Suzuki Truck V6: Timing Tensioner Replace -Part 1 of 5

[@stevest1300]

I wanted to pass along my greatest thanx to you for posting these videos. The timing chain rattle in my 02 XL7 had grown so loud that it indeed sounded like a diesel. I had to drive it back home 400 kms over the Coquihalla Highway (AKA: Highway Through Hell on Discovery Channel) and thought I'd see a couple of valves blow through the top of the engine. The fix went just as easily as you showed. One misstep: that little indexing key in the crank shaft. As you cautioned, don't let it drop out! Mine fell into the oil pan despite a rag that should have stopped it(!). It is loose in the slot and will not stay there happily. Horseshoes where well inserted for me as it fell out the oil drain plug after a blast of air when fishing with a magnet failed. Removing the oil pan is a huge job. Put a touch of RTV on it to act as a glue to hold it in place while you put the pulley to move the chain at times and watch it. The book time on this from Suzuki was 14.4 hours. One shop said 10 hours minimum. It took me 7 hours and 3 beers total that included cleaning some parts more than they warranted. Considered changing the accessories belts while you're there with all that clearance. The chain guides were good but as you, I swapped them out just cuz I was in the neighborhood. Thanx again! You saved me a sh-tload of cash and I gained more shop cred with my mechanic Son-in-Law.

[@PineHollowAutoDiagnostics]

That is fantastic! Job well done, definitely worthy of more than one beer :)

[@snoopygolf1970]

The struggle was real. I took the opportunity to put in a new high output alt., changed belts, hoses, and the water pump. Considering that my tensioner was only 3 clicks out and a lot of that noise may have been coming from the oil pump chain (mine was as slacked as his), I figure I'm good for the same 80k that she has on the odometer now. (knock on wood) Cheers!

[@1966cambo]

Ahhh the dreaded Coquihalla......smasher hill has claimed a crap ton of vehicles in winter heading down and summer going up!

[@zukiryder05]

Just performed this proceedure on my recently purchased 2005 Suzuki XL7. This video is invaluable! Couldn't have done it without it. It was like you were working on my Zuki! Ended up taking me 5 days from start to finish, but I also changed out the water pump and put in a new radiator. All 5 parts of this series was fantastic!

[@PineHollowAutoDiagnostics]

So she runs smooth and quiet now? Glad you found the vids helpful!

[@zukiryder05]

Yes. Runs really smooth. When I changed out the tension adjuster, it's spring was hanging outside the device - so it wasn't functioning at all. I also tightened the oil chain as you showed. Thank you again for posting these videos.

[@snoopygolf1970]

Hey, I just wanted to thank you for this very important video. I just did this job to my 2002 and had you not been there to show me how easily it can be done, I'm pretty sure the manual and forums would have meant a huge repair bill or early death to my truck. You did a fantastic job on this and I really really appreciate it. - Mike L.

[@PineHollowAutoDiagnostics]

Hey Mike, glad I could help! Keeping older vehicles on the road is one of my passions :) Great job on the repair, hopefully your Suzuki will give you many more years of trouble-free service!

[@davidt6849]

After watching the full series I feel pretty confident working on my 2002. I Don't have the tensioner problem yet, I do have a leaking valve cover gasket and a broken radiator and fan. I ordered all the parts, saved the videos and feel confident doing this repair, thanks man.

[@peterjacobs6290]

Might want to label this so guys with Chevy tracker 2.5 motors can see this also. This is a VERY INFORMATIVE VIDEO!

[@Oldbmwr100rs]

Mine's at that stage right now and I'm getting a random misfire code I suspect is being caused by timing variances between the crank and cam sensors, the engine runs perfect otherwise. I can't complain too much as the truck's got 184K miles and I've owned it since '01. It's been an amazingly great little truck without any real problems since I bought it used. Worth fixing. I'll be doing everything in the timing section chains, guides and all. And doing the water pump as it's never been done! Thanks for the vid series as it's going to help even though I do have the factory manual.

[@deezyXII]

Man am I glad I came across this video. I recently bought a 2002 XL7 and this video just gave me so much hope if I ever need to replace the tensioner. I have to do the cylinder head cover gasket which will take some time coz I have to take out the whole intake throttle body but after seeing this video I know it's not going to be that much work. I noticed that there is a little knock on the engine on cold start up but it goes away when it's warmed up. So I'm hoping it's nothing major. But thank you so much for making these video. I really love this car and I hope it can last me a long way. Currently at 93k miles. So hopefully I can take this bad boy to over 200k. #suzukixl7gang

[@PineHollowAutoDiagnostics]

They are solid trucks! If the tensioner starts rattling just try a little heavier oil. In the summer I run 0W-40 or 5W-40 synthetic, much better that the spec 5W-30 :)

[@deezyXII]

@@PineHollowAutoDiagnostics Brother! Thank you very much for that advice. I will do that on my next oil change.

