1999-2004 Suzuki Carry GA413 Service & Repair Manual

IMPORTANT WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. WARNING: Indicates a potential hazard that could result in death or injury. CAUTION: Indicates a potential hazard that could result in vehicle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. WARNING: This service manual is intended for authorized SUZUKI dealers and qualified service mechanics only. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the me- chanic and may render the vehicle unsafe for the driver and passengers. WARNING: For vehicles equipped with Supplemental Re- straint (Air Bag) System: D Service on or around the air bag system components must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS, CAUTIONS and “Service Precau- tions” under “On-Vehicle Service” in SEC- TION 10B before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in serve injury. D If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintentional activation of the air bag system. D Do not modify the steering wheel, instrument panel or any other air bag system component. Modifications can adversely affect air bag system performance and lead to injury. D If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking process), remove the air bag system components (air bag (inflator) modules, SDM and seat belt pretensioner (if equipped)) beforehand to avoid component damage or unintended activation of the system.

() x () x () x () x () x () x () x () x FOREWORD This manual contains procedures for diagnosis, maintenance, adjustments, minor service op- erations, replacement of components and for disassembly and assembly of major components. Applicable model: GA413 (4WD model only) The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section. This manual should be kept in a handy place for ready reference of the service work. Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description. All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval, and used as the main subject of description is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice. Related Manual Manual Name Manual Number APPLICABILITY AIR CONDITIONING BASIC MANUAL 99520-02130-01E Vehicle equipped with A/C GA413 SUPPLEMENTARY SERVICE MANUAL 99501-76A10-XXX Vehicle on and after the VIN below GA413 SERVICE MANUAL 99500-76A00-XXX This manual is the base manual for the supplementary service manuals GA413 WIRING DIAGRAM MANUAL 99512-76A00-015 Vehicle before the VIN below GA413 WIRING DIAGRAM MANUAL 99512-76A10-015 Vehicle on and after the VIN below VIN Van JSAFDA32V00126001 JS3DA32V 14126001 DA32V-126001 JSAFDA32V10126001 JS3DA32V Y4126001 JSAFDA32V14126001 JS4DA32V 14126001 Truck JSAFDA32T00116001 JS4DA32T 14116001 DA32T-116001 JS4DA32T Y4116001 OVERSEAS SERVICE DEPARTMENT  COPYRIGHT SUZUKI MOTOR CORPORATION 2001

7E 7A1 4B1 4A 3D1 0B1 0A1 SECTION TABLE OF CONTENTS GENERAL INFORMATION STEERING, SUSPENSION, WHEELS AND TIRES DRIVE SHAFT AND PROPELLER SHAFT TRANSMISSION, CLUTCH AND DIFFERENTIAL General Information (4WD) Maintenance and Lubrication (4WD) Front Suspension (4WD) Front Drive Shaft Propeller Shaft (4WD) Manual Transmission (4WD) Front Differential NOTE: This manual is for GA413 4WD model and contains only the different sections from GA413 Service Manual (99500-76A00-01E). Therefore, the section(s) not found in this manual, please refer to the related manual(s) described in FORE- WORD of this manual accordingly.

0A1 GENERAL INFORMATION 0A1-1 SECTION 0A1 GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL 0A1- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS 0A1- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Vehicle Equipped with a Supplemental Restraint (Air Bag) System 0A1- 3 . . . . . . . . . . . . . . Diagnosis 0A1- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing and Handling 0A1- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions 0A1- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Catalytic Converter 0A1- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Towing 4WD Vehicles 0A1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Electrical Circuit Service 0A1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Circuit Inspection Procedure 0A1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent and Poor Connection 0A1-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Installing Mobile Communication Equipment 0A1-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IDENTIFICATION INFORMATION 0A1-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Body Number 0A1-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Identification Number 0A1-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING, CAUTION AND INFORMATION LABELS 0A1-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE LIFTING POINTS 0A1-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRE COLOR SYMBOLS IN THIS MANUAL 0A1-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABBREVIATIONS MAY BE USED IN THIS MANUAL 0A1-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METRIC INFORMATION 0A1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metric Fasteners 0A1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fasteners Strength Identification 0A1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Tightening Torque 0A1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6) Install oil pump. Refer to OIL PUMP. 7) Install flywheel (for M / T vehicle) or drive plate (for A / T vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts to specified torque. Special Tool (A): 09924-17810 Tightening Torque (c): 78 N . m (7.8 kg-m, 56.0 lb-ft) 1. Flywheel bolts or drive plate bolts for A / T vehicle 0A1-2 GENERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the first page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed. 2) Each section of this manual has its own pagination. It is indicated at the top of each page along with the Section name. 3) The SPECIAL TOOL usage and TORQUE SPECIFICATION are given as shown in figure below. 4) A number of abbreviations are used in the text. For their full explanations, refer to ABBREVIATIONS MAY BE USED IN THIS MANUAL of this section. 5) The SI, metric and foot-pound systems are used as units in this manual. 6) DIAGNOSIS are included in each section as necessary. 7) At the end of each section, there are descriptions of SPECIAL TOOLS and REQUIRED SERVICE MATERIALS that should be used for the servicing work described in that section.

