Suzuki 4x4 - Tech: TSB Index for Samurai and Sierra - Trucks 4x4 @ Off-Road.com

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Suzuki 4x4 - Tech: TSB Index for Samurai and Sierra

Publish date: Nov 1, 2005
By: ORC STAFF
Source: Suzuki/Geo at Off-Road.com

People have asked for 'em, and we've managed to get them all assembled in one place. Here's a comprehensive index to Technical Service Bulletins issued for the Samurai. Note the following:

Bulletins addressing a similar topic and occurring under a common number have been combined into one line item. The notes will tell you the revision history.
Notes also indicate if the Bulletin addresses a specific model (2WD or 4WD) Samurai. The lack of any specific model indication means the bulletin applies to all models.
The Model Years column indicates what model years (not calendar years) the bulletin applies.
It appears that Suzuki may have issued some TSBs "across the board" regardless of whether there was specific applicability.
Many of the bulletins below appear to relate to dealer issues. In some cases it's been clear that they do and we've indicated such. In other places it's not clear, and we've left the bulletin entry intact.

You can get copies of bulletins from some Suzuki dealers, and also from Alldata. Corrections and updates to: Scott Gomez

Bulletin Number	Date	Title/Description	Model Years	Notes
805094	May-94	Paint Formula	1986-1994
010R	Mar-97	Air Bag System Enable/Disable Procedure	1995	Issued Jan 1995, revised Aug 1995
41505134C	May-94	Water Pipe and Hose Modification	1993-1994
ATRATB028	Oct-90	Engine Testing With A Vacuum Gauge - Auto Trans.	1986-1995
ATRATB078	Nov-91	How To Use A Pressure Gauge - Automatic Trans.	1986-1995
ATRATB8748	Aug-87	Metal Sealing Rings - Automatic Transmissions	1986-1995
ATRATB8754	Sep-87	All Automatics - Front Bushing Wear	1986-1995
ATRATB8923	Aug-89	Automatic Transmission Math Formulas	1986-1995
ATRATB8927	Sep-89	20 Steps To successful Auto Transmission Repair	1986-1995
ATRATB8930	Oct-89	Automatic Transmission Math Part 2	1986-1995
ATRATB9002006	Feb-90	Automatic Transmission Fluid	1986-1995
MEMO0289	Feb-89	Technical Service Bulletin System	1989
SA01	Jan-93	New Electrical Terminal Kit	1986-1993
SA01	Dec-92	Key Codes - Information	1986-1993
SA01	Jan-92	Training Schedule (January 1992 - March 1992)	1992
SA01	Nov-91	Security Alarm System	1992
SA01	May-91	ASMC Has A New Voicemail Access Number	1991
SA01	Mar-91	1986-90 TSB Package	1986-1990
SA01	Feb-90	Service Bulletin System Description	1986-1990
SA01	Feb-89	Service Manual Owner's Manual	1989
SA01	Jan-89	Customer Contacts (Complaints)	1989
SA01B	Sep-91	Information Materials	1992
SA02	Nov-92	Required Special Tools and Special Tool Panel	1993
SA02	Oct-91	1-800 ASMC's Technical Service Training	1991
SA02	Aug-91	Cartridge For the Tech 1 Scan Tool	1991-1992
SA02	Nov-90	Key Codes Information MEMO	1990-1991
SA02	Feb-89	Service Procedures Manual Update	1986-1989
SA03	Nov-91	Air-Conditioner Installation Manual	1990-1992
SA03	Oct-91	Sale of Emission Control Labels	1991-1992
SA03	Oct-88	Bridgestone Service Centers	1986-1989
SA04	Sep-91	Tool Boards Display	1991