[@dibble5674]

I'm no longer afraid of doing this job on my 2.5 v6 Tracker when the time comes thanks to this video series.

[@dibble5674]

@Tracker-Pete No I never had to do. I don't have the car anymore. Gave it to my son and he sold it. I miss it.

[@SuperGmann10]

I love partsgeek.com! They haven't failed me yet!

[@esaker]

Gee whiz! I have owned an '04 Grand Vitara since new and like the truck a lot, however, hope I never have to get after the timing chain, water pump, etc.. Looking forward to the rest of this series.

[@SteveRobReviews]

Wow, a water pump change 2 grand, Suzuki engineering at its best Ha. This is gona be a good series for us viewers not sure about you LOL

[@stuzman52]

Hey Ivan...this is going to be an interesting series. What a nightmare of chains that car has..I know you've already done the job, but hope it goes well...

[@billyr9840]

Wow is all I got to say ! Good luck Ivan !

[@joeheritage]

Where can I download the PDF of the manual? Thanks for the video.

[@fyx13579]

how did you get that TSB? looks handy

[@MACTFordEdge]

I had a 2002 Suzuki GV that had the water pump break twice!! Very expensive repair you should replace the water pump while you are in there to save yourself some work later.

[@PineHollowAutoDiagnostics]

+MAC T oh ohhh well I'll see how long this one holds out...if it ain't broke don't fix it right?

[@MACTFordEdge]

+motoYam82 I never had to replace the timing chain tensioners, but I did drive that GV for over 200k miles before trading it.

[@mminc81]

Thank You Suzuki

[@tecnaman9097]

Man..hate to think what a complete overhaul job of this douzy of a V6 would cost. Probably more than a 2002 Suzi 7 is worth!!!I agree with you Ivan... the engineers who designed this set up were on loan from the motorcycle engine division lol..

[@forgiven88]

which timing chain kit brand did you buy? did it last?

[@jahkawefrancis9996]

WHERE DID U DOWNLOAD THE PDF?

[@1966cambo]

4 years and no response? My major gripe about people posting is they don’t finish the job by answering those of us that are learning from them!

[@deezyXII]

I bought mine on ebay!

[@marcosantonioleon1607]

​@@1966cambo Please PDF 😁

[@huggybryn39]

With an old engine( high mileage) I'd use a 10/40 grade oil. also fit a new timing chain with a spring link, so you can join it to to old chain and feed it round the gears.Take the plugs out when turning the engine.

[@billrimmer5596]

Change the water pump!! And the main chain!! Go gettum. Thank u Ivan. Bazooka for the Sazooka

[@rrmech11]

Lol

[@jupiterfilms971]

I currently have a knock coming from my engine. What could be causing the knock? Was told pushrods by my cousin but multiple people have told me the engine doesn’t have pushrods.

[@mikechhay5020]

I have one more question you didn’t show how you unscrew the fan clutch did you use a special tool to hold the fan in place

[@rrmech11]

Good luck Ivan. What's Eric O. Input

[@inoldojhernandez6281]

Question. is there any way to lower the small crankcase of grand vitara xl7 2003 to clean the strainer ? is it possible to send me the link to the repair manual, thank you.

[@gabrielcuret8631]

thanks so much!!!!! very helpfull! wish me luck😂😂😂

[@leebarnes655]

That idling oil pressure is scary low when warmed up, any chance you can shorten the chain to put on a smaller pump sprocket and get some pressure? Used to fix these issues with high volume pump swap out but I doubt there is such a thing for this one. Quite a job to get to it too. Larger sprocket on crank with smaller sprocket on pump with the same chain also works. Lot of custom machining, maybe somebody does this for reasonable coin?

