Samuray 1994 1.3L

1994 Suzuki Samurai JL
1.3L 4-CYL - VIN [3] 1994 SUZUKI ENGINES 1.3L 4-Cylinder
1.3L 4-CYL - VIN [3]
1994 SUZUKI ENGINES 1.3L 4-Cylinder
ENGINE IDENTIFICATION
Engine code is stamped on rear portion of cylinder block at bellhousing, exhaust side. Vehicle Identification
Number (VIN) is stamped on a metal tag attached to left side of instrument panel near pillar. The sixth character
of VIN identifies engine model.
ENGINE IDENTIFICATION CODE

Application VIN
Samurai 1.3L SOHC 3
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
1. Remove rocker cover. Rotate crankshaft until TDC mark of timing belt cover is in line with timing mark
on crankshaft pulley with cylinder No. 1 at TDC on compression stroke.
2. Remove distributor cap and ensure rotor is pointed upward at distributor hold-down bolt and to No. 1
terminal of distributor cap. If not correctly oriented, rotate crankshaft 360 degrees.
3. Measure clearance between adjustment screw and valve stem using thickness gauge. Check intake valve
clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1 and 3.
4. Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3
and 4 and exhaust valve clearance of cylinders No. 2 and 4. Ensure clearance is within specification. See
VALVE CLEARANCE SPECIFICATIONS table.
5. If clearance adjustment is necessary, loosen lock nut and turn adjusting screw. After adjusting clearance,
tighten adjusting screw lock nut to 11-14 ft. lbs. (15-19 N.m). Recheck clearance.
VALVE CLEARANCE SPECIFICATIONS

Application In. (mm)
Engine Cold
Intake .005-.007 (.13-.18)
Exhaust .006-.008 (.15-.20)
Engine Hot
Intake .009-.011 (.23-.28)
Exhaust .010-.011 (.25-.28)
REMOVAL & INSTALLATION
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also, place mating marks on engine hood and other
major assemblies before removal.
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12:07:13 a. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
WARNING: ALWAYS relieve fuel pressure before disconnecting any fuel injection-
related component. DO NOT allow fuel to contact engine or electrical
components.
FUEL PRESSURE RELEASE
1. Place transmission in Neutral (M/T) or Park (A/T). Set parking brake and block drive wheels.
2. Disconnect fuel pump relay connector. Fuel pump relay is located on right kick panel, above ECM. See
Fig. 1 .
3. Remove fuel filler cap to release pressure. Reinstall fuel filler cap. Start engine, and idle until engine dies.
Crank engine 2 or 3 times to ensure lines are empty. Reconnect fuel pump relay connector.
Fig. 1: Locating Fuel Pump Relay

Courtesy of SUZUKI OF AMERICA CORP.
ENGINE
CAUTION: When raising or supporting engine or automatic transmission for any

reason, DO NOT use a jack under oil pan. Damage to oil pump and pick-up
strainer could result.
NOTE: Remove engine and transmission as an assembly.
jueves, 25 de febrero de 2021 12:07:13 a. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION.
Disconnect battery cables. Mark and remove hood. Remove warm air hose. Disconnect breather hose
from air cleaner case. Remove air cleaner case from throttle body and air inlet hose.
2. Mark all remaining connectors and disconnect from throttle body and intake manifold. Disconnect
accelerator cable from throttle body. Disconnect and mark wires from starter motor and alternator
terminals. Mark and disconnect vacuum hoses.
3. Disconnect fuel supply and return hoses from throttle body. Disconnect wire connector from oil pressure
sending unit and oxygen sensor. Disconnect wire connector from back-up light switch and 5th gear
switch.
4. Disconnect distributor primary wires at distributor. Remove high tension wire from ignition coil. Drain
radiator. Disconnect hoses from thermostat cap and inlet pipe. Remove cooling fan and clutch.
5. Remove fan shroud and radiator. Disconnect brake booster vacuum hose. Remove 4 bolts fastening
gearshift No. 2 lever boot, and move boot upward. Move gearshift No. 1 to upper side of shift lever.
6. Loosen 3 bolts on gearshift lever case, and remove shift lever from lever case. Raise vehicle. Disconnect
exhaust pipe from exhaust manifold. Disengage clutch cable from clutch release lever. Drain transmission
oil.
7. Remove drive shaft connecting transmission case to transfer case. Attach hoist to hooks provided on
engine. One hook is mounted on each side of engine.
8. Remove exhaust center pipe mounting bracket and 4 transmission mount bolts. Remove pipe connected to
chassis under transmission. Lower vehicle. Remove 4 bolts securing right and left engine mounting
brackets.
9. Ensure all hoses, electrical wires and cables are disconnected. Remove engine. Remove lower clutch
cover. Separate engine from transmission (if necessary).
Installation
Lower engine and transmission into vehicle. Install engine mountings to brackets. Install bolts into frame
brackets. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Replace cooling system, engine
and transmission fluids. To complete installation, reverse removal procedure.
INTAKE MANIFOLD
Removal
Disconnect negative battery cable. Drain cooling system. Remove air intake hoses and air breather hoses.
WARNING: To avoid severe burns, DO NOT remove radiator drain plug or cap
while engine and radiator are still hot.
2. Remove air cleaner assembly. Label and disconnect all electrical connections from intake manifold,
injectors and throttle body. Label and disconnect vacuum hoses from intake manifold.
3. Disconnect coolant hoses from manifold and throttle body and remove upper radiator hose. Remove fuel
supply and return lines from delivery pipe. Disconnect all control cables.
4. Remove intake manifold-to-cylinder head bolts. Remove intake manifold and throttle body and gasket.
Remove remaining components from intake manifold as required.
Installation
To install, reverse removal procedure using NEW gaskets. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Adjust all control cables and fill cooling system.
EXHAUST MANIFOLD
Removal
1. Disconnect negative battery cable. Remove air cleaner assembly (if necessary). Disconnect oxygen sensor
wire connector.
2. Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold cover. Remove exhaust
manifold-to-cylinder head bolts. Remove exhaust manifold and gasket.
Installation
To install, reverse removal procedure using NEW exhaust manifold gasket. Tighten bolts to specification. See
TORQUE SPECIFICATIONS .
CYLINDER HEAD
Removal
Remove intake and exhaust manifolds. See INTAKE MANIFOLD and EXHAUST MANIFOLD under
REMOVAL & INSTALLATION.
2. Remove timing belt. See TIMING BELT under REMOVAL & INSTALLATION. Loosen cylinder head
bolts in reverse order of tightening sequence. See Fig. 2 . Loosen head bolts in 2 or 3 steps to prevent
cylinder head warpage. Remove bolts and cylinder head.
Inspection
1. Check cylinder head for evidence of water leakage or damage. Remove carbon from combustion
chambers. Check cylinder head for cracks in intake and exhaust ports, combustion chambers and head
surface.
2. Check head warpage at 6 locations. If warpage exceeds specification, cylinder head should be machined
or replaced. See CYLINDER HEAD under ENGINE SPECIFICATIONS.
3. Check intake and exhaust manifold seating faces on cylinder head for warpage. Warpage limit for
manifold seating faces is .004" (.10 mm). If warpage exceeds specification, machine or replace cylinder
head.
Installation
To install cylinder head, reverse removal procedure. Use NEW head and manifold gaskets. Tighten cylinder
head bolts to specification in 3 steps using proper sequence. See Fig. 2 or Fig. 3 . See TORQUE
SPECIFICATIONS . Adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under
ADJUSTMENTS.
Fig. 2: Cylinder Head Bolt Tightening Sequence (Except 1.6L 16-Valve)

