Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Headlights

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REMOVAL & INSTALLATION



Samurai Models

See Figures 1 and 2

  1. Remove the grille from the front of the vehicle by loosening the five retaining screws.
  2.  
  3. Loosen the three mounting screws from the headlight retaining ring, then rotate the ring counterclockwise and pull the ring off of the headlight.
  4.  
  5. Carefully pull the headlight bulb out of the mounting bracket, then pull the wiring harness connector off of the bulb terminals.
  6.  



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Fig. Fig. 1: To remove the headlight, loosen the three ring retaining screws, rotate the ring counterclockwise, then remove the ring



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Fig. Fig. 2: Pull the headlight out of the mounting bracket, then detach the wiring harness connector from it

To install:
  1. Hold the new bulb close enough to the bulb mounting bracket so that the wiring harness connector can be reattached. Push the connector onto the light bulb until it is properly engaged.
  2.  
  3. Position the light bulb in the mounting bracket, then install the retaining ring. Tighten the three retaining ring screws securely.
  4.  
  5. Install the front grille on the vehicle.
  6.  

Sidekick, Tracker, Sidekick Sport and X-90 Models


WARNING
Do not touch the new glass bulb with your fingers. Oil from your fingers can severely shorten the life of the bulb. If necessary, wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation.

  1. Open the vehicle's hood and secure it in an upright position.
  2.  
  3. Depress the wiring harness connector retaining latch, then pull the connector off of the light bulb.
  4.  
  5. Unfasten the locking ring which secures the bulb and socket assembly, then withdraw the assembly rearward.
  6.  



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Fig. Fig. 3: To remove the headlight bulb, first detach the wiring harness connector from it ...



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Fig. Fig. 4: ... then disengage the retaining ring by turning it counterclockwise



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Fig. Fig. 5: Slide the retaining ring off of the bulb ...



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Fig. Fig. 6: ... then pull the bulb out of the headlight housing

To install:
  1. Before installing a light bulb into the socket, ensure that all electrical contact surfaces are free of corrosion or dirt.
  2.  
  3. Position the headlight bulb and secure it with the locking ring.
  4.  
  5. Insert the wiring harness connector onto the light bulb, and push the connector onto the bulb until the retaining latch is properly engaged.
  6.  



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Fig. Fig. 7: NEVER touch the glass portion (arrow) of the bulb with your bare hands

  1. To ensure that the replacement bulb functions properly, activate the applicable switch to illuminate the bulb which was just replaced. (If this is a combination low and high beam bulb, be sure to check both intensities.) If the replacement light bulb does not illuminate, either it too is faulty or there is a problem in the bulb circuit or switch. Correct if necessary.
  2.  
  3. Close the vehicle's hood.
  4.  

AIMING



See Figures 8, 9, 10, 11 and 12

The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made.


CAUTION
About once a year, when the headlights are replaced or any time front end work is performed on your vehicle, the headlight should be accurately aimed by a reputable repair shop using the proper equipment. Headlights not properly aimed can make it virtually impossible to see and may blind other drivers on the road, possibly causing an accident. Note that the following procedure is a temporary fix, until you can take your vehicle to a repair shop for a proper adjustment.

Headlight adjustment may be temporarily made using a wall, as described below, or on the rear of another vehicle. When adjusted, the lights should not glare in oncoming car or truck windshields, nor should they illuminate the passenger compartment of vehicles driving in front of you. These adjustments are rough and should always be fine-tuned by a repair shop which is equipped with headlight aiming tools. Improper adjustments may be both dangerous and illegal.

For Samurai vehicles, horizontal and vertical aiming of each sealed beam unit is provided by two adjusting screws which move the retaining ring and adjusting plate against the tension of a coil spring. There is no adjustment for focus; this is done during headlight manufacturing.

Because the composite headlight assembly used on Sidekick, Tracker, and Sidekick Sport models is bolted into position, no adjustment should be necessary or possible. The headlight assemblies on some models, however, are bolted to an adjuster plate or may be retained by adjusting screws. If so, follow this procedure when adjusting the lights, BUT always have the adjustment checked by a reputable shop.

Before removing the headlight bulb or disturbing the headlamp in any way, note the current settings in order to ease headlight adjustment upon reassembly. If the high or low beam setting of the old lamp still works, this can be done using the wall of a garage or a building:

  1. Park the vehicle on a level surface, with the fuel tank about 1 / 2 full and with the vehicle empty of all extra cargo (unless normally carried). The vehicle should be facing a wall which is no less than 6 feet (1.8m) high and 12 feet (3.7m) wide. The front of the vehicle should be about 25 feet from the wall.
  2.  



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Fig. Fig. 8: Location of the aiming screws on most vehicles with sealed beam headlights



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Fig. Fig. 9: To adjust the headlight aiming on Sidekick, Tracker, Sidekick Sport and X-90 models ...



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Fig. Fig. 10: ... turn the adjusting screw or gear until the bubble is properly positioned in the indicator gauge-key in previous illustration also applies to this illustration

  1. If aiming is to be performed outdoors, it is advisable to wait until dusk in order to properly see the headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible by closing shades or hanging cloth over the windows.
  2.  
  3. Turn the headlights ON and mark the wall at the center of each light's low beam, then switch on the brights and mark the center of each light's high beam. A short length of masking tape which is visible from the front of the vehicle may be used. Although marking all four positions is advisable, marking one position from each light should be sufficient.
  4.  



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Fig. Fig. 11: Low-beam headlight pattern alignment



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Fig. Fig. 12: High-beam headlight pattern alignment

  1. If neither beam on one side is working, and if another like-sized vehicle is available, park the second one in the exact spot where the vehicle was and mark the beams using the same-side light. Then switch the vehicles so the one to be aimed is back in the original spot. It must be parked no closer to or farther away from the wall than the second vehicle.
  2.  
  3. Perform any necessary repairs, but make sure the vehicle is not moved, or is returned to the exact spot from which the lights were marked. Turn the headlights ON and adjust the beams to match the marks on the wall.
  4.  
  5. Have the headlight adjustment checked as soon as possible by a reputable repair shop.
  6.  

The headlight assemblies used on X-90 models are equipped with aiming gauges, which consist of a graduated glass tube filled with liquid. There is a small air bubble in the liquid, the position of which indicates the aiming position. When the headlight assembly is correctly aimed, the air bubble should be at the center of the gauge (the vehicle must be parked on a level surface with a person sitting in the driver's seat for this to be true). If the air bubble is not located at the center of the gauge, adjust the aiming as follows:

  1. Place the vehicle on a level surface.
  2.  
  3. Be sure that any items, other than the original vehicle equipment, are not in the vehicle, and the fuel tank is full.
  4.  
  5. Double-check the air pressure in all of the tires. If the air pressure is not correct, add or remove air from the tries, as necessary.
  6.  
  7. Have someone weighing the same as the driver sit in the driver's seat.
  8.  
  9. Open the hood.
  10.  
  11. Observe the horizontal and vertical aiming gauges. If the air bubbles (in both gauges) are not at the center of the gauges, turn the adjusting screw (for vertical aiming) or the adjusting gear (for horizontal aiming) until the air bubble is at the center of the gauge.
  12.  

 
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