Suzuki Samurai REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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Suzuki Samurai CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Suzuki REPAIR SHOPS DON'T WANT YOU TO KNOW

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 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!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Suzuki mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your Suzuki Samurai vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR Suzuki Samurai AUTOMOBILES

Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Suzuki Samurai cars and light trucks from 1990+

Imported Cars & Light Trucks & Vans -> 1991-92 -> Oil Charge -> 1992 240SX -> 1992 Q45 -> 1992 Sonata -> 3000GT -> 323 -> 911 -> 928 -> 929 -> Accord -> Acura -> Amigo, Pickup & Rodeo -> B2200 & B2600i -> Civic -> Corrado & Passat -> Daihatsu -> Delco 4 Cylinder Radial Compressor -> Diamante -> Eclipse -> ES 300 -> Except 1992 240SX -> Except 1992 Q45 -> Except 1992 Sonata -> Except ES 300 -> Except SVX -> Except York Compressors -> Expo -> Galant -> Golf, GTI & Jetta -> Honda -> Hyundai -> Impulse & Stylus -> Infiniti -> Isuzu -> Jaguar -> Lexus -> Mazda -> Mercedes Benz -> Miata -> Mirage -> Mitsubishi -> Montero -> MPV -> MX-6 & 626 -> Navajo -> Nissan -> Peugeot -> Pickup -> Porsche -> Precis -> Prelude -> RX-7 -> Saab -> Sanden Compressor -> Seiko-Seiki Compressor -> Sterling -> Subaru -> Suzuki -> SVX -> Toyota -> Trooper -> Vanagon -> Volkswagen -> Volvo -> York Compressors
Vehicle: 1991 Suzuki Samurai JA 1.3 L4 GAS

Acura

When replacing compressor, drain 1 ounce of oil from replacement compressor prior to installation. When replacing other components, add oil as follows:

Condenser:
Integra 1/3 ounce
Legend 1/2 ounce
Vigor 2/3 ounce
Evaporator:
Integra-1 ounce
Legend 1/2 ounces
Vigor 1/2 ounce
Lines 1/3 ounce
Receiver/Drier 1/3 ounce

Daihatsu

When overhauling or replacing compressor, drain oil from old compressor and measure amount of oil recovered, add same amount measured plus an additional .7 ounce to compressor. When re...

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BRAKE SERVICE PROCEDURES FOR Suzuki Samurai AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Suzuki Samurai cars and light trucks from 1990+.

SUZUKI, ANTI-LOCK BRAKES -> TROUBLESHOOTING
Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS

Refer to Fig for troubleshooting flow charts. Refer t...

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FUEL FILTER REPLACEMENT PROCEDURES FOR Suzuki Samurai AUTOMOBILES

Fuel filter replacement procedures with corresponding images for most domestic and imported Suzuki Samurai cars and light trucks sold in the U.S. for 1980+.

Suzuki -> Fuel Filter Replacement -> Except Aerio, 1998-02 Swift & 1999-02 Esteem -> Fuel System Pressure Relief -> Removal & Installation -> With Onboard Refueling Vapor Recovery System
Vehicle: 1990 Suzuki Samurai 1.3 L4 GAS

With Onboard Refueling Vapor Recovery System

Fuel System Pressure Relief
  • Loosen the fuel filler cap to relieve fuel tank pressure.
  • Remove the fuel pump relay/fuse from relay or fuse box located in engine compartment.
  • Start the engine and allow to stall. Crank the engine for several seconds more to ensure relief of any remaining fuel pressure.
  • Disconnect the battery ground cable.
  • Install the fuel pump relay/fuse.
Removal & Installation

Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flamma...

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Suzuki Samurai AUTOMOBILES

Includes CV axle, universal joint, and driveline replacement, for domestic and imported Suzuki Samurai cars and light trucks from 1990+.

CV AXLE SHAFT, Replace
Vehicle: 1992 Suzuki Samurai JA 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 Suzuki Samurai AUTOMOBILES

Includes starter and alternator replacement procedures for domestic and imported Suzuki Samurai cars and light trucks from 1990+.

Alternator, Replace
Vehicle: 1990 Suzuki Samurai 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 Suzuki Samurai AUTOMOBILES

Maintenance lamp reset procedures with corresponding images for most domestic and imported Suzuki Samurai cars and light trucks sold in the U.S. from 1990+.

Suzuki -> Check Engine Lamp/Malfunction Indicator Lamp (MIL) -> 1992-95 Samurai & Sidekick
Vehicle: 1992 Suzuki Samurai JA 1.3 L4 GAS

Reset cancel switch after performing the required maintenance. The MIL canc...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Suzuki Samurai AUTOMOBILES

Includes radiator, cooling and heater hose replacement procedures for domestic and imported Suzuki Samurai cars and light trucks from 1990+

Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 1990 Suzuki Samurai 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 Suzuki Samurai AUTOMOBILES

Component location diagrams for most Suzuki Samurai cars and light trucks sold in the U.S. from 1990+.

Vacuum Hose Location Diagram for 1993 Suzuki Samurai JA 1.3 L4 GASVacuum Hose Location Diagram for 1993 Suzuki Samurai JA 1.3 L4 GAS

Components on diagram:
  • Pressure Sensor
  • Throttle Position Sensor
  • EGR Valve
  • Air Temperature Sensor
  • ISC Solenoid Valve
  • EFI Component Locations Diagram for 1991 Suzuki Samurai JA 1.3 L4 GASEFI Component Locations Diagram for 1991 Suzuki Samurai JA 1.3 L4 GAS

    Components on diagram:
  • Pressure Sensor
  • Oxygen Sensor
  • Fuel Pump Relay
  • Bimetal Vacuum Switching Valve
  • Diagnostic Switch Terminal
  • CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai PARTS/COMPONENTS LOCATION DIAGRAMS!

    WIRING DIAGRAMS FOR Suzuki Samurai AUTOMOBILES

    OEM drawn wiring diagrams for most Suzuki Samurai cars and light trucks sold in the U.S.

    1992 Suzuki Samurai JA 1.3 L4 GAS Wiring Diagram1992 Suzuki Samurai JA 1.3 L4 GAS Wiring Diagram

    Components on diagram:
  • Cigarette Lighter
  • Rear Defogger
  • License Light
  • Clock
  • Heater Blower Motor
  • 1993 Suzuki Samurai JA 1.3 L4 GAS Wiring Diagram1993 Suzuki Samurai JA 1.3 L4 GAS Wiring Diagram

    Components on diagram:
  • Battery
  • Wiper Motor
  • Ignition Coil
  • Horn
  • Washer Motor
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    TECHNICAL SERVICE BULLETINS FOR Suzuki Samurai AUTOMOBILES

    OEM TSB listings for most Suzuki Samurai cars and light trucks sold in the U.S. from 1985+.

    Document: SOUND SYSTEM - REPAIRS AND CLAIMS - S/M UPDATE
    Vehicle: 1987 Suzuki Samurai 1.3 L4 GAS

    Auto Systems:
  • Entertainment: Stereo, Radio, Cassettes
  • Document: UNDERHOOD (PRIMER) PAINT COLOR CODES - REV
    Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS

    Auto Systems:
  • Finishes, Body Structure, Frame, Bumpers
  • CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR Suzuki Samurai AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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

    CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai SPECIFICATIONS DATA!

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