2004 Forenza Timing Belt
My first recommendation would be buy the factory service manuals for this car. There're currently some up for auction on ebay for $60-$70http://cgi.ebay.com/ebaymotors/2004-Suzuki-FORENZA-RQ420-OEM-Shop-Service-Manual-SET-_W0QQcmdZViewItemQQhashZitem53e6c64130QQitemZ36035 4038064QQptZMotorsQ5fManualsQ5fLiterature
I had the timing belt and water pump replaced recently on my daughters 2004 Forenza by a local shop ($250USD) and shortly afterwards the crankshaft pulley/harmonic balancer failed (separated) and I replaced it myself. The timing belt tensioner was chattering so while I was replacing the balancer I adjusted the tensioner. After that I'm convinced I should have done the timing belt myself. If you have a good mechanical aptitude, a jack and some jack stands, along with a few basic hand tools, you can do the timing belt. I have the service manuals and will give you a text version of the procedure. If I have time tomorrow, I will scan the pages of the manual to .pdf files and post as the diagrams help quite a bit. I started by jacking the car up and placing jack stands on the unibody "frame rails" just behind the engine cradle mounting points. With the car supported by the jack stands, I used the floor jack to support the engine, due to the fact you have to remove the passenger side engine mount. Now to the factory service manual steps for "Timing Belt Removal and Installation" My notes
are in (parentheses).
1.) Disconnect the negative battery cable.
2.) Disconnect the manifold air temperature (MAT) sensor connector.
(this is on the back side of the air cleaner housing near the firewall)
3.) Disconnect the air cleaner outlet hose from the throttle body.
4.) Disconnect the breather tube from the camshaft cover.
5.) Remove the air cleaner housing bolts. (1) is near the shock tower and
the other is down low in the front by the frame rail.
6.) Remove the air cleaner housing.
7.) Remove the RF wheel
8.) Remove the RF wheel well splash shield
9.) Remove the serpentine accessory drive belt.
10.) Remove the crankshaft pulley bolts. (The (4) "bolts" are socket
head cap screws, requiring a metric allen wrench) 6mm I think)
11.) Remove the crankshaft pulley. (This is what most of us know as the
harmonic balancer, this one has the belt pulley integrated) (You should
check the condition of this unit as they have a habit of separating at
elastomer.) YOU MAY HAVE TO TAP WITH A MALLET TO REMOVE
12.) Remove the passenger side engine mount bracket. (1) nut near the
strut tower and (2) nuts and (1) bolt on the engine side of the mount.
13.) Remove the timing belt cover bolts. (There is a inspection window in
the cover directly behind the engine mount. Remove (1) bolt from it
and (2) or (3) from the cover down low. The top is retained by clips.)
14.) Remove the timing belt cover.
15.) 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. (This will be very easy once
you see the diagram).
16.) Align the camshaft gears with the notch on the camshaft cover. (The
camshafts turn at ~50% the rpm of the crank, so if you don't have
timing marks aligned on both the "Intake" (closest to the firewall) and
"Exhaust" gear, just rotate the crankshaft gear 360° to get all (3)
17.) Remove the timing belt. (It is important to not turn the crankshaft
or camshaft gears with the belt removed)
18.) Loosen the automatic tensioner bolt (in the center of the tensioner)
Turn the hex key tab to relieve belt tension. (This will be fairly
obvious when you get this point.)
GOOD IDEA TO REPLACE THE WATER PUMP WHILE YOU ARE IN THERE
1.) Verify your crankshaft timing mark (one more time).
2.) Verify your camshaft timing marks.
3.) Install the new timing belt.
4.) Turn the tensioner hex key tab in a clockwise direction to tension
the new timing belt. Turn the tab until the pointer aligns with the
5. Install the tensioner bolt.
Tighten the automatic tensioner bolt to 25 N.m (18 lb-ft.)
6.) Rotate the crankshaft (2) full turns clockwise using the crankshaft
7.) Recheck the automatic tensioner pointer.
8.) Install the timing belt cover.
9.) Install the timing belt cover bolts.
10.) Install the engine mount.
11.) Install the crankshaft pulley.
12.) Install crankshaft pulley bolts and torque to 15 lb-ft.
13.) Install the serpentine belt.
14.) You can guess the rest.......