Fig. 3: Cylinder Head Bolt Tightening Sequence (1.6L 16-Valve)

FRONT COVER OIL SEAL
Removal
1. Remove water pump, crankshaft pulley and alternator. Remove timing belt cover and timing belt. See
TIMING BELT under REMOVAL & INSTALLATION.
2. Drain engine oil. Remove oil dipstick and oil pan. Remove oil pump pick-up screen. Remove oil pump
assembly. Remove oil pump rotor plate.
3. Using felt pen, mark outer gear for reassembly reference. Remove inner and outer oil pump gears.
Remove plug, relief spring and relief valve. Drive out oil seal.
Installation
1. Drive in NEW oil seal. Ensure gears are assembled in same direction as originally installed. Apply thin
coat of engine oil to lip portion of oil seal and inside surfaces of oil pump case and plate. Install inner and
outer rotors.
2. Install gear plate. Tighten 5 screws. Install 2 oil pump pins, NEW dipstick "O" ring, NEW seal for oil
pick-up tube and NEW oil pump gasket. Use Oil Seal Guide (09926-18210) to prevent damage to oil seal
during installation of oil pump. See Fig. 4 .
3. Apply engine oil to guide and install oil pump. Install dipstick guide with NEW seal. Install oil pan using
silicone-type sealant. To complete installation, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS .
Fig. 4: Installing Oil Seal Guide

TIMING BELT
Removal
1. Remove cooling fan and fan shroud. Discharge A/C system using approved refrigerant recovery/recycling
equipment and disconnect compressor flexible suction hose from suction pipe (if equipped). Remove A/C
compressor belt (if equipped).
2. Loosen alternator, and remove water pump pulley and belt.
3. Remove crankshaft pulley. Remove timing belt cover. Align all sprocket timing marks with timing marks
on engine. See Fig. 5 . Move up and secure timing belt tensioner.
4. If timing belt is to be reused, mark belt with an arrow indicating direction of rotation. Remove timing belt
from camshaft and crankshaft sprockets.
CAUTION: With timing belt removed, DO NOT turn camshaft sprocket more than 20
degrees in either direction from aligned position. DO NOT turn crankshaft
more than 90 degrees in either direction from aligned position. Doing so
could damage piston(s) and/or valve(s) by interference. Also, DO NOT
bend timing belt.
Installation
1. Loosen all valve adjusting screws fully before installing timing belt. Allow camshaft to rotate freely
during belt tension adjustment. Align timing mark on camshaft sprocket with "V" mark on timing belt
inner cover. See Fig. 5 .
2. Turn crankshaft clockwise until punch mark on crankshaft sprocket is aligned with arrow mark on oil
pump. With timing marks aligned, install timing belt. Ensure direction arrow mark on timing belt is
pointed in direction of crankshaft rotation. Ensure drive side of belt is free of slack.
3. Move tensioner plate up with finger pressure, and loosely secure tensioner bolt. Turn crankshaft 2
revolutions clockwise to remove all slack from belt. Tighten tensioner nut and then tensioner bolt. See
TORQUE SPECIFICATIONS .
4. Ensure timing marks are aligned. Install timing belt outer cover and tighten to specification. See
TORQUE SPECIFICATIONS . Reverse removal procedure to complete installation. Adjust valve
clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.
Fig. 5: Aligning Timing Belt & Tensioner (Typical SOHC)

