1988 Suzuki Samurai Repair Manual

The 1988 Suzuki Samurai is a compact 4x4 utility vehicle featuring a 1.3L 4-cylinder engine, 5-speed manual transmission, part-time 4WD system, solid axles front and rear, and ladder frame construction. This repair manual covers maintenance, troubleshooting, and repair procedures for engine, transmission, drivetrain, suspension, brakes, electrical systems, and body components. Below are key sections for specifications, maintenance schedules, repair procedures, and troubleshooting.

Vehicle Specifications

Key technical data for the 1988 Suzuki Samurai including dimensions, capacities, and performance figures.

Maintenance Schedule

Recommended service intervals for optimal vehicle performance and longevity.

1. Every 3,000 miles: Change engine oil and filter
2. Every 7,500 miles: Rotate tires, inspect brakes
3. Every 15,000 miles: Replace air filter, check spark plugs
4. Every 30,000 miles: Change transmission fluid, transfer case fluid
5. Every 60,000 miles: Replace timing belt, inspect water pump
6. Every 2 years: Replace brake fluid and coolant

WARNING! Always use jack stands when working under vehicle. Use proper safety equipment.

Engine Repair

Procedures for engine maintenance, diagnosis, and repair.

1. Oil Change: Drain plug (14mm), filter location front-right of engine
2. Spark Plugs: NGK BPR5ES, gap 0.028-0.031 inches
3. Valve Clearance: Intake 0.004-0.006 in, Exhaust 0.006-0.008 in (cold)
4. Timing Belt: Replace every 60,000 miles, align marks carefully
5. Compression Test: Should be 156-185 psi, variation max 14 psi between cylinders
6. Cooling System: Capacity 5.8 quarts, thermostat opens at 180°F

CAUTION! Allow engine to cool before opening cooling system. Use proper torque specifications.

Transmission & Drivetrain

• Transmission Fluid: SAE 80W-90 GL-4, 2.1 quarts capacity
• Transfer Case: SAE 80W-90, 1.6 quarts capacity
• Front Differential: SAE 80W-90, 1.3 quarts capacity
• Rear Differential: SAE 80W-90, 1.3 quarts capacity
• Clutch: Hydraulic system, pedal free play 0.4-0.8 inches
• U-Joints: Grease every 15,000 miles

Suspension & Steering

Leaf spring suspension with solid axles. Steering is recirculating ball type.

Front Suspension: Leaf springs, telescopic shock absorbers, stabilizer bar

Rear Suspension: Leaf springs, telescopic shock absorbers

Steering Gear: Recirculating ball, 3.5 turns lock-to-lock

Wheel Alignment: Toe-in 0.08-0.20 inches, Camber 0°30' ± 30'

Tire Pressure: 20 psi front and rear (standard load)

Brake System

Drum brakes rear, disc brakes front. Hydraulic system with vacuum booster.

1. Front Brakes: Disc, pad thickness minimum 0.08 inches
2. Rear Brakes: Drum, shoe thickness minimum 0.04 inches
3. Master Cylinder: 7/8 inch bore, check for leaks
4. Brake Fluid: DOT 3, replace every 2 years
5. Parking Brake: Adjust at equalizer behind transmission

Tip: Always bleed brakes starting from wheel farthest from master cylinder.

Electrical System

12-volt negative ground system. Alternator output 45 amps.

1. Battery: 12V 45Ah, negative ground
2. Alternator: 45 amp output, check belt tension
3. Starter: 1.0 kW, check solenoid connections
4. Fuses: Located under dashboard, main fuse 60A
5. Bulbs: Headlight 60/55W, brake light 21W, turn signal 21W
6. Ignition System: Electronic ignition, no points

WARNING! Disconnect battery before working on electrical system. Avoid short circuits.

Body & Interior

Removable soft top or optional hardtop. Vinyl or cloth seats.

Troubleshooting Guide

Reset: Disconnect battery for 30 minutes to reset ECU if applicable.

Service: Refer to Suzuki dealership for complex electrical diagnoses.

Technical Service Bulletins

Common factory updates and improvements for the 1988 Samurai.

• TSB 88-001: Revised clutch master cylinder design
• TSB 88-015: Updated carburetor jetting for high altitude
• TSB 88-027: Improved transfer case shift linkage
• TSB 88-042: Brake proportioning valve update

Note: Contact Suzuki dealership for complete TSB information and applicability.