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Suzuki Samurai (All SJ Platform) 1981-1998 / 83 sj410 wiring diagram

« Last post by ontario410 on July 20, 2025, 02:32:53 PM »

Hello,
My headlights stopped working the other day so I started looking into it and found an absolute mess of a wiring job from the previous owner. Does anyone have a wiring schematic for a 1983 sj410?
I don't see a headlight relay so I'm thinking it's either the switch itself on the steering column or I've got a open wire somewhere
Any help would be greatly appreciated.

82

Technical Discussion - Beginner / Repair / Re: What causes high idle besides vacuum leaks ?

« Last post by 91 ragtop on July 16, 2025, 08:27:54 PM »

Thanks for the info. I'll see what I can figure out.


Ken..........

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Technical Discussion - Beginner / Repair / Re: What causes high idle besides vacuum leaks ?

« Last post by fordem on July 09, 2025, 06:35:28 AM »

On a fuel injected engine, high idle is caused by excessive air flow - the trick is to find where the air is getting in.  It can be the throttle plate open more than it should be, or air leaking into the intake, which is your so called "vacuum leak" - PCV valve & hose, brake booster, literally anything connecting on the manifold side of the throttle plate.  There's also I believe a throttle opener on those motors that holds the throttle plate open for the first 5 seconds or so after startup.

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Technical Discussion - Beginner / Repair / What causes high idle besides vacuum leaks ?

« Last post by 91 ragtop on July 08, 2025, 07:39:34 PM »

My 91 8 valve has a very high idle (around 2500 rpms) and I can't find any leaks or cracked hoses anywhere. Is there some other component that I should be looking at for a cure ?

Ken.............

85

Technical Discussion - Performance / Modify / Re: ignition timing after removing vacume line?

« Last post by the blackdog on June 18, 2025, 11:23:51 AM »

Thanks for the reply Eric.
This has tested what I thought I understood about timing.
If timing is too late (retarded) result is easy starting but poor performance and bad milage.
If too early (advanced) poor starting (learned that from kick starting large displacement motorcycles) pinging under load and over heating.
If that's true, how to get the best of bolth worlds?
What might work well on the highway might not be good rock crawling.

Also the PCV valve has now been capped off, might make some differance to the fuel/air mixture.
It is a little more fun to drive now so that's a win.

86

Technical Discussion - Performance / Modify / Re: 04 Grand Vit- where is the TCM located? I want to modify the TPS input

« Last post by fordem on June 17, 2025, 03:30:56 PM »

The 2004 doesn't have a separate TCM, the TCM function is integrated into the ECM, and the kickdown function is done via a cable.

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Technical Discussion - Performance / Modify / 04 Grand Vit- where is the TCM located? I want to modify the TPS input

« Last post by iadr on June 17, 2025, 09:32:31 AM »

2004 Grand Vitara, 2.5 V6.  Canadian Spec (should be same as US?).

The 4sp Auto is set to kick down way way too often.   I would rather it didn't kick down except in extreme circumstances.

I would like to find my TCM so that I can try a plan I have.  Where is my TCM located? Bonus if you can tell me colour codes at the plug.

My plan is to run a rheostat in the sensor feed coming from the throttle position sensor to the TCM, so it thinks it's at 40-50% throttle when it's at 75-80% throttle, so as to eliminate a number of kick down actions. This would be done by running that signal to ground via a resistor.
 If that works great, if not then I'll run a junkyard TPS, run 12V to it and let it send out a fixed 40% TPS signal.

My one concern is the transmission lowers internal (band) pressures drop at lower throttle positions, like some of the old mechanical systems did for a softer shift feel.  If so, then I may end up with more torque at a lower internal pressure, causing slippage.

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Technical Discussion - Performance / Modify / Re: Any easy short cut to allowing the fog light circuit to stay on w/hi beam?

« Last post by iadr on June 17, 2025, 09:24:13 AM »

Hoped for something "known" like this trick for some Fords  https://www.youtube.com/watch?v=5-94SZUEkdw:

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Technical Discussion - Performance / Modify / Any easy short cut to allowing the fog light circuit to stay on w/hi beam?

« Last post by iadr on June 17, 2025, 09:23:03 AM »

2004 Grand Vitara, 2.5 V6.  Canadian Spec (should be same as US?). 2 lighting issues:

So I have replaced my OEM fog lights with spot lights used as ditch lights (angled slightly right, drivers more than the other, remote part of Canada, we often do this...)

I'd really like to not cut up my harness and do a lot more work than I have to.  Is there someone who understands the circuit? I'm thinking of a diode and relay tagged into power and triggered by the high beam but that seems complex.

-
2nd concern

  Are these vehicles like a lot of Asian vehicles and switch the ground to turn the headlights on and off? I can go check but I last looked at this around New years and it's June and I want to get this done. I'm looking to do the upgrade to powering the headlights off the alternator output post.  I've tried two brands of LED light and both sucked, now have name brand 90/130W halogen filament and still lack of light cast-distance is scary bad. Hoping to re-power the high watt filament type and then use the ditch lights a lot, maybe a light bar if I keep the vehicle through the winter.

90

Technical Discussion - Beginner / Repair / Re: Swap 96 body to 91 frame ?

« Last post by ebewley on June 11, 2025, 08:30:56 PM »

Physically very possible with minimal differences. However, I'd look for a replacement engine or service the one that is in the 'donor' instead. Projects like body swaps can tend to end up with two dead vehicle projects setting and waiting for attention vs. having fun in one rig and selling the other to help offset the cost. YMMV - Eric