1991-1999 Suzuki Carry/Every Service & Repair Manual (+ Parts Catalog)

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)) be- forehand 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.

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1991-1999 Suzuki Carry/Every Service & Repair Manual (+ Parts Catalog)

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