Suzuki 2000 ,1.6 engine Timing chain broke,make a hole in timing cover just behind the idling pulley.Does anyone had this problem . 84000 KM. That's happen at low speed without noise before, the oil level is ok, and the engine was et normal temperature. I made a mistake in my post i ask for a 1.6 , and it's a 2.0

WOW you work on engines not knowing what is there?
the engines are: 7 engines.!!!
1.3 L I4; 1.5 L I4; 1.6 L I4; 1.8 L I4; 2.0 L I4; 2.3 L I4; 1.4 L Diesel I4 ill guess, ( (die roll)
2.3 L below.

all answers, USA cars, this a USA forum. so.....
ever heard of the FSM the oem factory service manual?

is the chain making noises? if yes, the guide is bad, most chains fail due to that (as a true cause)
the FSM is here , just $4 to look , so ????
https://suzukipitstopplus.com/Products/1178-2003-aerio-service-manual.aspx

the clone is Alldata.com DIY, log in and read like we do.
google alldtata.com , bingo....

now the 2.3L (just the first half, ill let you pay $4 like we do)

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove engine assembly from vehicle.
3. Remove oil pan.
4. Remove cylinder head cover.
5. Remove timing chain cover as follows:
   • Remove crankshaft pulley bolt. To lock crankshaft pulley, use special tool 09917-68221 (camshaft pulley holder).
   • Remove crankshaft pulley. To remove crankshaft pulley, use special tools 09944-36011 and 09926-58010 (steering wheel remover and bearing puller attachment).
   • Remove A/C compressor bracket.
   • Remove alternator belt idler pulley, water pump pulley and alternator belt tensioner.
   • Remove timing chain cover bolts and nut.
   • For reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and lower crankcase match with those on sprockets as shown in figure.
   • Remove second timing chain as follows:
     
     • Turn crankshaft to meet following conditions.
       
       • Key (I) on crankshaft is positioned as shown.
       • Arrow mark on idler sprocket (II) points upward.
       • Marks on sprockets (III) match with marks on cylinder head. Note that this step must be followed for reinstallation of timing chain.
     • Remove timing chain tensioner adjuster No.2 and gasket. To remove them, slacken second timing chain by turning intake camshaft counterclockwise a little while pushing back pad.
     • Remove intake and exhaust camshaft timing sprocket bolts. To remove them, fit a spanner to hexagonal part at the center of camshaft to hold it stationary.
     • Remove camshaft timing sprockets and second timing chain.
     • warning
     • After second timing chain is removed, never turn intake camshaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.
     • Remove timing chain guide No.1.
     • Remove timing chain tensioner adjuster No.1.
     • Remove timing chain tensioner.
     • Remove idler sprocket and first timing chain.
     • Remove crankshaft timing sprocket.
     • end.
   im not doing INSTALL, sorry.

got that? also there are a hole section on details of gasket seals and such, nothing trivial that.

wow no engine stated of the many.
1.3 L I4; 1.5 L I4; 1.6 L I4; 1.8 L I4; 2.0 L I4; 2.3 L I4; 1.4 L Diesel I4 amazing huh, no engine or COUNTRY stated.
my answer will be USA< as this is a USA forum
and like all cars in USA the engine list it smaller (EPA rule and Bs)
ever seen and FSM book, factory service manual
for any car made, ?
2nd best is always.... here. log in an read?
http://www.scantool.net/software/alldata-diy-1-month-subscription.html

real FSMs. here (official suz. site)
or at suzukipitstop (google it)

no my GUESS,(useless if outside USA totally, mostly)

2.0 or 2.3L: working on engines, not knowing what is there???
here is the teaser answer, no photos , no warnings, etc.

quoted in part, and remove chain only.
exploded view of first timing chain and related components-2.0L and 2.3L engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove engine assembly from vehicle.
3. Remove oil pan.
4. Remove cylinder head cover.
5. Remove timing chain cover as follows:
   • Remove crankshaft pulley bolt. To lock crankshaft pulley, use special tool 09917-68221 (camshaft pulley holder).

Be sure to use the following bolts instead of pins for fixing special tool to crankshaft pulley. Bolt size: M8, P1.25 L = 25 mm (0.98 in.) Strength: 7T

• Remove crankshaft pulley. To remove crankshaft pulley, use special tools 09944-36011 and 09926-58010 (steering wheel remover and bearing puller attachment).
• Remove A/C compressor bracket.
• Remove alternator belt idler pulley, water pump pulley and alternator belt tensioner.
• Remove timing chain cover bolts and nut.

