|
Manual Coverage
|
|
Systems Covered
|
|
Engine Mechanical:
|
Engine assembly, disassembly, inspection, repair of cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train.
|
|
Engine Management:
|
Fuel injection systems (if applicable), ignition systems, emission control systems, sensors, actuators, ECU diagnostics.
|
|
Transmission Manual:
|
Manual transmission overhaul, clutch service, gearshift mechanism.
|
|
Transmission Automatic:
|
Automatic transmission (if equipped) diagnosis, service, and repair.
|
|
Drivetrain:
|
Transfer case, driveshafts, differentials (front and rear), axle shafts, U-joints.
|
|
Suspension:
|
Front and rear suspension components, springs, shock absorbers, control arms, bushings, alignment specifications.
|
|
Steering:
|
Steering gear, steering column, power steering system (if equipped), tie rods, linkages.
|
|
Brakes:
|
Front and rear brake systems (disc/drum), hydraulic system, parking brake, ABS (if equipped), bleeding procedures, component replacement.
|
|
Electrical System:
|
Battery, charging system (alternator), starting system (starter motor), lighting, gauges, accessories, fuses, relays, wiring diagrams.
|
|
Body And Chassis:
|
Body panel repair, interior trim, doors, windows, convertible top (if applicable), frame inspection and repair.
|
|
HVAC:
|
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair.
|
|
Emissions Control:
|
Emission control devices and related components, diagnostic procedures.
|
|
Procedures Included
|
|
Routine Maintenance:
|
Oil changes, fluid checks and top-offs, filter replacements, lubrication points.
|
|
Diagnostics Troubleshooting:
|
Systematic troubleshooting guides, common problem diagnosis, diagnostic trouble codes (DTCs) if applicable.
|
|
Disassembly Assembly:
|
Step-by-step instructions for removing and reinstalling major components and systems.
|
|
Repair Rebuild:
|
Detailed instructions for repairing or rebuilding various vehicle components.
|
|
Cleaning Inspection:
|
Procedures for cleaning parts during disassembly and inspecting for wear or damage.
|
|
Technical Depth
|
|
Depth Level:
|
Factory-level repair and maintenance procedures suitable for professional technicians and advanced DIY enthusiasts.
|
|
Specificity:
|
Provides critical specifications, torque values, clearances, and tolerances necessary for accurate repairs.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Code Samurai:
|
G13A (1.3L SOHC I4)
|
|
Engine Code Sidekick Tracker:
|
G16A (1.6L SOHC I4) for earlier models, potentially G16B (1.6L DOHC I4) later in the year or for specific markets.
|
|
Performance Samurai G13A
|
|
Horsepower Samurai G13A:
|
Approx. 63-70 HP (depending on market and tuning)
|
|
Torque Samurai G13A:
|
Approx. 70-75 lb-ft (depending on market and tuning)
|
|
Performance Sidekick Tracker G16A
|
|
Horsepower Sidekick Tracker G16A:
|
Approx. 80-95 HP
|
|
Torque Sidekick Tracker G16A:
|
Approx. 85-105 lb-ft
|
|
Fuel System
|
|
Fuel Delivery Samurai:
|
Carbureted (most common for 1991 Samurai), some markets may have early fuel injection.
|
|
Fuel Delivery Sidekick Tracker:
|
Multi-point Fuel Injection (MPI)
|
|
Fuel Type
|
|
Fuel Type:
|
Unleaded Gasoline
|
|
Dimensions
|
|
Exterior
|
|
Wheelbase Samurai:
|
Approx. 80.0 inches (2030 mm)
|
|
Wheelbase Sidekick Tracker:
|
Approx. 86.6 inches (2200 mm)
|
|
Length Samurai Soft Top:
|
Approx. 140.0 inches (3555 mm)
|
|
Length Samurai Hardtop:
|
Approx. 146.0 inches (3710 mm)
|
|
Length Sidekick Tracker:
|
Approx. 154.0 inches (3910 mm)
|
|
Width Samurai:
|
Approx. 60.0 inches (1525 mm)
|
|
Width Sidekick Tracker:
|
Approx. 64.0 inches (1625 mm)
|
|
Height Samurai:
|
Approx. 64.0 inches (1625 mm) (varies with top)
|
|
Height Sidekick Tracker:
|
Approx. 63.0 inches (1600 mm)
|
|
Weights
|
|
Curb Weight Samurai:
|
Approx. 2000-2200 lbs (907-1000 kg)
|
|
Curb Weight Sidekick Tracker:
|
Approx. 2300-2600 lbs (1043-1179 kg)
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change Interval:
|
Typically every 3,000-5,000 miles (4,800-8,000 km) or 6 months, whichever comes first, depending on driving conditions.
|
|
Filter Replacement Interval:
|
Air filter and fuel filter replacement typically every 15,000-30,000 miles (24,000-48,000 km).
|
|
Fluid Specifications
|
|
Engine Oil Type:
|
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for specific ambient temperature ranges).
|
|
Coolant Type:
|
Ethylene glycol based antifreeze (typically a 50/50 mix with distilled water).
|
|
Transmission Fluid Type Manual:
|
API GL-4, SAE 75W-90 or 80W-90 gear oil.
|
|
Transmission Fluid Type Automatic:
|
Dexron II or equivalent.
|
|
Differentials Fluid Type:
|
API GL-5, SAE 80W-90 gear oil.
|
|
Brake Fluid Type:
|
DOT 3
|
|
Known Issues
|
|
Common Issues Samurai:
|
Rust on body panels and frame, clutch wear, starter issues, carburetor performance (if equipped), occasional steering wander.
|
|
Common Issues Sidekick Tracker:
|
Engine oil leaks (especially around valve cover and oil pan), power steering pump issues, alternator failure, rust in wheel wells and rocker panels.
|
|
Vehicle History
|
|
Brand Heritage
|
|
Suzuki Heritage:
|
Suzuki has a long history in small, rugged, off-road vehicles, epitomized by the LJ series leading to the Samurai.
|
|
Model Evolution Samurai
|
|
Samurai Evolution:
|
Successor to the Suzuki SJ series, the Samurai gained popularity in the US for its affordability and off-road capability. The 1991 model represents a mature iteration of this platform.
|
|
Model Evolution Sidekick Tracker
|
|
Sidekick Tracker Evolution:
|
Introduced as Suzuki's entry into the growing compact SUV market, also sold as the Geo Tracker by Chevrolet. This platform offered a more modern and comfortable experience compared to the Samurai.
|
|
Production
|
|
Manufacturing Location:
|
Japan (for Suzuki Samurai and many Sidekick/Tracker models), Canada (for Geo Tracker/Canadian market Suzuki Sidekick).
|
