1991 Suzuki Samurai JSFACTORY OEM SERVICE PROCEDURE

Samurai (Federal Models)

The CHECK ENGINE light will automatically flash at 50,000, 80,000 and 100,000 mile intervals. This is not an indication of a system failure; however, it indicates that system inspection and/or system component replacement is required. After necessary services have been performed, turn off CHECK ENGINE light by moving cancel switch to opposite position. Cancel switch is located below steering column lower trim panel.

  • At 50,000 Miles - Replace PCV valve and inspect EGR system.
  • At 80,000 Miles - Replace O2 sensor.
  • At 100,000 Miles - Replace PCV valve, O2 sensor and charcoal canister. Inspect catalytic converter for plugging, EGR system, ECM and related sensors.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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