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Samurai 1987
Service manual
Suzuki Samurai 1987 Service Manual
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Table Of Contents
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483
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General, Special Tools and Service Materials
Identification Number
Vehicle Identification Number
Engine Identification Number
Standard Shop Practices
Front Side
Rear Side
Rear Support Location
Front Support Location
When Using Frame Contact Hoist
Engine Cylinder Numbers
Special Tools
Required Service Materials
Metric Information
Metric Fasteners
Fastener Strength Identification
Standard Tightening Torque
Periodic Maintenance Service
Maintenance Recommended under Severe Driving Conditions
Severe Condition Code
Engine and Emission Control
Water Pump Belt Inspection and Replacement
Camshaft Timing Belt Inspection
Valve Lash Inspection
Cooling System Hoses and Connections Inspection
Proper Engine Oil Viscosity Chart
Engine Oil Capacity
Engine Coolant Change
Engine Oil and Filter Change
Exhaust Pipes and Mountings Inspection
Coolant Capacity
Bolts and Nut
Pcv Valve Replacement
Oxygen Sensor Replacement
Catalytic Converter Inspection
Charcoal Canister Replacement
Emission-Related Hoses and Tubes Inspection
Ecm and Associated Sensors Inspection
Wiring Harness and Connections Inspection
Spark Plugs Replacement
Plug Specification
Ignition Wiring Replacement
Distributor Cap and Rotor Inspection
Distributor Advancer Inspection
Fuel Filter Replacement
Carburetor Choke System Lubrication and Inspection
Air Cleaner Element
Fuel Tank Cap Gasket Inspection
Idle Speed Inspection
Idle Mixture Inspection
Mixture Adjusting Screw Pin
Carburetor Inspection
Chassis and Body
Clutch Pedal Inspection
Brake Discs, Pads, Brake Drums and Shoes Inspection
Brake Pedal Inspection
Free Wheeling Hub
Wheel Bearing Inspection
Tire Inspection and Rotation
Parking Brake Cable
Shock Absorbers Inspection
Propeller Shafts Inspection and Lubrication
Transfer Oil Change
Differential Oil Change (Front and Rear)
Transmission Oil Change
Steering System Inspection
Door Hinges Lubrication
Bolts and Nuts Tightening
Alignment Service Data
Final Inspection
Table of Contents
Trouble Shooting
Engine
Carburetor
Exhaust and Muffler
Clutch
Transmission
Differentials
Propeller Shafts
Brakes
Suspension, Steering System and Tires
Starting Motor
Alternator
Wiper Motor
Fuel Meter
Speedometer
Water Temperature Meter
Engine
General Description
Engine Lubrication
Crankshaft and Main Bearings
Cylinder Block
Cylinder Head and Valve Train
Pistons, Rings, Piston Pins and Connecting Rods
Engine Services Not Requiring Engine Removal
Engine Removal
Engine Disassembly
Inspection of Engine Components
Flatness of Gasketed Surface
Rocker-Arm Shaft and Rocker Arms
Runout of Rocker-Arm Shaft
Valve Guides
Valves
Seating Contact Width
Valve Seats
Exhaust Valve Seat
Valve Lapping
Valve Seat Repair
Measuring Free Length of Spring
Measuring Spring Preload
Spring Squareness
Valve Springs
Cam Wear
Camshaft
Journal Wear
Runout of Camshaft
Cylinder Bore
Distortion of Gasketed Surface
Positions to be Measured
Honing or Reboring Cylinders
Piston and Piston Rings
Measuring Piston Ring End Gap
Piston Pins
Piston Ring End Gap
Ring Groove Clearance
Connecting Rod Alignment
Crank Pin and Connecting Rod Bearings
Rod Bearing Clearance
Crankshaft Thrust Play
Measuring Rod Bearing Clearance
Crankshaft Main (Journal) Bearings
Out-Of-Round and Taper (Uneven Wear)
Upper Half of Bearing Installation
Paint on Standard Bearing
Faints on Undersize Bearing
Flywheel
Oil Pump
Radial Clearance
Rear Oil Seal
