Suzuki Samurai 1986 Bedienungsanleitung

FOREWORD

This manual contains procedures for diagnosis, maintenance adjustments, service operations,

replacement of components (Service) and for disassembly and assembly of major compo-

nents.

The contents are classified into sections each of which is given a section number as indicated

in the Table of Contents on next page. And on the first page of each individual section is an

index of that section.

This manual should be kept in a handy place for ready reference of the service work. Strict

observance of the so specified items will enable one to obtain the full performance of the

vehicle.

When replacing parts or servicing by disassembling, it is recommended to use SUZUKI

genuine parts, tools and service materials (lubricants, sealants, etc.) as specified in each

description.

All information, illustrations and specifications contained in this literature are based on the

latest product information available at the time of publication approval. The right is reserved

to make changes at any time without notice. And used as the main subject of description is

the vehicle of standard specifications among others. Therefore, note that illustrations and

photos may differ from the vehicle being actually serviced.

IMPORTANT:

It is important to note that, during any vehicle maintenance procedures, replacement

fasteners must have the same measurements as those removed.

Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possible

personal injury.

Therefore, fasteners removed from the vehicle should be saved for re-use whenever possible.

Where the fasteners are not satisfactory for reuse, care should be taken to select a replace-

ment that matches the original.

Additional information concerning this subject will be found in the section 0 (METRIC

INFORMATION).

This service manual is applicable to vehicles of and after the following body number.

Effective body No.:

J4235001

SUZUKI MOTOR

TECHNICAL DEPARTMENT

SERVICE DIVISION J&S

CO LTD

JS3JC51C J4235001

JS3JC51V J4150001

JS4JC51C J4235001

JS4JC51V 54150001

TABLE OF CONTENTS

GENERAL, SPECIAL TOOLS AND SERVICE MATERIALS

PERIODIC MAINTENANCE SERVICE

TROUBLE SHOOTING

ENGINE

FUEL SYSTEM (CARBURETOR, AIR CLEANER FUEL PUMP AND FUEL FILTER)

EMISSION CONTROL SYSTEM

ENGINE COOLING SYSTEM

CAR HEATER

IGNITION SYSTEM

CRANKING SYSTEM

CHARGING SYSTEM

CLUTCH

GEAR SHIFTING CONTROL

TRANSMISSION

TRANSFER GEAR BOX

PROPELLER SHAFTS

DIFFERENTIAL

SUSPENSION

STEERING SYSTEM

BRAKES

BODY SERVICE

BODY ELECTRICAL EQUIPMENT

SERVICE DATA

SECTION

SECTION 0

GENERAL, SPECIAL TOOLS AND

SERVICE MATERIALS

CONTENTS

-1.

IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-1

0-2.

STANDARD SHOP PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O-2

0-3.

SPECIAL TOOLS.. . . . . . . . . . . .

1..

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-4.

REQUIRED SERVICE MATERIALS . . . . . . . . . . . . . . . . . . . . .

. . . . .

-9

METRIC INFORMATION . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . .

-12

O-l. IDENTIFICATION NUMBER

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is on the instrument panel left side.

Refer to below figure for detailed VIN cord information and its location.

5 1 C G 4 100001

Sequential Number

Assembly Plant

Model Year

(“G” = 1986, “H” = 1987, “J”

1988)

Check Digit

Body Type

Design Sequence

Engine Type

Series, Chassis and

Restraint System Type

Car Line

World Manufacturer Identifier

Fig. O-l

ENGINE IDENTIFICATION NUMBER

The engine number is punched on the rear portion

of the left-hand skirt part of cylinder block.

Exhaust manifold

Fig. O-2 Location of Engine No.

O-l

JS4 J C

0-5.

O-5

O-2. STANDARD SHOP PRACTICES

1. Protect painted surfaces of the body, and

avoid staining or tearing seats. When working

on fenders and seats, be sure to cover them

up with sheets.

2. Disconnect negative terminal connection of

the battery when working on any electrical

part or component. This is necessary for

avoiding electrical shocks and short-circuit-

ing, and is very simple to accomplish: merely

loosen wing nut on negative terminal and

separate cable from terminal post.

3. In raising front or rear car end off the floor

by jacking, be sure to put the jack against

differential portion of axle housing.

NOTE:

Don’t get on the car, get under it or service it in

this state.

Fig. O-3 Front Side

4. To perform service with either front or rear

car end jacked up, be sure to place safety

stands under chassis frame so that body is

securely supported. Refer to below figures

for where to place safety stands. And then

check to ensure that chassis frame does not

slide on safety stands and the car is held

stable for safety’s sake.

WARNING:

Place chocks against both right and left

wheels on the ground from both front and

rear.

Fig. O-5 Front Side

Fig. O-6 Rear Side

Fig. 0.4 Rear Side

0-2

5. Fig. O-7 and O-8 show how to lift the car by

using a hoist.

WARNING:

l When using frame contact hoist, apply

hoist as shown below (right and left at

the same position), Lift up the car till 4

tires are a little off the ground and make

sure that the car will not fall off by try-

ing to move car body in both ways. Work

can be started only after this confirma-

tion.

l Before applying hoist to underbody,

always take car balance throughout serv-

ice into consideration. Car balance on

hoist may change depending of what

part to be removed.

For suspention parts removal, follow pre-

vious steps 3 and 4.

l Make absolutely sure to lock hoist after

car is hoisted up.

When using frame contact hoist:

6. Orderliness is a key to successful overhauling.

Trays, pans and shelves are needed to set

aside disassembled parts in groups or sets

in order to avoid confusion and misplace-

ment. This is particularly important for

engine overhauling.

7. Have on hand liquid packing-SUZUKI

BOND No. 1215 (99000-31110)

for

ready use. This packing dope is an essential

item to assure leak-free (water and oil) work-

manship.

8. Each bolt must be put back to where it was

taken from or for which it is intended. Do

not depend on your hunch in tightening

bolts for which tightening torque values are

specified: be sure to use torque wrenches on

those bolts.

9. It is advisable to discard and scrap gaskets

and “0” rings removed in disassembly. Use

new ones in reassembly, and try not to

econimize gaskets and “0” rings.

10. Use of genuine SUZUKI parts is imperative.

Use of imitation parts is a big gamble on

safety

and performance. Use genuine

SUZUKI parts and live up to the trust your

customer places on you.

11. Special tools save time and ensure good

workmanship: They are available from

SUZUKI. Use them where their use is

specified. Moreover, your own safety is

assured by the use of special tools in many

of the disassembly and reassembly steps.

Fig. O-7 Front Support Location

Fig. O-8 Rear Support Location

0-3

12. Refer to the contents of this MANUAL as

often as practical, and do each job properly

as prescribed.

NOTE:

Engine cylinders are identified by numbers.

See Fig. O-9. Counting from the front end, the

cylinders are referred to as No. 1, No. 2, No. 3

and No. 4 cylinders.

Fig. O-9 Engine Cylinder Numbers

0-4

O-3. SPECIAL TOOLS

Special tools assure three things: 1) improved workmanship; 2) speedy execution of jobs for which they

are meant; and 3) protection of parts and components against damage. Here are the special tools pres-

cribed for this Model:

0-5

0-9

0-6

Dieses Handbuch passt für folgende Modelle

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