Suzuki Samurai 1987 - Special Tools

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O-3. SPECIAL TOOLS

Special tools assure three things: 1) improved workmanship; 2) speedy execution of jobs for which they

are meant; and 3) protection of parts and components against damage. Here are the special tools pres-

cribed for this Model:

0-5

Main Page

Table of Contents3
General, Special Tools and Service Materials4
Identification Number4
Vehicle Identification Number4
Engine Identification Number4
Standard Shop Practices5
Front Side5
Rear Side5
Rear Support Location6
Front Support Location6
When Using Frame Contact Hoist6
Engine Cylinder Numbers7
Special Tools8
Required Service Materials9
Metric Information16
Metric Fasteners16
Fastener Strength Identification16
Standard Tightening Torque17
Periodic Maintenance Service18
Maintenance Recommended under Severe Driving Conditions21
Severe Condition Code21
Engine and Emission Control22
Water Pump Belt Inspection and Replacement22
Camshaft Timing Belt Inspection22
Valve Lash Inspection23
Cooling System Hoses and Connections Inspection24
Proper Engine Oil Viscosity Chart24
Engine Oil Capacity24
Engine Coolant Change24
Engine Oil and Filter Change25
Exhaust Pipes and Mountings Inspection26
Coolant Capacity26
Bolts and Nut26
Pcv Valve Replacement27
Oxygen Sensor Replacement27
Catalytic Converter Inspection27
Charcoal Canister Replacement28
Emission-Related Hoses and Tubes Inspection28
Ecm and Associated Sensors Inspection29
Wiring Harness and Connections Inspection29
Spark Plugs Replacement29
Plug Specification30
Ignition Wiring Replacement30
Distributor Cap and Rotor Inspection30
Distributor Advancer Inspection30
Fuel Filter Replacement31
Carburetor Choke System Lubrication and Inspection31
Air Cleaner Element31
Fuel Tank Cap Gasket Inspection31
Idle Speed Inspection32
Idle Mixture Inspection32
Mixture Adjusting Screw Pin33
Carburetor Inspection33
Chassis and Body34
Clutch Pedal Inspection34
Brake Discs, Pads, Brake Drums and Shoes Inspection34
Brake Pedal Inspection34
Free Wheeling Hub35
Wheel Bearing Inspection35
Tire Inspection and Rotation35
Parking Brake Cable35
Shock Absorbers Inspection36
Propeller Shafts Inspection and Lubrication36
Transfer Oil Change37
Differential Oil Change (Front and Rear)37
Transmission Oil Change37
Steering System Inspection38
Door Hinges Lubrication38
Bolts and Nuts Tightening38
Alignment Service Data38
Final Inspection39
Table of Contents40
Trouble Shooting40
Engine41
Carburetor48
Exhaust and Muffler48
Clutch48
Transmission49
Differentials50
Propeller Shafts51
Brakes51
Suspension, Steering System and Tires53
Starting Motor55
Alternator56
Wiper Motor57
Fuel Meter57
Speedometer58
Water Temperature Meter58
- Engine59
- General Description60
  - Engine Lubrication61
  - Crankshaft and Main Bearings62
  - Cylinder Block62
  - Cylinder Head and Valve Train62
  - Pistons, Rings, Piston Pins and Connecting Rods62
- Engine Services Not Requiring Engine Removal63
- Engine Removal64
- Engine Disassembly67
- Inspection of Engine Components75
  - Flatness of Gasketed Surface76
  - Rocker-Arm Shaft and Rocker Arms77
  - Runout of Rocker-Arm Shaft77
  - Valve Guides77
  - Valves78
  - Seating Contact Width79
  - Valve Seats79
  - Exhaust Valve Seat80
  - Valve Lapping80
  - Valve Seat Repair80
