Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION



During these procedures, 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.

1.3L Engine

See Figures 1 through 9

The 1.3L engine uses an 8-valve cylinder head.

  1. Disconnect the negative battery cable.
  2.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the engine coolant.
  2.  
  3. Remove the timing belt.
  4.  
  5. Remove the intake manifold.
  6.  
  7. Remove the exhaust manifold.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the cylinder head-1.3L and 1.6L 8-valve engines

  1. Remove the rocker arm cover, then loosen all of the valve lash locknuts and adjusting screws until no pressure is applied to the camshaft.
  2.  
  3. On carbureted models, remove the fuel pump and rod from the cylinder head.
  4.  

Although the manufacturer does not specify a bolt removal sequence, it is advisable to remove the bolts in reverse of the installation sequence.

  1. Loosen and remove the 10 cylinder head mounting bolts.
  2.  


WARNING
Do not attempt to loosen the cylinder head from the engine block by striking it with a hammer or mallet; the cylinder head is positioned on the engine block by locating pins. If the cylinder head is struck with a hammer or mallet, the cylinder head may be damaged, or the locating pins may shear off in the block.

  1. Lift the cylinder head up and off of the engine block. If the cylinder head is difficult to separate from the engine block, lift the cylinder head with a prytool positioned under one of the bolt bosses located on the side of the cylinder head. Do not strike the side of the cylinder head with a mallet or hammer because the head is positioned on the engine block with locating pins.
  2.  
  3. Insert clean shop rags in the cylinder bores to prevent dirt and other contaminants from falling into the cylinder bores.
  4.  
  5. Remove the old gasket from the engine block. Clean all gasket mating surfaces on the engine block and cylinder head, including the intake manifold, exhaust manifold, carburetor/throttle body, and fuel pump.
  6.  
  7. Inspect the locating pins and engine block gasket surface for damage. If the locating pins re damaged, new ones must be installed. Engine block damage will require engine disassembly and must be repaired, preferably by a qualified automotive machine shop.
  8.  
  9. Clean and inspect the cylinder head for damage, as described later in the engine reconditioning portion of this information.
  10.  

To install:
  1. Ensure that the locating pins are properly installed in the engine block.
  2.  
  3. Position the new cylinder head gasket on the engine block so that it is retained by the locating pins. The gasket should be situated so that the word TOP is facing upward (away from the engine block) and toward the front (timing belt end) of the engine.
  4.  
  5. Remove the shop rags from the cylinder bores.
  6.  
  7. Gently set the cylinder head on the engine block ensuring that the intake and exhaust sides of the cylinder head are facing the proper directions.
  8.  

Although not required by the manufacturer, it is always a good idea to use new cylinder head bolts.

  1. Lightly lubricate the threads of the cylinder head bolts, then install them finger-tight.
  2.  
  3. Using the sequence shown in the accompanying illustration, tighten the cylinder head bolts to 23-25 ft. lbs. (31-34 Nm), then to 35-37 ft. lbs. (3-5 Nm), and finally to 1-5 ft. lbs. (63-70 Nm) for 1986-88 models. For 1989-95 models, use the same sequence, but tighten the bolts to 27 ft. lbs. (37 Nm), then to 40 ft. lbs. (9 Nm), and finally to 7 ft. lbs. (71 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Install the cylinder head gasket so that the word TOP faces upward and toward the crankshaft pulley end of the engine-1.3L and 1.6L 8-valve engines



Click image to see an enlarged view

Fig. Fig. 3: When tightening the cylinder head bolts, be sure to follow the sequence shown, otherwise improper cylinder head sealing will result-1.3L and 1.6L 8-valve engines

  1. Install the fuel pump and rod, the intake manifold, the exhaust manifold, the timing belt and all other related items.
  2.  
  3. Fill the engine cooling system with the proper amount and type of coolant.
  4.  
  5. Adjust the valve lash for all valves.
  6.  
  7. Install the rocker arm cover.
  8.  
  9. Conenct the negative battery cable.
  10.  
  11. Start the engine and check for coolant, fuel, vacuum and exhaust leaks.
  12.  



Click image to see an enlarged view

Fig. Fig. 4: To remove the cylinder head, detach all hoses, wires and cables from the cylinder head and manifolds ...



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Fig. Fig. 5: ... then remove the timing belt and rocker arm cover



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Fig. Fig. 6: Loosen and remove all of the cylinder head bolts in the proper sequence ...



