Torque specs  for SideKick and Tracker 89 to 98.  G16a/b ,1.6 liter Engines.  ( no Samurai or Sport 1.8L engines)




This data is not Guaranteed, it is just a collation of facts for my journal.  Please consult your FSM for you car !

Values below 15 ft/lbs are best converted, to Inch/Lbs  , just multiply  by 12. and then an Inch/lb torque wrenched used.
Example: 10 ft/lbs X 12 = 120 Inch/lbs.
Never over torgue any 6mm bolt on this  engine, it is very easy to do and they well snap, and for sure easy those old EGR bolts! (I buy new ones for the EGR and use anti-seize on each I touch)
Compiled from 3+ sources and crosschecked with Mitchells, Chiltons Commercial DBase and OEM FSM from GM(GEO) and Suzuki's.  1989-1998.
GM torques  tend to be single numbers for whatever reason. (GM likes simple, so uses one number, it's all just a game for GM as all bolts really do have a range)
The Suzuki torque's all come in ranges (mostly), so you can decide to go low with oily bolts and higher for dry. (all bolts are spec'd that way.  ISO, SAE,  standards .)
I always apply all bolts wet and use the lower figures when offered.  I use anti-seize compound all external threads, that are very small 6mm threads.  Water pump for sure, EGR, Valve covers, etc.
The below data is is NO SUBSTITUTE for a matching FSM data, for your exact car engine , and year.
Green is my convenient inch/lb conversions (using low figure due  to anti-seize compound usage by me, SAE rules) I use a very accurate 0-200 inch/lb click torque wrench (on all  6mm thread bolts.)
Most ft/lb torque wrenches below 10, are grossly inaccurate so use the inch/lb wrench.
[ xxxxxxxx] =  or TSB revisions.
[ xxxxxxxx] =    16 valve (up to 95') values that are unique or out of 8v range.   
All numbers below without  inch or  ft foot marks, are Ft/lbs.


Engine     
                                                  Ft-lbs (newer tools are marked in  Lbs/Ft)   Look carefully for Inch pounds in BOLD and green and do not confuse them.

Spark Plugs............................................. ......  21

Intake/exhaust manifold nuts/bolts....................  13.5 to 20    [Geo 17]
Throttle body bolts ,same is above.
Exhaust header flange nuts (steel) ......................29 to 43   same for manifold stiffener
Exhaust shield nuts and bolts ..............................  7.5          90 inch/lbs
Fuel feed pipe bolt to TB .....................................6 to 8.5    72 inch/lbs
Head Oil Jet (gallery)...........................................44 inch/lbs.
Camshaft sprocket center bolt..........................  41 to 46  (use the rocker rail front 8mm hex plug and tool to lock this cam wheel)
Cam valve lash lock nuts................................    11 to 13.5     132 inch/lbs
Rocker arm shaft retaining screws......................  7 to 8.5  [Geo 89 inch/lbs] 84 inch/lbs The rumor is (no TSB filed) that the 8V engine the Philips screws used (countersunk ) were staked at the factory on later years.   "ask  a gun smith what stake means"
Rocker arm front shaft plug   16v....................... 24
16v Camshaft Carrier Cap bolts..x12................ 89 inch/lbs  GEO spec.    (must be staged up and down)
Valve Cover 8v ------------------------------  35-44 Inch/Lbs   (aka: Rocker cover bolts)  This is very very small torque, if you exceed this , the tin metal bends, and gasket leaks.
Valve Cover 16v-----------------------------  80-106 Inch/ Lbs  ( more forgiving this cover, but the 6mm bolts must never be over this number ! or they will snap)
Crank Shaft Oil seal housing bolt ...................   7  to 8.5   84 inch/lbs
Cylinder head bolts  ( always stage them 3 levels !)                                                                         CLICK HERE FOR SEQUENCE Map
        8 valve engine........................................  51 to 54 (91')
      16 valve engine
              Step 1..............................................  26
              Step 2..............................................  41
              Step 3..............................................  52

