1988 Suzuki Samurai Service Manual

The Suzuki Samurai features a water-cooled, in-line 4-cylinder, 4-stroke cycle gasoline engine with a single overhead camshaft (S.O.H.C.) valve mechanism arranged for V-type valve configuration. The camshaft is mounted over the cylinder head and is driven from the crankshaft through a timing belt, with no push rods provided in the valve train system.

Additionally, the Samurai was marketed as the Chevrolet Samurai in Colombia and was available in various configurations including Soft Top, Hard Top, Long Body, and Pickup. The Maruti Gypsy, a long-wheelbase variant, is produced by Maruti Suzuki in India and features a standard 16V 1.3L engine. The Suzuki Samurai is the successor of the Suzuki LJ and is known by different names in various countries, including Santana, Caribbean, Sierra, and Holden Drover.

This comprehensive service manual/workshop manual contains a wealth of information on maintenance, service, troubleshooting, overhaul, and inspection of the Suzuki Samurai, specifically for the 1988 model year.

The manual includes the following sections:

• GENERAL, SPECIAL TOOLS AND SERVICE MATERIALS
  • Identification Number
  • Standard Shop Practices
  • Special Tools Required
  • Service Materials
  • Metric Information
• PERIODIC MAINTENANCE SERVICE
  • Maintenance Schedule
  • Engine and Emission Control
  • Chassis and Body
• TROUBLESHOOTING
  • 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 Services Not Requiring Engine Removal
  • Engine Removal
  • Engine Disassembly
  • Inspection of Engine Components
  • Engine Reassembly
  • Engine Installation
  • Engine Maintenance Service
  • Recommended Torque Specifications
• FUEL SYSTEM
  • Carburetor - Removal and Installation & Unit Repair Overhaul
  • Air Cleaner - Maintenance Services
  • Fuel Pump, Filter, and Lines - Removal and Installation, Maintenance Services
  • Accelerator Pedal
• EMISSION CONTROL SYSTEM
  • Positive Crankcase Ventilation (PCV) System
  • Thermostatically Controlled Air Cleaner (TCAC) System
  • Evaporative Emission Control System
  • Hot Idle Compensator (HIC)
  • Deceleration Mixture Control System
  • Computer Controlled Emission Control System
  • Bowl Ventilation System
  • Fuel Cut System
  • Exhaust Gas Recirculation (EGR) System
• DIAGNOSIS
• ENGINE COOLING SYSTEM
  • Removal
  • Inspection of Components
  • Important Steps for Reinstallation
  • Maintenance Service
• CAR HEATER
  • Electrical Circuit
  • Heater Services
  • Removal and Installation
• IGNITION SYSTEM
  • Distributor
  • Ignition Coil
  • Spark Plug
  • Maintenance Service
  • Important Reminders for Installation Distributor
• CRANKING SYSTEM
  • Lubrication
  • Removal and Installation Disassembly
  • Starting Motor Inspection
  • Performance Test
• CHARGING SYSTEM
  • Alternator
  • Battery
• CLUTCH
  • Removal
  • Inspection of Components
  • Installation
  • Maintenance Services
  • Recommended Torque Specification
• GEAR SHIFTING CONTROL
  • Removal
  • Inspection of Components
  • Installation
• TRANSMISSION
  • Transmission Gear Ratio
  • Dismounting
  • Disassembly
  • Inspection of Components
  • Important Steps in Installation
  • Maintenance Services
  • Recommended Torque Specification
• TRANSFER GEAR BOX
  • Selective Flows of Transfer Drive Gear Ratio Data
  • Transfer Services Not Requiring Transfer Removal
  • Removal
  • Disassembly
  • Inspection of Components
  • Reassembly
  • Maintenance Services
  • Tightening Torque
• PROPELLER SHAFTS
  • General Description
  • Removal
  • Installation
  • Maintenance Services
  • Tightening Torque
  • Disassembly
  • Reassembly
• DIFFERENTIAL
  • Removal
  • Disassembly
  • Inspection and Adjustment of Components
  • Reassembly
  • Installation
  • Maintenance Services
  • Recommended Torque Specifications
• SUSPENSION
  • Front Suspension
  • Rear Suspension
  • Maintenance Services
  • Recommended Torque Specifications
  • Front Free Wheeling Hub (Optional)
• STEERING SYSTEM
  • Specifications and Data
  • Steering Gear Box Construction and Operation
  • Removal
  • Inspection of Components
  • Checking Steering Column for Accident Damage
  • Important Steps in Reinstallation
  • Wheel Alignment
  • Maintenance Services
  • Recommended Torque Specifications
• BRAKES
  • General Description
  • Front Disc Brake
  • Rear Drum Brake
  • Master Cylinder
  • Brake Booster
  • Parking Brake
  • Brake Pipes and Hoses
  • Maintenance Service
  • Torque Specification
• BODY SERVICE
  • Front Door
  • Windshield
  • Back Door (Applicable to Hard Top Vehicle)
  • Chassis Dimensions
• BODY ELECTRICAL EQUIPMENT
  • Combination Meter
  • Head Light
  • Turn Signal Light and Hazard Warning Light
  • Windshield Wiper Motor
  • Water Temperature Meter and Gauge
  • Fuel Level Meter and Gauge
  • Brake Warning Lamp
  • Oil Pressure Lamp
  • 4 Wheel Drive Lamp
  • Seat Belt Warning Lamp/Buzzer
  • Main Switch Key Warning Buzzer
  • Illumination Controller
  • Rear Defogger (Optional for Hard Top Model)
  • Fuse Box
  • Wiring Harness Routing
  • Wiring Diagram
• SERVICE DATA
  • Specifications
  • Service Data