I have replaced the water pump on my '03 triton 2.4 litre petrol engine . I lined up all the timing belt marks on assembly but I now have an engine vibration . Tony

This is found on the autozone.com website.

2.5L Engine
See Figures 3 through 7

1. Disconnect the negative battery cable.
2. Place a large drain pan under the radiator drain plug. Drain and properly contain the engine coolant.

This procedure requires removing the engine timing belt and the auto tensioner. To help assure proper alignment at assembly, it may be helpful to set the engine at TDC on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.

1. Remove the accessory drive belts and crankshaft damper.
2. Remove the right engine mount. This requires safely supporting the engine with a floor jack and wood block so the mount can be removed.
3. Remove the timing belt covers.
4. Remove the timing belt and tensioner.

Fig. Fig. 3: Remove the water pump mounting bolts

Fig. Fig. 4: Pull the water pump assembly off of the engine and inlet pipe

Fig. Fig. 5: Open the water pump housing and examine for cracks or damage

Fig. Fig. 6: Replace the water pump housing gasket using a scraper tool

Fig. Fig. 7: Always keep the water pump's mounting bolts lined up with their correct mounting holes

1. Remove the water pump mounting bolts.
2. Separate the water pump from the water inlet pipe and remove the pump.

To install:

1. Thoroughly clean all sealing surfaces. Inspect the pump for damage or cracks, signs of coolant leakage at the vent, and excessive looseness or rough turning bearings. Any problems require a new pump.
2. Install a new O-ring on the water inlet pipe. Wet the O-ring with water to make installation easier. DO NOT use oil or grease on the O-ring.
3. Install a new gasket on the water pump and fit the pump inlet opening over the water pipe. Press the assembly together to force the pipe into the water pump.
4. Install the water pump-to-engine bolts and tighten to 20 ft. lbs. (27 Nm).
5. Install the timing belt and timing belt tensioner. Set the timing belt tension.
6. Install the timing belt covers. Install the right engine mount. Remove the floor jack and engine block from underneath the engine.
7. Install the crankshaft damper.
8. Install the accessory drive belts and set to the proper tension.
9. Connect the negative battery cable.
10. Fill and bleed the engine cooling system.
11. Start the engine and verify proper operation, with no leaks

I'd be first confirming whether you have a 1.6 litre Grand Vitara (petrol), or a 2 litre turbo diesel. The 2 litre petrol (straight 4 or V6) or 2.5 litre petrol engines are all chain drive.
If your engine is petrol then no lock tool is required (to hold the camshaft). Of course, there is a specific position that an engine should be rotated too before removing the belt from ANY engine.
If it's diesel, then although I'm unfamilar with that particular engine, the general requirement for diesel engines with high pressure injection pumps is "yes, you require a lock tool" to hold the injection pump pulley. As I think these are a common rail set-up, this requirement may not be necessary. Check with your Suzuki Dealer, or maybe someone else here will know more. A similar question may have already been asked and answered here too.

go here for expert help on Villager & Quest

http://groups.yahoo.com/group/villagerquest/



Item Part Number Description 1 — 40 Timing Chain/Belt Teeth 2 6256 Camshaft Sprocket , Front 3 — 43 Timing Chain/Belt Teeth 4 6306 Crankshaft Sprocket 5 6268 Timing Chain/Belt 6 6256 Camshaft Sprocket , Rear
Removal

1. Drain the cooling system. Refer to Section 03-03 for the procedure.
   

1. Disconnect the battery ground cable (14301) .
   

1. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedure.
   

1. If equipped, remove the three A/C compressor drive belt idler pulley bolts and the A/C compressor drive belt idler pulley.
   

1. Remove the upper radiator hose bracket bolt.
   

1. Loosen the two upper radiator hose clamps and remove the radiator hose bracket bolt. Remove the upper radiator hose (8260) and the upper radiator hose bracket from the vehicle.
   