Engine Reassembly
Radial Clearances
Timing Belt End Tensioner
Crankshaft
Ins Tatting Thrust Bearing
Installing Bearing Half with Oil Groove
Cutting off Edges of Gasket
Oil Seal Housing
Piston, Connecting Rod and Piston Rings
Fitting Connecting Rod to Piston
Fitting Piston to Special Tool
14 Instatting Piston Pin
Line Marked on Driver Handle
Piston Ring End Gaps Positions
Guide Hoses Installation
Instailing Bearing Cap
Installing Piston to Cylinder
Applying Sealant to Oil Pan
Oil Level Gauge Guide
Oil Pan
Oil Pump Strainer
Cylinder Head
Reaming Guide Hole
Reaming Valve Guide Bore
Valve Guide Installation
Valve Installation
Valve Spring Installation
Valve Stem Seal Installation
Camshaft Installation
Valve Totters Installation
Intake Manifold and Carburetor
Rocker Arm Shafts Installation
Rocker-Arm Shafts
Water Inlet Pipe
Exhaust Manifold and Cover
Oil Filter
Water Pump
Installing Guide, Key and Pulley
Pulley Pin, Slot and Pulley Bolt
Timing Belt Inside Cover, Belt Pulleys
Lug and Hole
Timing Marks
Valve Adjusting Screw and Lock Nut
Installing Timing Belt
Tensioner Bolt and Nut
Distributor Case
Fuel Pump
Fuel Pump Rod Installation
Installing Crankshaft Pulley
Clutch Disc and Cover
Cylinder Head Cover
Transmission Assembly
Valve Lash (Clearance) Adjustment
Checking and Adjusting Procedures
Engine Installation
Engine Maintenance Service
Ignition Timing
Camshaft Timing Belt
Engine Oil Filter
Measuring Valve Lashes
Compression Pressure Measurement
Engine Coolant
Exhaust Line and Muffler
Oil Pump Discharge Pressure Measurement
Oil Pressure Gauge Installation
Oil Pressure Switch
Vacuum Measurement
Oil Filler Cap
Recommended Torque Specifications
Fuel System
Carburetor
General Description
Float System
Mixture Control Solenoid Valve
Primary Slow System
Primary System
Switch Vent Solenoid
Fuel Cut System
Secondary Slow System
Secondary System
Acceleration Pump System
Secondary Main System
Choke System
Operation of Choke System
When Coolant Temperature Is Low
When the Coolant Temperature Rises
Idle up System
Idle-Up System Operation
Unloader System
When Coolant Temp. Rises
Removal and Installation
Unit Repair Overhaul
Air Horn and Hoses, Etc
Needle Valve Seat and Filter
Drain Plugs
Throttle Chamber
Hooking Throttle Lever Return Spring
Installing Washer
Primary and Secondary Main Jets
Installing Drain Plugs
Installing Jets and Air Bleeders
Accelerator Cable Adjustment
Maintenance Services
Float Adjustment
Fuel Level
Idle up Adjustment
Idle-Up Adjusting Screw
Checking Actuator
Checking TWSV
Checking TWSV Circuit
Choke Adjustment
Choke Valve
Checking Choke Piston
Choke Lever
Choke Piston
Fast Idle Adjustment
Mark on Cam and Cam Follower
Unloader Adjustment
Checking Acceleration Pump
Checking Secondary System
VTV (Vacuum Transmitting Valve)
Idle Speed Adjustment
Idle Mixture Adjustment
Idle Mixture Inspection and Adjustment
Air Cleaner
General Description
Maintenance Services
Fuel Pump, Filter and Lines
General Description
Fuel Filter
Fuel Pulp
Fuel Filler Cap
Fuel Filler Cap Cross-Section
Removal and Installation
Fuel Tank
Fuel Filler (Tank) Cap
Fuel Lines
Fuel Tank Purging Procedure
Maintenance Services
Accelerator Pedal
Precautions to be Taken in Accelerator Pedal Installation
Emission Control System
Vehicle Emission Control Information Label
Positive Crankcase Ventilation (Pcv) System
TCAC System Operation
Thermostatically Controlled Air Cleaner (Tcac) System
(Tcac) System
Evaporative Emission Control System
Hot Idle Compensator (Hic)
Deceleration Mixture Control System
Computer Controlled Emission Control System
Electronic Control Module
Feed Back System
Engine Coolant Temperature
Engine Speed
Throttle Position
