Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Rocker Arms/Shafts

Print

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 and 1.6L 8-Valve Engines

See Figures 1, 2, 3, 4, 5, 6, 7 and 8

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. Disconnect the negative battery cable and drain the engine cooling system.
  2.  


CAUTION
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. Although not indicated by the manufacturer, it may be necessary on Samurai models (as it is on Sidekick models) to remove several components from the front of the vehicle for enough clearance to remove the rocker arm shafts. If this added clearance is necessary for rocker arm shaft removal, perform the following:
  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. If your vehicle is equipped with air conditioning, the manufacturer states that the compressor must be disconnected from the A/C hoses; refer to General Information & Maintenance before servicing any A/C components.
    2.  
    3. Remove the hood.
    4.  
    5. Remove the front grille.
    6.  
    7. Remove the hood lock from the front upper member, then remove the front upper member.
    8.  
    9. Remove the radiator cooling fan, shroud and radiator.
    10.  


  1. Loosen the water pump pulley mounting bolts, then remove the accessory drive belts and water pump pulley.
  2.  
  3. If equipped, remove the air intake case from the throttle body.
  4.  
  5. Remove the rocker arm cover.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Before removing the rocker arm shafts, be sure to label the rocker arms as shown so that they can be reinstalled in their original positions ...



Click image to see an enlarged view

Fig. Fig. 2: ... then loosen the rocker arm locknuts and adjusting screws to relieve any pressure from the camshaft lobes

  1. Loosen all of the valve lash locknuts and adjusting screws so that there is no pressure exerted on the camshaft lobes.
  2.  
  3. Remove the timing belt cover, timing belt, camshaft sprocket and inside timing belt cover from the engine.
  4.  
  5. Matchmark the rocker arms so that they can be reinstalled in their original positions.
  6.  
  7. Loosen the 10 rocker arm shaft securing screws, then slowly slide one of the rocker arm shafts out of the front of the cylinder head. While withdrawing the rocker arm shaft from the cylinder head, remove the rocker arms and springs. Set the rocker arms and springs aside in order.
  8.  



Click image to see an enlarged view

Fig. Fig. 3: Loosen all 10 rocker arm retaining screws ...



Click image to see an enlarged view

Fig. Fig. 4: ... then slowly slide the rocker arm shafts out of the cylinder head and remove each rocker arm one at a time

  1. Remove the other rocker arm shaft in the same manner.
  2.  
  3. Clean the rocker arms, shafts, springs and rocker arm shaft bores in the cylinder head.
  4.  

To install:
  1. Inspect the tip of the adjusting screw for excessive wear; if wear is evident, replace the adjusting screw.
  2.  
  3. Inspect the face of the rocker arm cam-riding surface for wear; if excessive wear is evident, replace the rocker arm.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Inspect the cam-riding face and adjusting screw tips for damage or excessive wear



Click image to see an enlarged view

Fig. Fig. 6: Use a micrometer and a bore gauge to measure and calculate the rocker arm-to-shaft clearance



Click image to see an enlarged view

Fig. Fig. 7: Position the rocker arm shaft on two wooden blocks equipped with V notches to inspect run-out

  1. Inspect the rocker arm-to-shaft clearance by using a micrometer to measure the outside diameter of the rocker arm shaft where the rocker arms ride on it. Use a bore gauge to measure the inside diameter of the rocker arm bore. Subtract the rocker arm bore inside diameter from the rocker arm shaft outside diameter to calculate the rocker arm-to-shaft clearance. Compare your findings with the values presented in the engine rebuilding specification charts at the end of this section. If your findings are not within the values in the charts, replace the rocker arm, shaft, or both.
  2.  
  3. Position the rocker arm shaft in two wooden blocks with V cutouts in them (refer to the accompanying illustration). Using a dial indicator, measure the amount of run-out at the center of the rocker arm shaft. If your measurement is not within the values presented in the engine rebuilding specifications chart.
  4.  
  5. Apply clean engine oil to the rocker arms and shafts.
  6.  

The two rocker arm shafts are not identical. To distinguish between the two, inspect the stepped ends of the rocker arm shafts. The intake rocker arm shaft stepped end is 0.55 in. (2mm) wide and the exhaust side rocker arm shaft stepped end is 0.59 in. (3mm) wide. Refer to the accompanying illustration.

  1. Insert the intake side rocker arm shaft into the cylinder head bore so that the stepped end is toward the timing belt end of the engine, then slowly slide the rocker arm shaft into position, while installing the rocker arms and springs onto the shaft. Ensure that the rocker arms and springs are installed in their original positions.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: Before installation, be sure to properly identify the two rocker arm shafts, since they are not identical

  1. Install the exhaust side rocker arm shaft in the cylinder head so that the stepped end faces the distributor end of the engine. While slowly sliding the rocker arm shaft into position, install the rocker arms and springs onto the shaft. Ensure that the rocker arms and springs are installed in their original positions.
  2.  
  3. Tighten the rocker arm shaft retaining screws to 80-106 inch lbs. (9-12 Nm). Do not attempt to adjust the valve lash at this point.
  4.  
  5. Install the timing belt inside cover, camshaft sprocket, timing belt and outer cover.
  6.  
  7. Adjust the valve lash as described in General Information & Maintenance .
  8.  
  9. Install the rocker arm cover.
  10.  
  11. If equipped, install the air intake case onto the throttle body.
  12.  
  13. Install the water pump pulley and tighten the mounting bolts until snug. Install the accessory drive belts and tighten the water pump pulley bolts fully.
  14.  
  15. If the front components were removed from the vehicle for added shaft removal clearance, perform the following:
    1. Install the radiator, shroud and cooling fan.
    2.  
    3. Install the hood lock and the front upper member.
    4.  
    5. Install the front grille.
    6.  
    7. Install the hood.
    8.  