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Fig. Fig. 7: ... and, with the help of an assistant, lift the cylinder head up and off of the engine block



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Fig. Fig. 8: Remove the old gasket from the engine block ...



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Fig. Fig. 9: ... and clean the gasket mating surfaces of all traces of old gasket material and dirt

1.6L TFI Engine

See Figures 1, 2 and 3

The 1.6L TFI engine uses an 8-valve cylinder head.

The manufacturer recommends removing the cylinder head with the distributor, exhaust manifold and intake manifold installed. If desired, these items can be removed from the cylinder head before the head is removed.

  1. Relieve fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the engine cooling system.
  2.  
  3. Remove the air intake case and throttle body.
  4.  
  5. Label and detach all cooling system and vacuum hoses from the intake manifold, throttle body and cylinder head.
  6.  
  7. Label and disengage all electrical wires from the distributor, intake manifold, cylinder head, throttle body and oxygen sensor. Detach the wiring harness from any retaining clamps on the cylinder head.
  8.  
  9. Relieve fuel system pressure as described in Fuel System .
  10.  
  11. Detach the fuel lines from the throttle body and pressure regulator.
  12.  
  13. Remove the timing belt.
  14.  
  15. Detach the exhaust pipe from the exhaust manifold by removing the attaching nuts.
  16.  

If your vehicle is equipped with air conditioning, refer to General Information & Maintenance for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified automotive technician should service the A/C system or its components.

  1. If applicable, remove the air conditioning compressor adjusting brace from the cylinder head. Do NOT disconnect any of the A/C refrigerant lines.
  2.  
  3. Remove the rocker arm cover, then loosen all of the valve lash locknuts and adjusting screws until all pressure is relieved from the camshaft.
  4.  

Although the manufacturer does not specify a bolt removal sequence, it is advisable to remove the bolts in reverse of the installation sequence.

  1. Loosen and remove the 10 cylinder head mounting bolts.
  2.  


WARNING
Do not attempt to loosen the cylinder head from the engine block by striking it with a hammer or mallet; the cylinder head is positioned on the engine block by locating pins. If the cylinder head is struck with a hammer or mallet, the cylinder head may be damaged, or the locating pins may shear off in the block.

  1. Lift the cylinder head up and off of the engine block. If the cylinder head is difficult to separate from the engine block, lift the cylinder head with a prytool positioned under one of the bolt bosses located on the side of the cylinder head. Do not strike the side of the cylinder head with a mallet or hammer because the head is positioned on the engine block with locating pins.
  2.  
  3. If desired, the intake manifold, exhaust manifold, distributor and distributor case may now be removed from the cylinder head.
  4.  
  5. Insert clean shop rags in the cylinder bores to prevent dirt and other contaminants from falling into the cylinder bores.
  6.  
  7. Remove the old gasket from the engine block. Clean all gasket mating surfaces on the engine block and cylinder head, including the intake manifold, exhaust manifold, and throttle body.
  8.  
  9. Inspect the locating pins and engine block gasket surface for damage. If the locating pins re damaged, new ones must be installed. Engine block damage will require engine disassembly and must be repaired, preferably by a qualified automotive machine shop.
  10.  
  11. Clean and inspect the cylinder head for damage, as described later in the engine reconditioning portion of this information.
  12.  

To install:
  1. Ensure that the locating pins are properly installed in the engine block.
  2.  
  3. Position the new cylinder head gasket on the engine block so that it is retained by the locating pins. The gasket should be situated so that the word TOP is facing upward (away from the engine block) and toward the front (timing belt end) of the engine.
  4.  
  5. Remove the shop rags from the cylinder bores.
  6.  
  7. If necessary, install the intake manifold, exhaust manifold, distributor case and distributor on the cylinder head. These components can also be installed after the cylinder head is mated to the engine block.
  8.  
  9. Gently set the cylinder head on the engine block ensuring that the intake and exhaust sides of the cylinder head are facing the proper directions.
  10.  

Although not required by the manufacturer, it is always a good idea to use new cylinder head bolts.