[@PineHollowAutoDiagnostics]

+Lee Barnes It did seem kind of low to me too, but the only spec Suzuki gives is 60psi at 4k rpm on a warm engine, which matches. When cold, I noticed it goes up to like 90psi so I don't think a higher-volume pump would be a good idea lol

[@leebarnes655]

I kind of expected that might be the case too. Just thinking out loud above. Of course you are right, 90 PSI is just as scary to me and makes me wonder why they don't have a higher flow pop off valve in the first place or if it's set for 120 in their infinite wisdom of it will never get stuck open if it never opens. High rpm capable engines just compound the issue where it becomes a double cringe issue, one for too low at warm idle and another for way too high when cold and in a hurry to be somewhere. The solution is rocket surgery where we have a variable capacity on the oil pump which regulates it's own output by the pressure it makes. Just like they have on automatic transmissions. Cheaper to cringe, say the all important bean counters. Still don't like it, but regretfully have to agree - pass on this issue.

[@kinghados]

took me 4 hours to replace water pump, Took off intake manifold, remove valve covers and remove gasket maker on timing cover, remove one timing chain tensioner then remove water pump and installed. then redid the gasket the timing cover and put everything back on. off course i removed the radiator and belts

[@marcinwnek1649]

How to instal oil pressure gauge in this engine ?

[@123Knam]

I once had to change the oil pan on a suzuki grand vitara if i remember correctly. What a freakin nightmare! Did not have to remove the rack and pinion or the front diff. Just kind of loosened them up and worked around them.. Still took me about 6-7 hours :S never again :p

[@e.c.jr.3580]

Do you have a video on how to replace the water pump on a 2005 Suzuki XL-7?

[@PineHollowAutoDiagnostics]

Well it's the same procedure as this video. You just bolt on a new pump before reinstalling the timing cover :)

[@akashtalon]

Howd you get the oil pressure gauge hooked up?

[@davegoodwin1848]

Do you think the average back yard mechanic could tackle this? I've never done internal engine work or transmissions however have fixed most everything else.

[@DarthPrater629]

Would this video series not apply to the H27 in an '07 grand vitara? It says up to the 2.5 in the 06's but how is this different than the '07 and above H27?

[@PineHollowAutoDiagnostics]

+DarthPrater629 Ah I guess they did offer the H27 in the GV in '07 and '08...so this procedure should be similar.

[@wtbm123]

Must be a hundred feet of chain in the little engine . Be interesting to see if you can get it down to 3 hours .

[@PineHollowAutoDiagnostics]

+wtbm123 Well I think Suzuki tried to cram motorcycle technology into an SUV engine...the results are interesting, to say the least. This baby likes to rev...really takes off above 3k rpm! Kind of fun, but I'd rather have some more torque lower down in the revs lol

[@joeshearer1247]

+motoYam82 on my Suzuki GSXR it was the thing to do to put a manual tensioner in place of the automatic ratcheting deal. for the same reason too...the clacking

[@4WDIESEL1]

great stuff,

[@zr2trackerjoe]

where did you tap in the oil pressure guage

[@PineHollowAutoDiagnostics]

+zr2trackerjoe Right at the oil pressure switch, driver's side below the exhaust manifold.

[@zr2trackerjoe]

+motoYam82 copy will be doing it to my h25. only rattles at startup

[@thadragon31]

Just a question... what size is your tires? And is that stock wheels? Did you get a lift kit? Thank you

[@PineHollowAutoDiagnostics]

Right now I am running P215/70R16. Stock size was P235/60R16. Everything else is stock, except rear shock absorbers are Monroe MaxAir that have a manual air assist for heavy loads.

[@thadragon31]

Looks nice bro. Do you have any rubbing on that size of tire? I'm planning to get 225/75/16 do you think it'll work? I don't have a lift either

[@PineHollowAutoDiagnostics]

hmmm I think you will get some tire rub on the front wheels with that size. Mine just barely clear the front mudflaps.

[@thadragon31]

What year is your truck? I have a 2002 XL7 that I just purchase with a low mileage . The stock wheel are 235/60/16 for me the tires are too small for the truck . I wanted a more bigger tires

[@sms3736]

I like Mobil 1 its a great product thats all I run in both my vehicles

[@larrypeterson315]

the Suzuki 2.5 L V6 is used in Chevy Trackers also

[@GiorgosC-rp5ms]

hi mat i am doing this job now on my tracker 2.5 and as i was holding the cam to unbolt the crank so it wouldnt move one cam turned on me

[@davegoodwin1848]

Hey gc...how did the job end up? I am hoping to do the work myself on mine. Is it something the average home guy can do?

[@henry30061951]

Hi had the misfortune to break the timing chaim and change pistons, the valbulas escape and I also changed the valves guides and gums of valbulas , but I eat a lot of oil , only when I turn blue smoke seen but after no blue smoke and consumption is approximately one liter every 1000 miles. PLEASE CAN YOU RECOMEND ME WHAT TO DO?

