Suzuki Samurai Service Manual (1986-1988)

Introduction

This service manual provides detailed information and illustrations for the maintenance, service, and repair of Suzuki Samurai models manufactured between 1986 and 1988. It is designed to assist owners and technicians in performing various tasks, from routine maintenance to complex repairs, ensuring the proper functioning and longevity of the vehicle.

The manual contains 482 pages of comprehensive content, including exploded illustrations, diagrams, and step-by-step instructions to guide you through each procedure. Refer to this manual for accurate and reliable service information.

Figure 1: Front cover of the Suzuki Samurai Service Manual, indicating coverage for 1986, 1987, and 1988 models.

General Information and Specifications

This section outlines general information pertinent to the Suzuki Samurai and provides key specifications of this service manual.

Manual Specifications

Using This Manual

This manual is organized into various sections, each dedicated to a specific system or component of the Suzuki Samurai. To effectively use this manual, locate the relevant section for the task you wish to perform. Each section contains detailed procedures, diagrams, and specifications.

Illustrations and figures are provided to clarify steps and component locations. Pay close attention to any warnings or notes accompanying the instructions to ensure safety and proper execution of repairs.

Periodic Maintenance Service

Regular periodic maintenance is crucial for the optimal performance and longevity of your Suzuki Samurai. This section details the recommended service intervals and procedures for routine checks and replacements.

Key areas covered include fluid checks, filter replacements, lubrication points, and general inspections to prevent potential issues before they escalate.

Troubleshooting

This section provides guidance on diagnosing common problems that may arise with your Suzuki Samurai. It includes symptoms, possible causes, and recommended diagnostic steps to help identify the root of an issue.

Refer to the specific system sections for detailed repair procedures once the problem has been identified.

Engine

The engine section covers all aspects of the Suzuki Samurai's engine, including removal, installation, overhaul, and specific component service. Detailed instructions are provided for various engine-related tasks.

Figure 2: Illustrations detailing engine maintenance procedures, such as oil filter removal (Fig. 3-4-17), water inlet pipe removal (Fig. 3-4-20), cylinder head cover removal (Fig. 3-4-21), and valve adjusting screw procedures (Fig. 3-4-22).

Figure 3: A detailed diagram illustrating the engine emission control systems, including components and their connections, for both U.S.A. and Canadian specification vehicles (Fig. 5-1-1).

Fuel System

This section covers the fuel system components, including the carburetor, air cleaner, fuel pump, and fuel filter. Procedures for inspection, adjustment, and replacement are detailed here.

Emission Control System

Detailed information on the emission control system, its components, and diagnostic procedures to ensure compliance with environmental standards.

Engine Cooling System

Instructions for maintaining and repairing the engine cooling system, including the radiator, water pump, thermostat, and hoses.

Car Heater

Service procedures for the car heater system, covering components such as the heater core, blower motor, and control mechanisms.

Ignition System

This section provides details on the ignition system, including spark plugs, ignition coil, distributor, and wiring. Troubleshooting and replacement guidelines are included.

Cranking System

Information on the starter motor, solenoid, and related components of the cranking system, with procedures for testing and repair.

Charging System

Covers the alternator, voltage regulator, and battery, detailing inspection, testing, and repair procedures for the charging system.

Clutch

This section provides instructions for the inspection, adjustment, removal, and installation of the clutch assembly and its hydraulic components.

Gear Shifting Control

Details on the gear shifting mechanism, including linkages, cables, and adjustments for smooth and precise gear changes.

Transmission

Comprehensive guide to the transmission system, covering disassembly, inspection, repair, and reassembly procedures for both manual and automatic transmissions.

Figure 4: An internal page from the manual illustrating the inspection of transmission components such as gear teeth (Fig. 14-27), gear shift seals (Fig. 14-28), and the transfer rear case assembly (Fig. 14-32, 14-35).

Transfer Gear Box

Instructions for servicing the transfer gear box, including removal, disassembly, inspection, and reassembly procedures.

Propeller Shafts

This section covers the inspection, removal, installation, and balancing of the propeller shafts.

Differential

Procedures for the inspection, adjustment, and overhaul of the front and rear differential assemblies.

Suspension

Details on the front and rear suspension systems, including springs, shock absorbers, control arms, and alignment procedures.

Steering System

Covers the steering gear, power steering pump (if applicable), steering linkage, and alignment procedures.

Brakes

This section provides comprehensive instructions for the brake system, including disc brakes, drum brakes, master cylinder, and brake lines. Procedures for inspection, pad/shoe replacement, and bleeding are included.

Figure 5: Illustrations detailing the removal of the front wheel hub and bearing (Fig. 17-1-8, 17-1-9, 17-1-10) and brake disc (Fig. 17-1-11), including notes on special tools like the circlip remover (Fig. 17-1-12-1).

Body Service

This section covers various body components, including doors, windows, exterior trim, and interior panels. Procedures for removal, installation, and adjustment are detailed.

Figure 6: Illustrations showing procedures for the front door lock (Fig. 20-1-19, 20-1-20) and window regulator assembly (Fig. 20-1-17, 20-1-18), including notes on waterproofing film and adjustment of the door open rod.

Body Electrical Equipment

Information on the electrical systems within the body, including wiring diagrams, component locations, and troubleshooting for lights, gauges, and accessories.

Service Data

This section compiles essential service data, including torque specifications, fluid capacities, and standard measurements for various components, crucial for accurate repairs.