  - Measuring Free Length of Spring81
  - Measuring Spring Preload81
  - Spring Squareness81
  - Valve Springs81
  - Cam Wear82
  - Camshaft82
  - Journal Wear82
  - Runout of Camshaft82
  - Cylinder Bore83
  - Distortion of Gasketed Surface83
  - Positions to be Measured83
  - Honing or Reboring Cylinders84
  - Piston and Piston Rings84
  - Measuring Piston Ring End Gap85
  - Piston Pins85
  - Piston Ring End Gap85
  - Ring Groove Clearance85
  - Connecting Rod Alignment86
  - Crank Pin and Connecting Rod Bearings86
  - Rod Bearing Clearance86
  - Crankshaft Thrust Play87
  - Measuring Rod Bearing Clearance87
  - Crankshaft Main (Journal) Bearings88
  - Out-Of-Round and Taper (Uneven Wear)88
  - Upper Half of Bearing Installation88
  - Paint on Standard Bearing90
  - Faints on Undersize Bearing91
  - Flywheel92
  - Oil Pump92
  - Radial Clearance92
  - Rear Oil Seal92
- Engine Reassembly93
  - Radial Clearances93
  - Timing Belt End Tensioner93
  - Crankshaft94
  - Ins Tatting Thrust Bearing94
  - Installing Bearing Half with Oil Groove94
  - Cutting off Edges of Gasket95
  - Oil Seal Housing95
  - Piston, Connecting Rod and Piston Rings96
  - Fitting Connecting Rod to Piston97
  - Fitting Piston to Special Tool97
  - 14 Instatting Piston Pin98
  - Line Marked on Driver Handle98
  - Piston Ring End Gaps Positions98
  - Guide Hoses Installation99
  - Instailing Bearing Cap99
  - Installing Piston to Cylinder99
  - Applying Sealant to Oil Pan100
  - Oil Level Gauge Guide100
  - Oil Pan100
  - Oil Pump Strainer100
  - Cylinder Head101
  - Reaming Guide Hole101
  - Reaming Valve Guide Bore101
  - Valve Guide Installation101
  - Valve Installation102
  - Valve Spring Installation102
  - Valve Stem Seal Installation102
  - Camshaft Installation103
  - Valve Totters Installation103
  - Intake Manifold and Carburetor104
  - Rocker Arm Shafts Installation104
  - Rocker-Arm Shafts104
  - Water Inlet Pipe104
  - Exhaust Manifold and Cover105
  - Oil Filter105
  - Water Pump105
  - Installing Guide, Key and Pulley106
  - Pulley Pin, Slot and Pulley Bolt106
  - Timing Belt Inside Cover, Belt Pulleys106
  - Lug and Hole107
  - Timing Marks107
  - Valve Adjusting Screw and Lock Nut107
  - Installing Timing Belt108
  - Tensioner Bolt and Nut108
  - Distributor Case109
  - Fuel Pump109
  - Fuel Pump Rod Installation109
  - Installing Crankshaft Pulley109
  - Clutch Disc and Cover110
  - Cylinder Head Cover110
  - Transmission Assembly110
  - Valve Lash (Clearance) Adjustment110
  - Checking and Adjusting Procedures111
- Engine Installation111
- Engine Maintenance Service111
  - Ignition Timing111
  - Camshaft Timing Belt112
  - Engine Oil Filter112
  - Measuring Valve Lashes112
  - Compression Pressure Measurement113
  - Engine Coolant113
  - Exhaust Line and Muffler113
  - Oil Pump Discharge Pressure Measurement113
  - Oil Pressure Gauge Installation114
  - Oil Pressure Switch114
  - Vacuum Measurement114
  - Oil Filler Cap115
- Recommended Torque Specifications116
- Fuel System117
- Carburetor118
- General Description118
  - Float System121
  - Mixture Control Solenoid Valve122
  - Primary Slow System122
  - Primary System122
  - Switch Vent Solenoid122
  - Fuel Cut System123
  - Secondary Slow System124
  - Secondary System124
  - Acceleration Pump System125