SC01	May-89	Campaign Follow-Up List K2	1989-1990
SC01	Mar-89	Service Campaign No. K2 Exhaust Center Pipe 1986-87 Samurai	1986-1987
SC02	Nov-90	Catalytic Converter Service Campaign	1986-1987
SO0015	Nov-85	Service Bulletin System	1986
SO0035	Nov-85	Glove Box Materials	1986
SO0136	Nov-86	Winterization of Samurai Vehicles	1986
SO0167	Jul-87	Samurai Key Codes	1987
ST0025	Apr-86	Samurai Paint (Updated)	1986
ST0035	Nov-85	Canvas Top Operation	1986	2WD
ST0056	Jan-86	Incorrect Shift Point Listed In the 1986 Samurai Owner's Manual	1986
ST0066	Feb-86	Air Conditioner Installation Instructions	1986
ST0076	Jan-86	Engine Performance	1986
ST0086	Jan-86	Vehicle Stripe Tape	1986
ST0096	May-86	Cooling System and Radiator Cap Adapter Test Set	1986
ST0106	Mar-86	Special Automatic Locking Hub Installation Tool	1986
ST0126	May-86	Paint -- Roof Members	1986
ST0136	Jun-86	"Towing Your Vehicle" Instruction Change	1986
ST0146	Jun-86	Anniversary Issue Samurai Paint Code	1986
ST0156	Jun-86	Differential Bearing Preload Checking Tool	1986
ST0166	Aug-86	Exhaust Sulfur Odor Hesitation On Acceleration From A Stop	1986
ST0176	Aug-86	Cylinder Head Removal	1986
ST0186	Aug-86	Fuel and Temperature Meter Replacement	1986
ST0196	Sep-86	Sumurai Paint Codes	1986-1987
ST0207	Jan-87	Samurai Paint Code Identification Plate	1987
ST0217	May-87	Convertible Top Modification	1986-1987
ST022	Jun-87	Transfer Case Bind-Up	1987
ST023	Jun-87	Automatic Free-Wheeling Hubs - Towing	1987
ST0247	Aug-87	Transfer Case Shift Lever Hang Tag	1987
ST0258	Feb-88	Thermostat Selection	1988
ST0268	Feb-88	A/C Installation On A 1988-1/2 Samurai	1988
ST0278	Feb-88	Suzuki Special Tool - Duty Cycle Meter	1988
ST0298	Mar-88	Use of Gasoline/Alcohol-Blended Fuels Ethanol - Methanol - Mtbe	1988
ST0308	Apr-88	Hazard Fuse Placed In Ashtray	1988
ST0318	Apr-88	Air Conditioner Installation	1988
ST0328	Apr-88	Hesitation/Flat Spot In Any Gear	1986-1988
ST0338	Aug-88	Exhaust Restriction Diagnostic Procedure	1986-1988
ST0408	Sep-88	1989 Suzuki Paint Codes	1989
ST0438	Sep-88	Piston Ring Modification	1986-1989
ST0448	Sep-88	Modification of Free Wheel Hub Position (Manual Type)	1988-1989
ST0458	Sep-88	Modification of Rear Bearing	1986-1989
SW0025	Mar-86	Model Codes (Updated)	1986
SW01	Jan-92	Warranty Claims	1986-1991	Warranty topics for dealers. Probably no good owner info.
SW0106	Apr-86	Brake Squeaks	1986
SW0126	May-86	State Warranty Laws or Regulations	1986
SW0146	May-86	Radio Warranty Procedures	1986
SW0156	May-86	Vehicle Conversions	1986
SW02	Oct-91	Fluids and Lubricants, Claims	1991
SW02	Feb-90	Labor and Time For Pre-Delivery Insp.	1990
SW0236	Oct-86	Short Block Assembly Replacement/Labor Operation/Time	1986
SW0246	Oct-86	Convertible Top Replacements Time Allowance	1986
SW0266	Dec-86	Vehicle Inquiries - Scat System	1986
SW0277	Feb-87	Air Conditioners Compressor/Clutch Replacements	1987
SW0287	Feb-87	Model, Specification, and Color Codes 1986 & 1987 Vehicles	1987
SW0297	Feb-87	Engine/Carburetor Adjustments	1987
SW02R	Aug-91	Pdi Procedures and Inspection Form	1991
SW03	Nov-94	Warranty Procedures	1986-1995	Warranty topics for dealers. Probably no good owner info.
