Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Valve Lash

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See Figure 1

This procedure can be performed with the engine cold (overnight cold) or hot (normal operating temperature), but it is not a good idea to perform it when the engine is warm. Either allow the engine to cool completely or operate the engine until normal operating temperature has been reached. If you decide to perform the adjustment with the engine hot and it takes too long to complete the procedure, you may need to stop in the middle to warm the engine up again. Therefore, it is better to allow the engine to cool completely before adjusting the valve lash.



Click image to see an enlarged view

Fig. Fig. 1: The valve lash is the clearance (A) between the bottom surface of the adjusting screw (2) and the valve stem tip (3)

Valve lash refers to the clearance between the rocker arm adjusting screw and the tip of the valve stem. A thickness gauge should be used to measure this gap. Valve lash should be inspected every 15,000 miles (24,000 km) or 15 months, whichever occurs first.

For this procedure you will need a new cylinder head cover gasket.

Throughout this procedure the cylinders are referred to by their number. The number of each cylinder is dependent upon their location; the frontmost cylinder is No. 1 and the numbering proceeds for each cylinder toward the rearmost cylinder, which is No. 4. Therefore, the cylinders are numbered, from front-to-back, 1 through 4.

INSPECTION & ADJUSTMENT



1986-88 1.3L Engines

See Figures 2 through 5

  1. Remove the cylinder head cover.
  2.  
  3. Remove the rubber ignition timing inspection plug from the clutch housing on the transmission.
  4.  
  5. Using a large wrench, or a socket and large ratchet on the crankshaft pulley center nut, have an assistant turn the crankshaft clockwise (viewing the crankshaft from the front of the engine) until the timing mark line, next to the T mark, on the flywheel is aligned with the match mark on the transmission case.
  6.  
  7. Locate the spark plug wire tower on the distributor cap that corresponds to the No. 1 cylinder spark plug. Matchmark the position of the No. 1 distributor tower with the engine block or other engine component.
  8.  
  9. Remove the distributor cap and ensure that the distributor rotor points toward the matchmark. If the rotor points 180 degrees away from the matchmark (in the opposite direction), have your assistant rotate the crankshaft 360 degrees (one full revolution), then realign the timing line (next to the T mark) with the match mark on the transmission.
    1. The distributor rotor should now point to the No. 1 cylinder distributor cap tower matchmark. The engine is now positioned with the No. 1 cylinder at Top Dead Center (TDC) on the compression stroke.
    2.  
    3. If it still does not point to the matchmark, you matchmarked the wrong tower. Reinstall the distributor cap and double-check the spark plug tower identification.
    4.  

  10.  
  11. With the No. 1 cylinder at TDC on the compression stroke, use feeler gauges to check the clearance between the rocker arm adjusting screws and the tips of the valve stems for valves 1, 2, 5 and 7. (Refer to the accompanying illustration for valve numbering.)
  12.  



Click image to see an enlarged view

Fig. Fig. 2: When adjusting the valve lash, valves 1, 2, 5 and 7, and valves 3, 4, 6 and 8 are adjusted at the same time

  1. If the valve clearance is not within the specifications shown in the tune-up specifications chart in this section, adjust the clearance as follows:
    1. Loosen the adjusting screw locknut of the valve needing adjustment.
    2.  
    3. Pass the appropriately-sized feeler gauge between the adjusting screw and the valve stem tip. Tighten or loosen the adjusting screw until a slight drag can be felt on the feeler gauge.
    4.  
    5. Once this drag is felt, tighten the locknut to 133-168 inch lbs. (15-19 Nm) while holding the adjusting screw to prevent it from turning. This may seem harder than it sounds and may take you several attempts to get the knack for it.
    6.  

  2.  


WARNING
Although it is important to properly adjust the valve lash, it is better to have too loose of a valve lash clearance than too tight of a clearance. Too tight of a valve lash clearance may cause the valves to burn or prematurely wear, necessitating expensive engine repairs.

  1. Once the locknut is tightened, double-check the valve lash of the valve you just adjusted. If the valve lash changed while tightening the locknut, loosen the locknut and readjust the lash. You can double-check the valve lash adjustment by using a feeler gauge that is 0.002 in. (0.05mm) bigger than the specification. If this larger feeler gauge passes between the adjusting screw and valve stem tip with less than moderate effort, the adjustment is still too loose.
  2.  

A set of stepped feeler gauges can also be used to ensure that the clearance is not too great.