  - Secondary Main System125
  - Choke System126
  - Operation of Choke System126
  - When Coolant Temperature Is Low126
  - When the Coolant Temperature Rises126
  - Idle up System127
  - Idle-Up System Operation127
  - Unloader System127
  - When Coolant Temp. Rises127
- Removal and Installation128
- Unit Repair Overhaul129
  - Air Horn and Hoses, Etc130
  - Needle Valve Seat and Filter130
  - Drain Plugs131
  - Throttle Chamber131
  - Hooking Throttle Lever Return Spring132
  - Installing Washer132
  - Primary and Secondary Main Jets132
  - Installing Drain Plugs133
  - Installing Jets and Air Bleeders133
  - Accelerator Cable Adjustment135
- Maintenance Services135
  - Float Adjustment136
  - Fuel Level136
  - Idle up Adjustment136
  - Idle-Up Adjusting Screw136
  - Checking Actuator137
  - Checking TWSV137
  - Checking TWSV Circuit137
  - Choke Adjustment138
  - Choke Valve138
  - Checking Choke Piston139
  - Choke Lever139
  - Choke Piston139
  - Fast Idle Adjustment140
  - Mark on Cam and Cam Follower140
  - Unloader Adjustment140
  - Checking Acceleration Pump141
  - Checking Secondary System141
  - VTV (Vacuum Transmitting Valve)141
  - Idle Speed Adjustment142
  - Idle Mixture Adjustment143
  - Idle Mixture Inspection and Adjustment143
- Air Cleaner145
- General Description145
- Maintenance Services145
- Fuel Pump, Filter and Lines147
- General Description147
  - Fuel Filter148
  - Fuel Pulp148
  - Fuel Filler Cap149
  - Fuel Filler Cap Cross-Section149
- Removal and Installation149
  - Fuel Tank150
  - Fuel Filler (Tank) Cap151
  - Fuel Lines151
  - Fuel Tank Purging Procedure151
- Maintenance Services151
- Accelerator Pedal152
  - Precautions to be Taken in Accelerator Pedal Installation152
  - Emission Control System153
  - Vehicle Emission Control Information Label156
- Positive Crankcase Ventilation (Pcv) System157
  - TCAC System Operation158
  - Thermostatically Controlled Air Cleaner (Tcac) System158
- (Tcac) System159
- Evaporative Emission Control System159
- Hot Idle Compensator (Hic)160
- Deceleration Mixture Control System161
- Computer Controlled Emission Control System162
  - Electronic Control Module162
  - Feed Back System162
  - Engine Coolant Temperature163
  - Engine Speed163
  - Throttle Position163
  - Altitude Compensation164
- Bowl Ventilation System164
  - Gear Position164
  - Three-Way Catalyst164
- Fuel Cut System165
- Exhaust Gas Recirculation (Egr) System166
- Diagnosis167
  - Possible Causes of Emissions Test Failures167
  - Pcv System Diagnosis169
  - Checking PCV System170
  - Checking PCV Valve for Sticking170
- General170
- Maintenance Service170
  - PCV Hoses170
  - Air Control Actuator171
  - Checking TCAC System171
- Tcac System171
  - Thermo Sensor171
  - Checking Canister172
  - Checking Check Valve172
  - Checking Vapor Storage Canister172
- Evaporative Emission Control System172
- Deceleration Mixture Control System173
- Hot Idle Compensator (Hic)173
- Mixture Control Valve (MCV)173
- Feed Back System174
  - System Check Flow Chart174
  - Checking Feed Back System175
  - Checking Idle and Wide Open Micro Switches175
  - Idle Micro Switch176
  - Checking Mixture Control Solenoid Valve177
  - Checking Wide Open Micro Switch177
  - Wide Open Micro Switch177
  - Wide Open Micro Switch Lever177
  - Checking Thermal Switch178
