Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Camshaft, Bearings and Lifters

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REMOVAL & INSTALLATION



1.3L and 1.6L 8-Valve Engines

See Figures 1 and 2

During this procedure, identify all components removed from the engine so that they may be reinstalled in their original positions. If discarding the old components so that new components can be installed, identifying the old items is not necessary.

  1. Remove the cylinder head.
  2.  
  3. Remove the intake and exhaust manifolds, the rocker arms and shafts, and the camshaft sprocket from the cylinder head.
  4.  



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Fig. Fig. 1: Exploded view of the cylinder head, showing camshaft mounting

  1. Remove the distributor from the distributor case.
  2.  
  3. Remove the distributor case mounting fasteners, then separate the case from the cylinder head.
  4.  
  5. Carefully slide the camshaft out of the rear (distributor) end of the cylinder head.
  6.  



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Fig. Fig. 2: Carefully slide the camshaft out of the rear end of the cylinder head

  1. Using a seal removal tool or small prytool, carefully pry the old camshaft oil seal out of the front of the cylinder head bore. Take care not to scratch the camshaft oil seal bore, otherwise oil leakage may occur. If using a small prytool, wrapping a piece of tape around the end of the tool may help reduce the change of scoring the bore by covering any sharp corners on the tool.
  2.  
  3. Clean the cylinder head, camshaft, rocker arms and shafts and all gasket mating surfaces of all dirt, corrosion and oil.
  4.  

To install:
  1. Apply a thin coat of clean engine oil to the oil seal lip, then drive the new seal into the housing only until the outer seal edge is flush with the cover surface.
  2.  

The new oil seal must be installed so that the side of the seal where the seal spring is visible is installed inward (toward the engine block).

  1. Apply clean engine oil to the camshaft, then carefully slide it into the rear end of the cylinder head.
  2.  
  3. Install the distributor case and tighten the mounting fasteners until secure.
  4.  
  5. Install the rocker arm shafts and rocker arms, the inside timing belt cover, the timing belt sprocket, the intake and exhaust manifolds, and the distributor.
  6.  
  7. Install the cylinder head on the engine block. Install all related items.
  8.  

1.6L 16-Valve Engine

See Figures 3, 4, 5, 6, 7 and 8

During this procedure, identify all components removed from the engine so that they may be reinstalled in their original positions. If discarding the old components so that new components can be installed, identifying the old items is not necessary.

  1. Disconnect the negative battery cable.
  2.  


CAUTION
Some models covered by this guide may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, refer to Chassis Electrical for SRS precautions. Failure to heed all precautions may result in accidental air bag deployment, which could easily result in severe personal injury or death. Also, never attempt any electrical diagnosis or service to the SRS components and wiring; this work should only be performed by a qualified automotive technician.

  1. Remove the hood.
  2.  



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Fig. Fig. 3: Exploded view of the camshaft and valve train components

  1. Remove the front grille.
  2.  
  3. Remove the hood lock from the front upper member, then remove the front upper member.
  4.  
  5. Remove the radiator.
  6.  
  7. Remove the timing belt cover, timing belt, camshaft sprocket and inside timing belt cover from the engine.
  8.  
  9. Remove the rocker arm cover.
  10.  
  11. Remove the distributor and distributor case from the cylinder head. When removing the distributor case, position a small catch pan or rag beneath it to catch any oil which may leak during removal.
  12.  



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Fig. Fig. 4: To remove the distributor case, loosen the three mounting bolts (arrows), then separate it from the cylinder head



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Fig. Fig. 5: Be sure to loosen the camshaft housing (bearing cap) bolts only in the sequence shown to avoid camshaft warpage

  1. Loosen all of the valve lash locknuts and adjusting screws so that there is no pressure exerted on the camshaft lobes.
  2.  
  3. Loosen the camshaft bearing cap bolts in the sequence shown in the accompanying illustration, then remove the caps from the cylinder head. Discard the old camshaft oil seal.
  4.  
  5. Lift the camshaft up and off of the cylinder head.
  6.  
  7. Clean the camshaft and bearing caps of all dirt and oil.
  8.  