  1. Once you have the lash properly adjusted on valves 1, 2, 5 and 7. Have your assistant rotate the crankshaft another full revolution (360 degrees) until the timing marks are once again aligned. At this point, valves 3, 4, 6 and 8 can be adjusted by repeating substeps 7a through 7d for each of them.
  2.  
  3. Once all of the valves have been properly adjusted, install the cylinder head cover and distributor cap.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Adjust all A valves with the No. 1 piston at TDC, turn the crankshaft 360 degrees, then adjust all B valves



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Fig. Fig. 4: To adjust the valve, loosen the locknut and turn the adjusting screw until the proper gap is attained



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Fig. Fig. 5: Hold the adjusting screw steady with the screwdriver while tightening the locknut

1989-95 1.3L and 1989-96 1.6L Engines

See Figures 6 through 9

  1. If equipped, remove the air intake case.
  2.  
  3. Remove the cylinder head cover.
  4.  
  5. Using a large wrench, or a socket (typically 17mm) and large ratchet on the crankshaft pulley center nut, turn the crankshaft clockwise (viewing the crankshaft from the front of the engine) until the Top Dead Center (TDC) line on the crankshaft pulley is aligned with the 0 mark on the timing mark tab attached to the timing belt cover.
  6.  
  7. Locate the spark plug wire tower on the distributor cap that corresponds to the No. 1 cylinder spark plug. Matchmark the position of the No. 1 distributor tower with the engine block or other engine component.
  8.  



Click image to see an enlarged view

Fig. Fig. 6: On 1989-95 1.3L engines, the distributor rotor should point in the direction shown when the No. 1 cylinder is positioned at TDC on the compression stroke



Click image to see an enlarged view

Fig. Fig. 7: With No. 1 cylinder at TDC on the compression stroke, the distributor rotor should point as indicated-1.6L engines with 8-valve cylinder heads



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Fig. Fig. 8: On 1.6L engines equipped with 16-valve cylinder heads, the distributor rotor should point in the direction shown when the No. 1 cylinder is properly positioned at TDC on the compression stroke

  1. Remove the distributor cap and ensure that the distributor rotor points toward the matchmark. If the rotor points 180 degrees away from the matchmark (in the opposite direction), have your assistant rotate the crankshaft 360 degrees (one full revolution) and realign the timing marks.
    1. The distributor rotor should now point to the No. 1 cylinder distributor cap tower matchmark. The engine is now positioned with the No. 1 cylinder at Top Dead Center (TDC) on the compression stroke.
    2.  
    3. If the rotor still does not point to the matchmark, you may have matchmarked the wrong tower, or the distributor is installed improperly. Reinstall the distributor cap and double-check the spark plug tower identification by tracing the spark plug wire back to the cylinder.
    4.  

  2.  
  3. With the No. 1 cylinder at TDC on the compression stroke, use feeler gauges to check the clearance between the rocker arm adjusting screws and the tips of the valve stems for valve-pairs 1, 2, 5 and 7. (Refer to the accompanying illustration for valve numbering.)
  4.  
  5. If the valve clearance is not within the specifications shown in the tune-up specifications chart in this section, adjust the clearance as follows:
  6.  



Click image to see an enlarged view

Fig. Fig. 9: The valves in 16-valve cylinder heads are paired for identification purposes-adjust both valves in each pair when their number is indicated in the procedure

  1. Loosen the adjusting screw locknut of the valve needing adjustment.
  2.  
  3. Pass the appropriately-sized feeler gauge between the adjusting screw and the valve stem tip. Tighten or loosen the adjusting screw until a slight drag can be felt on the feeler gauge.
  4.  

Valve lash adjusting tools (such as Suzuki Tool 09917-18210) can be purchased to help make adjusting the valve lash easier, but are by no means necessary for this procedure.

  1. Once this drag is felt, tighten the locknut to 133-168 inch lbs. (15-19 Nm) while holding the adjusting screw to prevent it from turning. This may seem harder than it sounds and may take you several attempts to get the knack for it.
  2.  


WARNING
Although it is important to properly adjust the valve lash, it is better to have too loose of a valve lash clearance than too tight of a clearance. Too tight of a valve lash clearance may cause the valves to burn or prematurely wear, necessitating expensive engine repairs.

  1. Once the locknut is tightened, double-check the valve lash of the valve you just adjusted. If the valve lash changed while tightening the locknut, loosen the locknut and readjust the lash. You can double-check the valve lash adjustment by using a feeler gauge that is 0.002 in. (0.05mm) bigger than specification. If this larger feeler gauge passes between the adjusting screw and valve stem tip with less than moderate effort, the adjustment is still too loose.
  2.  

A set of stepped feeler gauges can also be used to ensure that the clearance is not too great.

  1. Once you have the lash properly adjusted on valve-pairs 1, 2, 5 and 7. Have your assistant rotate the crankshaft another full revolution (360 degrees) until the timing marks are once again aligned. At this point, valve-pairs 3, 4, 6 and 8 can be adjusted by repeating substeps 7a through 7d for each of them.
  2.  
  3. Once all of the valves have been properly adjusted, install the cylinder head cover and distributor cap.
  4.  

1.8L Engine

The 1.8L engine utilizes automatic hydraulic lash adjusters to maintain proper valve lash at all times. The valve lash for this engine is not manually adjustable. Therefore, periodic valve lash inspection and adjustment is not necessary or possible.

 
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