Installation (All Models): Removal & Installation Suzuki X-90 I

Removal

1. Remove water pump, crankshaft pulley and generator. Remove timing belt cover and timing belt. See «TIMING BELT»(ref-49464-S20349189842001011500000) .
2. Drain engine oil. Remove oil dipstick and oil pan. Remove oil pump pick-up screen. Remove oil pump assembly. Remove oil pump rotor plate.
3. Using felt pen, mark outer gear for reassembly reference. Remove inner and outer oil pump gears. Remove plug, relief spring and relief valve. Drive out oil seal.

1. Drive in new oil seal. Ensure gears are assembled in same direction as originally installed. Apply thin coat of engine oil to lip portion of oil seal and inside surfaces of oil pump case and plate. Install inner and outer rotors.
2. Install rotor plate. Tighten 5 screws. Install 2 oil pump pins, NEW dipstick "O" ring, NEW seal for oil pick-up tube and NEW oil pump gasket. Use Oil Seal Guide (09926-18210) to prevent damage to oil seal during installation of oil pump. (Scheme 6)
3. Apply engine oil to guide and install oil pump. Install dipstick guide with NEW seal. Install oil pan using silicone-type sealant. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49464-S04193149722001011500000).

Scheme 6

1. Disconnect negative battery cable. On Sidekick and X90, remove cooling fan and fan shroud. Remove power steering and A/C compressor belt (if equipped).
2. On Esteem and Swift, raise vehicle and remove fender apron extension by pushing center pin into clip. DO NOT push in too far as pin may fall into fender. On all models, loosen generator, and remove water pump pulley and belt.
3. Remove crankshaft pulley. On Swift, remove center bolt to remove crankshaft pulley if engine is in vehicle. On all models, remove timing belt cover. Align all sprocket timing marks with timing marks on engine. (Scheme 7) Move up and secure timing belt tensioner.
4. If timing belt is to be reused, mark belt with an arrow indicating direction of rotation. Remove timing belt from camshaft and crankshaft sprockets.

1. Loosen all valve adjusting screws fully before installing timing belt. Allow camshaft to rotate freely during belt tension adjustment. Align timing mark on camshaft sprocket with "V" mark on timing belt inner cover. (Scheme 7)
2. Turn crankshaft clockwise until punch mark on crankshaft sprocket is aligned with arrow mark on oil pump. With timing marks aligned, install timing belt. Ensure direction arrow mark on timing belt is pointed in direction of crankshaft rotation. Ensure drive side of belt is free of slack.
3. Move tensioner plate up with finger pressure, and loosely secure tensioner bolt. Turn crankshaft 2 revolutions clockwise to remove all slack from belt. Tighten tensioner nut and then tensioner bolt. See «TORQUE SPECIFICATIONS»(ref-49464-S04193149722001011500000).
4. Ensure timing marks are aligned. Install timing belt outer cover and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-49464-S04193149722001011500000). Reverse removal procedure to complete installation. Adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-49464-S37045426872001011500000) under ADJUSTMENTS.

Scheme 7

1. Disconnect negative battery cable. Remove front grille. Remove hood lock and hood lock support member and disconnect lead wire from horn. Push center pin of clips to release grille clips.
2. Drain cooling system. Remove radiator, cooling fan and shroud. Remove A/C condenser and compressor (if equipped), leaving hoses connected. Remove air cleaner assembly and rocker arm cover.
3. Remove water pump belt and pulley. Remove timing belt. See «TIMING BELT»(ref-49464-S20349189842001011500000). Use Camshaft Pulley Holder (09917-68220) to secure camshaft pulley. Remove camshaft sprocket bolt and sprocket.
4. Remove CMP sensor (if equipped). Loosen all valve adjustment lock nuts and valve adjusting screws to allow rocker arms to move freely.
5. Loosen camshaft bearing caps in reverse order of tightening sequence. (Scheme 8) Loosen bolts in 2 or 3 steps. Remove camshaft bearing caps and camshaft. Remove rocker arm shaft plug and timing belt inside cover.
6. Remove intake rocker arms, with clip, from rocker arm shaft. Remove rocker arm shaft bolts. Push rocker arm shaft slightly to rear and remove "O" ring from shaft. Remove exhaust rocker arms and springs while pushing rocker arm shaft toward front of engine.

1. To install, reverse removal procedure. Install NEW "O" ring on rear of rocker arm shaft. Ensure flat surface of rocker arm shaft is facing down and is parallel with cylinder head gasket mating surface. Tighten camshaft bearing caps in 3 or 4 steps in sequence, finishing with final torque specification. (Scheme 8) Install CMP sensor (if equipped). See «TORQUE SPECIFICATIONS»(ref-49464-S04193149722001011500000).
2. Adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-49464-S37045426872001011500000) under ADJUSTMENTS. To complete installation, reverse removal procedure.

Scheme 8

For camshaft removal, see ROCKER ARM & VALVE LASH ADJUSTER .