  - Checking High Altitude Compensator179
  - Checking Switch in Hot Water179
  - Checking Thermal Engine Room Switch179
  - Checking Oxygen Sensor180
  - Connector of Oxygen Sensor180
  - Disconnecting Vacuum Hose180
  - Moving Lever180
  - Checking ECM Ground Circuit181
  - Checking ECM Ground Circuits181
  - Checking Feed Back System Circuits181
  - ECM and Coupler181
  - Body Ground182
  - Engine Ground182
  - Checking ECM Power Circuits183
  - Checking Sensors and Their Lead Wires184
  - Checking Function of Oxygen Sensor and Feed Back System185
  - Checking Idle-Up Signal187
  - Checking Fuel Cut System188
  - Checking Switch Vent Solenoid188
  - Replacing ECMI188
  - Checking EGR System189
  - Checking EGR Valve Diaphragm189
  - Movement of EGR Valve Diaphragm189
  - Vacuum Hoses189
  - Bi-Metal Vacuum Switching Valve (BVSV)190
  - Checking EGR Modulator190
  - Filter of EGR Modulator190
  - Engine Cooling System192
- 6-L. GENERAL DESCRIPTION193
  - Cooling System Circulation193
  - Radiator Cap194
  - Water Reservoir Tank194
- Thermostat195
  - Coolant Draining196
  - Cooling Water Pipes or Hoses196
- Radiator196
  - Water Pump Drive Belt196
  - Inspection of Components198
- Water Pump199
- Important Steps for Reinstallation200
- Thermostat200
- Water Pump200
- Maintenance Service201
- Radiator201
- Water Pump Belt201
- Anti-Freeze Proportioning Chart202
- Coolant Level202
- Cooling System Service203
- Cooling System, Flush and Refill203
  - Installation of Radiator Cap203
  - Radiator Drain Plug203
  - Cooling Fan Clutch204
  - Car Heater205
  - Electrical Circuit207
  - Blower Resistor208
  - Blower Switch208
  - Heater Hoses208
  - Heater Services208
  - Heater & Ventilator Control Cable Routing211
  - Ignition System212
- Distributor213
- General Description213
- Ignition Coil215
- Spark Plug215
- Distributor216
- High Tension Cord216
- Ignition Coil216
- Maintenance Service216
- Spark Plug216
  - Signal Rotor Air Gap217
  - Distributor Driven Gear219
- Ignition Timing220
- Checking Vacuum Advancer221
- Distributor Drive Gear221
- Distributor222
- High Tension Cords Distribution222
- Important Reminders for Installation222
  - Cranking System223
  - Cranking Circuit224
- General Description224
- Starting Motor224
- Specifications226
- Lubrication227
- Removal and Installation227
- Disassembly228
- Inspect Commutator229
- Starting Motor Inspection229
  - Ground Test230
  - Inspect Brush230
  - Inspect Field Coil230
  - Open Circuit Test230
  - Inspect Armature Shaft Bush231
  - Inspect Brush Holder and Spring231
  - Inspect Drive Lever231
  - Hold in Coil Open Circuit Test232
  - Inspect Magnetic Switch232
  - Pull-In Coil Open Circuit Test232
- Hold-In Test233
  - No-Load Performance Test233
  - Performance Test233
- Pull-In Test233
- Clutch Switch234
- Charging System235
- 10-L. ALTERNATOR236
- General Description236
- Data and Specification237
- Diagnosis237
  - Noisy Alternator237
  - Faulty Indicator Lamp Operation238
  - Undercharged Battery238
  - Voltmeter238
  - Load Check239
  - Overcharged Battery239
  - Alternator Service240
- Removal240
- Inspection242
  - Rotor242
  - Stator242
- Assembly243
  - Brush and Brush Holder243
  - Condenser243
  - Rectifier243
- Care of the Battery244
- General Description244