To install:
  1. Apply clean engine oil to the camshaft journals and cam lobes, then set the camshaft on the cylinder head.
  2.  
  3. Apply clean engine oil to the camshaft bearing surfaces. Apply silicone sealant to the mating surface of bearing cap No. 6. The camshaft bearing caps are marked with their position numbers (No. 1 is the foremost cap, and No. 6 is the rearmost bearing cap). Install bearing cap No. 1 first, then install the remaining bearing caps. Oil the camshaft bearing cap bolt threads, then tighten all of them first to 24 inch lbs. (2.7 Nm), then to 48 inch lbs. (5.4 Nm), then to 72 inch lbs. (8.2 Nm), and finally to 97 inch lbs. (11 Nm) in the sequence shown in the accompanying illustration.
  4.  
  5. Apply a thin coat of clean engine oil to the oil seal lip, then drive the new seal into the housing only until the outer seal edge is flush with the cover surface.
  6.  



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Fig. Fig. 6: Tighten the camshaft housing mounting bolts in the sequence shown and in four steps to 97 inch lbs. (11 Nm)



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Fig. Fig. 7: After installing the camshaft, install a new oil seal-when installing the oil seal, drive it in the bore until it is flush with the cylinder head surface

The new oil seal must be installed so that the open side of the seal is installed inward (toward the cylinder head).

  1. Apply silicone sealant on the distributor case, as shown in the accompanying illustration, then install the distributor case on the cylinder head. Tighten the mounting fasteners to 97 inch lbs. (11 Nm). Install the distributor to the distributor case.
  2.  
  3. Install the timing belt cover, timing belt, camshaft sprocket and inside timing belt cover on the engine.
  4.  



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Fig. Fig. 8: Apply silicone sealant to the distributor case at the area marked A-tighten the mounting bolts (a) to 97 inch lbs. (11 Nm)

  1. Install the radiator.
  2.  
  3. Install the remove the front upper member, then install the hood lock onto the front upper member.
  4.  
  5. Install the front grille.
  6.  
  7. Install the hood.
  8.  
  9. Adjust rocker arm valve lash.
  10.  
  11. Install the rocker arm cover.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill the cooling system with the proper type and amount of engine coolant.
  16.  
  17. Start the engine and check for coolant and fuel leaks.
  18.  

1.8L Engine

See Figures 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18

During this procedure, identify all components removed from the engine so that they may be reinstalled in their original positions. If discarding the old components so that new components can be installed, identifying the old items is not necessary.

  1. Disconnect the negative battery cable.
  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Drain the engine oil.
  2.  



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Fig. Fig. 9: Exploded view of camshaft mounting on the cylinder head



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Fig. Fig. 10: After removing the outer timing chain, rotate the crankshaft 90 degrees (1/4 turn) clockwise so that the valves and pistons will not come into contact



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Fig. Fig. 11: Loosen the camshaft housing mounting bolts only in the sequence shown, otherwise camshaft warpage may occur

  1. Remove the oil pan and oil pump pick-up.
  2.  
  3. Remove the rocker arm cover.
  4.  
  5. Remove the timing chain cover.
  6.  
  7. Remove the outer timing chain.
  8.  
  9. Remove the Camshaft Position (CMP) sensor.
  10.  
  11. After removing the outer timing chain, rotate the crankshaft 90 degrees clockwise (as shown in the accompanying illustration) so that interference between the valves and pistons is avoided.
  12.  
  13. Loosen the camshaft retaining housing bolts in the sequence shown in the accompanying illustration, then remove them.
  14.  
  15. Lift the camshaft housings from the cylinder head.
  16.  
  17. Lift the camshafts up and off of the cylinder heads. Set the camshaft aside so that they will not be confused, and can be reinstalled in their original positions. Marking them with an I (intake) and an E (exhaust) with a grease pencil, is a good idea to prevent mixing them up.
  18.  



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Fig. Fig. 12: Keep the hydraulic valve lash adjusters submerged in clean engine oil until ready for installation


WARNING
Never disassemble the hydraulic valve lash adjusters. Also, do not apply force to the body of the adjusters, otherwise the oil in the adjuster's high pressure chamber will leak.

  1. Remove the hydraulic lash adjusters from the cylinder head. Set the adjusters in a container filled with clean engine oil; they should be kept submerged in clean engine oil until ready to reinstall them. If a container of clean engine oil is not available, only set the lash adjusters with their bucket bodies facing down. NEVER set the lash adjusters on their sides or with their bucket bodies facing up.
  2.  
  3. Clean the camshaft journals on the cylinder head, the camshaft housings (caps) and the camshafts of all dirt, grime and oil.
  4.  

