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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!
    DIY REPAIR SAMPLES > CONTINUE EXPLORING >
    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 -> Evacuating System
    Vehicle: 1991 Suzuki Samurai JS 1.3 L4 GAS

    The system must be completely discharged before evacuation. After discharging the system, keep low pressure gauge hose connected to low pressure test fitting and both manifold gauge valves closed.

    • Connect high pressure gauge hose to vacuum pump, Fig. .
    • Connect center manifold gauge hose to refrigerant source with tapping valve closed.
    • Open high and low side gauge valves with vacuum pump operating.
    • Continue to operate pump for approximately 15-20 minutes after low side gauge reaches 29 or more inches of vacuum. If the system has been left open for an...

    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, DRUM BRAKES -> TIGHTENING SPECIFICATIONS -> SAMURAI & SIDEKICK
    Vehicle: 1990 Suzuki Samurai 1.3 L4 GAS

    [[table data]]

    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 -> Component Locations -> XL-7, 1999-06 Vitara, Grand Vitara, 1996-98 X90, 1989-98 Sidekick & 1986-95 Samurai
    Vehicle: 1990 Suzuki Samurai 1.3 L4 GAS

    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: 1991 Suzuki Samurai JS 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: 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...

    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+

    Heater Hose, Replace -> Bypass -> Inlet -> Outlet
    Vehicle: 1991 Suzuki Samurai JL 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...

    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+.

    Vacuum Hose Location Diagram for 1994 Suzuki Samurai JL 1.3 L4 GASVacuum Hose Location Diagram for 1994 Suzuki Samurai JL 1.3 L4 GAS

    Components on diagram:
  • Pressure Sensor
  • Throttle Position Sensor
  • EGR Valve
  • Air Temperature Sensor
  • ISC Solenoid Valve
  • Engine Compartment Diagram for 1993 Suzuki Samurai JA 1.3 L4 GASEngine Compartment Diagram for 1993 Suzuki Samurai JA 1.3 L4 GAS

    Components on diagram:
  • Pressure Sensor
  • Vehicle Speed Sensor
  • Throttle Position Sensor
  • Water Temperature Sensor
  • Main Relay
  • 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.

    1988 Suzuki Samurai  1.3 L4 GAS Wiring Diagram1988 Suzuki Samurai 1.3 L4 GAS Wiring Diagram

    Components on diagram:
  • Pressure Sensor
  • Fuel Pump
  • TCC Solenoid
  • Water Temperature Sensor
  • Battery
  • 1991 Suzuki Samurai JL 1.3 L4 GAS Wiring Diagram1991 Suzuki Samurai JL 1.3 L4 GAS Wiring Diagram

    Components on diagram:
  • Vent Solenoid
  • Radio
  • Wiper Motor
  • Ignition Coil
  • Horn
  • 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: UNDERHOOD (PRIMER) PAINT COLOR CODES - REV
    Vehicle: 1990 Suzuki Samurai 1.3 L4 GAS

    Auto Systems:
  • Finishes, Body Structure, Frame, Bumpers
  • Document: SEALANT & THREADLOCKER CROSS-REFERENCE CHART
    Vehicle: 1995 Suzuki Samurai JL 1.3 L4 GAS

    Auto Systems:
  • Seals, Gaskets, Sealants
  • 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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    Click here to view more details about 1995 Suzuki Samurai Bumper End, Front, Driver Side1995 Suzuki Samurai Bumper End, Front, Driver Side, A high quality, OE replacement bumper end; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $23.14

    Click here to view more details about 1995 Suzuki Samurai Antenna1995 Suzuki Samurai Antenna, 4-section mast; 2600 mm cable; A high quality pillar side mount antenna; May require modification or other adjustment to your vehicle upon installation; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $12.92

    Click here to view more details about 1995 Suzuki Samurai Door Mirror Driver Side1995 Suzuki Samurai Door Mirror Driver Side, Driver Side Manual Door Mirror; Black; Foldaway, , .

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    $22.45

    Click here to view more details1993 Suzuki Samurai JA L4, 1.3 L, 1298 CC, 79 CID Rebuilt Engine, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

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    Click here to view more details1986 Suzuki Samurai Used Distributor, Very Good.

    Source: Used Auto Parts Store

    $141.00

    Click here to view more details1987 Suzuki Samurai Used Fan Clutch, CLUTCH ONLY, Very Good.

    Source: Used Auto Parts Store

    $86.00
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