Altitude Compensation
Bowl Ventilation System
Gear Position
Three-Way Catalyst
Fuel Cut System
Exhaust Gas Recirculation (Egr) System
Diagnosis
Possible Causes of Emissions Test Failures
Pcv System Diagnosis
Checking PCV System
Checking PCV Valve for Sticking
General
Maintenance Service
PCV Hoses
Air Control Actuator
Checking TCAC System
Tcac System
Thermo Sensor
Checking Canister
Checking Check Valve
Checking Vapor Storage Canister
Evaporative Emission Control System
Deceleration Mixture Control System
Hot Idle Compensator (Hic)
Mixture Control Valve (MCV)
Feed Back System
System Check Flow Chart
Checking Feed Back System
Checking Idle and Wide Open Micro Switches
Idle Micro Switch
Checking Mixture Control Solenoid Valve
Checking Wide Open Micro Switch
Wide Open Micro Switch
Wide Open Micro Switch Lever
Checking Thermal Switch
Checking High Altitude Compensator
Checking Switch in Hot Water
Checking Thermal Engine Room Switch
Checking Oxygen Sensor
Connector of Oxygen Sensor
Disconnecting Vacuum Hose
Moving Lever
Checking ECM Ground Circuit
Checking ECM Ground Circuits
Checking Feed Back System Circuits
ECM and Coupler
Body Ground
Engine Ground
Checking ECM Power Circuits
Checking Sensors and Their Lead Wires
Checking Function of Oxygen Sensor and Feed Back System
Checking Idle-Up Signal
Checking Fuel Cut System
Checking Switch Vent Solenoid
Replacing ECMI
Checking EGR System
Checking EGR Valve Diaphragm
Movement of EGR Valve Diaphragm
Vacuum Hoses
Bi-Metal Vacuum Switching Valve (BVSV)
Checking EGR Modulator
Filter of EGR Modulator
Engine Cooling System
6-L. GENERAL DESCRIPTION
Cooling System Circulation
Radiator Cap
Water Reservoir Tank
Thermostat
Coolant Draining
Cooling Water Pipes or Hoses
Radiator
Water Pump Drive Belt
Inspection of Components
Water Pump
Important Steps for Reinstallation
Thermostat
Water Pump
Maintenance Service
Radiator
Water Pump Belt
Anti-Freeze Proportioning Chart
Coolant Level
Cooling System Service
Cooling System, Flush and Refill
Installation of Radiator Cap
Radiator Drain Plug
Cooling Fan Clutch
Car Heater
Electrical Circuit
Blower Resistor
Blower Switch
Heater Hoses
Heater Services
Heater & Ventilator Control Cable Routing
Ignition System
Distributor
General Description
Ignition Coil
Spark Plug
Distributor
High Tension Cord
Ignition Coil
Maintenance Service
Spark Plug
Signal Rotor Air Gap
Distributor Driven Gear
Ignition Timing
Checking Vacuum Advancer
Distributor Drive Gear
Distributor
High Tension Cords Distribution
Important Reminders for Installation
Cranking System
Cranking Circuit
General Description
Starting Motor
Specifications
Lubrication
Removal and Installation
Disassembly
Inspect Commutator
Starting Motor Inspection
Ground Test
Inspect Brush
Inspect Field Coil
Open Circuit Test
Inspect Armature Shaft Bush
Inspect Brush Holder and Spring
Inspect Drive Lever
Hold in Coil Open Circuit Test
Inspect Magnetic Switch
Pull-In Coil Open Circuit Test
Hold-In Test
No-Load Performance Test
Performance Test
Pull-In Test
Clutch Switch
Charging System
10-L. ALTERNATOR
General Description
Data and Specification
Diagnosis
Noisy Alternator
Faulty Indicator Lamp Operation
Undercharged Battery
Voltmeter
Load Check
Overcharged Battery
Alternator Service
Removal
Inspection
Rotor
Stator
Assembly
Brush and Brush Holder
Condenser
Rectifier
Care of the Battery
General Description
Built-In Indicator
Carrier and Hold-Down
Visual Inspection
Battery Cables
Remove and Replace
Clutch
11-L. GENERAL DESCRIPTION
Clutch Cover and Disc
Clutch Release Bearing
Clutch Release Shaft Bushes
Input Shaft End Bearing
Removal
Backlash in Disc Setration Fit
Clutch Cover
Clutch Disc Facing Surface Condition
