SuzukiSamurai1991Overview/suzuki/samurai/1991/base/

1991 Suzuki Samurai

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 1991 Samurai.

Transmission Manual 5-spd

The 1991 Suzuki Samurai paired a 5-speed manual transmission with EPA fuel-economy ratings of 24 city, 26 highway, and 25 combined mpg, while its engine oil specification listed a 3.9-quart capacity and viscosity grades of 20W-50, 15W-40, or 15W-50 API. Within the 1990–1998 complaint record, the 1991 model accumulated only three owner complaints and one recall, with service brakes/hydraulic issues standing out as the top reported area. That complaint count placed it on the lower-complaint side of the model run—below the 1992 peak of six complaints and above only the 1998 low of one—making the 1991 Samurai appear to be one of the more reliable years in the range by reported owner volume.

Model year199519941993199219911990198919881987

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity3.9 qtOEM · verified
Engine oil type20W-50 / 15W-40 / 15W-50 APIOEM · verified
EPA fuel economy24/26/25 mpgEPA · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionManual 5-spd

Dimensions & weight NHTSA vPIC

Overall length135 in
Overall width60.2 in
Overall height65.7 in
Wheelbase79.9 in
Curb weight2108 lb

Ratings & economy EPA / vPIC

EPA city / highway / combined24 / 26 / 25 mpg
DrivetrainRear-Wheel Drive
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 3.9 qt of 20W-50 / 15W-40 / 15W-50 API engine oil, 75W-80 · 75W-90 · GL-5 in the differential.

Lubricants & capacities

Differential Gear Oil75W-80 · 75W-90 · GL-5
Differential Gear Oil Capacity4.2 Pints
Differential Gear Oil75W-80 · 75W-90 · GL-5
Differential Gear Oil Capacity3.2 Pints
Engine OilABOVE 14 degrees F
Engine Oil Capacity3.9 qt
Power Steering FluidATF
Transfer Case Fluid75W-80 · 75W-90 · GL-4

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 60,000 mi; coolant every 30,000 mi. The big-interval services (every 30,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

At 7,500 miBrake System (inspect) · Drive Axle Assembly (drain & refill) · Suspension Shock or Strut (inspect) · Throttle Cable (inspect) · Transfer Case Assembly (drain & refill) · Transmission Assembly (drain & refill)
Every 7,500 miBody Fasteners (torque) · Door Stop (lubricate) · Engine Oil (drain & refill) · Engine Oil Filter (replace) · Frame Fasteners (torque) · Shift Linkage (inspect)
Every 15,000 miBrake Pedal Assembly (inspect) · Brake System (inspect) · CV Joint Boot (inspect) · Distributor Cap (inspect) · Distributor Rotor (inspect) · Driveshaft U-Joint (lubricate)
Every 30,000 miAir Injection System (inspect) · Choke System (inspect) · Drive Axle Assembly (drain & refill) · Engine Air Filter Element (replace) · Engine Coolant System (drain, flush & refill) · Exhaust System (Complete) (inspect)
Every 50,000 miEGR System (inspect)
At 60,000 miTransfer Case Assembly (drain & refill)
Every 60,000 miAccessory Drive Belt (inspect) · Brake Hydraulic System (drain, refill & bleed) · Emission Control System (inspect) · Fuel Line (inspect) · Ignition Timing (inspect) · Spark Plug Wires (replace)
Every 80,000 miOxygen Sensor (replace)
At 90,000 miTiming Belt (inspect)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

In 1990 the Samurai recorded 2 complaints, 1 recall, 1 investigation and 2 TSBs; in 1991 complaints rose to 3 while recalls and investigations remained at 1 each and TSBs stayed at 2. The next year, 1992, complaints jumped to 6 with no recalls or investigations, showing a shift from recall‑driven problems to higher complaint volume without formal recalls. By 1994 complaints fell back to 2 and remained low through 1998 (1 complaint), while recalls and investigations stayed at zero and TSBs continued at 2 each year. The 1991 model’s top complaint areas—service brakes hydraulic, seat belts and suspension—each accounted for one complaint, and the data does not specify the underlying cause of these issues. With only one crash complaint, no fire complaints, and a complaint level lower than the 1992 peak, the 1991 Samurai lies at the early stage of an upward complaint trend but still presents relatively low risk, making it a reasonable purchase provided a pre‑buy inspection verifies brake, seat‑belt and suspension condition.

1
Open recalls
NHTSA campaigns
2
Service bulletins
Manufacturer communications
1
ODI investigations
Office of Defects Investigation
3
Owner complaints
1 involved a crash · 0 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 3 complaints on record, top 3 components.

Service Brakes, Hydraulic1
Seat Belts1
Suspension1

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 1 of 1 campaigns on record for this vehicle.

95V103008Seat Belts:Front:Buckle AssemblyReported 24/05/1995

THE FRONT SAFETY BELT BUCKLE RELEASE BUTTONS CAN BREAK. THESE RED PLASTIC RELEASE BUTTONS ARE MARKED "PRESS." IF A BUTTON BREAKS, PIECES CAN FALL INTO THE BUCKLE ASSEMBLY CAUSING THE BUCKLE TO OPERATE IMPROPERLY. Remedy: OWNERS SHOULD PROMPTLY CHECK THE CONDITION AND OPERATION OF BOTH FRONT SAFETY BELT BUCKLES AND CAREFULLY INSPECT THE RED RELEASE BUTTON FOR ANY BREAKS OR CRACKS. THEY SHOULD…

Technical service bulletins NHTSA · verified

Showing 2 of 2 bulletins on record with NHTSA.

BulletinDateComponentSummary
N-Q-G-0452018-11-20SuspensionThis Service Bulletin was sent by Suzuki Motor Corporation to its authorized Suzuki…
0104145Engine And Engine CoolingCORRECT COOLANT USAGE. *EH

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Samurai. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 1991 Samurai take?

3.9 qt of ABOVE 14 degrees F: 20W-50 API, ABOVE 0 degrees F: 15W-40 OR 15W-50 API, ABOVE -4 degrees F: 10W-40 OR 10W-50 API, -4 degrees F TO 86 degrees F: 10W-30 API, BELOW 86 degrees F: 5W-30 API (STARBURS, per the factory manual.

Does the 1991 Samurai have open recalls?

NHTSA lists 1 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Samurai get?

EPA figures are 24 city / 26 highway / 25 combined mpg.