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1990 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!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
BRAKE SERVICE PROCEDURES FOR 1990 Suzuki Samurai AUTOMOBILES
SUZUKI, DRUM BRAKES -> TIGHTENING SPECIFICATIONS -> SAMURAI & SIDEKICK
Vehicle: 1990 Suzuki Samurai 1.3 L4 GAS
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1990 Suzuki Samurai AUTOMOBILES
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 1990 Suzuki Samurai AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1990 Suzuki Samurai 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 1990 Suzuki Samurai AUTOMOBILES
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 1990 Suzuki Samurai AUTOMOBILES
Suzuki -> Air Bag Warning Lamp ->
Vehicle: 1990 Suzuki Samurai 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 1990 Suzuki Samurai AUTOMOBILES
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 1990 Suzuki Samurai AUTOMOBILES
Component location diagrams for most 1990 Suzuki Samurai cars and light trucks sold in the U.S. from 1990+.
Four-Wheel Drive Switch Location Diagram for 1990 Suzuki Samurai 1.3 L4 GAS Components on diagram: |
Engine Compartment Wiring Harness Diagram for 1990 Suzuki Samurai 1.3 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1990 Suzuki Samurai AUTOMOBILES
OEM drawn wiring diagrams for most 1990 Suzuki Samurai cars and light trucks sold in the U.S.
1990 Suzuki Samurai 1.3 L4 GAS Wiring Diagram Components on diagram: |
1990 Suzuki Samurai 1.3 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1990 Suzuki Samurai AUTOMOBILES
OEM TSB listings for most 1990 Suzuki Samurai cars and light trucks sold in the U.S. from 1985+.
Document: CORRECT COOLANT USAGE Vehicle: 1990 Suzuki Samurai 1.3 L4 GAS Auto Systems: |
Document: OIL LEAK IDENTIFICATION Vehicle: 1990 Suzuki Samurai 1.3 L4 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1990 Suzuki Samurai AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1990 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 1990 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 1990 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 1990 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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