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Suzuki Samurai-Sidekick Geo Tracker 1990 Repair Service

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Basic Information Identification Make: Suzuki Model: Samurai, Sidekick, Geo Tracker Year: 1990 Codes Chassis Codes: SJ410, SJ413 (Samurai), ET/TA01, TD01 (Sidekick/Geo Tracker) Introduction Market Position Market Position: The Suzuki Samurai,...
Type: Cars
Myyjä:
Sku: 150879
Suzuki Samurai-Sidekick Geo Tracker 1990 Repair Service
Basic Information
Identification
Make: Suzuki
Model: Samurai, Sidekick, Geo Tracker
Year: 1990
Codes
Chassis Codes: SJ410, SJ413 (Samurai), ET/TA01, TD01 (Sidekick/Geo Tracker)
Introduction
Market Position
Market Position: The Suzuki Samurai, Sidekick, and Geo Tracker were popular for their rugged off-road capabilities, compact size, and affordability, appealing to adventurers and budget-conscious buyers.
Competitive Analysis
Competitive Analysis: Competed with other small SUVs and off-road vehicles of the era, offering a more utilitarian and off-road focused experience compared to more car-like crossovers.
Key Features
Key Features: Lightweight construction, body-on-frame chassis, selectable 4WD (on most models), compact dimensions, relatively simple mechanicals.
Target Audience
Target Audience: Professional automotive technicians and experienced do-it-yourself (DIY) mechanics with a foundational understanding of electrical and mechanical concepts.
Manual Details
Coverage Areas
Coverage Areas: All mechanical and electrical systems, bodywork, maintenance, troubleshooting, and repair procedures for the 1990 Suzuki Samurai, Suzuki Sidekick, and Geo Tracker.
Page Count
Page Count: Estimated 1000+ pages (typical for comprehensive factory service manuals)
Manual Type
Manual Type: Repair Service Manual, Workshop Manual
Language
Language: English
Format
Format: PDF
Manual Coverage
Systems Covered
Systems Covered: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, clutch, manual transmission, automatic transmission, transfer case, driveline, suspension (front and rear), steering, brakes (front discs/rear drums typical), electrical system (charging, starting, lighting, instrumentation, accessories), HVAC, body and chassis, interior trim, emissions control systems.
Body And Chassis: Covers structural components, body panels, doors, hinges, latches, glass, bumpers, and interior trim removal and installation procedures.
HVAC: Service and repair procedures for the heating, ventilation, and air conditioning systems, including refrigerant handling (where applicable) and component testing.
Procedures Included
Procedures Included: Routine maintenance, scheduled servicing, inspection procedures, disassembly, assembly, cleaning, repair, replacement, troubleshooting diagnostic procedures, wiring diagrams, torque specifications, component testing, adjustments, specifications, capacities, and more.
Electrical Diagnostics: Detailed diagnostic procedures for all electrical circuits, including starter system, charging system, ignition system, lighting, and accessories, supported by complete wiring diagrams.
Engine Rebuild: Comprehensive instructions for engine disassembly, inspection, measurement, component replacement, and reassembly, including specifications for pistons, rings, bearings, valves, and camshafts.
Suspension Service: Detailed procedures for servicing and replacing suspension components such as ball joints, tie rod ends, control arms, springs, shocks, and bushings, with relevant torque specifications.
Brake System Repair: Complete guide to brake system maintenance and repair, including brake pad/shoe replacement, caliper/wheel cylinder servicing, brake line inspection and replacement, bleeding the brake system, and troubleshooting common brake issues.
Transmission Overhaul: Step-by-step instructions for the overhaul of both manual and automatic transmissions, covering clutch replacement, gear set inspection, seal and gasket replacement, and torque converter servicing.
Diagnostic Tools: Details on diagnostic tools, test equipment, and procedures required for accurate diagnosis and repair, including the use of multimeters and specialized testers.
Component Replacement: Clear, detailed instructions for the replacement of virtually all components, from major assemblies like the engine and transmission to smaller parts like sensors and actuators.
Technical Depth
Technical Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers detailed diagnostic procedures, component-level repairs, and complete system overhauls.
Technical Specifications: Includes precise torque values for critical fasteners, engine component clearances, timing specifications, fluid capacities, and electrical system resistance values.
Troubleshooting Charts: Detailed troubleshooting charts and flow diagrams to help diagnose common problems related to engine performance, starting, electrical systems, and more.
Manual Specifications
File Format
File Format: PDF
Zoom Functionality: Yes, PDF zoom allows for detailed viewing of diagrams and text.
Print Quality
Print Quality: Full Printable, High Resolution for clear text and diagrams
Binding Type
Binding Type: Digital (PDF) - No physical binding
Paper Type
Paper Type: N/A (Digital Download)
Compatibility
Operating System Compatibility: Compatible with all versions of Windows and Mac operating systems.