  1. Lightly lubricate the threads of the cylinder head bolts, then install them finger-tight.
  2.  
  3. Using the sequence shown in the accompanying illustration, tighten the cylinder head bolts to 27 ft. lbs. (37 Nm), then to 40 ft. lbs. (9 Nm), and finally to 7 ft. lbs. (71 Nm).
  4.  
  5. If equipped, install the air conditioning compressor adjusting brace onto the cylinder head.
  6.  
  7. Install the timing belt inside cover, camshaft sprocket, timing belt, outer cover and all other related items, such as the crankshaft pulley, water pump pulley, water pump drive belt, cooling fan and shroud.
  8.  
  9. Reattach all fuel lines, vacuum hoses, cooling system hoses and wiring to their respective components.
  10.  
  11. Reattach the exhaust pipe to the exhaust manifold.
  12.  
  13. Connect the accelerator and, if equipped, the kickdown cables to the throttle body. Adjust cable end-play as described in Fuel System (accelerator cable) and (kickdown cable).
  14.  
  15. Fill the engine cooling system with the proper amount and type of coolant.
  16.  
  17. Adjust the valve lash for all valves.
  18.  
  19. Install the rocker arm cover.
  20.  
  21. Install the air intake case.
  22.  
  23. Conenct the negative battery cable.
  24.  
  25. Start the engine and check for coolant, fuel, vacuum and exhaust leaks.
  26.  

1.6L MFI Engine

See Figures 10 through 14

The 1.6L MFI engine utilizes a 16-valve cylinder head.

  1. Relieve fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative cable.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the cooling system.
  2.  



Click image to see an enlarged view

Fig. Fig. 10: Cross-sectional view of the cylinder head used on the 1.6L MFI engine



Click image to see an enlarged view

Fig. Fig. 11: Be sure to loosen the 10 cylinder head bolts in the sequence shown, otherwise cylinder head warpage may occur

  1. Remove the intake manifold brace from the engine.
  2.  
  3. Label and detach all wiring and vacuum hoses from the distributor, intake manifold, oxygen sensor, throttle body, and cylinder head.
  4.  
  5. Detach the fuel supply and return lines from the fuel injector supply manifold.
  6.  
  7. Remove the rocker arm cover, then loosen all of the valve lash locknuts and adjusting screws.
  8.  
  9. Disconnect all cooling system hoses from the engine.
  10.  
  11. Remove the timing belt from the engine.
  12.  
  13. Separate the exhaust pipe from the exhaust manifold and remove the exhaust manifold brace.
  14.  


WARNING
Failure to properly loosen the cylinder head bolts may result in cylinder head warpage.

  1. Loosen the cylinder head mounting bolts using Suzuki Tools 09900-00415 (A) and 09900-00411 (B) (or their equivalents) in the order shown in the accompanying illustration, then remove the bolts from the cylinder head.
  2.  
  3. Ensure that all wires, hoses and cables, which would restrict cylinder head removal, have been detached.
  4.  


WARNING
Do not attempt to loosen the cylinder head from the engine block by striking it with a hammer or mallet; the cylinder head is positioned on the engine block by locating pins. If the cylinder head is struck with a hammer or mallet, the cylinder head may be damaged, or the locating pins may shear off in the block.

  1. Lift the cylinder head up and off of the engine block. If the cylinder head is difficult to separate from the engine block, lift the cylinder head with a prytool positioned under one of the bolt bosses located on the side of the cylinder head. Do not strike the side of the cylinder head with a mallet or hammer because the head is positioned on the engine block with locating pins.
  2.  
  3. If desired, the intake manifold, exhaust manifold, distributor and distributor case may now be removed from the cylinder head.
  4.  
  5. Insert clean shop rags in the cylinder bores to prevent dirt and other contaminants from falling into the cylinder bores.
  6.  
  7. Remove the old gasket from the engine block. Clean all gasket mating surfaces on the engine block and cylinder head, including the intake manifold, exhaust manifold, and throttle body.
  8.  
  9. Inspect the locating pins and engine block gasket surface for damage. If the locating pins re damaged, new ones must be installed. Engine block damage will require engine disassembly and must be repaired, preferably by a qualified automotive machine shop.
  10.  
  11. Clean and inspect the cylinder head for damage, as described later in the engine reconditioning portion of this information.
  12.  

To install:
  1. Ensure that the locating pins are properly installed in the engine block.
  2.  
  3. Position the new cylinder head gasket on the engine block so that it is retained by the locating pins. The gasket should be situated so that the word TOP is facing upward (away from the engine block) and toward the front (timing belt end) of the engine.
  4.  



