Torque specification for Suzuki SideKick / Tracker

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.

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Engine parts torque specs

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

Part name	Ft/lbs	inch/lbs	Nm
Spark Plugs	21	252	28.5
Intake/exhaust manifold nuts/bolts	13.5 to 20 [Geo 17]
Throttle body bolts	13.5 to 20 [Geo 17]
Exhaust header flange nuts (steel), same for manifold stiffener	29 to 43
Exhaust shield nuts and bolts	7.5	90
Fuel feed pipe bolt to TB	6 to 8.5	72
Head Oil Jet (gallery)		44
Camshaft sprocket center bolt (use the rocker rail front 8mm hex plug and tool to lock this cam wheel)	41 to 46
Cam valve lash lock nuts	11 to 13.5	132
Rocker arm shaft retaining screws. 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”	7 to 8.5	84 [Geo 89]
Rocker arm front shaft plug 16v	24
16v Camshaft Carrier Cap bolts.x12 (must be staged up and down) [GEO spec]		89 Geo spec.
Valve Cover 8v. (aka: Rocker cover bolts) This is very very small torque, if you exceed this, the tin metal bends, and gasket leaks.		35–44
Valve Cover 16v ( more forgiving this cover, but the 6mm bolts must never be over this number! or they will snap)		80–106
Crank Shaft Oil seal housing bolt	7 to 8.5	84
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. 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	7.0 – 8.8 [89-91′] 12 – 13 [92+]
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 (old) [new 94] do not use.	58–65 (old)
16 valve engine (old) [new 94] do not use.	81 (old)
Oil pump gear plate bolts (rear)	7 to 8.5	84
Oil pump-to-block bolts (front)	7 to 8.5	84 [Geo 97]
Oil pressure switch	9 to 10.5
Oil pan bolts/nuts. No gaskets allowed after 1995	7 to 8.5	84
Oil pan drain bolt	22 to 28.5
Oil Strainer and basket bolt		97
Flywheel/drive plate bolts	54.5 to 57.5
Timing belt cover (nuts&bolts)	7 to 8.5	84 [Geo 89]
Rear main seal housing bolts	8	96 [Geo 106]
Timing belt tensioner Idler center bolt	17.5 to 21.5 [Geo 20]
Timing belt tensioner STUD nut	7 to 8.5	84 [Geo 97]
Engine mounting center member bolt	43 [Geo 40]
Engine mount chassis or engine side mounts	36.5 to 43 [Geo 40 right and left]
Distributor gear case bolts	6 to 7.2	72 [Geo 89]
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′) 9 – 12 (95′) 9 [96 Geo]	90 (91′) 108 – 144 (95′) 106 [96 Geo]
Water coolant pump pulley Nuts		84–97
Cooling fan /clutch nut	7.5 to 9	90
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.

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Transmission parts torque specs

Manual transmission

Part name	Ft/lbs	inch/lbs	Nm
Oil fill and drain plugs. I don’t use loctite as prescribed. (especially that side plug)	20
Transmission-to-engine bolts/nuts (Bell outer front flange) Upper and lower
Sidekick/Tracker	51 to 72 [Geo 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
Speedo driven case bolt 6mm		106
Shift extension case bolts	20
Gear shift boot plate to body screws		62
Starter bolts /nuts	22

For Clutch and more transmission torque data see below:

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Auto Transmission

Part name	Ft/lbs	inch/lbs	Nm
Transmission-to-engine bolts and nuts	62
Torque converter-to-driveplate bolt	62
Oil pan bolts	9	108 [Geo 97]

 

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Transfer Case

 

Part name	Ft/lbs	inch/lbs	Nm
Transfer case-to-transmission nuts	20
Shift lever case center bolt		60
Shift lever case bolts
Sidekick		144
Tracker	20

 

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Clutch and Drivetrain

 

Part name	Ft/lbs	inch/lbs	Nm
Pressure plate-to-flywheel bolts	14 – 20
Driveshaft nuts and bolts
Sidekick and Tracker	36 – 43
Freewheeling hub
Manual locking
Hub body bolts	15 – 22
Hub cover bolts		72 – 109
Automatic locking
Hub body bolts	15 – 21
Pressure plate-to-flywheel bolts	14 – 20 [Geo 17]
Driveaxle flange bolt and nut (Sidekick/Tracker)	29 – 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 – 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 – 20
Wheel lug nuts	60
Bell housing to Tranny case (see full spec here on type 1 5speed Transmissions )	36.5
Front bearing plate	12.5

 

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Suspension

Front Suspension

 

Part name	Ft/lbs	inch/lbs	Nm
Sidekick and Tracker
Front strut/shock absorber upper mounting nuts	14 – 22
Front strut/shock absorber-to-steering knuckle nuts	58 – 75
Lower control arm
Front nut	50 – 75
Rear nut	65 – 100
Balljoint stud nut	32 – 50
Balljoint-to-lower arm nuts	50 – 75
Spindle-to-steering knuckle bolts	29 – 43

Rear Suspension

Part name	Ft/lbs	inch/lbs	Nm
Sidekick and Tracker
Rear balljoint boss bolts	29 – 43
Upper arm bolts	58 – 72
Proportioning stay bolts	17
Trailing rod nuts	58 – 72

 

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Steering

Part name	Ft/lbs	inch/lbs	Nm
Steering wheel nut	18 – 28
Steering gear mounting bolts	51 – 65
Intermediate shaft pinch bolt	14 – 22
Pitman arm-to-steering gear nut	101 – 129
Tie-rod end ballstud nut	22 – 40
Steering shaft rubber joint bolts	11 – 18
Pitman arm nut	101 – 129
Center link nut (Sidekick/Tracker)	22 – 50
Idler arm nut (Sidekick/Tracker)	50 – 72
Steering knuckle seal retainer bolts		96

 

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Fuel and Exhaust

Part name	Ft/lbs	inch/lbs	Nm
O2 sensor	40

 

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Cooling

Part name	Ft/lbs	inch/lbs	Nm
Thermostat housing bolts	7 – 12	84
Water pump-to-block bolts/nuts	7 – 9	84

 

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Brakes

Part name	Ft/lbs	inch/lbs	Nm
Brake bleeder screw	8
Brake hose-to-caliper inlet fitting bolt	14 – 18
Caliper carrier bolts	51 – 72
Caliper mounting bolts	18 – 20
Master cylinder mounting nuts	7 – 12
Power brake booster mounting nuts	7 – 12
Wheel cylinder mounting bolts	6 – 9

 

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Body

Part name	Ft/lbs	inch/lbs	Nm
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

 

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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. 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)

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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).