1. For reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and lower crankcase match with those on sprockets as shown in figure.
2. Remove second timing chain as follows:
   • Turn crankshaft to meet following conditions.
     • Key (I) on crankshaft is positioned as shown.
     • Arrow mark on idler sprocket (II) points upward.
     • Marks on sprockets (III) match with marks on cylinder head. Note that this step must be followed for reinstallation of timing chain.
   • Remove timing chain tensioner adjuster No.2 and gasket. To remove them, slacken second timing chain by turning intake camshaft counterclockwise a little while pushing back pad.
   • Remove intake and exhaust camshaft timing sprocket bolts. To remove them, fit a spanner to hexagonal part at the center of camshaft to hold it stationary.
   • Remove camshaft timing sprockets and second timing chain.

After second timing chain is removed, never turn intake camshaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.

1. Remove timing chain guide No.1.
2. Remove timing chain tensioner adjuster No.1.
3. Remove timing chain tensioner.
4. Remove idler sprocket and first timing chain.
5. Remove crankshaft timing sprocket.

end remove section.



why not log in and read all words, steps and warnings..>>???

http://www.scantool.net/software/alldata-diy-1-month-subscription.html

end teaser.

Pull your Serpentine belt, remove the Cam Belt Cover, (it may be advantageous to remove front wheel in the Cam Belt side) Remove the timing belt and time the engine to specifications, make sure you are on #1TDC, remove the tensioner and replace. if there is and Idler pulley replace that as well. You can use Spray Carb Cleaner to clean the pulleys before replacing the belt. Note, you may have to also remove the Harmonic Balancer and pulleys from the crankshaft.

I wouldnt crank it til I kno---u need a repair manual--go to magicmechanic in the states--send him issue-he replies-nothn he doesnt kno

I think you had better have a local shop inspect this for a failed engine connecting rod.

1. Remove the fan and generator V belt:



2. TIMING CHAIN (2az-FE Engine):
Before servicing the vehicle, refer to the Precautions Section.
Drain the engine oil.
Remove or disconnect the following:
Negative battery cable
Hood Right-side front wheel Engine under covers Right-side fender apron seal Front exhaust pipe Engine moving control rod and bracket Right-side engine mounting stay and bracket Accessory drive belt Engine appearance cover Engine wire Alternator Power steering pump, leave the hoses connected Ignition coils Ventilation hoses Cylinder head cover Turn the crankshaft pulley to set the No. 1 cylinder to TDC compression. Align the groove on the pulley with the timing mark -0- on the front cover. Remove the crankshaft pulley as follows:

1. TMC made: Use Special Tool 09213-54015 to hold the pulley to loosen the bolt. Use Special Tool 09950-50013 to remove the bolt and pulley.

2. TMMK made: Use Special Tool 09960-10010 to hold the pulley to remove the bolt. Use Special Tool 09950-40011 to remove the crankshaft pulley


Fig. Removing the crankshaft pulley-TMC-2.4L (2AZ-FE) engine


Fig. Removing the crankshaft pulley-TMMK-2.4L (2AZ-FE) engine


Remove or disconnect the following:
Crankshaft position sensor Lower oil pan No. 1 chain tensioner Accessory drive belt tensioner

Support the engine with a suitable engine lifting device.

Remove or disconnect the following:
Engine mounting insulators Right-side engine mounting bracket Stud bolt for the accessory drive belt tensioner from the block Front cover mounting bolts and nuts Front cover Crankshaft position sensor plate Timing chain tensioner slipper Timing chain vibration damper Timing chain Crankshaft timing sprocket

• Turn the crankshaft counterclockwise by 90°, and align an adjusting hole of the oil pump driven sprocket with the groove of the oil pump.

Fig. Align the adjusting hole of the oil pump drive sprocket with the oil pump groove-2.4L (2AZ-FE) engine


Fig. Insert a bar to lock the sprocket in position-2.4L (2AZ-FE) engine
Put a bar in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut.


Remove the bolt, chain tensioner and spring.


Remove the chain tensioner, oil pump sprocket and No. 2 timing chain.


To install:
Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top

Fig. Align the crankshaft key and drive shaft cutout as shown for installation-2.4L (2AZ-FE) engine
Align the yellow colored links with the timing marks of the sprocket as shown in the illustration.

Insert the sprockets with chain to the crankshaft and oil pump shaft.

Temporarily tighten the oil pump driven sprocket with the nut.

Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the nut. Tighten to 9 ft. lbs. (12 Nm).

