[Jerryx4]

Hey guys, with getting a new radiator once I ripped everything out I noticed the fan belt was rubbing on the cover. After a quick squizz on here I took off the fan belt crank pully and found the cover has got loose on a few bolt holes.
There is a steel backing plate at the top under the cam pulley. I noted the grommets on the bolts were buggered and the top cover was loose. I started removing these bolts to pull out the grommets and first one no probs...
Second one however .... *SNAP* "F$#K" the bolt snapped in the head. How I don't know but now I'm sitting here thinking jesus do I take the whole front panel off to get the drill in and bore it out or get the other bolt nice and tight, put washers over the plastic on the lower holes and just ignore the bolt ever broke and hope the cover steers clear with the washers in place.
What's the general consensus as once this is back together and then I get extractors and new zorst Zook is back on the road after 14months!!!
I'm slightly tech mind as in can pull shit apart and get it working and back together but when its snaking bolts out of heads or welding and fabrication im as useless as tits on a bull unless I'm shown how first!

Thanks in advance!


A Pic of such bolts. Taken of my neighbors zook which appears to have had the same prob fixed before.

[want33s]

The cam belt usually only chews the timing cover if the idler bearing has slop in it.


Replace the cam belt, idler bearing & timing cover and you should be right for quite a few thousand K's.

[Jerryx4]

Oh hell, am I going to be able to do this without effing it up lol
Might need to get a haynes manual

[want33s]

Jerryx4 wrote:

Oh hell, am I going to be able to do this without effing it up lol
Might need to get a haynes manual

Don't waste your money on a Haynes (Halfa) manual. They don't cover any of the techo ($$$) bits.

Download the FSM from www.suzukiinfo.com

[skyman]

I agree, I think the timing info is wrong in one of them as well. FSM is the way to go.

[krat]

I had a similar issue with my 96 Vit. Obviously when the previous owner did the timing belt change they did not put the gasket back on the cover.
Hence, all the bolt holes in the plastic cover had broken, the cover had moved forward, and the fan belt had carved a hole, ripping of some of the cover and depositing it in amongst the timing belt and pulley.
Luckily there was no major damage caused.
Mine is a G16B, but it looks different from yours, so I'm assuming it's a 16A.
Personally, I would drill and re thread to accept a new bolt so that you know the new cover will go back on and sit firmly in place, clear of the fan belt. The clearance on mine is very small even when fitting snug.
I know its easy for me to give an opinion sitting in front of the monitor, but for peace of mind, fix the problem or it might get costly if the cover stuffs up your timing belt.
It looks like you are not drilling straight into the head, its off to the side, so less risk of a major stuff up.
I'm sure there will be others here with more experience and knowledge with this one, but thats what I would be doing.

Kev

PS New timing belt cover and seal from Suzi Store $88 delivered to country Vic

[Jerryx4]

thanks heaps guys!
Ok to drill it out is gunna be quite an issue fk!
I have d/l'd the FSM and trying to find about timing belt now.
Ok so the bearing/tensioner is this that I need?
http://www.suzistore.com.au/shopexd.asp?id=297

hope i can beg steal and borrow this week!

Any serious things I should know about removing timing belt and reinstalling?

[want33s]

Jerryx4 wrote:

Ok so the bearing/tensioner is this that I need?
http://www.suzistore.com.au/shopexd.asp?id=297

Any serious things I should know about removing timing belt and reinstalling?

Yep that's the one.

Make sure to take notice (or pictures) of the belt and timing marks before disassembly.
Be sure to turn engine over a few times(by hand) with new belt and ensure that marks still line up.

[Jerryx4]

Ordered stuff from suzi store on Wed so should get here next week, need it done fast as shifting house asap!

[Jerryx4]

Cheers guys for help so far, all bits came and drilled new bolt hole got cover mounted again. all together turn the key and...

click click click... o ill try jump it...15mins then click click click...fk knew battery would die soon.
Got new battery...click click click. turns motor until its first compression stroke and nothing, a bit tough to turn but nothing difficult. take to TDC and try again, same thing. different spot, saame thing.
Take plugs out incase one cyclinder is holding pressure.... quarter wind click click click..

Any ideas? could the drive belt be too tight? all timing marks were fine and nothing moved until new belt was on.

[Jerryx4]

Ok pushed it into the garage tonight. Still just clicking or nothing at all. Almost seems like a short, contacts on starter look corroded, will look tomorrow in daylight :S
Got till Tuesday to get it to new apartment :S