Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Rear Main Seal

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REMOVAL & INSTALLATION



1.3L and 1.6L Engines
RECOMMENDED METHOD
See Figures 1 through 6

It is recommended to replace the oil seal by dropping the oil pan and removing the entire rear main seal housing. It is possible to remove the oil seal without doing this, but it is often difficult because the oil seal is extremely stiff and can easily cock in the bore. If you wish to try to replace the seal without removing the oil pan, refer to the alternative method.

  1. Remove the transmission, the flywheel and the oil pan from the vehicle.
  2.  



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Fig. Fig. 1: To remove the oil seal (A) and housing (B), remove the transmission, then the oil pan (C) from the vehicle



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Fig. Fig. 2: The oil seal housing is secured to the engine block with five bolts (A), and to the oil pan with two (B)

  1. Loosen the five rear main seal housing mounting bolts, then separate the housing from the back of the engine block. Discard the old gasket.
  2.  
  3. Position the housing on wooden blocks so that the outer side is facing down and the seal is not being supported. Use a blunt drift and hammer to drive the old seal out of the housing.
  4.  
  5. Clean the rear main seal housing and engine block mating surfaces of all dirt, grime, oil and old gasket material.
  6.  

To install:
  1. Position the rear main seal housing with the outer surface facing up, and on a flat, clean piece of wood.
  2.  
  3. Position the new oil seal in the seal housing bore and using a seal driver, or a large flat block of wood, and a hammer seat the seal in the housing until the outer edge of the seal is flush with the outer surface of the housing.
  4.  



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Fig. Fig. 3: After tightening the oil seal housing mounting bolts, trim any protruding gasket from the oil pan mating surface

  1. Apply a thin coat of clean engine oil to the oil seal lip.
  2.  
  3. Along with a new gasket, position the oil seal housing against the engine block, and install the mounting bolts finger-tight.
  4.  
  5. Tighten the housing mounting bolts to 80-106 inch lbs. (9-12 Nm).
  6.  
  7. After the oil seal housing mounting bolts are tightened, the gasket may protrude out from the bottom of the housing. Use a sharp knife or razor blade to trim the gasket flush with the oil pan mating surface.
  8.  
  9. Install the oil pan, flywheel and transmission.
  10.  


WARNING
Operating the engine without the proper amount and type of engine oil can result in severe engine damage.

  1. Be sure to fill the engine with clean engine oil before starting it.
  2.  

ALTERNATIVE METHOD
  1. Remove the transmission and flywheel from the engine.
  2.  
  3. Using a small prytool, carefully remove the old rear main oil seal from the oil seal housing. Be careful not to scratch or gouge the oil seal bore.
  4.  

To install:


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Fig. Fig. 4: Position the seal driver against the new oil seal ...



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Fig. Fig. 5: ... and carefully tap the seal into position with a mallet



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Fig. Fig. 6: The outer edge of the new seal (A) should sit flush with the housing surface (B)

  1. Apply a thin coat of clean engine oil to the new oil seal lip.
  2.  
  3. Position the new oil seal in the seal housing bore and using a seal driver and a hammer seat the seal in the housing until the outer edge of the seal is flush with the outer surface of the housing.
  4.  
  5. Install the flywheel and transmission.
  6.  

1.8L Engine

See Figure 7

  1. Remove the transmission and flywheel from the engine.
  2.  
  3. Using a small prytool, carefully remove the old rear main oil seal from the oil seal housing. Be careful not to scratch or gouge the oil seal bore.
  4.  

To install:


Click image to see an enlarged view

Fig. Fig. 7: Use the two Suzuki tools 0991-97710 (A) and 09911-97810 (B), or their equivalents, to drive the new seal into the seal bore

  1. Apply a thin coat of clean engine oil to the new oil seal lip.
  2.  
  3. Using Suzuki Tools 09911-97710 and 09911-97810, or their equivalents, install the new oil seal in the seal housing bore. Seat the seal in the housing until the outer edge of the seal is flush with the outer surface of the housing.
  4.  
  5. Install the flywheel and transmission.
  6.  

 
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