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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 131 (2.0L 4-Cylinder) >> Repair Instructions >> Timing Chain Cover Removal & Installation >> Removal

Timing Chain Cover Removal & Installation: Removal

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative cable at battery.
  2. Drain engine oil.
  3. Drain coolant.
  4. Remove oil pan and oil pump strainer. See OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION .
  5. Remove cylinder head cover. See CYLINDER HEAD COVER REMOVAL & INSTALLATION .
  6. Remove water bypass pipe (1) and bypass hose No.2 (2).
  7. Remove cooling fan and fan shroud. See COOLING FAN AND FAN CLUTCH REMOVAL & INSTALLATION . And then remove cooling fan belt and cooling fan pulley (3).
  8. Remove generator belt by turning generator belt tensioner center bolt clockwise to loosen tension of generation belt. See COOLING FAN BELT REMOVAL & INSTALLATION .
  9. Remove water pump pulley (4).
  10. Remove generator belt tensioner (5).
    Fig 1: Identifying Water Pump Pulley, Cooling Fan Pulley & Generator Belt Tensioner
    G01351838Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove generator belt idler pulley (1).
  12. Disconnect radiator outlet hose (3) from thermostat cap.
  13. With hoses connected, detach A/C compressor from compressor bracket if equipped.
  14. Remove A/C compressor bracket (2), if equipped.
    Fig 2: Identifying Radiator Outlet Hose, Generator Belt Idler Pulley & A/C Compressor Bracket
    G01351839Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool (camshaft pulley holder) with it as shown in the figure.

    Special tool 

    1. (A):  09917-68221
    Fig 3: Removing Crankshaft Pulley Bolt
    G01351840Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Be sure to use the following bolt for fixing special tool to crankshaft pulley.
    Bolt size:  M8, P 1.25, L = 45 mm
    Strength:  7T
    Fig 4: Identifying Bolt Length
    G01351841Courtesy of SUZUKI OF AMERICA CORP.
  16. Remove crankshaft pulley (1).

    If it is hard to remove, use special tools (Steering wheel remover and Bearing puller attachment) as shown in the figure.

    If bolts of steering wheel remover are too long, replace them with those of suitable length.

    Special tool 

    1. (A):  09944-36011
    2. (B):  09926-58010
    Fig 5: Removing Crankshaft Pulley
    G01351842Courtesy of SUZUKI OF AMERICA CORP.
  17. Remove timing chain cover.
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