Auto Parts Search
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 Year
1995 | 1994 | 1993 | 1992 |
1991 | 1990 | 1989 | 1988 |
1987 | 1986 | 1985 |
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 -> Flushing System
Vehicle: 1991 Suzuki Samurai JA 1.3 L4 GAS
Several factors, particularly compressor failure can cause contamination of the A/C system. If the A/C system is suspected of being contaminated, or if any system components have been stored in open air for extended periods, the entire system should be flushed. If contaminati...
CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai A/C & HEATER SERVICE PROCEDURES
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, POWER BRAKE UNITS -> BRAKE BOOSTER OVERHAUL
Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS
Refer to Figs through when performing this procedure.
- Remove piston rod from booster, then push rod clevis and nut.
- Set booster in booster overhaul set No. 09950-88210, Fig.
- Tighten tool bolt clockwise until No. 1 body projecting part and No.2 body depressed part fit each other, Fig. Mark both body parts.
- Remove booster from tool, then separate No. 1 and No. 2 bodies. Hold both bodies carefully to prevent either body from jumping off by spring force.
- Remove piston return spring.
- From No. 2 body, remove boot, air cleaner elements and air cleaner separator.
- On Sidekick models, ...
CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai BRAKE SERVICE PROCEDURES
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 Scheduled Maintenance -> 1990-95 Samurai -> Normal Service -> Severe Service
Vehicle: 1990 Suzuki Samurai 1.3 L4 GAS
Normal Service
Replace every 30,0...
CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai FUEL FILTER REPLACEMENT PROCEDURES
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...
CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES
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...
CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai STARTER & ALTERNATOR REPLACEMENT PROCEDURES
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...
CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai MAINTENANCE LAMP RESET PROCEDURES
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+
Radiator, Replace
Vehicle: 1992 Suzuki Samurai JA 1.3 L4 GAS
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Remove radiator shroud and cooling fan/clutch.
- Discon...
CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai RADIATOR & HOSE REPLACEMENT PROCEDURES
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 Diagram for 1994 Suzuki Samurai JL 1.3 L4 GAS Components on diagram: |
Diagram for 1995 Suzuki Samurai JL 1.3 L4 GAS Components on diagram: |
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.
1986 Suzuki Samurai 1.3 L4 GAS Wiring Diagram Components on diagram: |
1991 Suzuki Samurai JA 1.3 L4 GAS Wiring Diagram Components on diagram: |
CLICK HERE TO GET FULL ACCESS TO Suzuki Samurai WIRING DIAGRAMS!
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: WINTERIZATION OF SAMURAI VEHICLES Vehicle: 1986 Suzuki Samurai 1.3 L4 GAS Auto Systems: |
Document: REQUIRED TECHNICAL LITERATURE LIST Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS Auto Systems: |
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!
Shop online for auto body parts, engines, wheels, lights...
More parts |
Get the Complete Technical Service Bulletins! |
Access diagrams and repair information such as wiring diagrams, diagnosis and repair charts, manufacturer service bulletins, and OEM Part numbers of your Suzuki Samurai vehicle. |
Access the Complete guide! |