  16.  
  17. Connect the negative battery cable and fill the engine cooling system.
  18.  
  19. If your vehicle is equipped with air conditioning, have the A/C compressor installed and your system evacuated and recharged by a qualified MVAC technician.
  20.  

1.6L 4-Valve Engine

See Figures 9 through 15

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the camshaft from the cylinder head.
  4.  
  5. Matchmark the positions of the intake rocker arms so that they can be reinstalled in their original positions.
  6.  



Click image to see an enlarged view

Fig. Fig. 9: Prior to rocker arm removal, be sure to loosen the exhaust rocker arm locknut and adjusting screw



Click image to see an enlarged view

Fig. Fig. 10: To remove the rocker arms, remove the oil plug (rocker arm shaft plug) and the timing belt inside cover from the cylinder head ...



Click image to see an enlarged view

Fig. Fig. 11: ... then remove the intake rocker arms from the shaft

  1. Remove the rocker arm shaft plug and timing belt inside cover from the cylinder head.
  2.  


WARNING
Be sure not to bend the rocker arm clip during removal.

  1. Remove each intake rocker arm with its clip from the rocker arm shaft.
  2.  
  3. Matchmark the positions of the exhaust rocker arms so that they can be reinstalled in their original positions.
  4.  



Click image to see an enlarged view

Fig. Fig. 12: Remove the rocker arm shaft bolts ...



Click image to see an enlarged view

Fig. Fig. 13: ... and slide the rocker arm shaft rearward until the O-ring and groove are exposed, then remove the O-ring and pull the shaft forward

  1. Remove the rocker arm shaft bolts, then slide the rocker arm shaft toward the rear of the engine until the O-ring is exposed. Remove the O-ring from the rocker arm shaft groove.
  2.  
  3. Remove the exhaust rocker arms by sliding the rocker arm shaft out of the front of the cylinder head.
  4.  
  5. Position the rocker arms and springs on a clean work surface in order so that they can be reinstalled in their original positions.
  6.  
  7. Clean the rocker arms, springs and rocker arm shaft.
  8.  

To install:
  1. Inspect the tip of the adjusting screw for excessive wear; if wear is evident, replace the adjusting screw.
  2.  
  3. Inspect the face of the rocker arm cam-riding surface for wear; if excessive wear is evident, replace the rocker arm.
  4.  



Click image to see an enlarged view

Fig. Fig. 14: Inspect the cam-riding faces and adjusting screw tips of the rocker arms for damage or excessive wear

  1. Inspect the exhaust rocker arm-to-shaft clearance as follows:
    1. Use a micrometer to measure the outside diameter of the rocker arm shaft where the rocker arms ride on it. Use a bore gauge to measure the inside diameter of the rocker arm bore. Subtract the rocker arm bore inside diameter from the rocker arm shaft outside diameter to calculate the rocker arm-to-shaft clearance. Compare your findings with the values presented in the engine rebuilding specification charts at the end of this section. If your findings are not within the values in the charts, replace the rocker arm, shaft, or both.
    2.  

  2.  
  3. Position the rocker arm shaft in two wooden blocks with V cutouts in them (refer to the accompanying illustration). Using a dial indicator, measure the amount of run-out at the center of the rocker arm shaft. If your measurement is not within the values presented in the engine rebuilding specifications chart.
  4.  
  5. Apply clean engine oil to the rocker arms and shafts.
  6.  

Ensure that the rocker arm is installed in the cylinder head so that the O-ring groove is toward the distributor end of the engine.



Click image to see an enlarged view

Fig. Fig. 15: After installing the rocker arm shaft, rotate it so that the flat on its end is positioned parallel with the cylinder head-to-engine block gasket mating surface

  1. Insert the rocker arm shaft into the cylinder head bore so that the O-ring groove end is toward the distributor end of the engine, while installing the exhaust rocker arms and springs onto the shaft. Ensure that the rocker arms and springs are installed in their original positions.
  2.  
  3. Push the rocker arm out of the back side of the cylinder head until the O-ring groove is exposed. Install a new O-ring into the groove, then slide the rocker arm shaft back into the cylinder head so that both ends are flush with the head. Rotate the shaft so that the flat surface on its front end faces down and is parallel with the cylinder head-to-engine block gasket surface.
  4.  
  5. Install and tighten the rocker arm shaft retaining screws to 97 inch lbs. (11 Nm). Do not attempt to adjust the valve lash at this point.
  6.  
  7. Fill a small amount of clean engine oil into the rocker arm pivot holding part of the rocker arm shaft, then install the intake rocker arms so that their clips are properly engaged on the shaft.
  8.  
  9. Install the camshaft and all other items removed earlier.
  10.  
  11. Adjust the valve lash as described in General Information & Maintenance , then install the rocker arm cover.
  12.  

1.8L Engine

The 1.8L DOHC engine does not utilize rocker arms or rocker arm shafts.

 
label.common.footer.alt.autozoneLogo