1. Remove the water bypass hose (8597) from between the thermostat housing and the water hose connection (8592) .
   

1. Remove the main wiring harness from the upper engine front cover (6019) .
   

1. Remove the eight upper engine front cover bolts and the upper engine front cover .
   

1. Raise and support the vehicle.
   

1. Remove the RH front wheel and tire assembly.
   

1. Remove the four RH outer engine and transmission splash shield bolts and two screws and remove the RH outer engine and transmission splash shield (6775) .
   

1. Use Strap Wrench 303-D055 (D85L-6000-A) or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
   

1. Remove the water pump pulley from the water pump (8501) .
   

1. Remove the crankshaft pulley (6312) . Refer to the procedure in this section.
   

1. Remove the five lower engine front cover bolts and the lower engine front cover .
   
2. Ensure that the timing marks between the crankshaft sprocket (6306) and the oil pump housing line up.
   
3. NOTE: The directional arrow is necessary to ensure that the timing chain/belt (6268) can be reinstalled in the same direction.
   
4. Loosen the timing chain/belt tensioner nut.
   
5. Remove the timing chain/belt .
   
   
6. Installation
   NOTE: Ensure that the timing marks on the camshaft sprockets (6256) and the seal plate are properly aligned. Ensure that the timing marks on the crankshaft sprocket and the oil pump housing are still aligned. NOTE: A new timing chain/belt has three white timing marks that indicate the correct timing positions of the camshafts (6250) and the crankshaft (6303) . These marks will help ensure that the engine (6007) is timed properly. When the engine is properly timed each white timing mark on the timing chain/belt will be aligned with the corresponding camshaft and crankshaft timing mark on the sprocket. Because the white timing marks are not evenly spaced you will need to refer to the following illustration for proper timing chain/belt placement. There should be 40 timing belt teeth between the timing marks of the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket .
   
   NOTE: Verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump (6600) .
   
   Install the timing chain/belt starting at the crankshaft sprocket and moving around to the camshaft sprocket following a counterclockwise path. Do not allow any slack in the timing chain/belt between the timing sprockets. After all of the timing marks are matched up with the timing chain/belt installed, slip the timing chain/belt onto the timing chain/belt tensioner .
   
   
   
   
   
   

Remove the hood bracket bar, 4bolts, then the fan shroud assembly, then the belts, belt adjuster, and timing covers, line up the cam gears, crank gear to the marks , cam has 1 dot, they line up to timing housing 2 dots, (single dot to middle of the 2 dots), crank has 1 dot to mark on the oil pump housing to your right of crank gear, thats TDC. now remove the timing belt tensioner, 2 bolts, and remove the belt, if the pump has leaked, replace the belt, and tensioner if it is NOT metal Pulley, the fibre one will break down from the antifreeze. its a good idea to replace the water pump housing orings behind it, ac bracket has to come off, as the right cam on engine, this not a retiming iussue with the gear. GOOD LUCK. RDJRP

It's a fairly invlved process and you usually do the serpentine belt and timing belt along with it. It's about 2 hours worth of work all together. Here's a good tutorial on it: http://volvospeed.com/Repair/timingbelt.php

Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10.Remove crankshaft pulley assembly using
5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm.
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.
6A–30 ENGINE MECHANICAL
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
014RY00043
Legend
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9) Alignment Mark (notch) on Crankshaft Timing
Pulley.
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.
1. Align the mark (notch) of crankshaft timing pulley
(2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft timing
pulley (3) with alignment mark (white dots line) on
the timing belt (4).
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt
ENGINE MECHANICAL 6A–31
2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive gear pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00004
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 N·m (2.5 Kg·m/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
014RW011

This is a job for an experienced technician. Probably about a $300 job. Maybe more.

Here is procedure for 1996:

Removal

1. Drain the cooling system. Refer to Section 03-03 for the procedure.
   

1. Disconnect the battery ground cable (14301).
   

1. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedure.
   

1. If equipped, remove the three A/C compressor drive belt idler pulley bolts and the A/C compressor drive belt idler pulley.
   

