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Suzuki Samurai CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Suzuki REPAIR SHOPS DON'T WANT YOU TO KNOW
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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!
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 -> Charging System -> Charging Station Method -> Disposable Can Method
Vehicle: 1991 Suzuki Samurai JL 1.3 L4 GAS
Disposable Can Method
- Connect a suitable refrigerant dispensing valve to refrigerant can, then connect manifold gauge set to system.
- Connect center line of gauge set to fitting on container valve, Fig. .
- Purge air from center line by loosening connection at center fitting on gauge set, then slightly opening valve at container for a second or two. Retighten connection at gauge...
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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, HYDRAULIC BRAKES -> TROUBLESHOOTING -> BRAKE PULL -> BRAKE WARNING LIGHT ON OR FLASHING, AFTER ENGINE START -> BRAKE WARNING LIGHT ON, WITH BRAKE PEDAL APPLIED -> DRAGGING BRAKES -> EXCESSIVE PEDAL TRAVEL -> LOW BRAKING FORCE
Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS
LOW BRAKING FORCE
- Fluid leakage from brake lines and/or hoses.
- Air in brake system.
- Malfunctioning wheel cylinder and/or caliper assembly.
BRAKE PULL
- Malfunctioning wheel cylinder and/or caliper assembly.
- Loose calipers.
- Restricted brake line or hose.
EXCESSIVE PEDAL TRAVEL
- Partial brake system failure.
- Insufficient fluid in master cylinder reservoirs.
- Air in system.
DRAGGING BRAKES
- Master cyl...
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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: 1991 Suzuki Samurai JL 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: 1995 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 Suzuki Samurai AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Suzuki Samurai cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 1991 Suzuki Samurai JL 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 -> Air Bag Warning Lamp ->
Vehicle: 1994 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 Suzuki Samurai AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Suzuki Samurai cars and light trucks from 1990+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1993 Suzuki Samurai JA 1.3 L4 GAS
Lower
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at radiator outlet.
- Remove hose from radiator.
- Reposition hose clamp at water intake pipe.
- Remove hose from water intake pipe.
- Remove hose from vehicle.
- Reverse procedure t...
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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+.
 Instrument Panel Harness Diagram for 1991 Suzuki Samurai JA 1.3 L4 GASComponents on diagram: |
 Vacuum Hose Location Diagram for 1994 Suzuki Samurai JL 1.3 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Suzuki Samurai AUTOMOBILES
OEM drawn wiring diagrams for most Suzuki Samurai cars and light trucks sold in the U.S.
 1994 Suzuki Samurai JL 1.3 L4 GAS Wiring DiagramComponents on diagram: |
 1987 Suzuki Samurai 1.3 L4 GAS Wiring DiagramComponents on diagram: |
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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+.
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Document: SOUND SYSTEM - REPAIRS AND CLAIMS - S/M UPDATE Vehicle: 1987 Suzuki Samurai 1.3 L4 GAS Auto Systems: |
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Document: HOOD HINGE - RATTLES DASH/COWL AREA OVER ROUGH ROADS Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS Symptoms: |
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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
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