1. Steering wheel 2. Driver air bag (inflator) module 3. Passenger air bag (inflator) module (if equipped) 4. SDM 5. Air bag harness 6. DLC GENERAL INFORMATION 0A1-3 PRECAUTIONS PRECAUTIONS FOR VEHICLE EQUIPPED WITH A SUPPLEMENTAL RESTRAINT (AIR BAG) SYSTEM WARNING: D The configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, rein- stall and inspect) these parts, be sure to follow procedures described in SECTION 10B. Failure to follow proper procedures could result in possible air bag system activation, personal injury, damage to parts or air bag system being unable to activate when necessary. D If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation. D Do not modify the steering wheel, dashboard, or any other air bag system components. Modifications can adversely affect air bag system performance and lead to injury. D If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking process), remove the air bag system components beforehand to avoid component damage or unintended air bag system activation. DIAGNOSIS D When troubleshooting air bag system, be sure to follow DIAGNOSIS in SECTION 10B. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement. D Never use electrical test equipment other than that specified in this manual. WARNING: Never attempt to measure the resistance of the air bag (inflator) modules (driver and passenger). It is very dangerous as the electric current from the tester may deploy the air bag.

ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY FROM BODY. ALWAYS PLACE AIR BAG (INFLATOR) MODULE ON WORKBENCH WITH TRIM COVER (AIR BAG OPENING) UP, AWAY FROM LOOSE OBJECTS. 1. Slit on workbench 2. Workbench vise 3. Lower mounting bracket 0A1-4 GENERAL INFORMATION SERVICING AND HANDLING WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver and Passenger Air Bag (Inflator) Modules D For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise. D When carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with mini- mal chance of injury. Never carry the air bag (inflator) module by the wires or connector on the underside of the module. When placing a live air bag (inflator) module on a bench or other surface, always face the bag up, away from the surface. As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit or use the workbench vise to hold it securely at its lower mounting bracket. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result. D Never dispose of live (undeployed) air bag (inflator) modules (driver and passenger). If disposal is necessary, be sure to deploy them according to deployment procedures described in SECTION 10B before disposal. D The air bag (inflator) module immediately after deployment is very hot. Wait for at least half an hour to cool it off before proceeding the work. D After an air bag (inflator) module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubri- cate the bag as it inflates) and by-products of the chemical reaction. As with many service procedures, gloves and safety glasses should be worn.

GENERAL INFORMATION 0A1-5 WARNING: SDM During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued to ensure proper opera- tion of the air bag system. The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury. CAUTION: D Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under REPAIR AND INSPECTION REQUIRED AFTER AN ACCIDENT in SECTION 10B. D When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, remove those parts beforehand. D When handling the air bag (inflator) modules (driver and passenger) or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied (e.g., dropped from a height of 90 cm (3 feet) or more), never attempt disassembly or repair but replace it with a new one. D When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and passenger), wipe off immediately with a dry cloth. D Air bag wire harness can be identified easily as it is cov- ered with a yellow protection tube. Be very careful when handling it. D When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly. D Do not apply power to the air bag system unless all components are connected or a diagnostic flow table requests it, as this will set a diagnostic trouble code. D Never use air bag system component parts from another vehicle.

0A1-6 GENERAL INFORMATION CAUTION: D When using electric welding, be sure to temporarily dis- able air bag system. Refer to DISABLING AIR BAG SYS- TEM under SERVICE PRECAUTIONS in SECTION 10B. D Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or flames. D WARNING/CAUTION labels are attached on each part of air bag system components. Be sure to follow the instructions. D After vehicle is completely repaired, perform AIR BAG DIAGNOSTIC SYSTEM CHECK in SECTION 10B.

1. – terminal 2. + terminal GENERAL INFORMATION 0A1-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under VEHICLE LIFTING POINTS on SECTION 0A. D When it is necessary to do service work with the engine running, make sure that the parking brake is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts when the engine is running. D When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors. D Do not perform service work in areas where combustible materials can come in contact with a hot exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant), make sure that the area you work in is well-ventilated. D To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail- pipe, muffler, etc. D New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil, recycle or properly dispose of used oil and filters. D Make sure the bonnet (front hood) is fully closed and latched before driving. If it is not, it can fly up unexpectedly during driving, obstructing your view and resulting in an accident. CAUTION: D Before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or stained during servicing. Also, be aware that what you wear (e.g. but- tons) may cause damage to the vehicle’s finish. D When performing service to electrical parts that does not require use of battery power, disconnect the negative cable of the battery.

1999-2004 Suzuki Carry GA413 Service & Repair Manual

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