To install:
  1. Fill the oil passages of the cylinder head with clean engine oil by pouring the oil through the oil holes. Ensure that the oil comes out from the oil holes in the sliding part of the valve lash adjuster bore.
  2.  
  3. Apply clean engine oil to the sides of the lash adjusters, then slide them into their bores in the cylinder head.
  4.  
  5. Rotate the crankshaft 1 3 / 4 revolutions (630 degrees) so that the crankshaft key is aligned with the mark on the engine block and the timing mark (dot) on the idler gear is positioned up.
  6.  
  7. Oil the camshaft journals and lobes, and lubricate the camshaft seats in the cylinder head, then set the camshafts on the cylinder head. Rotate the camshafts so that the locating pins on their front ends are positioned as shown in the accompanying illustration.
  8.  



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Fig. Fig. 13: Prior to valve lash adjuster installation, pour clean engine oil through the oil holes in the cylinder head until it exits the holes in the adjuster bores



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Fig. Fig. 14: Before installing the camshafts, rotate the crankshaft so that the matchmarks are aligned



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Fig. Fig. 15: After installing the camshafts, rotate them so that the locating dowels are positioned as shown

Install the camshafts so that the end with the CMP sensor groove is oriented toward the exhaust side.

  1. Install the camshaft housing pins in the cylinder head, then apply silicone sealant to the areas marked A in the accompanying illustration.
  2.  

Each camshaft housing (bearing cap) is equipped with identification as to whether it is an intake or exhaust camshaft housing, what position it should take from the timing chain end of the engine, and an arrow (should point to the timing chain end of the engine).

  1. Lubricate the camshaft housing-to-camshaft surfaces with clean engine oil, then position the housings on the cylinder head.
  2.  
  3. Lubricate the housing mounting bolts with clean engine oil, then install them finger-tight.
  4.  
  5. Using an inch-pound torque wrench and the sequence shown in the accompanying illustration, tighten all of the housing mounting bolts first to 24 inch lbs. (2.7 Nm), then to 48 inch lbs. (5.4 Nm), then to 72 inch lbs. (8.2 Nm), and finally to 97 inch lbs. (11 Nm).
  6.  



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Fig. Fig. 16: Apply sealant to the cylinder head in the areas marked A ...



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Fig. Fig. 17: ... then install the camshaft housings-the housings are stamped with identification marks, which help with housing positioning during installation



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Fig. Fig. 18: Tighten the camshaft housing mounting bolts ONLY in the sequence shown

  1. Install the CMP sensor.
  2.  
  3. Install the outer timing chain.
  4.  
  5. Install the timing chain cover.
  6.  
  7. Install the rocker arm cover.
  8.  
  9. Install the oil pan and pump pick-up.
  10.  
  11. Install the cooling system and all other components.
  12.  
  13. Refill the cooling system with coolant, the front differential with gear oil and the engine with clean engine oil.
  14.  


WARNING
Do not turn the camshafts or start the engine for approximately1/2hour after installing the valve lash adjusters and camshafts; it takes time for the valves to settle in place. Operating the engine before this time period may result n interference between the valves and pistons, which can easily cause expensive and time-consuming internal engine damage.

  1. After a half hour period, start the engine. Check the ignition timing and adjust it as necessary.
  2.  
  3. If the valve lash adjusters make a tapping sound when the engine started, air may be trapped in the adjuster(s). In such a case, run the engine at 2000 rpm for approximately 1 / 2 hour, after which the air should be bled from the adjuster(s). If the tapping sound continues, the adjuster is most likely defective. To check the adjuster, perform the following:
    1. Remove the rocker arm cover.
    2.  
    3. With you thumb, press down on each of the adjusters with a force of less than 44 lbs. (20 kg) when the valve adjuster is resting against the camshaft lobe base circle. If clearance exists between the adjuster and the camshaft, that adjuster is defective.
    4.  
    5. Perform this inspection for all 16 adjusters. Replace any that are found to be defective.
    6.  
    7. Install the rocker arm cover.
    8.  

  4.  

INSPECTION



1.3L and 1.6L 8-Valve Engines
LOBE WEAR
See Figure 19

Using a micrometer, measure the height of each of the camshaft lobes at its highest point. If the measured height is below the allowable range, replace the camshaft(s).