Align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump.

Put a bar in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Tighten the nut to 22 ft. lbs. (30 Nm).

Rotate the crankshaft counterclockwise by 90°, and align the crankshaft key to the top.

Install the timing chain vibration damper. Tighten to 80 inch lbs. (9 Nm).

Align the timing marks of the camshaft timing sprockets and bearing caps.

Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.

Align the gold or orange colored link with the timing mark of the crankshaft timing sprocket.

Using Special Tool 09309-37010, tap in the sprocket.

Align the gold or yellow colored links with the timing marks of the camshaft timing gear and camshaft timing sprocket. Install the chain.

Fig. Align the marks of the sprockets and bearing caps to set the No. 1 cylinder at TDC-2.4L (2AZ-FE) engine

Fig. Set the crankshaft set key facing upward-2.4L (2AZ-FE) engine

Fig. Align the marked link of the timing chain with crankshaft sprocket timing mark-2.4L (2AZ-FE) engine

Fig. Tap the crankshaft sprocket in with Special Tool 09309-37010-2.4L (2AZ-FE) engine


Fig. Align the marked links of the timing chain with the camshaft sprockets during installation-2.4L (2AZ-FE) engine

1998-2003 To Remove:

1. Remove or disconnect the following:
   • Crankshaft pulley and hub
   • Drive belt tensioner
     
     
   • Timing chain cover bolts
     
     
   • Timing chain cover and gasket
2. Install a bolt in the end of the crankshaft CAUTION
   Do not install the crankshaft balancer bolt or a bolt longer than 1 inch or damage to the crankshaft threaded hole will result.
   
3. Rotate crankshaft until the number 1 piston is at Top Dead Center of compression stroke.
4. Make sure that the alignment marks are aligned with the tabs on the timing chain tensioner.
   
   
5. Measure distance between hole in bracket and unworn surface of timing chain tensioner shoe. NOTE: If distance between the hole and unworn surface of timing chain tensioner is greater than 0.314 in (8 mm), replace tensioner, timing chain and sprockets.
   
6. Remove timing chain tensioner bolts.
7. Remove the timing chain, timing chain tensioner and camshaft sprocket at the same time.
8. Remove the crankshaft sprocket using special tool J 22888-20A or equivalent.
9. Remove crankshaft sprocket alignment key.

NOTE: If any camshaft components are being replaced to correct a noise problem, all camshaft drive components must be replaced.
To Install:

1. Install the crankshaft sprocket alignment key.
2. Install the crankshaft sprocket using special tool J 5590 or equivalent.
   
   
3. Compress the timing chain tensioner spring and insert a pin into the tensioner hole to retain the tensioner shoe.
4. Install timing chain and timing chain tensioner (do not tighten tension bolts).
5. Align the crankshaft and camshaft timing marks with the tab on the timing chain tensioner.
6. Tighten the timing chain tensioner bolts.
   • Torque to: 18 ft lbs (24 Nm)
7. Tighten the camshaft sprocket bolt.
   • Torque to: 96 ft lbs (130 Nm)
8. Remove pin from timing chain tensioner hole.
9. Remove bolt from end of crankshaft. CAUTION
   Inspect the timing chain cover for warping or damage. Replace if needed.
   
10. Clean all timing chain cover mating surfaces.
11. Install or connect the following:
    • Timing chain cover to the engine block
      1. Ensure that the gasket is installed properly in the groove in the timing chain cover
    • Timing chain cover and make sure it fully seated on the alignment dowel pins
    • Timing chain cover bolts
      1. Torque to: 97 inch lbs (11 Nm)
    • Drive belt tensioner
    • Crankshaft damper hub and the crankshaft pulley

Take a dry bar of soap and touch it against the sides of the belt(s) while the engine is running. If the noise goes away for a little while, the noise is from the belt settling into the grove of the pulley. Belts can really make loud pooping noises.

If this has no effect, then your timing chain may be too loose for the timing chain tensioner to compensate, and the chain is slapping against the inside of the timing chain cover.

If this is the case, do not let this condition go on. The timing chain cover is aluminum, and the chain is high grade steel. The chain will wear a hole in the cover if it is hitting the inside of it, and that is allowed to continue.

Hi There,
Is this a 4 or 6 cylinder? How many miles?

there will be a rattle the front of the engine. the end with all your pulleys and belts on. And it will be hard to work out if it's in the engine or the pulleys.

It is a common that a TICKING coming from the front of the engine is the timing chain guide.

This -->LINK<-- will help you alot.

Regards

Philip