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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
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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
Suzuki -> Component Replacement & Adjustment -> BLOWER MOTOR, REPLACE -> SAMURAI -> SIDEKICK & SWIFT
Vehicle: 1991 Suzuki Samurai JL 1.3 L4 GAS
SAMURAI
- Disconnect battery ground cable.
- Drain cooling system, then disconnect heater hoses from heater unit inlet and outlet pipes.
- Remove instrument panel as follows:
- Remove horn pad, then the steering wheel using tool No. 09944-38210 or equivalent.
- Disconnect radio and cigarette lighter lead wires, remove radio case stay screw, pull out radio case, radio and cigarette lighter then remove radio case bracket.
- Pull out ashtray and remove ashtray plate screws.
- Disconnect hood opening cable from lock assembly.
- R...
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BRAKE SERVICE PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
SUZUKI, ANTI-LOCK BRAKES -> DIAGNOSIS TESTING -> DIAGNOSTIC TESTS -> READING DIAGNOSTIC CODE
Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS
READING DIAGNOSTIC CODE
Release parking brake. Momentarily jump terminal 5 of monitor coupler to terminal 3, Fig Connect jumper for longer than 2 seconds. Brake warning light should start flashing.
Each code consists of short flashes and a final long flash. Flashing is repeated until ignition key is turned off.
If engine is turned ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
Suzuki -> Fuel Filter Scheduled Maintenance -> 1990-95 Samurai -> Normal Service -> Severe Service
Vehicle: 1991 Suzuki Samurai JL 1.3 L4 GAS
Normal Service
Replace every 30,0...
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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
Starter, Replace
Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS
- Disconnect battery ground cable.
- Disconnect solenoid electrical connector and battery cable fr...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Suzuki Samurai AUTOMOBILES
Suzuki -> Air Bag Warning Lamp ->
Vehicle: 1991 Suzuki Samurai JA 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+.
 EFI Component Locations Diagram for 1991 Suzuki Samurai JA 1.3 L4 GASComponents on diagram: |
 Instrument Panel Harness 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 JL 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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