Removal
1. Remove negative battery cable. Remove air cleaner and airflow meter assembly. Raise vehicle and
remove right fender apron extension by pushing center pin into clip. DO NOT push in too far, as pin may
fall into fender. Remove water pump pulley and belt.
2. Remove crankshaft pulley 5-mm hexagon bolts. If engine is in vehicle, remove crankshaft pulley center
bolt. Remove crankshaft pulley. Loosen right engine mount bolt, and push air cleaner bracket aside.
Remove timing belt covers.
3. Align all sprocket timing marks with timing marks on engine. See Fig. 6 . Move timing belt tensioner up
and secure. Mark timing belt for direction of rotation if it is to be reused. Remove timing belt from
sprockets.
Installation
1. Align timing marks. Bolts with flanged nuts may be wedged between cam sprocket teeth to hold camshaft
on timing mark during belt installation (if necessary).
CAUTION: While aligning timing marks, DO NOT turn camshaft sprockets more
than 20 degrees in either direction from aligned position. DO NOT
turn crankshaft more than 90 degrees in either direction from aligned
position.
2. Install timing belt so no slack exists on drive side of belt. Adjust tensioner to remove timing belt slack
from other side of belt, and hand tighten tensioner bolt and nut. Turn crankshaft 2 revolutions to seat
timing belt, and readjust tensioner.
3. Tighten tensioner bolt and nut. Ensure drive side of belt is free of slack. Ensure timing marks are aligned.
Install timing belt outer covers and tighten to specification. See TORQUE SPECIFICATIONS . To
complete installation, reverse removal procedure. Tighten bolts to specification.
ROCKER ARM & VALVE LASH ADJUSTER
Removal
1. Remove cylinder head valve cover. Remove distributor and distributor case.
2. Loosen all valve adjustment lock nuts and valve adjusting screws. Leave screws in place. Remove 10
rocker arm shaft retaining screws. Slide rocker arm shaft(s) out of rear side of head assembly. Remove
rocker arms and springs.
Installation
1. To install, reverse removal procedure. Intake rocker shaft has a .55" (14 mm) stepped end. Exhaust rocker
shaft has a .59" (15 mm) stepped end. Ensure intake rocker shaft stepped end faces front of engine and
exhaust rocker shaft stepped end faces rear of engine. Adjust valve clearance. See VALVE
CLEARANCE ADJUSTMENT under ADJUSTMENTS.
CAMSHAFT
NOTE: Cylinder head removal is necessary to obtain enough clearance for camshaft
removal.
Removal
1. Remove cylinder head. See CYLINDER HEAD under REMOVAL & INSTALLATION. Remove
rocker arms and shafts. See ROCKER ARM & VALVE LASH ADJUSTER under REMOVAL &
INSTALLATION.
2. Use .35" (9 mm) rod to lock camshaft. See Fig. 6 . Remove camshaft sprocket. Remove camshaft from
rear of head. Remove oil seal.
Fig. 6: Locking Camshaft For Timing Belt Sprocket Removal

Inspection
1. Check cam lobes and journals for wear and damage. Use Plastigage to check bearing clearance. If wear
exceeds specification, repair or replace as necessary. See CAMSHAFT under ENGINE
SPECIFICATIONS.
2. Use dial indicator and "V" blocks to measure camshaft runout at center of shaft. If wear exceeds
specification, repair or replace as necessary. See CAMSHAFT .
Installation
1. Lubricate camshaft lobes and camshaft bearing journals. Install camshaft and NEW oil seal in cylinder
head.
2. Install camshaft sprocket. Ensure camshaft sprocket timing marks align with timing marks on cylinder
head. To complete installation, reverse removal procedure.
REAR CRANKSHAFT OIL SEAL
Removal
Remove engine or engine and transmission. See ENGINE under REMOVAL & INSTALLATION. Separate
transmission from engine. Remove flywheel. Remove oil seal housing. Remove seal. Inspect oil seal housing
for wear or damage. Repair or replace as necessary. See Fig. 7 .
Installation
Install oil seal in housing. Apply oil to seal lip. Install oil seal housing with NEW gasket. Tighten housing bolts
to specification. See TORQUE SPECIFICATIONS . Oil seal housing gasket will bulge after mounting bolts
have been tightened. Trim excess gasket material even with oil pan gasket surface.
Fig. 7: Identifying Rear Crankshaft Oil Seal & Housing

WATER PUMP
Removal
1. Drain cooling system. Disconnect negative battery cable. Remove drive belts. Discharge A/C system
using approved refrigerant recovery/recycling equipment and disconnect compressor flexible suction hose
from suction pipe (if equipped). Remove cooling fan, fan shroud and fan clutch.
2. Remove pump pulley. Ensure No. 1 piston is at TDC of compression stroke. Remove crankshaft pulley
bolts and crankshaft pulley. Remove timing belt cover, tensioner and timing belt. See TIMING BELT
under REMOVAL & INSTALLATION. Remove dipstick and tube. Remove alternator mounting bracket.
Remove water pump.
Installation
To install, reverse removal procedure. Ensure all mating surfaces are clean. Use NEW water pump gasket and
NEW dipstick tube "O" ring.
NOTE: For further information on cooling systems, see appropriate COOLING SYSTEM
SPECIFICATIONS article in ENGINE COOLING.
OIL PAN
Removal
1. Raise and support vehicle. Remove front differential assembly. See article in DRIVE AXLES - FRONT
& REAR . Drain engine oil.
2. Remove clutch housing lower cover or torque convertor housing lower cover. Remove oil pan nuts and
bolts. Remove oil pan then oil pump strainer.
Installation
To install, reverse removal procedure. Install oil pan using silicone-type sealant. Tighten bolts to specification.
See TORQUE SPECIFICATIONS .
OVERHAUL
CYLINDER HEAD
Cylinder Head Disassembly
1. Remove cylinder head. See CYLINDER HEAD under REMOVAL & INSTALLATION. Remove
manifolds and distributor assembly. Remove rocker arms and shafts. Remove camshaft. See
CAMSHAFT under REMOVAL & INSTALLATION.
2. Use a Valve Spring Compressor (09916-14510) and Valve Lifter Attachment (09916-48210) to remove
retainer locks. See Fig. 8 . Remove retainers, springs, spring seats and valves. Keep all components in
order for reassembly reference.
Cylinder Head Reassembly
To assemble, reverse disassembly procedure. Ensure valve springs are installed with close coiled (small pitch)
end down, toward cylinder head.
Fig. 8: Removing Valve Lock (SOHC Is Similar)

