Suzuki Samurai SJ 410 Manual, 1987 edition (P/N 99500-83310-33E)

• Official 482-page OEM publication (P/N 99500-83310-33E) issued in 1987
• Developed for professional workshops and DIY technicians servicing the Suzuki Samurai and SJ 410
• Focuses on the 4-cylinder gasoline engine and associated drivetrain
• Documents engine disassembly, cylinder head inspection, valve seat repair, and bottom-end assembly
• Features over 100 technical drawings and cross-reference tables for the 410-series body and 1.3L-class powertrain build

Engine and Chassis Walkthrough

This factory reference provides the technical data necessary for major component teardowns and reassembly. You get exact S.O.H.C. engine internal specifications, covering everything from camshaft inspection to piston-to-cylinder clearance and valve lash adjustments. Working on the fuel system? The manual clearly defines maintenance parameters for the carburetor, fuel pump, and air cleaner.

Beyond the engine block, the documentation delivers oil specifications and gear-shifting control diagnostics for the transmission and transfer case. Suspension, steering, and braking systems are broken down by component. This logical organization allows technicians to quickly reference factory standards during complex jobs. Always ensure the vehicle is properly supported on jack stands and the battery is disconnected before beginning any heavy chassis or electrical diagnostics.

Specification Highlights

Precise technical data is laid out for critical assemblies across the entire vehicle to verify mechanical tolerances on the J4-series build. For the engine lubrication system, relief valve pressure settings are documented at exactly 3.0 kg/cm² (42.7 psi, 300 kPa).

Clearance metrics are equally detailed. Connecting rod bearing clearance sits at 0.10–0.20 mm, and you will find exact end gaps for the top, second, and oil piston rings. When reassembling the engine, tightening torques are clearly defined—such as 9–12 Nm for the oil pan bolts, alongside full cylinder head bolt torque sequences.

Electrical specifications for the starting motor and charging system detail coil resistance and regulator troubleshooting. Intake valve clearance is mapped out at 0.13–0.17 mm in the primary specification table. Additional vital stats include a 4.8-liter coolant system capacity and exact differential drive pinion backlash measurements, ensuring every rebuild meets the original factory standard.