[@Fred7038]

Your valve pan covers are dirty. There is a plate in top of them that has oil passage ways in it they clog and force the oil threw the pcv valve (drivers side cover) then into the fuel system.

[@gavenf6794]

What oil pressure gauge did you use.?

[@1966cambo]

Oil pressure seems really low at idle!

[@martinarrieta7779]

how do you install a oil presure gage

[@fieldsofomagh]

Hope you'r not thinking of buying another Suzuki or your neighbours will think you've gotten lost after those tensioner marathons.Never seen as many chains and bound to cause trouble.Is there a possibility that the main timing chain is worn ? Timing belts don't seem hard work considering.

[@emtscythe3782]

Do the water pump while your there bud. If your luck is anything like mine. Lol.

[@gianfrancoa]

Nice to see a manual transmission on a V6 SUV. What a pain of a job..

[@PineHollowAutoDiagnostics]

+gianfrancoa Looking for a replacement for the MPV, it had to be 4x4 and manual tranny. Kind of narrows down the options a bit here in the USA; drove two hours to pick up the XL-7 from a sketchy small dealer lol

[@AiahBayoh]

How to adjust backfire in Suzuki

[@techlove67]

aye bub I have a question for you. totally unrelated. same truck as yours.. I broke Two studs on my front wheel Because some dumbass stripped the piss out of them. I was going to replace them but there is a tone ring on the bearing assembly. is it possible to do without replacing the whole assembly?

[@PineHollowAutoDiagnostics]

See if they are sold separately. If not, then you need the entire hub assembly.

[@magnagaurd]

what underbody shield is that?

[@PineHollowAutoDiagnostics]

www.rocky-road.com/tracker-skid-plates.html

[@magnagaurd]

Yay! Will be ordering soon. Where does it mount to? I see the front two look like it's the subframe but the rear two look like the cross member?

[@PineHollowAutoDiagnostics]

yup 4 bolts. It's saved me quite a few times now, especially the front diff and oil pan that hangs low

[@magnagaurd]

Yeah, I use a Grand Vitara to deliver mail and there's been several times that I've hit a piece of washed out asphalt when getting back on the road on the cross member. Thankfully it hasn't hurt anything though, but you can see the gouges on the cross member.

[@kdmq]

Pulling the engine is honestly quicker than taking out both the steering rack and diff housing with the engine in.

[@PineHollowAutoDiagnostics]

Would also be a good time to put in a new clutch :)

[@joeshearer1247]

I think Eric O said hard right into guardrail and collect insurance money! Lol jk

[@PineHollowAutoDiagnostics]

+Joe Shearer Only one problem with that...I don't have collision insurance hahaha

[@joeshearer1247]

+motoYam82 oh well...plan b lol

[@roadkill5333]

I've already learned all that I need to know about this issue. Don't buy, or work on a Suzuki! However, I am still gonna watch all of these, just to see if there will be any bleeps, or edited words or phrases!! Plus, bloody knuckles, or Eric O burns!! Maybe best To have a pastor and a nurse, close by, just in case!!!

[@rrmech11]

Lol

[@EaStxVaNxiNc]

roadkill5333 u r a fuckin idiot who clearly wastes his time watching pointless shit and maken pointless comments must have a good life sad

[@wysetech2000]

Personally, I would be pushing it over the nearest cliff. (JK) I know you can handle that job and in less than half the time especially without dropping the oil pan.

[@miguelrosales1559]

Friends I have this problem sound like timingshein bat all this is the injectors yuo ned to.replace the fuel filter and is all sound wired bat all this noise is from the injectors Nat inaft fuel I fix this problem that way is Nat the timing shine

[@PineHollowAutoDiagnostics]

wow amazing! Wish it was that easy ;)

[@daniel_z]

"Remove rack and pinion assembly...HOLY CRAP!"

[@ابناليمن-ج5ر]

أنا معي سيارة سزوكي أكس ال7 لھا معي16سنة

[@thezofamilychannel7204]

Crap!! I'm selling my xl7. Might as well pull the engine out

[@felipesalgado6347]

Well that settles it, I gonna ride the tracker till it can’t ride no more, buys me time to save a down payment on another truck now

[@PineHollowAutoDiagnostics]

They are tough little trucks!

[@neilm8263]

Sounds like a skeleton in a biscuit tin

[@alexlevy8197]

I'm stealing this saying lol...

[@417cameron]

Won't be buying one of those. Jesus.