  - Built-In Indicator245
  - Carrier and Hold-Down245
  - Visual Inspection245
  - Battery Cables246
- Remove and Replace246
- Clutch247
- 11-L. GENERAL DESCRIPTION248
  - Clutch Cover and Disc250
  - Clutch Release Bearing250
  - Clutch Release Shaft Bushes250
  - Input Shaft End Bearing250
- Removal250
  - Backlash in Disc Setration Fit251
  - Clutch Cover251
  - Clutch Disc Facing Surface Condition251
  - Clutch Facing Wear251
- Inspection of Components251
  - Input Shaft Bearing252
  - Release Bearing252
  - Clutch Disc and Clutch Cover253
- Installation253
  - Clutch Pedal Height254
  - Clutch Release Arm254
  - Clutch Release Shaft Fork254
  - Maintenance Services254
  - Clutch Cable Lubrication255
  - Clutch Cable Routing255
- Recommended Torque Specification256
- Gear Shifting Control257
- General Description258
- Gear Shift Lever Select Guide Pins259
- Removal259
- Gear Shift Fork Shaft260
- Gear Shift Lever260
- Inspection of Components260
- Reverse & Low Speed Select Guide Pins260
- Gear Shift Lever Case261
- Installation261
- Reverse & Low Speed Guide Pins261
- Gear Shift Control Lever Seat262
  - Transmission263
  - In Engine Room266
  - In Passenger Compartment266
  - Under Engine266
  - Precautions on Bush Reinstallation267
  - Replacing Clutch Release Shaft Bush267
  - Separating Upper Case from Lower Case268
  - Removing Countershaft269
  - Removing Main Shaft and Input Shaft270
  - Gear Shift Fork and Shaft272
  - Gear Shift Yoke272
  - Neutral Position272
  - Removing Shift Yokes, Forks and Shafts272
  - Bearings and Bushes274
  - Gears274
  - Main Shaft274
  - Synchronizer Hubs, Sleeves and Keys274
  - Chamfered Tooth Ends of Ring275
  - Combination of Gear and Synchronizer Ring275
  - Input Shaft275
  - Fork Shaft Locating Springs276
  - Synchronizer Rings276
  - Extension Case Bush277
  - Gear Shift Shafts277
  - Main Shaft and Input Shaft277
  - Gear Shift Fork282
  - Yokes283
  - Transmission Lower Case and Upper Case284
  - Extension Case285
  - Input Shaft Bearing Retainer286
  - Transmission Oil287
  - Transfer Gear Box289
- General Description290
  - 2-Wheel Drive (Rear-Wheel Drive)291
  - 4-Wheel Drive HIGH (All-Wheel Drive on HIGH)291
- Selective Flows of Transfer Drive291
- 4-Wheel Drive LOW (All-Wheel Drive on LOW)292
- Gear Ratio Data292
- Transfer Services Not Requiring Transfer Removal293
- Removal294
- Disassembly296
  - Speedometer Driven Gear296
  - Transfer Front Case296
  - Universal-Joint Yoke Flanges296
  - Transfer Center Case297
  - Gear Teeth300
- Inspection of Components300
  - Locating Spring300
  - Transfer Rear Case300
  - Output High Gear301
  - Output Low Gear301
  - Side Clearance of Gears301
  - 4WD Gear Shift Lever302
- Reassembly302
  - Output Rear Shaft303
  - Shim Adjustment of Input and Output Shafts304
  - Center Case306
  - Center and Rear Cases308
  - Front Case309
- Maintenance Services310
  - Oil and Oil Capacity310
  - Oil Level310
- Tightening Torque311
- Propeller Shafts312
- General Description313
- Installation314
- Removal314
- Maintenance Services315
  - Universal Joint Noise315
  - Bolts & Nuts316
- Tightening Torque316
- Disassembling on Flange Yoke Side317
- Reassembly318
- Differential320
- General Description321
- Removal322
- Disassembly325
- Inspection and Adjustment of Components326
