Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Engine Options for the Samurai There are a number of possibilities for changing the engine in your Samurai, depending on where you live and what you want to accomplish. Suzuki Sidekick or Geo Tracker I (1989-1995) – The block from the 1.6 8-valve Sidekick or Tracker can be swapped in easily. This is by far the simplest upgrade, requiring modified engine mounts, transmission adapter plate, and provision (some sort of lift, or an adaptation from a G12 series engine) for the oil pan. Intake and Exhaust Manifold will fit, and finally the addition of an electronic fuel pump since the 1.6 head does not have lobes on it for the fuel pump. Petroworks can supply almost all necessary parts required for this task. Motors are a little harder to come by though. The next level to this swap would be the use of the Sidekick/Tracker Throttle Body intake system. This is a much more complex task and requires the complete under hood wiring harness, parts of the under dash harness, and computer from a donor car. Modification of the harness is required to install it into the Samurai. TR Also, the Speedometer cluster needs to be modified on the Samurai to add in a Vehicle Speed Sensor (VSS). This is needed by the computer to adjust timing during operation. Suzuki Swift – This is a G13 series engine with a counterbalanced crankshaft, twin overhead cams and fuel injection. One of the easier swaps to make, requiring only some minor wiring changes and a hole in the Samurai’s firewall for the horizontally mounted distributor (this engine was originally designed for a transverse mounting). Suzuki Sidekick or Geo Tracker II (1993-1995) – The motor from these cars are 1.6 16v, multiport fuel-injected. These motors are usually found in 4 door cars and will say “16 Valve” On the valve cover, Timing Belt cover or injector manifold. This is a much more complicated swap and requires a lot of wiring to interface with the Samurai harness.

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IDENTIFICATION Transmission is identified by identification plate attached to transmission case, located on left side, above oil pan. Vehicle Identification Number (VIN) may also be used in identifying transmission. VIN locations are at top left of instrument panel and driver’s-side door post. VIN is used to ensure correct application of component parts and assemblies. DESCRIPTION & OPERATION Automatic transmission provides 3 forward speeds and reverse. Main internal components are; oil pump, Torque Converter w/Clutch (TCC), reverse clutch, 2nd clutch, 3rd clutch, one-way clutch (sprag type), compound planetary gear set, low brake, governor and valve body. See Fig. 1. Gear shifting is controlled by valve body. Components that regulate shifting schedules are; governor, modulator and kick-down valve. TCC is operated by an electric solenoid. TCC solenoid operation depends on signals provided by the Engine Coolant Temperature (ECT) sensor, brake switch, Throttle Position (TP) sensor, Vehicle Speed Sensor (VSS) and gear position.

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MALFUNCTION INDICATOR LIGHT (MIL) RESET PROCEDURE Federal Models MIL (also known as CHECK ENGINE light) will automatically flash at 50,000, 80,000 and 100,000 mile intervals, indicating system inspection and/or system component replacement is required. After necessary services have been performed, turn off light by moving cancel switch to opposite position. Cancel switch is located below steering column lower trim panel: * At 50,000 Miles – Replace PCV valve and inspect EGR system. * At 80,000 Miles – Replace oxygen sensor. * At 100,000 Miles – Replace PCV valve and charcoal canister. Inspect catalytic converter for plugging, EGR system, ECM and related sensors. RETRIEVING CODES

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Manual locking hubs engage and disengage front wheels from axle shafts on 4WD vehicles. These hubs are are optional. When hubs are engaged in LOCK position, wheels and axle shafts rotate together. When hubs are disengaged or unlocked in FREE position, front wheels free-wheel on hub bearings. REMOVAL & INSTALLATION MANUAL LOCKING HUB Removal 1) Position locking hub in FREE position. Remove cover-to- body retaining bolts. Remove cover assembly and gasket. 2) Remove snap ring from drive axle. Remove body-to-hub retaining bolts. Remove body and gasket. See Fig. 1. CAUTION: Lubricate sliding surfaces with multipurpose grease, but DO NOT pack hub with grease.

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VALVE LASH (CLEARANCE) 1. Remove negative cable at battery. 2. Remove cylinder head cover. Zoom Sized for Print 3. Using 17 mm socket, turn crankshaft pulley clockwise until “V” mark (in white paint) on pulley aligns with “O” (zero) calibrated on timing belt cover. 4. Remove distributor cap and check rotor position. If it is positioned as shown in figure (i.e. No.1 piston is at Top Dead Center (TDC) of compression stroke), check valve lashes at valves (1), (2), (5) and (7). If it is at ignition position of No.4 cylinder, check valve lashes at valves (3), (4), (6) and (8). NOTE: When checking valve clearance, insert thickness gauge between camshaft and cam-riding face of rocker arm.