Valve Springs
Check valve springs for damage. Use a square and flat surface plate to check spring squareness. Maximum out-
of-square is .079" (2.00 mm). Using valve spring tester, check valve spring preload pressure. See VALVES &
VALVE SPRINGS under ENGINE SPECIFICATIONS. Replace any weak or out of square springs.
NOTE: DO NOT reuse old valve stem oil seals
Valve Stem Oil Seals
Place NEW lubricated stem seal on valve guide. Use Valve Stem Seal Installer (09917-98210 on 8-valve
SOHC). Press seal on valve guide using hand pressure only. When installer bottoms on head, seal is properly
positioned. Avoid twisting seals during installation.
Valve Guides
1. Check valve stem-to-guide clearance. If clearance exceeds specification, replace with oversize valve
guide. See CYLINDER HEAD under ENGINE SPECIFICATIONS.

2. Ream guide bore in cylinder head with 12-mm Reamer (09916-37310) for 8-valve SOHC engines. Heat
cylinder head to 176-212°F (80-100°C).
3. Using Valve Guide Installer Attachment (09917-88210 for 8-valve SOHC), drive in new oversized valve
guide until valve guide installer contacts cylinder head.
4. Valve guide protrusion is .55" (14.0 mm) for 8-valve SOHC. Ream valve guide with 7-mm Reamer
(09916-34520) for 8-valve SOHC.
5. Clean valve guide bore after reaming. Install valve and ensure valve stem oil clearance is correct. See
CYLINDER HEAD .
Valve Seat
1. Inspect valve seats for damage or wear. If exhaust valve seat rework is necessary, use 3 cutters to obtain
required angles. The first cut should be 15 degrees. Second cut should be 75 degrees. Third cut should be
45 degrees to obtain correct seat angle.
2. For intake valves, procedure is the same, except second cut should be 60 degrees. After cutting valve
seats to correct angles, lap valve seat.
Valves
1. Remove carbon deposits. Inspect for wear, burns or distortion at face and stem. Replace as necessary.
Measure valve head margin. Check valve stem end for pitting or wear.
2. Measure valve length. Valve stem end may be resurfaced if no more than .14" (3.6 mm) is removed from
valve length. See VALVES & VALVE SPRINGS under ENGINE SPECIFICATIONS. Using "V" block
and dial gauge, check valve head radial runout. Maximum limit is .003 (.08 mm). If runout exceeds limit,
replace valve.
Seat Correction Angles
On 8-valve SOHC exhaust valves, use 15-degree stone and 75-degree stone to narrow seat and 45-degree stone
to widen seat. On 8-valve SOHC intake valves, use 15-degree stone and 60-degree stone to narrow seat and 45-
degree stone to widen seat.
VALVE TRAIN
Rocker Arm Shaft Assembly
Check rocker arm-to-shaft oil clearance. Maximum clearance is .0035 (.09). Check rocker arm shaft runout.
Rocker arm shaft runout limit is .008" (.20 mm) on 16-valve SOHC or .004" (.10 mm) on all others.
Lash Adjusters
If tip of rocker arm adjusting screw is worn, replace screw. If cam riding face of rocker arm is badly worn,
replace rocker arm.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
1. Remove cylinder head. See CYLINDER HEAD under REMOVAL & INSTALLATION. Remove oil
dipstick guide, oil pan and screen. See OIL PAN under REMOVAL & INSTALLATION.
2. Ensure pistons, connecting rods and rod caps are marked for reassembly reference. Remove carbon from
top of cylinder bores. Remove connecting rod caps. Install protective hose over connecting rod bolts.
3. Remove connecting rod and piston assembly through top of cylinder block. Mark cylinder number on
piston crown. Remove piston rings.
4. Use Piston Pin Remover/Installer (09910-38211) on 1.3L SOHC engines.
5. Check piston pin-to-bore fit. Pin should press in piston smoothly by hand at room temperature. When
assembling, apply engine oil to outside of pin and to piston pin bore.
6. Position piston upward. Align piston, pin and rod with Piston Pin Remover/Installer (09910-38211) for
1.3L SOHC. Press pin into piston and rod using a hydraulic press. See Fig. 9 .
Fig. 9: Installing Piston Pin (1.3L SOHC)

Fitting Pistons
1. Check cylinder bore for damage, wear and taper. See CYLINDER BLOCK under CYLINDER BLOCK
ASSEMBLY under OVERHAUL. See CYLINDER BLOCK under ENGINE SPECIFICATIONS to
determine if block must be rebored.
2. Pistons are available in .0098" (.25 mm) and .0197" (.50 mm) oversizes. Check outside diameter of
piston. On 1.6L engine, measure at a point .63" (16.0 mm) from bottom of skirt and at 90 degrees to pin
bore. On 1.3L engine, measure at a point .59" (15.0 mm) from bottom of skirt and at 90 degrees to pin
bore.
3. Standard pistons are available in 2 sizes. Piston diameter is determined by numerical mark ("1" or "2")
stamped on piston crown. See Fig. 10 .
4. Cylinder bore diameter is determined by numerical mark ("1" or "2") stamped on cylinder block.
Numerical marks on cylinder block, read left to right, indicate bore sizes of cylinders No. 1, 2, 3 and 4,
respectively. See Fig. 10 .
5. When installing piston into cylinder, ensure piston numerical mark matches cylinder bore numerical mark
to provide correct piston-to-cylinder clearance.
Fig. 10: Matching Pistons To Cylinders