Crankshaft pulley bolts.............8mm head.......  7.0 to 8.8  [89-91'] (92+ spec is 12-13 ft/lbs)  In 1992 both GEO's & Suzuki motors changed part numbers of the bolt. {harder?}  THIS BOLT M6 HAS A NON ISO HEAD, its 8mm hex wrench
Crankshaft pulley center bolt  17mm head  ........ [ TSB # 423-07196  says 94 ft/lbs for both  89' to 96 years , factory started Feb-96]   retroactive spec. Always is this torque.
        8 valve engine.........................................  58-65 (old) [new  94] do not use.
      16 valve engine.........................................  81 ( old)   [new 94] do not use.
Oil pump gear plate bolts..................................  7 to 8.5  rear   84 inch/lbs
Oil pump-to-block bolts....................................  7 to 8.5  front  84 inch/lbs   [Geo 97 inch/lbs]
Oil pressure switch ----------------------------- 9 to 10.5
Oil pan bolts/nuts...........................................  7 to 8.5  84 inch/lbs   No gaskets allowed after 1995
Oil pan drain bolt ..........................................   22 to 28.5
Oil Strainer and basket bolt.............................  97 inch/lbs
Flywheel/drive plate bolts..................................  54.5 to 57.5
Timing belt cover.....nuts&bolts........................   7 to 8.5   (GEO 89 Inch/lbs)  84 inch/lbs
Rear main seal housing bolts.............................  8      96 inch/lbs  [Geo 106 inch/lbs ]

Timing belt tensioner  Idler center bolt.............  17.5 to 21.5   (GEO 20 Ft/lbs)
Timing belt tensioner STUD nut .......................  7 to 8.5   (Geo 97 inch-lbs)
Engine mounting center member bolt..................  43      [Geo 40ft/lbs]
Engine mount chassis or engine side mounts .......  36.5 to 43   [Geo 40 ft/lbs right and left]
Distributor gear case bolts................................  6 to 7.2  ( 89 inch /lbs GEO)  72 inch/lbs
Main bearing cap bolts.....................................  36.5 to 41
Connecting rod cap nuts..................................  24 to 26.5
Spark plugs ....................................................  14.5 to 21.5
Water coolant pump base bolts .........................7.5  to 9  (91')  (96 GEO 106 inch/lbs ) [1995 Suzuki shows 9-12 ft/lbs]  90 inch/lbs
Water coolant pump pulley Nuts.........................97 inch/lbs  84 inch/lbs
Cooling fan /clutch nut .....................................   7.5  to 9    90 inch/lbs
Torque Converter bolt ..................................... 36.5 to 43  

Special Sealants:
Distributor base box over rocker rail uses Silicon RTV , use Permatex high temp silicon rubber sealants. No bath tube caulk.
#6 rear ,Cam Cap Cover , cap bottom , with RTV  ,
No PAN gaskets allowed after 1995 or the crank CKP crank sensor WILL fail. (it will bounce and drive you and ECU nuts)
No G16 left the factory with any sort of  real pan gasket.  Its glued on in the factory and pressure tested, day 1.
How ever most gasket kits come one a pan gasket, as  this is far more easy to use then doing a good RTV glue job.   1989 to 1995.
The  pre 95s you can use a nice Felpro gasket saving you lots of grief of RTV; praying  that it seals.  Yes, do use gaskets, on the early engines.
Starting in 1996 the CKP crank sensors ,all malfunction if you add a pan gasket , due to stand off error at sensor. Don't do this or get DTC P0355 errors, smog tests, fail , and now the OBD2 "misfire monitor" is dead, failing smog 2 ways now.
Loctite(tm) 414 the flywheel center bolts.   I use this substitute called loctite  Blue Removable No.242 ,into the crank.
Loctite(tm) 414 Super bonder ,the Rear main seal housing bolts.    Cyanoacrylate adhesives or Super Glue works ok, on this aluminum thread.




