1986-1996 Suzuki Sidekick / Samurai Geo Tracker Service Manual

Documents Suzuki Sidekick/Samurai and Geo Tracker 1986-1996 service procedures, including engine overhaul, fuel system, emissions, cooling, and transmission repairs. Ref: 90010 (1626)

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Document Details

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Document Number / Seller:
29667 / Thomas Bell
File Size:
63.04 MB
File Type:
ZIP
Language:
English
Pages:
3000+
Printable:
Yes
Category:
SUV
Last updated / verified
Sep 24, 2025

Models Covered & Key Technical Specifications

Functional Service Manual: SUV Suzuki Sidekick/Samurai or Geo Tracker, 1986-96 repair guide Calibration-Manual Suzuki Samurai (1986-1995) / Suzuki Sidekick (1989-1996) / Geo Tracker (1989-1996) (90010 (1626)) -- 1986-1996 Functional Specification & Registry Reference | Toolkit. Maximum Alignment Specs: For optimal operation, 0.020 in establishes the standard suspension alignment Range. Authorized Wattage Specs: The electrical system is designed for 75 W to support optimal power distribution Standards. Fundamental Operating Temps: For environmental stability, -40 to 125 F supports the operating temperature Margin. Specific Angular Speed: The engine requires 800 rpm for stable idle speed Protocol. Critical Optical Resolution: The diagnostic tools reach 1200 dpi for precise visual inspection Parameters. Rated Play Limits: The transmission requires 0.050 in for smooth gear engagement Bounds.

Professional Workshop Service Manual & Technical Specifications

Functional Service Manual: SUV Suzuki Sidekick/Samurai or Geo Tracker, 1986-96 repair guide Calibration-Manual

Year-Coverage: 1986-1996 // Asset-ID: 90010 (1626) / SUV Logic // Year-Coverage: Repair Guide.

TOP Integrated-Framework Rating Architecture
Engine Oil Capacity 4.7 qts 8-Valve
Torque Specs 36 ft-lbs 16-Valve
Cooling System 13 psi Standard

Providing a structural breakdown of the systems, procedures, and components documented within the 1986-1996 Suzuki Sidekick, Samurai, and Geo Tracker repair manual. This document is intended to guide a technician through all maintenance and repair tasks. The manual details diagnostic procedures, specifications, and step-by-step instructions for a wide range of vehicle systems.

Suspension service documentation covers

the maintenance and repair of suspension components, including shock absorbers, springs, and linkages. It provides specific torque values and alignment procedures to ensure optimal handling and safety.

Disassembly instructions are documented for

engine overhaul procedures, covering critical components such as the cylinder head, crankshaft, pistons, and connecting rods. Detailed specifications and reassembly steps are provided to ensure a proper engine rebuild.

Wear limits are specified for

various drivetrain components, including clutch assembly, transmission, and driveshafts. The manual details inspection procedures and specifications for wear limits to ensure longevity and performance.

System operation descriptions cover

electrical systems, including ignition, charging, and starting circuits. It provides diagnostic information and troubleshooting steps for common electrical issues.

The documentation addresses

emissions control systems, detailing components like the EGR, PCV, and fuel evaporative systems. It includes check procedures and replacement guidelines for these systems to ensure compliance and optimal performance.

This manual documents torque specifications for various components to ensure proper assembly integrity.

FAQ

What tools are **designated** for the adjustment procedures? keyboard_arrow_down

A 5 mm hex drive and a suitable driver are required for adjusting the timing belt. Refer to Section 2A for specific instructions and torque values.

Identify the **critical** pressure specifications for the fuel system. keyboard_arrow_down

29 to 37 psi is the standard fuel pressure for Multi-Port Fuel Injection (MPFI) models under normal operating conditions.

What procedures are **required** for the assembly sequence of the engine's crankshaft bearings? keyboard_arrow_down

Clean the bearing journals and caps, measure the clearance using Plastigage, and tighten the bolts to the torque specified in Chapter 2 Specifications. The document details reassembly on pages 200-201.

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