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.
|
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.
|