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1991 Suzuki Samurai CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Suzuki REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 Suzuki Samurai car and truck
repair procedures including Suzuki engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Suzuki Samurai automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
Imported Cars & Light Trucks & Vans -> 1991-92 -> Evacuating System
Vehicle: 1991 Suzuki Samurai JA 1.3 L4 GAS
The system must be completely discharged before evacuation. After discharging the system, keep low pressure gauge hose connected to low pressure test fitting and both manifold gauge valves closed.
- Connect high pressure gauge hose to vacuum pump, Fig. .
- Connect center manifold gauge hose to refrigerant source with tapping valve closed.
- Open high and low side gauge valves with vacuum pump operating.
- Continue to operate pump for approximately 15-20 minutes after low side gauge reaches 29 or more inches of vacuum. If the system has been left open for an...
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BRAKE SERVICE PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
SUZUKI, DISC BRAKES -> FRONT DISC BRAKE SERVICE -> Caliper Overhaul -> Caliper Service -> Caliper, Replace -> Disc, Replace -> Pads, Replace -> SAMURAI -> SIDEKICK & SWIFT
Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS
SAMURAI
Pads, Replace
- Raise and support vehicle, then remove wheel assembly.
- Remove caliper antirattle clip, Fig. .
- Remove caliper guide pin caps.
- Using a 6mm Allen wrench, remove caliper guide pins.
- Remove pad protectors, then caliper cylinder.
- Remove pads.
- Reverse procedure to install noting the following:
- Torque caliper bolts to specifications.
- Install wheel assemblies.
- Lower vehicle and perform brake test.
Caliper Service
- Raise and support vehicle.
- Disconnect brake hose from caliper.
- Remove caliper guide pin caps.
- Using a 6mm Allen wrench, remove caliper guide pins, then caliper.
- Cl...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
Suzuki -> Component Locations -> XL-7, 1999-06 Vitara, Grand Vitara, 1996-98 X90, 1989-98 Sidekick & 1986-95 Samurai
Vehicle: 1991 Suzuki Samurai JL 1.3 L4 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1991 Suzuki Samurai JL 1.3 L4 GAS
- Loosen wheel lug nuts, then raise and support vehicle. Position jack stands under axle housing.
- Remove lug nuts, then wheel assembly.
- Remove caliper carrier bolts, then support caliper with wire.
- Remove brake disc. If brake disc cannot be removed by hand, install two 8 mm bolts in holes provided, then tighten to remove disc.
- On models with free wheeling hubs, proceed as follows:
- Remove free wheeling hub cover attaching screws, then cover.
- Using needlenose pliers, remove free wheeling hub circlip, then free wheeling hub body.
- On models less free wheeling hub, proceed as follows:
- R...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS
- Disconnect battery ground cable at battery.
- Disconnect alternator lead wire and coupler.
- Disconnect canister with canister mounting b...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
Suzuki -> Air Bag Warning Lamp ->
Vehicle: 1991 Suzuki Samurai JL 1.3 L4 GAS
When the ignition system is placed in the on position, the Air Bag Warning lamp will illuminate for a few seconds and then go off as a bulb check. I...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 1991 Suzuki Samurai JL 1.3 L4 GAS
Inlet
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at heater core.
- Remove hose from heater core.
- Reposition hose clamp at water outlet on cylinder head.
- Remove hose from water outlet.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at hea...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Suzuki Samurai AUTOMOBILES
Component location diagrams for most 1991 Suzuki Samurai cars and light trucks sold in the U.S. from 1990+.
 Instrument Panel Harness Diagram for 1991 Suzuki Samurai JL 1.3 L4 GASComponents on diagram: |
 EFI Component Locations Diagram for 1991 Suzuki Samurai JL 1.3 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 Suzuki Samurai AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Suzuki Samurai cars and light trucks sold in the U.S.
 1991 Suzuki Samurai JA 1.3 L4 GAS Wiring DiagramComponents on diagram: |
 1991 Suzuki Samurai JS 1.3 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Suzuki Samurai AUTOMOBILES
OEM TSB listings for most 1991 Suzuki Samurai cars and light trucks sold in the U.S. from 1985+.
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Document: CORRECT COOLANT USAGE Vehicle: 1991 Suzuki Samurai JA 1.3 L4 GAS Auto Systems: |
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Document: OIL LEAK IDENTIFICATION Vehicle: 1991 Suzuki Samurai JA 1.3 L4 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Suzuki Samurai AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Suzuki Samurai cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Suzuki Samurai cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Suzuki Samurai cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Suzuki Samurai cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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