Manual Transmission                                Ft-lbs

Oil fill and drain plugs.......................................  20   I  don't use loctite as prescribed. (especially that side plug)
Transmission-to-engine bolts/nuts  (Bell outer front flange)  Upper and lower
               Sidekick/Tracker.......................................  51 to 72   [Geo shows 72]
Input shaft bearing retainer bolts.......................  14 to 20
Transmission cross member bolts --------------- 44
Transmission mount bolts ----------------------  44
Lower transmission to engine --------------------72
Left and right transmission to engine side braces-- 72
Gear shift lever case bolts ------------------------17
Inspection cover bolts 6mm --------------------- 89 inch/lbs
speedo  driven case bolt 6mm --------------------106 inch/lbs
shift extension case bolts --------------------------- 20
Gear shift boot plate to body screws --------------- 62 inch/lbs
Starter bolts /nuts ---------------------------------- 22

For Clutch and more transmission torque data see below:




Auto Transmission                                    Ft-lbs

Transmission-to-engine bolts and nuts................  62
Torque converter-to-driveplate bolt...................  62
Oil pan bolts............................................. .....  9       [GEO 97 inch lbs]  108 inch/lbs


Transfer Case                                            Ft-lbs

Transfer case-to-transmission nuts.....................  20
Shift lever case center bolt...............................  60 in-lbs
Shift lever case bolts
        Sidekick...................................... ............  144 in-lbs
        Tracker....................................... ............  20



Clutch and Drivetrain             
                      Ft-lbs

Pressure plate-to-flywheel bolts..............................  14 to 20 
Driveshaft nuts and bolts
    
        Sidekick and Tracker.......................................  36 to 43
Freewheeling hub
        Manual locking
              Hub body bolts.........................................  15 to 22
              Hub cover bolts........................................  72 to 109 in-lbs
        Automatic locking
              Hub body bolts.........................................  15 to 21

Pressure plate-to-flywheel bolts..............................  14 to 20    [Geo 17]

Driveaxle flange bolt and nut (Sidekick/Tracker).........  29 to 43
Front axle housing mounting bolts (Sidekick/Tracker)
        Left side.............................................. .........  37
        Right side.............................................. ........  37
        Rear.......................................... ...................  37
Front wheel bearing locknut (Sidekick/Tracker)
        1992 and earlier (all models).............................  89 to 148
        1993 and later
              Tracker.................................... ...............  155
              Sidekick................................... ................  180
Differential carrier bolts
  
        Sidekick/Tracker........................................... ..  41
Differential drain plugs
        Front......................................... ...................  32
        Rear.......................................... ...................  36
Brake backing plate bolts/nuts.................................  14 to 20
Wheel lug nuts.............................................. ........   60
Bell housing to Tranny case ...................................    36.5 Ft/lbs  ( front bearing plate is 12.5 ft/lbs) (  see full spec here on type 1 5speed Transmissions )



Suspension         
                                                    Ft-lbs

Front Suspension 

Sidekick and Tracker
        Front strut/shock absorber upper mounting nuts..........  14 to 22
        Front strut/shock absorber-to-steering knuckle nuts....  58 to 75
        Lower control arm
              Front nut............................................... ..........  50 to 75
              Rear nut............................................... ...........  65 to 100
        Balljoint stud nut............................................... .....  32 to 50
        Balljoint-to-lower arm nuts.......................................  50 to 75
        Spindle-to-steering knuckle bolts...............................  29 to 43
Rear Suspension 
Sidekick and Tracker
        Rear balljoint boss bolts...........................................  2 9 to 43
        Upper arm bolts............................................. .........  58 to 72
        Proportioning stay bolts...........................................  1 7
        Trailing rod nuts.............................................. .......  58 to 72


Steering                                                    Ft-lbs

Steering wheel nut........................................  18 to 28
Steering gear mounting bolts...........................  51 to 65
Intermediate shaft pinch bolt..........................  14 to 22
Pitman arm-to-steering gear nut......................  101 to 129
Tie-rod end ballstud nut.................................  22 to 40
Steering shaft rubber joint bolts.......................  11 to 18
Pitman arm nut.............................................  101 to 129

Center link nut (Sidekick/Tracker).....................  22 to 50
Idler arm nut (Sidekick/Tracker).......................  50 to 72
Steering knuckle seal retainer bolts...................  96 in-lbs



Fuel and Exhaust                                      Ft-lbs
O2 sensor............................................ ..........  40



Cooling     
                                                  Ft-lbs
Thermostat housing bolts.................................  7 to 12   84 inch/lbs
Water pump-to-block bolts/nuts......................  7 to 9   84 inch/lbs