1. Remove the upper radiator hose bracket bolt.
   

1. Loosen the two upper radiator hose clamps and remove the radiator hose bracket bolt. Remove the upper radiator hose (8260) and the upper radiator hose bracket from the vehicle.
   

1. Remove the water bypass hose (8597) from between the thermostat housing and the water hose connection (8592).
   

1. Remove the main wiring harness from the upper engine front cover (6019).
   

1. Remove the eight upper engine front cover bolts and the upper engine front cover.
   

1. Raise and support the vehicle.
   

1. Remove the RH front wheel and tire assembly.
   

1. Remove the four RH outer engine and transmission splash shield bolts and two screws and remove the RH outer engine and transmission splash shield (6775).
   

1. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
   

1. Remove the water pump pulley from the water pump (8501).
   

1. Remove the crankshaft pulley (6312). Refer to the procedure in this section.
   

1. Remove the five lower engine front cover bolts and the lower engine front cover.
   
2. Ensure that the timing marks between the crankshaft sprocket (6306) and the oil pump housing line up.
   

18. NOTE: The directional arrow is necessary to ensure that the timing chain/belt (6268) can be reinstalled in the same direction.

If the timing chain/belt is to be reused, mark the direction of rotation on the timing chain/belt.

19. Loosen the timing chain/belt tensioner nut.

1. Remove the timing chain/belt.
   

Installation
NOTE: Ensure that the timing marks on the camshaft sprockets (6256) and the seal plate are properly aligned. Ensure that the timing marks on the crankshaft sprocket and the oil pump housing are still aligned.



CAUTION: Pay special attention to the tooth shape of the timing belt. The current timing belts are not interchangeable with the timing belts from the 1993 model year. The 1993 model year uses a square or trapezoidal tooth timing belt while the current model year uses a rounded tooth design. The design change was made to extend the service life of the timing belt from 60,000 miles for the square or trapezoidal toothed belt to 105,000 miles for the rounded tooth belt. If the proper timing belt is not used, the customer may complain of a "whining" noise coming from the engine compartment. If the camshaft sprocket has a square cut in the valley of the gear tooth, it will require a square or trapezoidal tooth timing belt. If the camshaft sprocket has a rounded cut in the valley of the gear tooth, it will require a rounded tooth timing belt.
NOTE: If a new timing chain/belt is to be installed, make sure that the arrow is pointing away from the engine. If a timing chain/belt is to be reused, make sure that the directional arrow that was marked during disassembly is facing the correct direction.

NOTE: A new timing chain/belt has three white timing marks that indicate the correct timing positions of the camshafts and the crankshaft. These marks will help ensure that the engine (6007) is timed properly. When the engine is properly timed each white timing mark on the timing chain/belt will be aligned with the corresponding camshaft and crankshaft timing mark on the sprocket. Because the white timing marks are not evenly spaced you will need to refer to the following illustration for proper timing chain/belt placement. There should be 40 timing belt teeth between the timing marks of the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket.

NOTE: Verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump (6600).

Install the timing chain/belt starting at the crankshaft sprocket and moving around to the camshaft sprockets following a counterclockwise path. Do not allow any slack in the timing chain/belt between the timing sprockets. After all of the timing marks are matched up with the timing chain/belt installed, slip the timing chain/belt onto the timing chain/belt tensioner.

1. While holding the timing chain/belt tensioner with an Allen wrench, loosen the timing chain/belt tensioner nut.
   

1. Allow the timing chain/belt tensioner to put pressure on the timing chain/belt.
   

1. Use an Allen wrench to turn the timing chain/belt tensioner 70-80 degrees clockwise and tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 lb-ft).
   
2. 
   
   1. Rotate the crankshaft (6303) clockwise twice and align the No. 1 piston to Top Dead Center (TDC) on its compression stroke.
      
1. Apply 98N (22 lbs) of force on the timing chain/belt between the rear camshaft sprocket and the timing chain/belt tensioner.
   