Piston Rings
1. Install rings with "R", "RN" or "T" mark facing upward. Some Samurai top rings are unmarked and can
be installed either side upward. Install oil ring spacer first, then rails. Position piston ring gaps. See Fig.
11 . Lubricate all internal surfaces with engine oil before installation.
2. Ensure arrow on piston head faces front of engine. Ensure oil hole in connecting rod faces intake side of
engine. Install cylinder head, oil pick-up screen and oil pan. To complete installation, reverse removal
procedure.
CAUTION: Install spacer gap more than 45 degrees from side rail gaps. Rails should
turn smoothly when installed.
Fig. 11: Positioning Piston Ring Gaps

Rod Bearings
1. Inspect journals for wear, taper and out-of-round. If specifications are exceeded, grind journals to
undersize or replace crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
under ENGINE SPECIFICATIONS.
2. Inspect bearing shells for signs of fusion, pitting, burning or flaking. Observe contact pattern. Standard
bearings are unmarked. Undersized bearings are stamped US025 on back of bearing to indicate .010" (.25
mm) undersize.
3. Check bearing clearance using Plastigage measuring method. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS . Standard connecting rod side play is .0039-.0078" (.10-.20mm),
with a service limit of .0138" (.35 mm).
4. To install, reverse removal procedure. Tighten rod nuts to specification. See TORQUE
SPECIFICATIONS .
Crankshaft & Main Bearings
1. Remove engine, or engine and transmission. See ENGINE under REMOVAL & INSTALLATION.
Separate transmission from engine. Remove timing belt, sprockets, pulley and tensioner. See TIMING
BELT under REMOVAL & INSTALLATION.
2. Remove flywheel and oil pan. Remove rear main oil seal housing. Remove connecting rod caps. Remove
main bearing caps. Remove crankshaft.
3. Inspect journals for wear, taper and out-of-round condition. If specifications are exceeded, grind journals
to undersize or replace crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
4. Standard main bearings are color-coded. Upper half of bearing has an oil groove. An arrow mark and
number are embossed on each main bearing cap.
5. Ensure arrow mark on main bearing cap faces toward crankshaft pulley. Bearing No. 1 is at crankshaft
pulley end of engine. Bearing No. 5 is at flywheel end of engine.
6. Main bearing journal diameter is determined by numerical mark ("1", "2" or "3") stamped on crankshaft
webs of cylinders No. 2 and 3. See Fig. 12 .
7. The numerical marks on crankshaft web, read left to right, indicate journal diameters of bearings No. 1, 2,
3, 4 and 5, respectively.
8. Determine bearing cap bore diameter with bearing removed. Bearing cap bore diameter is determined by
letter ("A", "B" or "C") stamped on cylinder block mating surface. See BEARING CAP BORE
DIAMETERS .
9. The letters stamped on cylinder block mating surface, read left to right, indicate cap bore diameters of
bearing caps No. 1, 2, 3, 4 and 5, respectively. Five standard main bearing sizes are available. Bearing
thickness is determined by color code. See COLOR CODE FOR STANDARD BEARINGS .
10. Use numerical marks on crankshaft webs and letters stamped on cylinder block mating surface to
determine correct replacement bearing. See STANDARD BEARING APPLICATION .
Fig. 12: Locating Numerical Marks On Crankshaft Webs

CRANKSHAFT JOURNAL DIAMETERS

Numbers Stamped On Webs In. (mm)
"1" 1.7714-1.7716 (44.994-45.000)
"2" 1.7712-1.7714 (44.988-44.994)
"3" 1.7710-1.7712 (44.982-44.988)
Fig. 13: Locating Letters Stamped On Cylinder Block

BEARING CAP BORE DIAMETERS

Letters Stamped On Block In. (mm)
"A" 1.9292-1.9294 (49.000-49.006)
"B" 1.9294-1.9296 (49.006-49.012)
"C" 1.9296-1.9298 (49.012-49.018)
COLOR CODE FOR STANDARD BEARINGS

Color Painted Thickness - In. (mm)
Green .0786-.0787 (1.996-2.000)
Black .0787-.0788 (1.999-2.003)
No Paint .0788-.0789 (2.002-2.006)
Yellow .0789-.0790 (2.005-2.009)
Blue .0790-.0791 (2.008-2.012)
STANDARD BEARING APPLICATION

Number Stamped On
Letter Stamped On Block Crankshaft Webs Color

"A" "1" Green
"A" "2" Black
"A" "3" No Paint
"B" "1" Black
"B" "2" No Paint
"B" "3" Yellow
"C" "1" No Paint
"C" "2" Yellow
"C" "3" Blue
Undersize Bearings
1. Bearings are available in .010" (.25 mm) undersize. Undersize bearing thickness is determined by 2 color
marks. See Fig. 14 . See COLOR CODE FOR UNDERSIZE BEARINGS .
2. Use journal finished diameters, 1.7611-1.7618" (44.732-44.750 mm), and letters stamped on cylinder
block mating surface to determine correct undersize bearing for replacement. See appropriate
UNDERSIZE BEARING APPLICATION .
3. Use Plastigage method to ensure correct clearance of installed undersize bearing. Lubricate bearings
before installing. Tighten bolts to specification in 3 steps. Tighten main bearing caps in following order:
center cap, No. 2 cap, No. 4 cap, front cap and rear cap. See TORQUE SPECIFICATIONS .
Fig. 14: Identifying Undersize Main Bearing Color Marks