SW0307	Apr-87	Modification Kit For Removable Hardtop (# 99980-69410)	1987
SW0387	Jun-87	Clarion Radio Exchange Charge-Back for Cut Leads	1987
SW0397	Jun-87	Convertible Top Replacements	1987
SW04	Nov-90	Warranty Claim Info. For Cold Start Harness	1990
SW04	Feb-90	Scat System Vehicle Inquiries	1990
SW0417	Jul-87	Vehicle Alterations and Warranty	1987
SW0548	Jan-88	Procedures Manual Update Page 6	1988
SW0568	Feb-88	Pre-Delivery Inspection P.D.I. 1988-1/2 Samurai Models	1988
SW0578	Feb-88	Service Literature and Forms	1988
SW05888	Apr-88	Procedures Manual Update Pages 3 & 5	1988
SW0598	Apr-88	New Flat Rate Manual/Labor Operations	1986-1988
SW0628	May-88	Lost Keys - Transportation Damage	1988
SW0638	Jun-88	Multi-Claim Form Scat P.D.I. Submission	1988
SW0648	Jun-88	Complaint Code/Defect Code	1988
SW0668	Aug-88	Suzuki Parts or Accessory Warranties	1989
SW07	Feb-90	Problems During Claim Preparation or Submission	1986-1990
SW08	Feb-90	Fluids and Lubricants Warranty Part Number	1986-1990
SW09	Feb-90	Revision to Authorization Requirements and Procedures	1986-1990
SW10	Feb-90	Tire Warranties	1986-1990
TS001R	Mar-96	Authorized AC Refrigerant	1986-1995	Originally issued Jun 1991
TS002R	May-97	Tech 1-A Cartridges	1991-1995	Originally issued Feb 1995, updates to include Cartridge changes, ECM additions, Air Bag additions & replacement operator's manuals.
TS003	Oct-92	New Model Changes	1993
TS00404263	Sep-93	Cooling System Tester Adapter	1986-1993
TS004R	Dec-93	Cooling System Adapter	1993
TS006R	Nov-93	Bumper Painting Precautions	1986-1994
TS007	Nov-93	Stop Light Switch Modification	1993
TS008R	Jan-98	Underhood Primer Color Codes	1986-1995	Originally issued May 1994: revised Jun & Aug 1995; Mar, Jun & Jul 1996; Oct 1997 (proper primer [for] Red Pearl); Jan 1998 ([proper primer for] Atoll Blue & Light Grey)
TS009	Jun-94	Information Label	1994
TS010	Nov-94	Air Bag Disable Procedure	1995
TS011	May-95	A/C Compressors - Recommended Oil	1995
TS012R	Sep-95	Essential Special Tools	1990-1995
TS015	Dec-95	On-Board Diagnostics (OBDII)	1995
TS018	Aug-95	New Color Standard for Service Literature Cover	1986-1995
TS-019	Jan-98	Sealant and Threadlocker Cross-Reference Chart	1986-1995
TS102R	Feb-89	Convertible Top Replacement	1986-1987
TS103R	Feb-89	Paint and Rustproofing In Engine Compartment	1988-1989
TS10404053R	Sep-93	Samurai Paint Codes	1986-1993
TS104R	Oct-94	Paint Codes - Colors	1986-1995	Originally issued Jul 1990. Revised Aug 1991, Aug 1992, Apr 1993, Jul, Oct 1994
TS105	Sep-90	Additional Instructions For PDI	1991
TS106	Nov-90	Rattle From Hood Hinge	1986-1991
TS107	Jan-95	Anti-Corrosion Treatment Procedure	1986-1995
TS107R	Jul-94	Paint Codes 86-95	1986-1995
TS111	Jun-92	Slow Retraction of Automatic Seat Belts	1990-1992
TS201R	Feb-89	Gauge Service Procedures and Precautions	1986-1994
TS202R	Feb-89	Hazard Fuse In Ashtray At Delivery	1988-1994
TS203R	Feb-89	A/C Installation Kits	1986-1989
TS204R	Feb-89	Brake/Seat Belt Warning Lamp On	1986-1994
TS205R	Feb-89	Loss of Electrical Circuits / Burned Fuse Link	1986-1994
TS206B	Mar-90	A/C Installation, Manual Revision	1990
TS207	Nov-90	Two Causes of Engine Stalling	1986-1991