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Fig. Fig. 19: Use a micrometer to measure the highest point on the camshaft lobe-if the height is not within the specified range, replace the camshaft

RUN-OUT

See Figure 20

Position the camshaft so that both ends of the camshaft sit in V notches cut into wooden blocks. The center of the camshaft should not be supported. Situate a dial indicator so that it is reading off of the center camshaft journal. Spin the camshaft and observe the dial indicator; the total range measured is the total amount of run-out. If the run-out measured is not within the specified range, replace the camshaft.



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Fig. Fig. 20: Place both ends of the camshaft in V-notches cut into wooden blocks, position a dial indicator on the middle journal, then spin the camshaft and observe the dial indicator to measure run-out

JOURNAL WEAR

See Figures 21 and 22

  1. Using a micrometer, measure each of the camshaft journals at four places (every 90 degrees) around its circumference, and record the findings. Do this for all camshaft journals.
  2.  
  3. Using a bore gauge, measure each of the camshaft bores in the cylinder head, also at four positions for each bore, then record the measurements. Measure all of the camshaft bores.
  4.  



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Fig. Fig. 21: Measure each of the camshaft journals in four positions around their circumferences ...



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Fig. Fig. 22: ... and use a bore gauge to measure the inside diameter of the camshaft journal bores in the cylinder head-subtract the journal measurements from the bore diameters to calculate oil clearance

  1. Subtract the journal diameter measurements from the journal bore findings to calculate the camshaft journal-to-camshaft bore clearance for all journals and bores.
  2.  
  3. If the clearance exceeds the allowable limits, replace the camshaft, and, if necessary, the cylinder head.
  4.  

1.6L 16-Valve Engine

LOBE WEAR AND RUN-OUT

Use the same procedures as presented for the 1.3L and 1.6L 8-valve engines.

JOURNAL WEAR

See Figures 23 and 24


WARNING
During this procedure, do not rotate the camshaft since it is not, nor should be, oiled at this time. Rotating the camshaft without lubrication may cause scratching or scoring of either the cylinder head or the camshaft journals.

Inspect the camshaft journal and housings (bearing caps) for pitting, scratches, wear or damage. If any defects are evident, replace the camshaft or cylinder head and housings. Never replace the cylinder head and not the housings; these components are matched sets and should be replaced together.



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Fig. Fig. 23: Inspect the camshaft housing surfaces for scratches, pitting, wear or damage



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Fig. Fig. 24: Use the scale included with the Plastigage® kit to measure the piece of flattened Plastigage® for clearance

Check the camshaft-to-cylinder head oil clearance as follows:

  1. Clean the housings and camshaft journals of all oil, dirt and grime.
  2.  
  3. Set the camshaft on the cylinder head.
  4.  
  5. Position a piece of Plastigage® along the full width of each of the camshaft journals. (The Plastigage® should be set on the camshaft journal so that it runs parallel to the camshaft rotational axis.)
  6.  
  7. Install the camshaft housings (bearing caps) and tighten the mounting bolts as described in the removal and installation procedure.
  8.  
  9. Remove the camshaft housings and measure the Plastigage® width with the scale enclosed with the Plastigage® kit.
  10.  
  11. If the specifications are not within the allowable range, use a micrometer to measure the camshaft journals and a bore gauge to measure the camshaft bores (with the housings installed). Replace the component which is out of specifications.
  12.  

1.8L Engine

LOBE WEAR AND RUN-OUT

Use the same procedures as presented for the 1.3L and 1.6L 8-valve engines.

JOURNAL WEAR

Use the same procedures as presented for the 1.6L 16-valve engine.

HYDRAULIC VALVE LASH ADJUSTER WEAR

See Figure 25

Inspect the adjuster for pitting, scratches, or other damage. If any defects are found, replace the lash adjuster.

Measure the inside diameter of the lash adjuster bores and the outside diameter of the lash adjusters. Subtract the adjuster diameter from the bore measurement to calculate the adjuster-to-bore clearance. If the clearance exceeds the allowable value, replace the cylinder head or lash adjuster.



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Fig. Fig. 25: Use a micrometer and bore gauge to calculate the lash adjuster-to-cylinder head bore clearance

 
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