🏷️ Basic Information Identification Make: Suzuki Model: SJ Samurai Model Generations Covered: SJ Series (all generations of SJ Samurai) Production Eras Covered: 1980s - 1990s (primarily, with some early model variations) Codes Chassis Codes: SJ410, SJ413, JA11, JA12, JA22 Engine Codes: F10A (970cc), F8A (797cc), G13A (1.3L SOHC), G13B (1.3L SOHC VVT), G16A (1.6L SOHC), G16B (1.6L DOHC VVT) 👋 Introduction Market Position Vehicle Market Segment: Compact SUV / Off-road vehicle. Competitive Analysis Key Competitors Era: Jeep Wrangler, Toyota Land Cruiser (FJ40/FJ60), Lada Niva, Ford Bronco II. Key Features Vehicle Key Attributes: Compact size, robust 4WD system, high ground clearance, simplicity, affordability, excellent off-road capability. Manual Value Proposition: Empowers owners and technicians with detailed knowledge for reliable maintenance and repair of a cult classic off-road vehicle. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service and repair procedures for the entire vehicle. Page Count Estimated Page Count: 1000+ Manual Type Manual Format Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Download Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanicals (disassembly, assembly, overhaul), cooling system, lubrication system, fuel system (carbureted and fuel injected), ignition system, emissions control systems. Drivetrain Systems: Clutch system, manual transmission (transfer case, 4WD system), differentials, axle shafts, driveshafts. Suspension Steering Brakes: Front and rear suspension (leaf spring, coil spring), steering system (steering box, linkage), brake system (front disc, rear drum), parking brake. Electrical Systems: Battery, charging system (alternator, starter), lighting system, wiring diagrams, fuses, relays, instrumentation, engine control unit (ECU) diagnostics (for fuel-injected models). Body Chassis: Body panels, doors, interior trim, seats, chassis frame, body mounts, exhaust system. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt adjustments, battery maintenance, general inspection and cleaning. Repair Procedures: Engine rebuilding, transmission overhaul, differential repair, brake component replacement, suspension component replacement, steering system repair, electrical component troubleshooting and replacement. Troubleshooting Diagnostics: Step-by-step diagnostic charts for common drivability issues, electrical faults, and mechanical problems. Identification of symptoms and probable causes. Technical Depth Depth Of Information: Detailed disassembly and reassembly procedures, torque specifications, clearance measurements, timing adjustments, diagnostic procedures, wiring diagrams, component identification. 📊 Manual Specifications File Format Digital File Format: PDF Print Quality Scanned Image Quality: High-resolution scans, often with searchable text (OCR). Binding Type Digital Binding Analogy: N/A (Digital download) Paper Type Digital Paper Analogy: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Most Common Engine Variant: 1.3L G13A SOHC I4 (Carbureted/Fuel Injection) Performance Typical Horsepower 1.3L: 60-70 HP (varies by year/market) Typical Torque 1.3L: 70-75 lb-ft (varies by year/market) Fuel System Fuel Delivery 1.3L Early: Carburetor (e.g., Mikuni 2-barrel) Fuel Delivery 1.3L Late: Multi-point Fuel Injection (MPI) for later models (e.g., G13B) Engine Construction Engine Block Material: Cast Iron Cylinder Head Material: Aluminum Alloy Cooling System Cooling System Type: Pressurized Liquid Cooling Lubrication System Oil Capacity W Filter: Approx. 3.5 Liters (3.7 Quarts) 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Optional Optional Transmission Type: 3-Speed Automatic (less common) Features Transfer Case Type: 2-Speed Transfer Case with High/Low Range and Neutral Drive System: Part-time 4WD (selectable 2WD/4WD High/4WD Low) Fluid Requirements Manual Transmission Fluid Type: API GL-4 Hypoid Gear Oil (e.g., 75W-90 or 80W-90) Transfer Case Fluid Type: API GL-4 Hypoid Gear Oil (e.g., 75W-90 or 80W-90) Differential Fluid Type: API GL-5 Hypoid Gear Oil (e.g., 80W-90) 📐 Dimensions Exterior Wheelbase Typical: 2030 mm (80 inches) Overall Length: 3,565 mm (140.4 inches) Overall Width: 1,505 mm (59.3 inches) Overall Height: 1,670 mm (65.7 inches) (Hardtop) Weights Curb Weight Typical: 960 kg (2,116 lbs) Gross Vehicle Weight Rating Gvwr: Approx. 1400-1500 kg (3086-3307 lbs) Cargo Cargo Volume Rear Seats Folded: Variable, but compact 🛡️ Safety Features Ratings Crash Test Ratings Era: Limited official ratings due to era and vehicle type; known for rollovers in certain conditions. Active Features Braking System: Front disc brakes, rear drum brakes. Power assist (optional/later models). Passive Features Seatbelts: Standard lap belts, front shoulder belts (later models). Rollover Protection: Integral roll cage in hardtop models, roll bar in soft-top models. 💡 Technology Features Infotainment Infotainment Features Era: Basic AM/FM radio, optional cassette player, analog gauges. Driver Assistance Driver Assistance Systems: None standard; basic power steering (optional/later models). Connectivity Connectivity Features: N/A (pre-digital era connectivity). 🔧 Maintenance Service Intervals Engine Oil Change Interval: Every 3,000-5,000 miles (5,000-8,000 km) or 6 months. Transmission Fluid Change Interval: Every 30,000-50,000 miles (50,000-80,000 km). Differential Fluid Change Interval: Every 30,000-50,000 miles (50,000-80,000 km). Fluid Specifications Engine Oil Specification Typical: API SG or SH, SAE 10W-30 or 10W-40 (consult manual for specific engine/climate recommendations) Coolant Specification: Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Brake Fluid Specification: DOT 3 or DOT 4. Known Issues Common Wear Item Corrosion: Frame rust and body corrosion, particularly in areas exposed to salt. Common Engine Issue Carburetor: Carburetor...