TS208	Dec-90	Battery Test	1986-1991
TS209	Dec-90	Battery Testing	1986-1991
TS211	Dec-90	Testing Batteries	1986-1991
TS301R	Feb-89	Shift Point Incorrect In Owners Manual	1986
TS302R	Feb-96	Transfer Case Binds - Procedure To Unbind	1986-1995	4WD
TS302R	Feb-89	Transfer Case Bind-Up	1986-1994
TS303R	Feb-89	Transfer Case Replacement	1986-1987
TS304R	Jul-89	Rear Axle Modification	1986-1994
TS305	Aug-90	Transfer Case and Shift Fork Modification	1988-1990
TS306	Aug-90	Transfer Case and Shift Lever Modification	1988-1990
TS307	Dec-90	Transmission/Transfer Case Squeal	1986-1991
TS308A	Nov-90	Differential Ring Gear Bolts Modified	1989-1991
TS309	Feb-91	Change In Pedal Feel After Replacing the Clutch	1990-1991
TS310	Jan-92	Modification of Drive Intermediate Shaft	1992
TS310	Aug-91	Modification of Differential Bevel Pinion and Flange	1991
TS311	Oct-91	Modification of 5TH Speed Synchronizer Keys	1991-1992
TS312	Dec-91	Modification of Speedometer Drive and Driven Gears	1992
TS313	Jan-93	Modification of Transfer Gear Shift Locating Parts	1993
TS314	Sep-94	Rear Differential Thrust Washer Modification	1994-1995
TS314R	Feb-93	Harsh Shifting - Modification of A/T Controller Revised	1992-1993
TS321	Dec-92	Gear Noise Reduction When In Reverse	1992-1993
TS401R	Feb-89	Poor Engine Performance At Approximately 2500 RPM	1986-1994
TS402	Mar-89	Camshaft and Rocker Modification	1989
TS403R	Feb-89	Cylinder Head Removal Precautions	1986-1994
TS404R	Feb-96	Spark Plug Use	1989-1993
TS404R	Oct-92	Modified Intake Manifold and Thermostat	1986-1992
TS404R	Feb-89	Thermostat Selection	1986-1994
TS405R	Feb-89	Fuel Recommendations	1986-1994
TS406R	Mar-89	Hesitation On Acceleration	1986-1988
TS407R	Feb-89	Restricted Exhaust Test	1986-1989
TS408	Feb-89	Oil Filter Recommendations	1986-1989
TS409R	Feb-89	Piston Ring Modification	1986-1989
TS410	Dec-89	Use of Gasoline Methyl Blended Fuels	1986-1990
TS411	Mar-90	Timing Belt Sprocket Modification	1986-1990
TS412	Oct-90	Muffler/Catalytic Converter Rattle/Vibration Noise	1986-1991
TS413A	Nov-90	Heat Shield Rattle	1986-1991
TS413R	Jul-92	Center Pipe Rear Heat Shield Rattle	1986-1992
TS413R	Feb-91	Loose Heat Shield Causes Vibration/Rattle Noise	1986-1991
TS414	Mar-94	Timing and Crank Pulley Modifications	1993-1994
TS415	Dec-91	Updated Idle Speed and Idle Speed Control (ISC) Duty	1992
TS416	Jun-92	TPS Specification Correction	1986-1992
TS501R	Jul-89	Towing With Automatic Free-Wheeling Hubs	1986-1990
TS502R	Feb-89	Freewheel Hub Position At Delivery	1989
TS503	Jul-93	Master Cylinder Modification	1993-1994
TS504	Mar-94	Caliper and Proportioning Valve Modifications	1994
TS601R	Feb-89	Duty Cycle Usage	1986-1989
TS602R	Feb-89	Auto-Locking Hub Tool	1989-1994
TS603R	Feb-89	Radiator Cap Adapter	1986-1994
TS604	Mar-90	Special Tools Listing	1986-1994
TS604B	Mar-90	Required Special Tools	1986-1990
TS605	Apr-91	Fuel Pressure Gauge Adapter	1990-1994
TS701R	Jan-96	List of Required Technical Service Literature	1986-1995	Originally issued Aug 1993 under title "Service Literature Availability". Revised Sep, Dec 1994
TS702	Jul-91	Speedometer Cable Service	1986-1992

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