Suzuki Samurai Supplementary Service Manual 1990 - 1994

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🏷️ Basic Information Identification Make: Suzuki Model: Samurai Year: 1990-1994 Generation Generation Designation: Second Generation (SJ Series) Codes Chassis Code: SJ413 👋 Introduction Market Position Vehicle Segment: Compact Sport Utility...

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类型: Car

斯库: 40659

标签: 1990 1991 1992 1993 1994 Car Misc Motorcycles Samurai Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Samurai

Year:

1990-1994

Generation

Generation Designation:

Second Generation (SJ Series)

Codes

Chassis Code:

SJ413

👋 Introduction

Market Position

Vehicle Segment:

Compact Sport Utility Vehicle (SUV) / Off-Road Vehicle

Reputation:

Renowned for its go-anywhere capability, robust construction, and simple, utilitarian design. A cult favorite for off-roading and customization.

Competitive Analysis

Competitors 1990S:

Jeep Wrangler (YJ), Toyota Land Cruiser (FJ70/80 series), Nissan Patrol (Y60), Mitsubishi Pajero (first generation).

Key Features

Off Road Capability:

Lightweight construction, short wheelbase, high ground clearance, selectable 4WD with low-range gearing, solid front and rear axles (early models).

Simplicity:

Mechanical fuel injection (early models), basic electrical systems, easy to maintain and repair.

Versatility:

Available in soft-top, hard-top, and pickup configurations.

📋 Manual Details

Coverage Areas

Coverage Scope:

Supplementary Service Manual - Comprehensive diagnosis, maintenance, adjustments, service operations, component replacement, and disassembly procedures.

Page Count

Estimated Page Count:

High (Specific number not provided, but implies full workshop manual content)

Manual Type

Manual Type:

Supplementary Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download (Software Database Download)

📖 Manual Coverage

Systems Covered

Engine:

G13A (1.3L SOHC Inline-4) - Fuel system, ignition system, cooling system, lubrication system, emission control, engine mechanicals.

Transmission:

Manual (M50, M52) and Automatic (less common for this period, but coverage implied if equipped) - Clutch, gearbox, driveline, transfer case, propeller shafts, CV joints.

Suspension And Steering:

Front and rear leaf spring suspension, shock absorbers, steering gear, power steering (if equipped).

Brakes:

Front disc, rear drum brakes - Hydraulic system, brake lines, calipers, wheel cylinders, parking brake.

Electrical System:

Battery, charging system (alternator, starter), lighting, ignition, instruments, wiring diagrams, fuses, relays, body control modules (basic).

Body And Chassis:

Frame, body panels, doors, hood, tailgate, interior trim, seats, convertible top (if applicable).

Wheels And Tires:

Wheel specifications, tire sizing, rotation, balancing.

HVAC:

Heating, ventilation, and air conditioning (if equipped).

Procedures Included

Maintenance:

Routine checks, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, lubrication.

Diagnosis:

Troubleshooting guides, symptom-based diagnosis, component testing procedures.

Repair:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Adjustments:

Carburetor idle speed and mixture, ignition timing, clutch free play, parking brake adjustment.

Special Tools:

Identification and usage of specialized tools required for specific repair or diagnostic procedures.

Technical Depth

Depth:

Comprehensive Workshop Level - Suitable for professional technicians and experienced DIY mechanics covering full rebuilds, complex diagnostics, and precise adjustments.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable for efficient information retrieval.

Printability:

Printable for workshop use.

Print Quality

Quality:

Dependent on original source, but typically high resolution for diagrams and text.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

Inline-4 Cylinder, SOHC (Single Overhead Camshaft)

Displacement:

1298 cc (1.3 Liters)

Bore X Stroke:

74.0 mm x 75.5 mm

Compression Ratio:

8.8:1

Performance

Horsepower Net:

Approx. 63-66 hp @ 5500 rpm (depending on market and specific configuration)

Torque Net:

Approx. 76-79 lb-ft @ 3500 rpm (depending on market and specific configuration)

Fuel System

Fuel Delivery:

Carburetor (common for this period and engine) or Fuel Injection (MPI on later JDM/some export models, but manual covers G13A which is typically carbureted for this generation in North America).

Recommended Fuel:

87 Octane Unleaded Gasoline

Fuel Tank Capacity:

Approx. 40 Liters (10.6 US Gallons)

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission

Transfer Case:

2-Speed Transfer Case with 2WD/4WD High/4WD Low selector.