  - Side Gear Thrust Play326
  - Determination of Shim Thickness for Bevel Pinion327
  - Bevel Pinion Bearing Preload Adjustment328
  - Bevel Gear Backlash Adjustment329
  - Drive Bevel Pinion Bearing Starting Torque (Preload)329
  - Pinion-To-Gear Tooth Contact Pattern Check and Adjustment330
  - Differential Pinion Shaft (Shorter)332
  - Differential Side Bearings332
  - Drive Bevel Gear Bolts332
- Reassembly332
  - Bevel Pinion Bearings333
  - Brake Circuit Air Purging334
  - Differential Gear Oil334
- Installation334
  - Rear Brake Drum334
  - Side Bearings Caps334
- Maintenance Services335
- Oil Change335
- Recommended Torque Specifications335
  - Suspension336
  - Front Suspension337
  - Barfield Joint Construction and Operation339
  - Leaf Spring340
  - Shock Absorber340
  - Stabilizer340
  - Front Wheel Hub 81 Bearing341
  - Circlip Remover342
  - Steering Knuckle343
  - Front Axle Shaft Joint344
  - Barfield Joint345
  - Front Wheel Bearing345
  - Leaf Spring Bushes345
  - Stabilizer and Its Bush345
  - Kingpins and Bearings346
  - Steering Knuckle Oil Seal346
  - Rear Suspension350
  - Rear Axle Shaft351
  - Leaf Spring and Bumper355
  - Bolts and Nuts359
  - Rear Wheel Bearing359
  - Front Free Wheeling Hub362
  - Steering System365
- General Description366
  - Right-Hand Steering Vehicle366
  - Left-Hand Steering Vehicle367
- Specifications and Data368
- Removal369
  - Steering Column369
  - Steering Hand Wheel369
  - Gear Box372
  - Steering Lock372
  - Tie Rod and Tie Rod End372
  - Adjustment of Worm Shaft Starting Torque373
- Inspection of Components373
  - Left Hand Steering Vehicle373
  - Steering Gear Box373
- Checking Steering Column for Accident Damage375
- Important Steps in Reinstallation376
  - Steering Damper377
  - Steering Handwheel380
  - Toe Setting380
- Wheel Alignment380
  - Camber381
  - Camber and Caster Adjustment381
  - Reference Information381
  - Toe Adjustment381
- Maintenance Services382
  - Steering Handwheel Play382
  - Steering Rubber Joint382
  - Steering Shaft Joint382
  - Tire Wear Indicato383
  - Tires383
  - Inflation of Tires384
  - Tire Rotation384
  - Wheels384
  - Tire Demounting and Mounting385
  - Tire Repair385
- Recommended Torque Specifications386
- Brakes387
- General Description388
  - Master Cylinder Assembly390
  - Master Cylinder OPERATION390
  - Normal Operation390
  - One-Circuit Operation391
  - Disc Brake Caliper Assembly392
  - Clearance Correction393
  - Single Piston Floating Caliper Type393
  - Drum Brake Assembly394
  - Rear Brake Operation395
  - Booster Assembly397
  - Booster398
  - Vacuum Booster Assembly398
  - When Foot Brake Pedal Is Not Depressed398
  - When Foot Brake Pedal Is Depressed399
  - When Foot Brake Pedal Is Released399
  - Brake Pad400
- Front Disc Brake400
  - Caliper401
  - Disc402
  - Brake Disc403
  - Bush Dust Boot and Cylinder Boot403
  - Cylinder Slide Bush403
  - Piston and Boot404
  - Piston Seal404
  - Precautions on Installation404
  - Front Brake Disc and Pad405
  - Front Brake Flexible Hose405
  - Front Wheel Spindle405
  - Brake Drums406
  - Inspection for Front Brake after Installing406
- Rear Drum Brake406
  - Brake Drum407
  - Brake Shoes and Strut407
  - Cracked, Scored, or Grooved Drum407
  - Brake Shoe and Rim408
  - Brake Strut408
  - Wheel Cylinder408