Clutch Facing Wear
Inspection of Components
Input Shaft Bearing
Release Bearing
Clutch Disc and Clutch Cover
Installation
Clutch Pedal Height
Clutch Release Arm
Clutch Release Shaft Fork
Maintenance Services
Clutch Cable Lubrication
Clutch Cable Routing
Recommended Torque Specification
Gear Shifting Control
General Description
Gear Shift Lever Select Guide Pins
Removal
Gear Shift Fork Shaft
Gear Shift Lever
Inspection of Components
Reverse & Low Speed Select Guide Pins
Gear Shift Lever Case
Installation
Reverse & Low Speed Guide Pins
Gear Shift Control Lever Seat
Transmission
In Engine Room
In Passenger Compartment
Under Engine
Precautions on Bush Reinstallation
Replacing Clutch Release Shaft Bush
Separating Upper Case from Lower Case
Removing Countershaft
Removing Main Shaft and Input Shaft
Gear Shift Fork and Shaft
Gear Shift Yoke
Neutral Position
Removing Shift Yokes, Forks and Shafts
Bearings and Bushes
Gears
Main Shaft
Synchronizer Hubs, Sleeves and Keys
Chamfered Tooth Ends of Ring
Combination of Gear and Synchronizer Ring
Input Shaft
Fork Shaft Locating Springs
Synchronizer Rings
Extension Case Bush
Gear Shift Shafts
Main Shaft and Input Shaft
Gear Shift Fork
Yokes
Transmission Lower Case and Upper Case
Extension Case
Input Shaft Bearing Retainer
Transmission Oil
Transfer Gear Box
General Description
2-Wheel Drive (Rear-Wheel Drive)
4-Wheel Drive HIGH (All-Wheel Drive on HIGH)
Selective Flows of Transfer Drive
4-Wheel Drive LOW (All-Wheel Drive on LOW)
Gear Ratio Data
Transfer Services Not Requiring Transfer Removal
Removal
Disassembly
Speedometer Driven Gear
Transfer Front Case
Universal-Joint Yoke Flanges
Transfer Center Case
Gear Teeth
Inspection of Components
Locating Spring
Transfer Rear Case
Output High Gear
Output Low Gear
Side Clearance of Gears
4WD Gear Shift Lever
Reassembly
Output Rear Shaft
Shim Adjustment of Input and Output Shafts
Center Case
Center and Rear Cases
Front Case
Maintenance Services
Oil and Oil Capacity
Oil Level
Tightening Torque
Propeller Shafts
General Description
Installation
Removal
Maintenance Services
Universal Joint Noise
Bolts & Nuts
Tightening Torque
Disassembling on Flange Yoke Side
Reassembly
Differential
General Description
Removal
Disassembly
Inspection and Adjustment of Components
Side Gear Thrust Play
Determination of Shim Thickness for Bevel Pinion
Bevel Pinion Bearing Preload Adjustment
Bevel Gear Backlash Adjustment
Drive Bevel Pinion Bearing Starting Torque (Preload)
Pinion-To-Gear Tooth Contact Pattern Check and Adjustment
Differential Pinion Shaft (Shorter)
Differential Side Bearings
Drive Bevel Gear Bolts
Reassembly
Bevel Pinion Bearings
Brake Circuit Air Purging
Differential Gear Oil
Installation
Rear Brake Drum
Side Bearings Caps
Maintenance Services
Oil Change
Recommended Torque Specifications
Suspension
Front Suspension
Barfield Joint Construction and Operation
Leaf Spring
Shock Absorber
Stabilizer
Front Wheel Hub 81 Bearing
Circlip Remover
Steering Knuckle
Front Axle Shaft Joint
Barfield Joint
Front Wheel Bearing
Leaf Spring Bushes
Stabilizer and Its Bush
Kingpins and Bearings
Steering Knuckle Oil Seal
Rear Suspension
Rear Axle Shaft
Leaf Spring and Bumper
Bolts and Nuts
Rear Wheel Bearing
Front Free Wheeling Hub
Steering System
General Description
Right-Hand Steering Vehicle
Left-Hand Steering Vehicle
Specifications and Data
Removal
Steering Column
Steering Hand Wheel
Gear Box
Steering Lock
Tie Rod and Tie Rod End
Adjustment of Worm Shaft Starting Torque
Inspection of Components
Left Hand Steering Vehicle
Steering Gear Box
Checking Steering Column for Accident Damage
Important Steps in Reinstallation
Steering Damper
Steering Handwheel
