2003 Suzuki w/ bad engine... Any advice?

[DYNOBOB]

Yesterday I picked up a different 2003 Suzuki Carry from a facility maintenance company that will not start. It turns out that the motor has low compression, 47,65,84 psi. Does anyone have an idea where to source a used long block? Can you buy overhaul kits? I believe this is an aluminum block, does it use liners or nickasil plating? Is this thing a 1400lb paperweight?

The truck was used on a very dusty construction site before they acquired it. To the best knowledge it always had an air filter though. I suppose it is a cautionary tale when buying a vehicle that isn't running/running right to do a compression check if you can. You can fix fuel or spark problems...compression is different story.

[werase643]

do a wet and dry compression and determine why the compression is low anything can be rebuilt.

[greg0187]

The best advice I can give you is just give it to me. but yes the wet compression test is a good idea. Maybe it jumped time? Rebuild kits are available. I think minibutes, fg procurement has them, from what I recall, and some others as well... that is if the kit works on the newer body styles.

[fupabox]

could simply be tight valves not closing all the way as well

[DYNOBOB]

Don't the late model trucks have hyd cams? If not that might explain why it slowly got worse...

I thought about jumped timing but everyone says timing chains very rarely jump? I also poured some 15w40 down the cylinders and it tried to hit but never caught. Considered doing a leak down but either way it has to come apart and they've got to decide how far they're going. I let the cust know what I found and waiting to hear back. Doubting they're going to put a thousand or two in getting it fixed.

I'll contact FG Procurement. At this point I'm just trying to gather a little info to give them options. So far I'm not seeing where anyone sells rebuild kits for the late model truck.

Makes me thankful for how good my truck runs...

Bob

[greg0187]

Don't know about hyd cams or not but have seen, over the past couple years, a thread or two with members that post that the chain on the newer suzukis have jumped time (actually this is the only case that I recall where a truck has jumped time). Have also seen a bunch of threads where members post that they used a air filter they found in the parts store that seems to fit but don't actually seal completely and dusted the motor but from what I recall thats more of a oil consumption smoking issue.

[fupabox]

Don't the late model trucks have hyd cams? If not that might explain why it slowly got worse...

I thought about jumped timing but everyone says timing chains very rarely jump? I also poured some 15w40 down the cylinders and it tried to hit but never caught. Considered doing a leak down but either way it has to come apart and they've got to decide how far they're going. I let the cust know what I found and waiting to hear back. Doubting they're going to put a thousand or two in getting it fixed.

I'll contact FG Procurement. At this point I'm just trying to gather a little info to give them options. So far I'm not seeing where anyone sells rebuild kits for the late model truck.

Makes me thankful for how good my truck runs...


Bob

Just checked a parts diagram and it appears the 2003 and newer Carrys had adjustable valves ..but they are bucket and shim...can't see them expanding to make the valves remain open,but maybe it's possible with neglected oil changes...also possible that severe carbon build up/deposits on the valves could keep them from sealing shut inside the combustion chamber

[DYNOBOB]

I appreciate the info guys. Sounds like it would be worth checking the cam timing. It does have a stock air filter (very dirty/may be orig). Truck has 45,000 km. Good chance the truck has spent a lot of time idling in its life, valve deposits are a possibility. The other '03 Carry I've got here working on bought a fram air filter, I'm not impressed w/ how it fits.

Anyone know what I'm looking for on cam timing? Cyl 1 tdc, lines on cam gears aligned or ???

[DYNOBOB]

Here's a little more info...

Spoke further w/ the owner, the truck never smoked or showed signs of burning oil. Ran perfect last summer and fall, became hard to start when it got cold (Nov). Basically would not start since.

What I've done so far:
Disconnected the fuel line to the engine and pumped the tank dry (direct wired the fuel pump temporarily), put in fresh gas.
It has strong spark.
It wets the plugs quickly so I unplugged the injectors, put in new plugs, and tried to start on starting fluid.

Of course all this was useless given the compression numbers I'm getting.

I'm going to pull the valve cover and look at cam timing if someone has the info. I've searched and don't see a thread where someone was sure theirs had jumped timing. It looks like Willyboy eventually said his problem was bad rings or gas.

Does anyone know what the fuel press should be w/ the truck running?

Bob

[greg0187]

Yeah. I see what you mean now. He said it jumped time then in another thread proved himself wrong. It was a long time ago. You probably saw this but just in case you didn't he explained how to time the cams.

The crank sprocket keyway needs to point at the line on the crank case then there is a line on the back of the sprocket that is where you put the painted yellow link on the chain at. Then on the cam side there is two black sections of the chain bout 10-15 links apart from each other. that is where your arrows on your cam gear go into.

Also I think I have parts catalog for this truck. Not sure if it goes back to 03 but it goes up to 09. JIC you need part numbers or something.

[werase643]

check the timing marks.
check the valve lash
what is the fuel pressure you get?

[DYNOBOB]

I'm buying that it may have jumped timing but need better info on how to check. With valve cover off I see the yellow link but no black links. As you rotate motor the chain goes from tight to quite loose, sometimes there is almost an inch of slack. When the chain is tight you can push it and watch the tensioner move to allow slack into the chain. When slack it's almost like the tensioner lacks enough travel to keep it tight.

Greg, can you tell looking at the parts view if there is a bolt you loosen from outside the motor to allow the tensioner to take up more slack? I've seen motorcycles that work that way.

[werase643]

find the timing mark on the crank pulley.....
look for the timing marks on both of the cams
do they line up to any marks on the casting of the head or the plane of the valve cover
rotate 360 and check again

[fupabox]

timing parts list,and diagram.if you can't get the link.....sorry I couldn't get the diagram to resize ???
actually everything you need is in this pdf link..takes a bit to load,but has your engine in it,and service info
http://products.jacobsen.com/img/manuals/4120402.pdf
1
The distribution chain
12761-73G01-000
1687 p.
2
Chain guide
12771-73G00-000
369 p.
3
Bolt
12776-85FA0-000
Bolt, timing chain guide
78 p.
4
Tensioner, chain
12811-73G01-000
not sold

Tensioner, timing chain
12811-58J00-000
1246 p.

Link, tensioner
12821-58J10-000
152 p.
5
Gasket tensioner chain
12812-73G10-000
109 p.
6
Bolt
01550-08253-000
not sold

Bolt
01 550-0825B-000
109 p.
7
Gasket tensioner
12813-73G00-000
72 p.
8
Link
12821-78G00-000
152 p.
9
Bolt
01550-06123-000
not sold

Bolt cementing
01 550-0612B-000
109 p.
10
Adjuster assy, tensioner
12831-58J00-000
1802 p.

アジャスタアッシ, テンショナ
12831-78G01-000
not sold
11
Gasket, tensioner adjuster
12832-58J00-000
57 p.
12
Bolt
01550-06203-000
not sold

Bolt, inspection cap
01 550-0620B-000
109 p.

[DYNOBOB]

find the timing mark on the crank pulley.....
look for the timing marks on both of the cams
do they line up to any marks on the casting of the head or the plane of the valve cover
rotate 360 and check again

If memory serves my CBR gears have marks which point at each other and line up w/ the plane of the valve cover. I'll check this out tomorrow.

Man! Thanks for that link to manual! Anyone have knowledge of how to adjust the tension on the chain? Actually in the diagram it doesn't look adjustable. May be looking at a stretched chain.

EDIT: Looks like oil pressure when running provide extra tension.