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NOTE: Samurai & Sidekick 1) Remove rocker cover. Rotate crankshaft until zero degree (TDC) timing mark of timing belt cover is in line with timing mark on crankshaft pulley. 2) Cylinder No. 1 should be at TDC on compression stroke. Remove distributor cap, and ensure rotor is pointed upward at distributor hold-down bolt and to No. 1 terminal of distributor cap. If not as described, rotate crankshaft 360 degrees. 3) Measure valve clearance between adjustment screw and valve stem using thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1 and 3. 4) Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4. Ensure clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. 5) If clearance adjustment is necessary, loosen lock nut and turn adjusting screw. After adjusting clearance, tighten adjusting Swift DOHC uses hydraulic lifters. Adjustment is not required. screw lock nut to 11-14 ft. lbs. (15-19 N.m) on Samurai or 90-108 INCH lbs. (10-13 N.m) on Sidekick. On all models, recheck clearance. VALVE CLEARANCE SPECIFICATIONS TABLE ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡ Application SOHC Engines Samurai, Sidekick 8-Valve TBI & Swift (1) Engine Cold Exhaust ……………………. .006-.008 (.15-.20) Intake …………………….. .005-.007 (.13-.17) Engine Hot Exhaust ……………………. .010-.012 (.25-.30) Intake …………………….. .009-.011 (.23-.27) Sidekick 16-Valve PFI Engine Cold Exhaust & Intake ………….. .0031-.0047 (.08-.12) Engine Hot Exhaust & Intake ………….. .0047-.0063 (.12-.16) DOHC Engine Swift (1) …………………………………. (2) (1) – Swift is available with 1.3L DOHC and SOHC engines. (2) – Hydraulic valve lash adjusters are used. Adjustment is not required. ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡ Swift SOHC 1) Remove rocker cover. Remove right side inner fender apron extension to enable timing marks to be seen. Align crankshaft pulley timing mark with TDC mark on timing belt cover. 2) Remove distributor cap. Ensure rotor is pointing upward toward distributor hold-down bolt and to No. 1 terminal of distributor cap. If not as described, rotate crankshaft 360 degrees. 3) Measure valve clearance between adjustment screw and valve stem using thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1 and 3. Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4. 4) Ensure clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. If clearance adjustment is necessary, loosen lock nut and turn adjusting screw. Hold adjusting screw while tightening lock nut to 11-14 ft. lbs. (15-19 N.m). Recheck clearance. In. (mm)

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NOTE: Hydraulic valve lifters are used; no valve adjustment is required. When valve and/or valve seat is machined, valve clearance is reduced and may cause improper valve operation. Different length push rods are available for correcting clearance. Valve lifter must be collapsed to check valve clearance. 1. With valve cover removed, position piston No. 1 at TDC of compression stroke. Completely collapse cylinder No. 1 intake valve lifter and hold valve lifter collapsed. Using feeler gauge, measure clearance between rocker arm and valve stem. 2. Clearance should be within specification. Refer to COLLAPSED VALVE LIFTER CLEARANCE table. Replace push rod, if necessary, to obtain correct clearance. 3. Position crankshaft as specified. See, in this article, VALVE CLEARANCE CHECKING SEQUENCE table, and check appropriate valves. Replace push rods if clearance is not within specification. 4. If push rod(s) is replaced, ensure corresponding cylinder piston is below TDC. It will be necessary to loosen or remove rocker arm to replace push rod. CAUTION: DO NOT operate or crank engine after installing push rod until valve lifter has leaked down to normal operating position. COLLAPSED VALVE LIFTER CLEARANCE

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HINT: Inspect and adjust the valve clearance when the engine is cold. 1. 2. 3. 4. DRAIN ENGINE COOLANT REMOVE INTAKE AIR CONNECTOR REMOVE CYLINDER HEAD COVERS SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with the timing mark “0″ of the No. 1 timing belt cover. b. Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 5. INSPECT VALVE CLEARANCE a. Check only the valves indicated in the illustration. ^ Using a feeler gauge, measure the clearance between the valve lifter and camshaft. ^ Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold)

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VALVE LASH (CLEARANCE) 1. Remove negative cable at battery. 2. Remove cylinder head cover. Zoom Sized for Print 3. Using 17 mm socket, turn crankshaft pulley clockwise until “V” mark (in white paint) on pulley aligns with “O” (zero) calibrated on timing belt cover. 4. Remove distributor cap and check rotor position. If it is positioned as shown in figure (i.e. No.1 piston is at Top Dead Center (TDC) of compression stroke), check valve lashes at valves (1), (2), (5) and (7). If it is at ignition position of No.4 cylinder, check valve lashes at valves (3), (4), (6) and (8). NOTE: When checking valve clearance, insert thickness gauge between camshaft and cam-riding face of rocker arm.

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REMOVAL NOTE: The oil pump and valve body are removed as an assembly. 1. Disconnect battery ground cable, then remove battery, battery tray, and remote air cleaner. 2. Position supply hoses, vacuum hoses, and wiring away from pump and valve body cover. 3. Remove shift lever. 4. On models equipped with Anti-lock Brake System (ABS) , remove splash shield cover, then disconnect brake reservoir hose and cap to prevent contamination. 5. On all models, remove EGR bracket attaching bolts, then install lifting eye. 6. Remove throttle body bracket attaching bolt, install lifting eye, then using suitable equipment support engine. 7. Remove lefthand transaxle mount. 8. Remove transaxle side pan upper attaching bolts. 9. Raise and support vehicle. 10. Remove lefthand front wheel and tire assembly. 11. Remove inner fender cover and position aside, then disconnect ride height sensor. 12. Remove rear transaxle mount attaching bolt. 13. Loosen but do not remove two lefthand subframe attaching bolts. 14. Remove two engine support mount attaching bolts. 15. Remove four lefthand engine support attaching bolts, then remove the engine support. 16. Position suitable drain pan, then remove remaining transaxle side pan attaching bolts and remove pan. 17. Using suitable screwdriver, place manual shift shaft in Park position. 18. Disconnect upper bulkhead electrical connector wiring retainer clip from valve body. 19. Disconnect electrical connectors. Oil Pump And Valve Body Bolt Removal 20. Remove valve body attaching bolts, then disengage linkage and remove valve body. NOTE: Do not remove oil pump cover attaching bolts. INSTALLATION 1. Install new pump and valve body to chain cover gasket. 2. Slide pump and valve body onto pump shaft. 3. Rotate pump and valve body assembly toward dash panel, then engage manual valve link with manual valve. 4. Slightly rotate pump and valve body assembly to engage oil pump shaft splines with oil pump rotor splines. Valve body should slide flush with chain cover. A suitable 7/8 inch deep well socket on crankshaft pulley may be required for complete engagement. 5. On models less anti-skid, if engagement is not as indicated in step 4, proceed as follows: a. Remove manual valve from valve body. b. Rotate assembly to allow full engagement, up to 360° . c. After full engagement, return assembly to installed position, then install manual valve.