I have put a 2.3 in place of the tired 2.0 in my 1999 Suzuki Vitara. Everything bolted up just perfect, what has happened is now I have a vibration that was not there before. It has brand new engine mounts, the harmonic balancer was changed over from the 2.0 to the 2.3 and the flex plate was also changed over. The engines look excatly the same on the outside, all mounting holes lined up perfect for the auto transmission to the a/c , p/s pump, alt. Any hep would be great.

I would start by using the right balancer in the new motor just because it fit don't mean its right. call brent at trail tough about the felxplate being able to be interchanged he should know

I will give them a call as soon as I can. The pulley had to be changed because the Vitara balancer has an extra belt on it to run the water pump. I have thought of looking at how the Aerio runs it water pump. Right now I am in Colorado working, but as soon as I get back the balancer is the first thing I thought about changing to see if it smooths out. Its amazing what you start thinking about when you start typing. Thanks for the advice, anything else would be of gerat help. This all started with Hawk telling me about the upgrade.

I could be wrong on this, but I think the Aerio runs the waterpump (as well as the alternator, a/c compressor and p/s pump) off of one belt, exactly the same way the Vitara does - I believe it's the fan that is different - the Vitara has a belt driven viscous clutch fan and the Aerio has an electric fan.

Try the Vitara with the Aerio pulley and leave the fan off - it'll be fine as long as you don't get caught in heavy traffic or leave it stationary with the engine idling - if that solves the vibration, consider replacing the clutch fan with an electric.

That is right, you are not wrong, it has been a couple of weeks since I looked at it. I can always hook up an electric fan on a manual switch like I did on my Samurai. I just watch the temp. gauge and turn it on when it starts getting a little warm. Or I can set it up for a thermostat that will start it automaticly. Working these 12 hour shifts I have not had alot of time to put much thought into it. Removing the fan should give me enough room to replace it with electric.

We had a 1.6 flywheel redrilled to use on an Aerio without any vibrations, but did not change the harmonic balancer.  No vibrations.
We used also went with electric fan.  If you are not using the AC, you can use the AC side of engine temperature sensor (which goes to ground at 205 degrees) to pickup a relay for power to fan motor.  It is a little high, but when you forget the fan it is not as high as it could get.

For information, did you use the Vitara exhaust manifold?  Are you running on the Vitara ECM or the Aerio.  If using the Aerio ECM, do you have any codes? 

We did use the Vitara exhaust manifold, also used the Vitara ECM and fuel injectors. Everything that came off the Vitara bolted right up to the 2.3 Aerio engine. The engines looked so much alike that I had the parts store look up the numbers on the engine to make sure it was a 2.3.