
   
8. Gradually screw in the special tool and then align the timing belt tensioner adjuster rod set hole “A” with the timing belt tensioner adjuster cylinder set hole “B”.
   
9. Insert a wire or pin in the set holes to lock the assembly in place. After removing the special tool, loosen the timing belt tensioner pulley mounting bolts and remove the timing belt. If the belt is being reused be sure to mark the direction of rotation (clockwise) on the belt.
   
10. Remove the timing belt tensioner pulley, tensioner arm and adjuster.
    
11. Remove the timing belt idler pulley. Remove the timing belt lower cover bracket. Remove the crankshaft position sensor.
    
12. Remove the crankshaft pulley center bolt and washer. Remove the drive sprocket. Remove the crankshaft angle sensing blade.
    
13. Remove the balancer timing belt tensioner. Remove the timing belt “B” (balancer belt) from its mounting.
    

Timing belt tensioner adjuster rod set hole “A” and cylinder set hole “B”—2004–2005 Galant and 2004–2005 Lancer 2.4L engine

To install:



Belt tension checking—2004–2005 Galant and 2004–2005 Lancer 2.4L engine



Cylinder block plug location—2004–2005 Galant and 2004–2005 Lancer 2.4L engine



Timing belt sprocket alignment—2002–2004–2005 Galant and 2004–2005 Lancer 2.4L engine

3.5L Engine

Remove or disconnect the following:

1. Negative battery cable
   

• Engine coolant
  
• Water pump pulley bolts
  
• Alternator bolt, loosen only
  
• Water pump pulley and drive belts
  
• Crankshaft pulley
  
• Timing belt cover(s)
  

1. Turn the crankshaft until the timing marks on the camshaft sprocket and cylinder head are aligned.
   
2. Loosen the timing belt tensioner bolt and turn the tensioner counterclockwise as far as it will go. Tighten the adjusting bolt.
   
3. Mark the timing belt with an arrow showing direction of rotation.
   
4. Remove the timing belt.
   
5. If defective, remove the timing belt tensioner.
   

Timing belt sprocket alignment mark positioning for belt removal and installation—3.5L engine

To install:

1. If necessary, install the timing belt tensioner.
   
2. Attach the top of the tensioner spring on the engine coolant pump pin. Ensure the hook on the pin is facing down and the hook on the tensioner is facing away from the engine
   
3. Rotate the timing belt tensioner to the extreme counterclockwise position. Temporarily lock the tensioner in place.
   
4. Align the timing marks of the camshaft and crankshaft sprockets.
   
5. Install the timing belt on the crankshaft sprocket, then onto the rear camshaft sprocket.
   
6. Route the belt to the coolant pump pulley, the front camshaft sprocket and the timing belt tensioner.
   
7. Apply force counterclockwise to the rear camshaft sprocket with tension on the tight side of the belt and check that timing marks are aligned.
   
8. Loosen the tensioner bolt 1–2 turns and tighten the timing belt to a tension of 57–84 lbs. (260–380 N).
   
9. Turn the crankshaft two turns clockwise.
   
10. Readjust the sprocket timing marks and tighten the tensioner bolts.
    
11. Install the timing belt covers.
    
12. Install the crankshaft pulley and tighten to 108–116 ft. lbs. (150–160 Nm).
    
13. Install or connect the following:
    
    • Timing belt cover(s)
      
    • Crankshaft pulley
      
    • A/C compressor belt
      
    • Water pump pulley
      
    • V belt
      
    • Negative battery cable
      
    • Engine with coolant
      

1. Remove all necessary components for access to the timing belt cover, then remove the cover.
2. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at Top Dead Center (TDC) of the compression stroke.
3. Loosen the tensioning bolt and the pivot bolt on the timing belt tensioner. Move the tensioner as far as it will go toward the water pump. Tighten the adjusting bolt.
4. Mark the timing belt with an arrow showing direction of rotation.
5. Remove the timing belt.
6. If defective, remove the timing belt tensioner.
7. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
8. If removed, install the timing belt tensioner, spring and spacer with the bottom end of the spring free. Tighten the adjusting bolt slightly with the tensioner moved as far as possible away from the water pump.
9. Install the free end of the spring into the locating tang on the front case.
10. Position the timing belt over the crankshaft sprocket, then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel.
11. Turn the camshaft sprocket in the opposite of its normal direction of rotation until the straight side of the belt is tight and be sure the timing marks align.
    NOTE If the timing marks are not properly aligned, shift the belt 1 tooth at a time in the appropriate direction until they are aligned.
    
12. Loosen the tensioner mounting bolts so the tensioner works, without the interference of any friction, under spring pressure. Be sure the belt follows the curve of the camshaft pulley so the teeth are engaged all the way around. Correct the path of the belt, if necessary.
13. Tighten the tensioner adjusting bolt, then the tensioner pivot bolt to 15-18 ft. lbs. (20-26 Nm).
    NOTE Bolts must be tightened in the stated order or tension won't be correct.
    
14. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt.
15. Loosen both tensioner attaching bolts and let the tensioner position itself under spring tension. Retighten the bolts.
16. Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward the water pump. The belt should move toward the pump until the teeth are approximately 1 / 2 of the way across the head of the tensioner adjusting bolt. Re-tension the belt, if necessary.
17. Install the timing belt covers and all other related components.