COLOR CODE FOR UNDERSIZE BEARINGS

Color Painted Thickness - In. (mm)
Green & Red .0835-.0836 (2.121-2.125)
Black & Red .0836-.0837 (2.124-2.128)
Red Only .0837-.0838 (2.127-2.131)
Yellow & Red .0838-.0839 (2.130-2.134)

Blue & Red .0839-.0840 (2.133-2.137)
UNDERSIZE BEARING APPLICATION

Measured Journal Diameter -
In. (mm) Letter Stamped On Block Color
1.7616-1.7618 (44.744-44.750) "A" Green & Red
1.7616-1.7618 (44.744-44.750) "B" Black & Red
1.7616-1.7618 (44.744-44.750) "C" Red Only
1.7614-1.7616 (44.738-44.744) "A" Black & Red
1.7614-1.7616 (44.738-44.744) "B" Red Only
1.7614-1.7616 (44.738-44.744) "C" Yellow & Red
1.7612-1.7614 (44.732-44.738) "A" Red Only
1.7612-1.7614 (44.732-44.738) "B" Yellow & Red
1.7612-1.7614 (44.732-44.738) "C" Blue & Red
Thrust Bearing
1. With crankshaft bearing caps installed, check thrust clearance (end play) using dial gauge to read
displacement in axial thrust direction of crankshaft.
2. Standard thickness of thrust bearing is .0984" (2.50 mm). Oversize thrust bearings are available in
increments of .0049" (.125 mm). If clearance exceeds specification, replace thrust bearing. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS under ENGINE SPECIFICATIONS.
Cylinder Block
1. Inspect block for distortion of deck surface. Warpage limit is .0012-.0024" (.03-.06 mm). Inspect block
for cracks, scratches and other defects. Measure bores at 3 levels for wear, taper and out-of-round
condition.
2. If bore wear, taper or out-of-round exceed specification, rebore cylinders. See CYLINDER BLOCK
ENGINE OILING
ENGINE LUBRICATION SYSTEM
A force-feed type lubrication system is used. The oil pump is a trochoid-type pump mounted on the forward
portion of the crankshaft. See Fig. 15 .
Fig. 15: Cross-Sectional View Of Engine Oil Circuit (Typical)

Crankcase Capacity
Crankcase capacity, including filter, is 3.7 qts. (3.5L). Check dipstick to verify oil level is correct.
Oil Pressure
Normal oil pressure is 42.7-59.7 psi (3.0-4.2 kg/cm2 ) at 3000 RPM.
OIL PUMP
Removal & Disassembly
1. Disconnect negative battery cable. Remove radiator cooling fan, shroud, water pump pulley and drive
belt. Remove timing belt cover, timing belt and tensioner. See TIMING BELT under REMOVAL &
INSTALLATION. Remove alternator and bracket and air conditioner compressor bracket bolts (if
equipped).
2. Raise vehicle and drain engine oil and front differential oil (if equipped). Remove oil dipstick and oil pan.
Remove oil pump pick-up screen. Lock crankshaft with Gear Stopper (09927-56010) installed at flywheel
ring gear. With crankshaft locked, remove timing belt pulley. Remove oil pan and oil pump
strainer/pickup. Remove oil pump assembly. Remove dip stick guide. Remove oil pump rotor plate.
3. Mark outer gear with felt pen for reassembly reference. Remove inner and outer oil pump gears. Remove
plug, relief spring and relief valve.
Inspection
1. Inspect oil pump housing for cracks or damage. Inspect oil screen for clogging or damage. Inspect oil
screen "O" ring. Ensure relief valve slides smoothly in bore. Inspect pressure relief spring for damaged
coils.
2. Inspect oil pump gears for wear or damage. Using a feeler gauge, measure radial and side clearance. See
Fig. 16 and Fig. 17 . If clearance exceeds specification, replace outer rotor or case. See OIL PUMP
SPECIFICATIONS table.
OIL PUMP SPECIFICATIONS

Application Radial Clearance: In. (mm) Side Clearance: In. (mm)
Samurai .0122 (.310) .0059 (.150)
Reassembly & Installation
1. Ensure gears are assembled in same direction as originally installed. Apply thin coat of engine oil to inner
and outer rotors, lip portion of oil seal and inside surfaces of oil pump case and plate. Install inner and
outer rotors.
2. Install gear plate. Ensure gears turn freely by hand after gear plate is installed. Install oil pump pins,
NEW dipstick "O" ring, NEW seal for oil pick-up tube and NEW oil pump gasket. Use Oil Seal Guide
(09926-18210) to prevent damage to oil seal during installation of oil pump.
3. Apply engine oil to guide, and install pump. Install dipstick guide with NEW seal. Install oil pan using
silicone-type sealant. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
Fig. 16: Checking Oil Pump Radial Clearance

Fig. 17: Checking Oil Pump Side Clearance

ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
Displacement 79.2 Cu. In. (1.3L)
Bore 2.91" (74.0 mm)
Stroke 2.97" (75.5 mm)
Compression Ratio 9.5:1
Compression Pressure (1)
Standard 199 psi (14 kg/cm2 )
Service Limit 171 psi (12 kg/cm2 )
Maximum Variation 14 psi (1 kg/cm2 )
Fuel System TBI
Horsepower HP @ RPM 66 @ 6000
Torque Ft. Lbs. @ RPM 76 @ 3500
Compression Ratio 8.9:1
Compression Pressure (1)
Standard 199 psi (14 kg/cm2 )
Limit 171 psi (12 kg/cm2 )
Maximum Variation 14.2 psi (1.0 kg/cm2 )

Fuel System TBI
Horsepower HP @ RPM 80 @ 5400
Torque Ft. Lbs. @ RPM 94 @ 3000
(1) Checked at 250 RPM or higher.
CONNECTING RODS
CONNECTING RODS
Pin Bore (1)
Maximum Bend .0020 (.05)

