Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Air Cleaner (Element)

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REMOVAL & INSTALLATION



See Figures 1 through 4

The air cleaner element helps prevent airborne contaminants from entering the engine through the intake system (carburetor or throttle body, intake manifold, cylinder head). Such airborne contaminants as dirt, soot, smoke, etc. can lead to an increase in engine wear if allowed into the engine. Also, a dirty or dusty air cleaner element can increase fuel consumption and lower engine power output. Therefore, it is important to periodically inspect and replace the air cleaner element.

During normal (non-severe) vehicle usage, the air cleaner element should be replaced with a new one every 30,000 miles (50,000 km) or 30 months, whichever occurs first. If the vehicle is driven under severe conditions, inspect the air cleaner element every 3,000 miles (5,000 km) or 3 months, and replace it at least every 15,000 miles (25,000 km) or 15 months (whichever occurs first).

The Samurai models utilize a cylindrical air cleaner element, whereas the other models use a flat, rectangular element. The air cleaner element is located in a large, black plastic housing (cylindrical for Samurai models and rectangular for all other models) attached to the carburetor/throttle body via large air tubes. To replace the air cleaner element:

  1. Open the hood.
  2.  
  3. Locate the air cleaner element housing. If unsure of its location, trace the air tube from the carburetor or throttle body (depending on your particular model) back to the black plastic housing.
  4.  
  5. On Samurai models, detach the air cleaner outlet hose (air tube) from the housing cover by loosening the hose clamp with a screwdriver, then by pulling the hose off of the cover flange.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the air inlet system, including the air cleaner element, used on Samurai models



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Fig. Fig. 2: The Sidekick, Tracker, Sport and X-2 models utilize a rectangular, flat element, rather than the cylindrical one used by Samurai models

  1. Loosen the housing cover hold-down screws or clamps, then lift the cover up and off of the housing.
  2.  
  3. Note the installed position of the element, then pull it out of the housing.
  4.  
  5. Inspect the element by holding a 75W drop light, or similar lamp, inside the element (Samurai models), or on one side of the element (all other models). If light from the lamp can be seen through the element, it is still usable. If no light is visible through the element, or if the element is oily, ripped or otherwise damaged, replace it with a new one. If the element is only a little dusty or dirty and you have access to pressurized air, you can clean the element by blowing air through the element from the engine side of the element. (In other words, you should blow the air through the element in the opposite direction the air going into the engine normally flows during vehicle operation.)
  6.  



Click image to see an enlarged view

Fig. Fig. 3: To replace the air cleaner element, loosen the cover hold-down screws ...



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Fig. Fig. 4: ... then raise the cover and remove the element-note that some models utilize cover hold-down clamps

  1. Use a clean shop rag to wipe clean the inside of the housing. If there is oil or oily grime present in the housing, inspect the PCV system.
  2.  

To install:
  1. Position the element in the housing, then install the cover onto the housing. Ensure that the groove in the housing cover is properly engaged on the housing lip, then engage the hold-down screws or clamps to securely hold the cover in place.
  2.  
  3. If applicable, reattach the air cleaner outlet hose to the cover flange, and tighten the hose clamp until snug.
  4.  
  5. Close the hood.
  6.  

 
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