Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



1.3L and 1.6L 2-Valve Engines

See Figure 1 through 13

  1. Disconnect the negative battery cable.
  2.  
  3. If necessary for added clearance, remove the air inlet hose and air intake case (fuel-injected models) or air cleaner housing (carbureted engines).
  4.  
  5. Detach the PCV valve hose from the PC valve (mounted in the rocker arm cover).
  6.  



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Fig. Fig. 1: Rocker arm cover and related components-1.3L and 1.6L 2-valve engines



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Fig. Fig. 2: To remove the rocker arm cover, detach the air inlet hose from the air intake case ...



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Fig. Fig. 3: ... then loosen the air intake support bracket bolts ...



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Fig. Fig. 4: ... and remove it from the engine



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Fig. Fig. 5: Detach the breather hose from the intake case by compressing the clamp and sliding it down the hose



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Fig. Fig. 6: Remove the intake case hold-down bolts ...



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Fig. Fig. 7: ... and lift the intake case up and off of the throttle body

  1. Disengage the spark plug wires and the accelerator cable from their clips (mounted on the rocker arm cover).
  2.  
  3. Completely loosen the rocker cover hold-down bolts, then lift the cover up and off of the cylinder head.
  4.  
  5. Discard the old rocker arm cover gasket.
  6.  



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Fig. Fig. 8: Detach the breather hose from the rocker arm cover ...



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Fig. Fig. 9: ... and disengage the spark plug wires from the routing clips



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Fig. Fig. 10: Loosen the rocker arm cover hold-down bolts ...



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Fig. Fig. 11: ... then remove the bolts, ensuring that the rubber seals are retained for later use



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Fig. Fig. 12: Lift the rocker arm cover off of the cylinder head



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Fig. Fig. 13: Be sure to discard the old gasket-a new one is necessary for installation

To install:
  1. Clean the cylinder head and rocker arm cover mating surfaces of all dirt, grime, oil, etc.
  2.  
  3. Install a new gasket in the groove on the bottom of the rocker arm cover.
  4.  
  5. Position the rocker arm cover on the cylinder head, then install and tighten the hold-down bolts until snug.
  6.  
  7. Engage the spark plug wires and the accelerator cable in the holding clips.
  8.  
  9. Reattach the rubber hose to the PCV valve.
  10.  
  11. If necessary, install the air intake case, or air cleaner housing (as applicable), and the air inlet hose.
  12.  
  13. Connect the negative battery cable.
  14.  

1.6L 16-Valve Engine

See Figures 14 and 15

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the throttle body cover.
  4.  
  5. Detach the PCV valve hose from the PCV valve.
  6.  
  7. Disconnect the accelerator cable and the kickdown cable (3-speed automatic models) or the throttle cable (4-speed automatic models) from the throttle body.
  8.  



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Fig. Fig. 14: Exploded view of the rocker arm cover mounting

  1. Remove the air inlet tube and bracket.
  2.  
  3. Label and disengage the spark plug wires from the spark plugs.
  4.  
  5. Completely loosen the rocker cover hold-down bolts, then lift the cover up and off of the cylinder head.
  6.  
  7. Discard the old rocker arm cover gasket and O-rings.
  8.  

To install:
  1. Clean the cylinder head and rocker arm cover mating surfaces of all dirt, grime, oil, etc.
  2.  
  3. Install a new gasket in the groove on the bottom of the rocker arm cover. Also, install new O-rings to the spark plug holes in the rocker arm cover.
  4.  



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Fig. Fig. 15: When installing the rocker arm cover, ensure that the gasket and O-rings remain in position

When installing the rocker arm cover on the cylinder head, ensure that the gasket or O-rings do not become dislodged from the cover; this could lead to improper sealing and oil leakage.

  1. Position the rocker arm cover on the cylinder head, then install and tighten the hold-down bolts until snug.
  2.  
  3. Engage the spark plug wires to their respective spark plugs.
  4.  
  5. Install the air intake tube and bracket.
  6.  
  7. Reattach the accelerator and kickdown, or throttle, cables to the throttle body. Be sure to adjust the play in all of the cables.
  8.  
  9. Reattach the rubber hose to the PCV valve.
  10.  
  11. Install the throttle cover.
  12.  
  13. Connect the negative battery cable.
  14.  

1.2L Engine

See Figures 16, 17 and 18

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the ignition coils.
  4.  
  5. Detach the accelerator cable from its mounting clip.
  6.  
  7. Remove the oil level gauge.
  8.  



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Fig. Fig. 16: To remove the rocker arm cover, detach the breather and PCV hoses, and remove the oil level gauge

  1. Disconnect the breather hose and PCV hose from the rocker arm cover.
  2.  
  3. Loosen the rocker arm cover hold-down nuts, then lift the cover up and off of the cylinder head.
  4.  
  5. Discard the old cover gasket and O-rings.
  6.  

To install:
  1. Clean the cylinder head and rocker arm cover mating surfaces of all dirt, grime, oil, etc.
  2.  
  3. Apply sealant (such as Suzuki Sealant 33000-3550) to the cylinder head surface, as shown in the accompanying illustration.
  4.  
  5. Install a new gasket in the groove on the bottom of the rocker arm cover. Also, install new O-rings to the spark plug holes in the rocker arm cover.
  6.  



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Fig. Fig. 17: Before installing the rocker arm cover, apply sealant to the shaded areas for proper sealing



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Fig. Fig. 18: When positioning the rocker arm cover on the cylinder head, ensure that the gasket, side seal and O-rings do not become dislodged or malpositioned

  1. Install a new side seal in the cylinder head.
  2.  

When installing the rocker arm cover on the cylinder head, ensure that the gasket or O-rings do not become dislodged from the cover; this could lead to improper sealing and oil leakage.

  1. Position the rocker arm cover on the cylinder head, then install and tighten the hold-down nuts until snug.
  2.  
  3. Install the ignition coils and cover.
  4.  
  5. Install the oil level gauge.
  6.  
  7. Reattach the breather hose and the PCV hose to the rocker arm cover.
  8.  
  9. Engage the accelerator cable in the mounting clip, then connect the negative battery cable.
  10.  

 
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