  - Self Shoe Clearance Adjusting System409
  - Springs409
  - Master Cylinder413
  - Master Cylinder Inner Parts414
  - Reservoir414
  - Precaution of Installation415
- Brake Booster416
  - Inner Parts419
  - Metal Parts419
  - Rubber Parts419
  - Booster Inspection Table420
- Parking Brake424
- Brake Pipes and Hoses425
  - B-Way Joint426
  - Brake Flexible Hose and E-Ring426
  - Clamp426
  - Upper Side426
  - Brake Pipes (Right427
  - Brake Fluid Leaks428
  - Brake Fluid Level Inspection428
  - Fill Reservoir428
- Maintenance Service428
  - Road Testing Brakes428
  - Brake Pedal Free Height Adjustment429
  - Excessive Pedal Travel Check429
  - Stop Light Switch Adjustment429
  - Brake Hose and Pipe Inspection430
  - Disc Inspection430
  - Hose430
  - Rear Brake Shoe & Lining Inspection430
  - Brake Pedal Play Inspection431
  - Flushing Brake Hydraulic System431
  - Parking Brake Lever Stroke Adjustment431
  - Rear Drum Brake Shoe Adjustment431
  - Bleeding Brakes432
  - Check Air Tightness433
  - Inspect Booster Operation433
  - Inspection Without Tester433
  - Check Air Tightness under Load434
  - Check Operation434
- Torque Specification435
- Body Service436
- Description437
- Front Door437
  - Door Window Glass438
  - Door Glass440
  - Door Window Glass or Regulator440
  - Door Window Regulator440
  - Front Door Lock440
- Installation440
  - Door Outside Open Rod441
  - Regulator Handle441
  - Water Proof Film441
  - Door Lock Inside Handle442
  - Door Lock Rod Pin442
  - Door Lock Striker442
  - Cleaning443
  - Windshield443
- Installation444
- Back Door (Applicable to Hard Top Vehicle)446
  - Door Lock and Stricker Adjustment446
  - Door Lock Stricker447
  - Handling of Back Door Balancer447
  - Chassis Dimensions448
  - Body Electrical Equipment449
  - Combination Meter450
  - Combination Meter Circuit and Components450
  - Combination Meter with Tachometer451
  - Combination Meter Without Tachometer451
- Head Light452
  - Wiring Circuit452
  - Beam Alignment453
  - Headlight Beam Setting (Standard Procedure)453
  - Headlight Inspection453
  - Combination Switch (Lighting Switch Circuit)454
  - Head Light Dimmer Switch454
  - Headlight Adjustment454
  - Switch Connector454
- Turn Signal Light and Hazard Warning Light455
  - Hazard Warning Switc456
  - Turn Signal & Hazard Warning Switch456
  - Turn Signal Switch456
  - 2-Speed Type457
  - Interval Wiper Relay Circuit457
- Windshield Wiper Motor457
  - No-Load Run Test458
  - Wiper Trouble Diagnosis458
  - Automatic Stop Action Test459
  - Internal Wiper Relay Test459
- Water Temperature Meter and Gauge459
- Fuel Level Meter and Gauge460
  - Gauge Unit460
  - Resistance- Temp. Relationship460
- Brake Warning Lamp461
  - Resistance-Fuel Level Relationship461
  - Brake Fluid Level Switch462
- Oil Pressure Lamp462
- 4WD Switch463
- Seat Belt Warning Lamp/Buzzer463
- Wheel Drive Lamp463
- Ilumination Controller464
- Main Switch Key Warning Buzzer464
- REAR DEFOGGER ( Hard-Top )464
  - Checking Wire for Damaged Place465
  - Defogger Circuit465
  - Defogger Wire465
  - Repair465
- Fuse Box466
- Engine Room Wiring467
- Wiring Harness Routing467
- Instrument Panel Wiring469
- Wiring Diagram470
Service Data471

Suzuki Samurai 1987 - Special Tools

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