Brakes                                                        Ft-lbs

Brake bleeder screw........................................  8
Brake hose-to-caliper inlet fitting bolt................  14 to 18
Caliper carrier bolts.........................................  51 to 72
Caliper mounting bolts.....................................  18 to 20
Master cylinder mounting nuts...........................  7 to 12
Power brake booster mounting nuts....................  7 to 12
Wheel cylinder mounting bolts...........................  6 to 9


Body                                                        Ft-lbs

Door 
        Glass stud nut...........................................  4
        Hinge bolt.............................................. ...  26
        Handle nut............................................... .  4
        Latch screw............................................. .  7
Front door vent window screw............................  1
Rear door stationary glass channel frame screw.....  1
Hood hinge bolt.............................................. ..  23
Lift gate
        Hinge bolt.............................................. ...  7
        Latch screw............................................. .  7
        Striker screw.............................................   22
Front seat frame-to-floor nut..............................  18
Rear seat-to-seat back cushion hinge bolt.............  33
Safety belt anchor bolt......................................  36                                     

Errata:  (making these GM errors , destroys the screw or the object that you are screwing into.... strips out....)
The 96 Geo Tracker a few horrible errors. but obvious<<< ERRORS Galore!.
Page 6A1-4  Shows tighten the RAD shroud botls to 89 ft/lbs   the Ft should be inch or they will strip out instantly. these errors by GM repeats through out manual.
Page 6A1-62  Shows , Coolant pump pulley nuts as 97 ft/lbs ,again they mean inch.  (off by a factor 12 :1  ,  sadly)
Any 6mm bolt with huge Ft/lb spec is wrong  anything over 106 inch/lbs is wrong on 6mm !
and this FSM forgets the Crank timing gear bolt  spec. published in same year, of 94 ft/lbs.

NO , I'M SORRY 100 Foot POUNDs of torque will never work for any m6 or m8 machine screw on the whole car. (any car)   Only some M14 bolts can use that torque, see link to left for why!
The big limit is the aluminun you are screwing INTO, then if steel , either can fail if over torqued.
Our bolts are mostly 8.8 grade,  The crank my be grade 10. not sure. but 94/ft-lbs is spec.
If you ever over torque a screw and the object screwed into was not destroyed, then the bolt was yielded, (a word for bad) throw it away and start over, with a new bolt.
Steel in to steel dry: 8.78 grade
M8 is 18 ft/lbs  (in aluminum use SUZUKI spec, not steel to steel spec,)
M6 is  7 ft/lbs   (the cam caps 16v are 89 inch /lbs, or  7.4 foot/lbs, and never 89 ft/lbs (12times error)

For bolts not covered in the tables.  We use the generic spec. on bolts.  This is covered in the FSM in the general service pages. seen here. Page 9,  figure 17 seen here.
Example of above.  m6 bolt steel,  4 Ft/lbs that is 48 inch/lbs. (note the gross error in GM book above, using the words lb.in.  what pray tell is that?  "they meant Ft./lbs....sadly one more GM error.
This 4 Ft/lbs is for the softest metal bolts made, and is not correct for this car,  the correct numbers are listed as Grade 8.8.  and for M6 bolts that is 5.8 to 7.7 ft/lbs or 92 inch lbs max,  ( except pan or valve cover if using cork !)
The key facts here, are not to exceed the bolts actual spec. as seen the last link above . When reading any GM books , assume there are huge errors from the translation from Suzuki book to GM books,  it is very common. (be a skeptic with GM books)

Oddities: 
In the N.American cars, we have. Odd sized (non SAE/non ISO head sized, crank pulley tiny machine screws (bolts)
 See Suzuki P/N here. for crank pulley parts
The pulley uses a  BOLT M6 that HAS A NON standard ISO HEAD, it's 8mm hex wrench size (odd)  ,  if you buy any standard. ISO bolt it will have 10mm head and will NOT work, the socket wrench will not fit and binds against the pulley curve.
buy a real Suzuki bolt , see link above, or buy an Allen socket head M6 bolt. So you can turn it with  wrench (Allen).

ver3   5-1-2015 ,small edits , typo's... and better links. added the factory staking trick. seen on many older 8v.




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