1988 Suzuki Samurai Service Manual PDF Download

Suzuki Samurais engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its S.O.H.C. (Single overhead camshaft) valve mechanism arranged for V -type valve configuration. This single overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through timing belt, and no push rods are provided in the valve train system. Samurai also was sold as Chevrolet Samurai in Colombia, it also has Soft Top, Hard Top, Long Body and Pickup. Maruti Gypsy, a long wheel base Samurai variant is produced by Maruti Suzuki in India with a standard engine 16V 1.3L engine. Suzuki Samurai is a successor of Suzuki LJ, in various different country it also called as Santana, Caribbean, Sierra and Holden Drover. This service manual/workshop manual contains great deal informations on maintenance, service, troubleshoot, overhaul, inspection of the Suzuki Samurai specially for 1988 model year. Contents: 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 ] TROUBLE SHOOTING [ ENGINE CARBURETOR EXHAUST AND MUFFLER CLUTCH TRANSMISSON 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, FI LTER 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 VENTI LATION SYSTEM FUEL CUT SYSTEM EXHAUST GAS RECIRCULATION (EGR) SYSTEM ] DIAGNOSIS MAINTENANCE SERVICE [ PCV SYSTEM TCAC SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM HOT IDLE COMPENSATOR (HIC) DECELERATION MIXTURE CONTROL SYSTEM FEED BACK SYSTEM SWITCH VENT SOLENOID FUEL CUT SYSTEM EGR SYSTEM ] ENGINE COOLING SYSTEM REMOVAL INSPECTION OF COMPONENTS [ THERMOSTAT RADIATOR WATER PUMP ] IMPORTANT STEPS FOR REINSTALLATION [ WATER PUMP THERMOSTAT COOLING FAN AND WATER PUMP BELT RADIATOR ] MAINTENANCE SERVICE [ WATER PUMP BELT COOLANT COOLANT LEVEL COOLING SYSTEM SERVICE COOLING SYSTEM, FLUSH AND REFILL ] CAR HEATER [ ELECTRICAL CIRCUIT HEATER SERVICES REMOVAL AND INSTALLATION ] IGNITION SYSTEM DISTRIBUTOR IGNITION COIL SPARK PLUG MAINTENANCE SERVICE [ HIGH TENSION CORD SPARK PLUG IGNITION COIL DISTRIBUTOR IGNITION TIMING DISTRIBUTOR DRIVE GEAR ] IMPORTANT REMINDERS FOR INSTALLATION DISTRIBUTOR CRANKING SYSTEM LUBRICATION [ REMOVAL AND INSTALLATION DISASSEMBLY ] STARTING MOTOR INSPECTION [ COMMUTATOR FIELD COIL BRUSH BRUSH HOLDER AND SPRING DRIVE LEVER PINION ARMATURE SHAFT BUSH MAGNETIC SWITCH PERFORMANCE TEST [ PULL-IN TEST HOLD-IN TEST PLUNGER RETURN PERFORMANCE TEST CLUTCH SWITCH ] CHARGING SYSTEM ALTERNATOR [ DATA AND SPECIFICATION DIAGNOSIS REMOVAL DISASSEMBLY INSPECTION ASSEMBLY BATTERY [ GENERAL DESCRIPTION CARE OF THE BATTERY REMOVE AND REPLACE BATTERY CABLE ] CLUTCH [ REMOVAL INSPECTION OF COMPONENTS INSTALLATION MAINTENANCE SERVICES RECOMMENDED TORQUE SPECIFICATION ] GEAR SHIFTING CONTROL REMOVAL [ GEAR SHIFT LEVER GEAR SHIFT LEVER SELECT GUIDE PINS INSPECTION OF COMPONENTS [ GEAR SHIFT LEVER REVERSE & LOW SPEED SELECT GUIDE PINS GEAR SHIFT FORK SHAFT INSTALLATION [ REVERSE & LOW SPEED GUIDE PINS GEAR SHIFT LEVER CASE GEAR SHIFT CONTROL LEVER SEAT TIGHTENING TORQUE & GREASING POINT ] 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 [ CONTENTS 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 ]