2. NOTE: An assistant may be needed to adjust the timing chain/belt.
   
   While holding the timing chain/belt tensioner steady with an Allen wrench, loosen the timing chain/belt tensioner nut. Remove the Allen wrench and adjust the timing chain/belt tensioner as follows:
   
1. Install a 0.35mm (0.0138 inch) thick and 12.7mm (0.500 inch) wide feeler gauge as shown.
   

1. Turn the crankshaft clockwise to position the feeler gauge between the timing chain/belt tensioner and the timing chain/belt

1. Tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 lb-ft).

1. Turn the crankshaft clockwise to remove the feeler gauge from between the timing chain/belt tensioner and the timing chain/belt.

1. Rotate the crankshaft clockwise twice and align the No. 1 piston to TDC on its compression stroke.
   

1. Apply 98N (22 lbs) of force on the timing chain/belt between the rear and front camshaft sprocket.
   
1. Measure the timing chain/belt deflection. Timing chain/belt deflection should be between 13-15mm (0.51-0.59 inch). If timing chain/belt deflection is not within specification, repeat steps 3-11. If the timing chain/belt cannot be adjusted to within specification, the timing chain/belt will have to be replaced.
   
1. Position the lower engine front cover and install the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in).
   
1. Install the outer timing chain/belt guide and the crankshaft pulley. Refer to the procedure in this section.
   
1. Position the water pump pulley on the water pump and install the four water pump pulley bolts
   
1. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley, and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft).
   
1. Position the RH outer engine and transmission splash shield and install the four RH outer engine and transmission splash shield bolts and two screws.
   
1. Install the RH front wheel and tire assembly. Tighten the lug nuts (1012) to 98-118 Nm (72-87 lb-ft).
   

The only other thing could the the timing belt tensioner if there is any doubt. Here's the timing marks.

3.0l Mitsubishi 6 cylinder.
support engine... remove engine mount... remove alternator, power stearing pump, compressor (if equipt) do not remove hoses from power stearing pump or compressor move them out of the way were they wont get damaged. Remove the tension pulley for the serpentine belt, and the tensioner for the compressor belt if equipt. then remove the compressor mounting bracket. Next remove the engine mounting plate and the crank pulley and balancer assembly. you should now be able to remove the the 3 piece timing cover. Once removed remove the tensioner spring from the water pump and loosen the tensioner nut. Remove the belt. At this point it is also recommended to replace the water pump and plumbing as well. The water pump service life is aproximately the same as the timing belt at 60,000 miles. This engine in stock form is a non interfering type engine. Meaning that moving the cams or crank out of sync will not cause damage. Turn each of the cams over by hand and line them up with the timing mark on the top of the back cover with the marks on the pulleys. Using a wrench turn the crank so that the pulley mark lines up with the mark cast into the block. replace the belt, tensioner spring (replace tensioner if warn) and tighten the tensioner bolt. roll the crank over 2 complete turns forward and recheck the cams to make sure the marks are still lined up. roll the crank backwards and recheck the timing marks again. (this process is much easier done with the plugs removed.) If everything is still lined up correctly (crank at TDC and cam pulleys pointing to each designated mark on the covers.) reassemble the cover and assessorys in the reverse order that they were removed and reinstall the old motor mount or replace if needed.

Alright, here's a pic of the mechanicals:



The bad news is on your vechile you have to remove the timing belt, but here's a step by step.

1. Disconnect the negative battery cable.
2. Remove the drive belts.
3. Drain the cooling system.

CAUTION When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1. Remove the timing case cover and timing belt. Refer to Timing Belt Covers and Timing Belt Removal procedures.
2. Remove the pump assembly mounting bolts.
3. Separate the pump assembly from water pipe and remove.
4. Clean gasket and O-ring mounting surfaces.
5. Install a new O-ring on water pipe and lubricate with water.
6. Install a new gasket on pump body.
7. Press the water pump assembly into water pipe.
8. Install pump mounting bolts and tighten to 27 Nm (20 ft. lbs.).
9. Install timing belt and cover. Refer to Timing Belt procedures.
10. Install drive belts.
11. Fill the cooling system

To remove timing:

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.

Hope this helps.