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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+
Suzuki -> Cooling Fans -> SWIFT -> 1991 -> 1992 -> A/C CONDENSER FAN -> COMPONENT REPLACEMENT -> Cooling Fan, Replace -> DESCRIPTION -> ENGINE COOLING FAN -> Radiator Fan -> SYSTEM DIAGNOSIS & TESTING -> Thermo Switch, Replace -> TROUBLESHOOTING
Vehicle: 1992 Suzuki Samurai JA 1.3 L4 GAS
DESCRIPTION
Radiator Fan
When the ignition switch is in the On position, system voltage is applied through ignition fuse to radiator fan switch. The fan switch closes when engine coolant temperature reaches 208°F. With fan switch closed, voltage is applied to radiator fan motor. Since fan motor is permanently grounded, fan operates as soon as voltage is applied. When temperature falls below 199°F, fan switch opens and voltage to fan motor is interrupted.
A/C Condenser Fan
When ignition switch is in On position, system voltage is applied to dual pressure swit...
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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 -> MASTER CYLINDER REPLACEMENT
Vehicle: 1992 Suzuki Samurai JA 1.3 L4 GAS
- Clean any dirt from around reservoir cap. Remove cap, then brake fluid.
- Remove reservoir connector screw, Fig., then reservoir.
- Disconnect brake lines from master cylinder. Do not allow brake fluid to get on painted surfaces.
- Remove master cylinder attaching bolts, then master cylinder.
- Adjust clearance of booster piston rod to master cylinder piston as follows:
- Push piston rod several times to ensure reaction disc is in place.
- Measure with gasket in place on master cylinder and booster at atmospheric pressure.
- Set measuring tool No. 09950-98210 or equivalent, on 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: 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: 1993 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+.
Starter, Replace
Vehicle: 1995 Suzuki Samurai JL 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 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) -> 1990-91 Samurai & Sidekick
Vehicle: 1991 Suzuki Samurai JL 1.3 L4 GAS
The Check Engine light will flash or light at 50,000, 80,000 and 100,000 miles to indicate emission maintenance is required. After performing the ...
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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: 1991 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 coolant pipe.
- Remove hose from coolant pipe.
- Remove hose from vehicle.
- Reverse procedure to ins...
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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+.
 EFI Component Locations Diagram for 1991 Suzuki Samurai JS 1.3 L4 GASComponents on diagram: |
 Diagram for 1991 Suzuki Samurai JA 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.
 1986 Suzuki Samurai 1.3 L4 GAS Wiring DiagramComponents on diagram: |
 1995 Suzuki Samurai JL 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: PAINT CODES Vehicle: 1991 Suzuki Samurai JA 1.3 L4 GAS Auto Systems: |
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Document: LABELS/EMISSION CONTROL - SELLING GUIDELINES Vehicle: 1992 Suzuki Samurai JA 1.3 L4 GAS Auto Systems: |
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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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Shop online for auto body parts, engines, wheels, lights...
 | 1995 Suzuki Samurai Cargo Mat, 34 x 48 in; Made from premium rubber that can withstand the harshest weather conditions; Features raised lips that help keep spills in the tray and off the carpet and anti-skid spikes that prevent the mat from slipping; Great for muddy boots, gardening supplies, fishing gear, or pets; Can be trimmed down to 26 x 36 in. in 1 in. increments; Conforms to fit floor contours; Easy installation and removal.. | $55.46 |
 | 1995 Suzuki Samurai Seat Belt, Front, Driver And Passenger Side. | $94.42 |
 | 1989 Suzuki Samurai L4, 1.3 L, 1325 CC, 81 CID Rebuilt Engine, Warranty: 7-Year/70,000 Mile, . | Ad Hoc |
 | 1995 Suzuki Samurai Used Headlight, Driver Side, Very Good. | $71.00 |
| 1988 Suzuki Samurai Used Radiator Assembly, soft top, from VIN 235001, Very Good. | $149.00 |
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