Click image to see an enlarged view

Fig. Fig. 12: Install the cylinder head gasket on the engine block so that the word TOP faces upward and is toward the crankshaft pulley side of the engine



Click image to see an enlarged view

Fig. Fig. 13: If necessary, tighten the oil jet (venturi plug) to 35-8 inch lbs. (4-6 Nm)



Click image to see an enlarged view

Fig. Fig. 14: Tighten the cylinder head bolts in the sequence shown to ensure proper cylinder head sealing

  1. Ensure the oil jet (venturi plug) is installed in the cylinder head, and that it is not clogged. If it is not installed, tighten it to 35-8 inch lbs. (4-6 Nm).
  2.  
  3. Remove the shop rags from the cylinder bores.
  4.  
  5. If necessary, install the intake manifold, exhaust manifold, distributor case and distributor on the cylinder head. These components can also be installed after the cylinder head is mated to the engine block.
  6.  
  7. Gently set the cylinder head on the engine block ensuring that the intake and exhaust sides of the cylinder head are facing the proper directions.
  8.  

Although not required by the manufacturer, it is always a good idea to use new cylinder head bolts.

  1. Lightly lubricate the threads of the cylinder head bolts, then install them finger-tight.
  2.  
  3. Using the sequence shown in the accompanying illustration and using Suzuki Tools 09900-00415 (A) and 09900-00411 (B) (or their equivalents), tighten all of the cylinder head bolts to 25 ft. lbs. (35 Nm), then to 40 ft. lbs. (10 Nm), and finally to 2.5-5.5 ft. lbs. (65-70 Nm).
  4.  
  5. Reattach the exhaust pipe to the exhaust manifold, and install the exhaust manifold brace.
  6.  
  7. Install the timing belt.
  8.  
  9. Connect all cooling system hoses to the engine.
  10.  
  11. Attach the fuel supply and return lines to the fuel injector supply manifold.
  12.  
  13. Reconnect all wiring and vacuum hoses to the distributor, intake manifold, oxygen sensor, throttle body, and cylinder head.
  14.  
  15. Install the intake manifold brace.
  16.  
  17. Fill the cooling system.
  18.  
  19. Connect the negative cable.
  20.  
  21. Adjust the valve lash and the accelerator and kickdown (if equipped) cables.
  22.  
  23. Turn the ignition key ON , but do not start the engine; this allows the fuel system to pressurize. Check for fuel system leaks.
  24.  
  25. Afdter checking for fuel system leaks, start the engine and inspect for engine coolant, fuel, vacuum and exhaust leaks.
  26.  

1.8L Engine

See Figures 15 through 20

  1. Relieve fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the engine cooling system.
  2.  



Click image to see an enlarged view

Fig. Fig. 15: Exploded view of the cylinder head mounting



Click image to see an enlarged view

Fig. Fig. 16: Be sure to loosen the cylinder head bolts in the sequence shown to avoid head warpage-do not forget to loosen the small M6 bolt (3)

  1. Remove the camshafts and valve lash adjusters.
  2.  
  3. Remove the intake manifold brace from the engine.
  4.  
  5. Label and detach all wiring and vacuum hoses, which will interfere with cylinder head removal, from the intake manifold, oxygen sensor, throttle body, and cylinder head.
  6.  
  7. Detach the fuel supply and return lines from the fuel injector supply manifold.
  8.  
  9. Detach the water pipe from the intake manifold, and disconnect any other cooling system hoses from the engine.
  10.  
  11. Separate the exhaust pipe from the exhaust manifold and remove the exhaust manifold brace.
  12.  


WARNING
Failure to properly loosen the cylinder head bolts may result in cylinder head warpage.

  1. Loosen the cylinder head mounting bolts in the order shown in the accompanying illustration, then remove the bolts from the cylinder head.
  2.  

Be sure to loosen the small M6 bolt located on the side of the cylinder head, near the crankshaft pulley end.

  1. Ensure that all wires, hoses and cables, which would restrict cylinder head removal, have been detached.
  2.  


WARNING
Do not attempt to loosen the cylinder head from the engine block by striking it with a hammer or mallet; the cylinder head is positioned on the engine block by locating pins. If the cylinder head is struck with a hammer or mallet, the cylinder head may be damaged, or the locating pins may shear off in the block.