Maximum Twist .0039 (.10)
Side Play
Standard .0039-.0078 (.10-.20)
Service Limit .0138 (.35)
(1) Information is not available.
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Crankshaft
End Play
Standard .004-.012 (.11-.31)
Runout Limit .002 (.06)
Main Bearings
Journal Diameter (1)
"1" 1.7714-1.7716 (44.994-45.000)
"2" 1.7712-1.7714 (44.988-44.994)
"3" 1.7710-1.7712 (44.982-44.988)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance
Standard .0008-.0016 (.020-.040)
Main Bearing Cap Bore Diameters (2)
"A" 1.9292-1.9294 (49.000-49.006)
"B" 1.9294-1.9296 (49.006-49.012)
"C" 1.9296-1.9298 (49.012-49.018)

Connecting Rod Bearings
Journal Diameter 1.6529-1.6535 (41.982-42.000)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance
Standard .0012-.0020 (.030-.050)
(1) Main bearing journal diameter is determined by numerical mark ("1", "2" or "3") stamped on
crankshaft web.
(2) Main bearing cap bore diameter is determined by letter ("A", "B" or "C") stamped on cylinder block
mating surface. See Fig. 13 .
PISTONS, PINS & RINGS
PISTONS, PINS & RINGS

Pistons
Clearance .0008-.0016 (.02-.04)
Diameter (1)
"1" 2.9126-2.9130 (73.980-73.990)
"2" 2.9122-2.9126 (73.970-73.980)
Pins
Diameter (2)
Piston Fit Slip

Rod Fit Interference
Rings
No. 1
End Gap
Standard .0079-.0118 (.20-.30)
Side Clearance .0012-.0027 (.030-.070)
No. 2
End Gap
Standard .0079-.0118 (.20-.30)
Side Clearance .0008-.0024 (.02-.06)
No. 3 (Oil)
End Gap
Standard .0079-.0276 (.20-.70)
Service Limit .0709 (1.8)
(1) Piston diameter is determined by numerical mark ("1" or "2") stamped on piston. See Fig. 10 .
(2) Information is not available.
VALVES & VALVE SPRINGS
VALVES & VALVE SPRINGS

Intake Valves
Seat Angle 45°
Valve Head Thickness
Standard .039" (1.0 mm)
Service Limit .024" (.6 mm)
Stem Diameter .2742-.2748" (6.965-6.980
mm)
Valve Tip Maximum Refinish .0197" (.5 mm)
Maximum Head Radial Runout .003" (.08 mm)
Exhaust Valves
Seat Angle 45°
Valve Head Thickness
Standard .039" (1.0 mm)
Stem Diameter .2736-.2742" (6.950-6.964
mm)
Valve Tip Maximum Refinish .0197" (.5 mm)
Maximum Head Radial Runout .003" (.08 mm)
Valve Springs
Free Length
Standard 1.9409" (49.30 mm)
Out-Of-Square .079" (2.0 mm)
Lbs. @ In. (kg @ mm)
Valve Spring Preload
Standard 54.7-64.3 @ 1.63 (24.8-
29.2 @ 41.5)
Service Limit 50.2 @ 1.63 (22.8 @
41.5)
CYLINDER BLOCK
CYLINDER BLOCK
Cylinder Bore
Standard Diameter (1)

"1" 2.9138-2.9142 (74.010-
74.020)
"2" 2.9134-2.9138 (74.000-
74.010)
Maximum Taper .0039 (.10)
Maximum Out-Of-Round .0039 (.10)
Maximum Deck Warpage .002 (.05)
(1) Cylinder bore diameter is determined by numerical mark ("1" or "2") stamped on cylinder block. See
Fig. 10 .
CYLINDER HEAD
CYLINDER HEAD
Maximum Warpage
Head-To-Block .002" (.05 mm)
Manifold-To-Head .004" (.10 mm)
Valve Seats
Intake & Exhaust Valves
Seat Angle 45°
Seat Width .0512-.0591" (1.3-1.5 mm)
Valve Guides
Valve Stem End Deflection Limit
Intake .006" (.14 mm)
Exhaust .007" (.18 mm)
Intake Valve
Valve Guide I.D. .2756-.2762" (7.000-7.015 mm)
Valve Guide Installed Height .55" (14.0 mm)
Valve Stem-To-Guide
Oil Clearance .0008-.0019" (.020-.050 mm)
Exhaust Valve
Valve Guide I.D. .2756-.2762" (7.000-7.015 mm)
Valve Guide Installed Height .55" (14.0 mm)
Valve Stem-To-Guide Oil Clearance .0014-.0026" (.035-.065 mm)
CAMSHAFT
CAMSHAFT
Bore Diameter (1)
No. 1 1.7402-1.7408 (44.200-44.216)

No. 2 1.7480-1.7487 (44.400-44.416)
No. 3 1.7560-1.7565 (44.600-44.616)
No. 4 1.7638-1.7644 (44.800-44.816)
No. 5 1.7717-1.7723 (45.000-45.016)
Journal Diameter (1)
No. 1 1.7372-1.7382 (44.125-44.150)
No. 2 1.7451-1.7461 (44.325-44.350)
No. 3 1.7530-1.7539 (44.525-44.550)
No. 4 1.7608-1.7618 (44.725-44.750)
No. 5 1.7687-1.7697 (44.925-44.950)
Journal Runout .0039 (.10)
Lobe Height
Standard 1.4764 (37.500)
Service Limit 1.4724 (37.400)
Oil Clearance
8-Valve Standard .0020-.0036 (.050-.091)
8-Valve Service Limit .0059 (.15)
(1) Journals are numbered from front of engine.
ROCKER ARM & ROCKER ARM SHAFT
ROCKER ARM & ROCKER ARM SHAFT

