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1996: "Coily" Samurai
For the rest of the world, 1996 brought the biggest changes for the SJ series. The new "Coily" Samurai was most easily identified from beneath, where the all-new coil springs suspended the same live axles, which now housed 3.909 gears instead of the 3.727s. The transfer case ratios were raised from 1.409 high to 1.320 high, and 2.268 low to 2.123 low.
A lot of attention was paid to making the Samurai a much more comfortable vehicle. Engine bay insulation, new transmission and body mounts, totally redesigned dashboard, steering wheel, doors, console, and front and rear seats along with additional luxury items, and of course the improved suspension, made it a much higher-class vehicle. Upgraded brakes, power steering, engine fan, ignition coil, clutch cable, and a new exhaust system squeeze out higher performance. Fuel and radiator capacities were increased slightly and chassis strength was improved though the use of additional bracing and side-impact beams.
Outside, a tough looking hood, fenders, grille, and bumpers smooth out the looks while recalling the style of the LJ series with the twin marker and turn signal lights on each front corner, making this the best-looking SJ series yet. Not all Suzuki factories switched to the coil sprung chassis with the 1996 redesign of the Samurai and not all factories installed the same engines. Japan still used the narrow-track 1.0-liter 550cc 12-valve turbo 3-cylinder, in addition to the updated 16-valve MPFI twin cam 1300.
1996 found a 2.0-liter Mazda turbo diesel inline four introduced to the Vitara destined for the Asian and Australian markets. The following year an intercooler was added to the engine, extracting 23% more power and 29% more torque to the already powerful, tractable engine and further increasing the diesel's fuel economy. For the European markets, the Santana and others factories installed a Peugeot 1.9-liter inter-cooled turbo diesel into the Samurai and the Vitara.