  1. Lift the cylinder head up and off of the engine block. If the cylinder head is difficult to separate from the engine block, lift the cylinder head with a prytool positioned under one of the bolt bosses located on the side of the cylinder head. Do not strike the side of the cylinder head with a mallet or hammer because the head is held in position on the engine block with locating pins.
  2.  
  3. If desired, the intake manifold, exhaust manifold, and any other items may now be removed from the cylinder head.
  4.  
  5. Insert clean shop rags in the cylinder bores to prevent dirt and other contaminants from falling into the cylinder bores.
  6.  
  7. Remove the old gasket from the engine block. Clean all gasket mating surfaces on the engine block and cylinder head, including the intake manifold and exhaust manifold.
  8.  
  9. Inspect the locating pins and engine block gasket surface for damage. If the locating pins re damaged, new ones must be installed. Engine block damage will require engine disassembly and must be repaired, preferably by a qualified automotive machine shop.
  10.  
  11. Clean and inspect the cylinder head for damage, as described later in the engine reconditioning portion of this information.
  12.  

To install:
  1. Ensure that the locating pins are properly installed in the engine block.
  2.  
  3. Position the new cylinder head gasket on the engine block a shown in the accompanying illustration.
  4.  
  5. Remove the shop rags from the cylinder bores.
  6.  
  7. If necessary, install the intake manifold, exhaust manifold, and any other components on the cylinder head. These components can also be installed after the cylinder head is mated to the engine block.
  8.  
  9. Gently set the cylinder head on the engine block ensuring that the intake and exhaust sides of the cylinder head are facing the proper directions.
  10.  



Click image to see an enlarged view

Fig. Fig. 17: Position the new cylinder head gasket on the engine block as shown



Click image to see an enlarged view

Fig. Fig. 18: Tighten the cylinder head bolts in the sequence shown to ensure proper cylinder head sealing



Click image to see an enlarged view

Fig. Fig. 19: When loosening the cylinder head bolts during installation, be sure to do so in the sequence indicated

Although not required by the manufacturer, it is always a good idea to use new cylinder head bolts.

  1. Lightly lubricate the threads of the cylinder head bolts, then install them finger-tight.
  2.  

Be sure to follow the cylinder head bolt tightening sequence exactly, otherwise improperly cylinder head sealing will occur.

  1. Using the sequence shown in the accompanying illustration, tighten the cylinder head bolts in the following steps:
    1. Tighten all cylinder head bolts, in sequence, to 38.5 ft. lbs. (8 Nm).
    2.  
    3. Tighten the head bolts, in sequence, to 61 ft. lbs. (84 Nm).
    4.  
    5. Loosen all of the head bolts in the indicated sequence until they can be rotated by hand.
    6.  
    7. Retighten the head bolts, in sequence, to 27 ft. lbs. (37 Nm).
    8.  
    9. Tighten the cylinder head bolts, in sequence, to 76 ft. lbs. (105 Nm).Tighten the small M6 bolt ONLY after the other bolts are fully tightened.
    10.  
    11. Tighten the small M6 bolt to 97 inch lbs. (11 Nm).
    12.  

  2.  
  3. Ensure that the crankshaft sprocket key is aligned with the timing mark on the engine block. If it is not aligned, rotate the crankshaft until it is.
  4.  



Click image to see an enlarged view

Fig. Fig. 20: Rotate the crankshaft so that the crankshaft timing sprocket key is aligned with the timing mark on the engine block

  1. Attach the exhaust pipe to the exhaust manifold, and install the exhaust manifold brace.
  2.  
  3. Reattach the water pipe to the intake manifold, and connect any other cooling system hoses to the engine.
  4.  
  5. Reattach the fuel supply and return lines to the fuel injector supply manifold.
  6.  
  7. Attach all applicable wiring and vacuum hoses to the intake manifold, oxygen sensor, throttle body, and cylinder head.
  8.  
  9. Install the intake manifold brace from the engine.
  10.  
  11. Install the camshafts, valve lash adjusters and all other related components.
  12.  
  13. Fill the cooling system.
  14.  
  15. Connect the negative cable.
  16.  
  17. Adjust the accelerator and kickdown (if equipped) cables, as described in Fuel System (accelerator cable) or (kickdown cable).
  18.  
  19. Turn the ignition key ON , but do not start the engine; this allows the fuel system to pressurize. Check for fuel system leaks.
  20.  
  21. Afdter checking for fuel system leaks, start the engine and inspect for engine coolant, fuel, vacuum and exhaust leaks.
  22.  

 
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