Rocker Arm Inside Diameter .6293-.6301 (15.985-
16.005)
Rocker Arm Shaft Outside Diameter .6287-.6293 (15.969-
15.984)
Rocker Arm-To-Shaft Oil Clearance
Standard .0005-.0018 (.012-
.045)
Rocker Arm Shaft Runout .005 (.12)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Alternator Mount & Adjusting Bolts 13-21 (18-28)
Alternator Pulley Bolt 37-48 (50-65)
Camshaft Sprocket Bolt 41-47 (56-64)
Connecting Rod Cap Nut 24-27 (33-37)

Crankshaft Main Bearing Cap Bolt 37-42 (50-57)
Crankshaft Sprocket Bolt 77-85 (105-115)
Cylinder Head Bolt (1) 52-55 (70-75)
Engine-To-Transmission Bolt 16-26 (22-35)
Exhaust Manifold Bolt 13-21 (18-28)
Exhaust Pipe 26-36 (35-49)
Flywheel Bolt (Drive Plate For A/T) 42-48 (57-65)
Intake Manifold Bolt 13-21 (18-28)
Oil Pan Drain Plug 22-30 (30-40)
Oil Filter Mount 15-18 (20-25)
Rocker Arm Adjustent Lock Nut 11-14 (15-19)
Spark Plug 15-22 (20-30)
Timing Belt Tensioner Bolt 18-22 (24-30)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt 80-106 (9-12)
Cooling Fan Nut 71-106 (8-12)
Crankshaft Pulley Bolt 80-106 (9-12)
Distributor Case Bolt 71-106 (8-12)
Oil Pan Bolt 80-106 (9-12)
Oil Pressure Switch 106-133 (12-15)
Oil Pump Mounting Bolt 80-106 (9-12)
Oil Pump Rotor Plate Screw 80-106 (9-12)
Oil Pump Strainer Bolt 80-106 (9-12)
Oil Seal Housing Bolt 80-106 (9-12)
Rear Main Seal Bolt 89-115 (10-13)
Rocker Arm Shaft Screw 80-106 (9-12)
Rocker Cover Bolt 35-44 (4-5)
Timing Belt Outer Cover Bolt 80-106 (9-12)
Timing Belt Tensioner Stud Nut 80-106 (9-12)
Water Pump Mounting Bolt 80-106 (9-12)
Water Pump Pulley Bolt 89-115 (10-13)
(1) Tighten in sequence. See Fig. 5 or Fig. 6 .

Samuray 1994 1.3L

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Samuray 1994 1.3L

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1994 Suzuki Samurai JL

1.3L 4-CYL - VIN [3] 1994 SUZUKI ENGINES 1.3L 4-Cylinder

1.3L 4-CYL - VIN [3]

1994 SUZUKI ENGINES 1.3L 4-Cylinder

ENGINE IDENTIFICATION CODE

VALVE CLEARANCE SPECIFICATIONS

REMOVAL & INSTALLATION

jueves, 25 de febrero de 2021 12:07:16

FUEL PRESSURE RELEASE

Fig. 1: Locating Fuel Pump Relay

CAUTION: When raising or supporting engine or automatic transmission for any

NOTE: Remove engine and transmission as an assembly.

Fig. 2: Cylinder Head Bolt Tightening Sequence (Except 1.6L 16-Valve)

Fig. 3: Cylinder Head Bolt Tightening Sequence (1.6L 16-Valve)

FRONT COVER OIL SEAL

Fig. 4: Installing Oil Seal Guide

Fig. 5: Aligning Timing Belt & Tensioner (Typical SOHC)

ROCKER ARM & VALVE LASH ADJUSTER

Fig. 6: Locking Camshaft For Timing Belt Sprocket Removal

REAR CRANKSHAFT OIL SEAL

Fig. 7: Identifying Rear Crankshaft Oil Seal & Housing

Cylinder Head Disassembly

Cylinder Head Reassembly

Fig. 8: Removing Valve Lock (SOHC Is Similar)

NOTE: DO NOT reuse old valve stem oil seals

Valve Stem Oil Seals

guide. See CYLINDER HEAD under ENGINE SPECIFICATIONS.

Seat Correction Angles

Rocker Arm Shaft Assembly

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

Fig. 9: Installing Piston Pin (1.3L SOHC)

Fig. 10: Matching Pistons To Cylinders

Fig. 11: Positioning Piston Ring Gaps

Crankshaft & Main Bearings

Fig. 12: Locating Numerical Marks On Crankshaft Webs

CRANKSHAFT JOURNAL DIAMETERS

Fig. 13: Locating Letters Stamped On Cylinder Block

BEARING CAP BORE DIAMETERS

COLOR CODE FOR STANDARD BEARINGS

STANDARD BEARING APPLICATION

Letter Stamped On Block Crankshaft Webs Color

Fig. 14: Identifying Undersize Main Bearing Color Marks

COLOR CODE FOR UNDERSIZE BEARINGS

Yellow & Red .0838-.0839 (2.130-2.134)

UNDERSIZE BEARING APPLICATION

Fig. 15: Cross-Sectional View Of Engine Oil Circuit (Typical)

Normal oil pressure is 42.7-59.7 psi (3.0-4.2 kg/cm2 ) at 3000 RPM.

Removal & Disassembly

OIL PUMP SPECIFICATIONS

Reassembly & Installation

Fig. 16: Checking Oil Pump Radial Clearance

Fig. 17: Checking Oil Pump Side Clearance

Maximum Variation 14.2 psi (1.0 kg/cm2 )

Maximum Bend .0020 (.05)

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

"C" 1.9296-1.9298 (49.012-49.018)

PISTONS, PINS & RINGS