Requirements
Software Requirements: Requires Adobe PDF Reader and WinZip for extraction.
Engine Specifications
Primary Engine
Primary Engine: 1.3L G13A SOHC I4 (Samurai), 1.6L G16A SOHC I4 (Sidekick/Geo Tracker)
Performance
Horsepower 1 3L: Approx. 66 hp @ 5500 rpm (G13A)
Torque 1 3L: Approx. 73 lb-ft @ 3500 rpm (G13A)
Horsepower 1 6L: Approx. 80-100 hp @ 5500 rpm (G16A, depending on configuration)
Torque 1 6L: Approx. 85-105 lb-ft @ 3000-3500 rpm (G16A, depending on configuration)
Fuel System
Fuel System: Multi-point fuel injection (MPFI) for 1990 models.
Engine Codes
Engine Codes: G13A (1.3L), G16A (1.6L).
Transmission
Standard
Standard Transmission: 5-speed manual transmission
Optional
Optional Transmission: 3-speed automatic transmission (primarily on Sidekick/Geo Tracker)
Features
Transfer Case: Part-time 4WD with a 2-speed transfer case (Hi-Lo range) and manual locking hubs.
Dimensions
Exterior
Wheelbase: Approx. 86.6 inches (2199 mm) for Samurai; Approx. 86.6 inches (2199 mm) for Sidekick/Tracker.
Length: Approx. 140-150 inches (3556-3810 mm), depending on model and body style.
Width: Approx. 60-63 inches (1524-1600 mm).
Height: Approx. 63-65 inches (1600-1651 mm).
Weights
Curb Weight: Approx. 2000-2500 lbs (907-1134 kg), depending on model and configuration.
Cargo
Cargo Capacity: Minimal in standard configuration; expandable with rear seat folded or removed. Specific cubic feet not widely published but is compact.
Safety Features
Ratings
Safety Ratings: As a lightweight, older vehicle, safety ratings from modern standards are not directly comparable. Rollover risk was a concern for early Samurai models.
Active Features
Active Features: Four-wheel anti-lock braking system (4WABS) available on some higher trims of Sidekick/Geo Tracker.
Passive Features
Passive Features: Seat belts, collapsible steering column (standard).
Technology Features
Infotainment
Infotainment Features: Basic AM/FM radio, cassette player, and optional CD player. Limited by era; no touchscreens or advanced connectivity.
Driver Assistance
Driver Assistance Features: Minimal for the era. ABS available on some models. No modern driver aids like lane keeping assist or adaptive cruise control.
Connectivity
Connectivity Options: None standard. Aftermarket solutions for Bluetooth or aux input would be required.
Maintenance
Service Intervals
Oil Change Interval: Every 3,000-5,000 miles or 6 months, whichever comes first (refer to manual for exact specification).
Tune Up Interval: Spark plug replacement typically every 30,000 miles. Distributor cap and rotor inspection/replacement as needed.
Fluid Specifications
Engine Oil Viscosity: 10W-30 API SG or higher (typical specification, refer to manual).
Coolant Type: Ethylene glycol-based antifreeze with water (50/50 mix). Consult manual for specific color/type.
Transmission Fluid Type: Manual: GL-4 gear oil. Automatic: Dexron-II or equivalent.
Transfer Case Fluid Type: GL-4 gear oil (same as manual transmission).
Brake Fluid Type: DOT 3 or DOT 4 (refer to manual for specific type).
Power Steering Fluid: ATF Dexron-II or equivalent (if equipped).
Known Issues
Common Issues Samurai: Rust (especially frame rails, body mounts, rocker panels), differential seals, clutch wear, carburetor issues (if applicable on earlier models, though 1990 is likely EFI), power steering pump leaks (if equipped).
Common Issues Sidekick Tracker: Head gasket failures, timing belt wear (critical replacement interval), ABS sensor issues, exhaust manifold cracks, power window motor failures, interior trim wear.
Vehicle History
Brand Heritage
Brand Heritage: Suzuki has a long history of producing small, capable off-road vehicles, starting with the iconic Jimny. The Samurai and Sidekick/Geo Tracker built upon this legacy.
Model Evolution
Model Evolution: The Samurai (SJ series) was a global product. The Sidekick and its rebadged Geo Tracker counterpart were developed in partnership with General Motors and were more modernly styled and comfortable, targeting a broader market.
Production
Production Years Samurai: Globally from 1970s; North America from 1985.
Production Years Sidekick Tracker: 1989-1998 for the first generation.
Awards & Recognition
Recognitions
Recognitions: The Suzuki Samurai was lauded for its off-road prowess and affordability in its segment during its production run.
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