Optional

Type:

3-Speed Automatic Transmission (less common, may be specific to certain markets or later models)

Features

Drivetrain:

Part-time 4WD

Clutch Type:

Dry Single Plate

📐 Dimensions

Exterior

Wheelbase:

Approx. 2030 mm (80 inches)

Length:

Approx. 3500 mm (138 inches)

Width:

Approx. 1545 mm (60.8 inches)

Height:

Approx. 1650 mm (65 inches) (with hardtop)

Ground Clearance:

Approx. 200 mm (7.9 inches)

Approach Angle:

Approx. 42 degrees

Departure Angle:

Approx. 41 degrees

Weights

Curb Weight:

Approx. 950 kg (2094 lbs)

Gross Vehicle Weight Rating Gvwr:

Approx. 1300 kg (2866 lbs)

Towing Capacity:

Not officially specified for road use in many markets due to its lightweight and chassis design; intended for light trailer towing.

🛡️ Safety Features

Ratings

Crash Test Data:

Limited data available from standardized modern crash tests due to its design era and market segment. Rollover potential is a known concern for all light utility vehicles, especially with a high center of gravity.

Active Features

Braking System:

Front disc brakes, rear drum brakes. ABS not available.

Steering:

Recirculating ball steering mechanism. Power steering optional or market dependent.

Passive Features

Seatbelts:

Lap and shoulder belts (front), lap belts (rear).

Rollover Protection:

Integrated roll bar within the windshield frame and B-pillars. Hardtop models offer more structural protection.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player (optional), single-DIN standard.

Driver Assistance

Not equipped.

Airbags:

Driver-side airbag introduced in later models for North America (1990 onwards), but not universally standard across all configurations and markets during this entire period.

Connectivity

Vehicle Connectivity:

None (basic utilitarian vehicle, no modern connectivity features).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 miles (4,800 km) or 3 months, whichever comes first.

Oil Filter Replacement:

Every engine oil change.

Engine Coolant Change:

Every 2 years or 24,000 miles (38,000 km).

Spark Plugs:

Inspect every 6,000 miles (9,600 km), replace as needed (typically every 15,000-30,000 miles depending on usage and plug type).

Transmission Fluid Change:

Manual: Inspect every 15,000 miles (24,000 km), change as needed. Automatic: Typically every 30,000 miles (48,000 km).

Transfer Case Fluid Change:

Inspect every 15,000 miles (24,000 km), change as needed.

Differential Fluid Change:

Inspect every 15,000 miles (24,000 km), change as needed.

Fluid Specifications

Engine Oil:

API SG or SH classification, SAE 10W-30 recommended for most climates. Check owner's manual for specific viscosity.

Coolant:

Ethylene glycol based coolant, 50/50 mix with distilled water. Suzuki genuine coolant recommended.

Brake Fluid:

DOT 3.

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90.

Transfer Case Fluid:

API GL-4, SAE 75W-90 or 80W-90.

Differential Fluid:

API GL-5, SAE 80W-90 (hypoid gear oil).

Known Issues

Carburetor Performance:

Can become finicky, require adjustment, or suffer from vapor lock in hot conditions due to location and design.

Rust And Corrosion:

Susceptible to rust, especially in the frame, rocker panels, floor pans, and tailgate, particularly in areas with salt use.

Clutch Wear:

Can wear out prematurely with heavy off-road use or aggressive driving.

Suspension Bushings:

Leaf spring bushings and shackle bushings can wear and require replacement, leading to clunking noises and poor handling.

Steering Play:

Steering box can develop play over time, requiring adjustment or replacement.

Starter Solenoid Failure:

Common failure point, often requires replacement of the solenoid or the entire starter.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation - Japanese automotive manufacturer known for its compact and lightweight vehicles, motorcycles, and marine engines.

Model Evolution

Samurai Lineage:

Direct descendant of the Suzuki Jimny (SJ series), first introduced in the late 1970s. The Samurai name was primarily used for export markets, particularly North America.

Key Changes 1990-1994:

Introduction of a longer wheelbase (from the original SJ30/SJ40) and wider track for improved stability. Engine upgrades in some markets (though the G13A remained prevalent for the US market during this period).

Discontinuation North America:

Discontinued in the North American market after 1995 due to a significant lawsuit related to rollover accidents, which severely impacted its reputation despite its off-road capabilities.

Production

Production Locations:

Japan (primarily) and assembled in various locations globally.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently ranked highly by off-road enthusiasts and publications for its capabilities relative to its price and size.

Ratings

Consumer Reports Reputation:

While known for reliability in its mechanical simplicity, its safety profile (particularly rollover risk) led to poor ratings from some consumer advocacy groups.

Certifications

Emissions Standards:

Meets applicable emissions standards for the model years and markets sold, often via catalytic converters and engine management systems.