Toe Setting
Wheel Alignment
Camber
Camber and Caster Adjustment
Reference Information
Toe Adjustment
Maintenance Services
Steering Handwheel Play
Steering Rubber Joint
Steering Shaft Joint
Tire Wear Indicato
Tires
Inflation of Tires
Tire Rotation
Wheels
Tire Demounting and Mounting
Tire Repair
Recommended Torque Specifications
Brakes
General Description
Master Cylinder Assembly
Master Cylinder OPERATION
Normal Operation
One-Circuit Operation
Disc Brake Caliper Assembly
Clearance Correction
Single Piston Floating Caliper Type
Drum Brake Assembly
Rear Brake Operation
Booster Assembly
Booster
Vacuum Booster Assembly
When Foot Brake Pedal Is Not Depressed
When Foot Brake Pedal Is Depressed
When Foot Brake Pedal Is Released
Brake Pad
Front Disc Brake
Caliper
Disc
Brake Disc
Bush Dust Boot and Cylinder Boot
Cylinder Slide Bush
Piston and Boot
Piston Seal
Precautions on Installation
Front Brake Disc and Pad
Front Brake Flexible Hose
Front Wheel Spindle
Brake Drums
Inspection for Front Brake after Installing
Rear Drum Brake
Brake Drum
Brake Shoes and Strut
Cracked, Scored, or Grooved Drum
Brake Shoe and Rim
Brake Strut
Wheel Cylinder
Self Shoe Clearance Adjusting System
Springs
Master Cylinder
Master Cylinder Inner Parts
Reservoir
Precaution of Installation
Brake Booster
Inner Parts
Metal Parts
Rubber Parts
Booster Inspection Table
Parking Brake
Brake Pipes and Hoses
B-Way Joint
Brake Flexible Hose and E-Ring
Clamp
Upper Side
Brake Pipes (Right
Brake Fluid Leaks
Brake Fluid Level Inspection
Fill Reservoir
Maintenance Service
Road Testing Brakes
Brake Pedal Free Height Adjustment
Excessive Pedal Travel Check
Stop Light Switch Adjustment
Brake Hose and Pipe Inspection
Disc Inspection
Hose
Rear Brake Shoe & Lining Inspection
Brake Pedal Play Inspection
Flushing Brake Hydraulic System
Parking Brake Lever Stroke Adjustment
Rear Drum Brake Shoe Adjustment
Bleeding Brakes
Check Air Tightness
Inspect Booster Operation
Inspection Without Tester
Check Air Tightness under Load
Check Operation
Torque Specification
Body Service
Description
Front Door
Door Window Glass
Door Glass
Door Window Glass or Regulator
Door Window Regulator
Front Door Lock
Installation
Door Outside Open Rod
Regulator Handle
Water Proof Film
Door Lock Inside Handle
Door Lock Rod Pin
Door Lock Striker
Cleaning
Windshield
Installation
Back Door (Applicable to Hard Top Vehicle)
Door Lock and Stricker Adjustment
Door Lock Stricker
Handling of Back Door Balancer
Chassis Dimensions
Body Electrical Equipment
Combination Meter
Combination Meter Circuit and Components
Combination Meter with Tachometer
Combination Meter Without Tachometer
Head Light
Wiring Circuit
Beam Alignment
Headlight Beam Setting (Standard Procedure)
Headlight Inspection
Combination Switch (Lighting Switch Circuit)
Head Light Dimmer Switch
Headlight Adjustment
Switch Connector
Turn Signal Light and Hazard Warning Light
Hazard Warning Switc
Turn Signal & Hazard Warning Switch
Turn Signal Switch
2-Speed Type
Interval Wiper Relay Circuit
Windshield Wiper Motor
No-Load Run Test
Wiper Trouble Diagnosis
Automatic Stop Action Test
Internal Wiper Relay Test
Water Temperature Meter and Gauge
Fuel Level Meter and Gauge
Gauge Unit
Resistance- Temp. Relationship
Brake Warning Lamp
Resistance-Fuel Level Relationship
Brake Fluid Level Switch
Oil Pressure Lamp
4WD Switch
Seat Belt Warning Lamp/Buzzer
Wheel Drive Lamp
Ilumination Controller
Main Switch Key Warning Buzzer
REAR DEFOGGER ( Hard-Top )
Checking Wire for Damaged Place
Defogger Circuit
Defogger Wire
Repair
Fuse Box
Engine Room Wiring
Wiring Harness Routing
Instrument Panel Wiring
Wiring Diagram
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