Suzuki WAGON R Service Repair Workshop Manual 1999-2008
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🏷️ Basic Information Identification Make: Suzuki Model: Wagon R Generation: Second Generation (MH21S/MH22S) Applicable Years: 1999-2008 Codes Chassis Codes: MH21S, MH22S 👋 Introduction Market Position Vehicle Type: Kei car / City car / Subcompact MPV Target Demographic: Urban commuters, small families, individuals seeking economical and practical transportation Competitive Analysis Key Competitors: Daihatsu Move, Honda Life, Mitsubishi eK Wagon, Nissan Otti Key Features Design Philosophy: Maximizing interior space within kei car dimensions, fuel efficiency, practicality Manual Value Proposition: Enables DIY maintenance and repair, reduces reliance on costly dealership services, empowers owners with technical knowledge 📋 Manual Details Coverage Areas Markets Covered: Global (specifically targeting models sold within these years, often with variations for Japanese Domestic Market (JDM) and export models) Page Count Estimated Pages: 500+ Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system Transmission Drivetrain: Automatic transmission (AT), Continuously Variable Transmission (CVT), manual transmission (MT), drivetrain components (axles, driveshafts) Chassis Suspension: Suspension systems (front and rear), steering system, braking system Electrical Electronics: Body electrical systems, lighting, instrument cluster, infotainment, power accessories, engine control module (ECM) wiring diagrams Body Interior: Body construction, exterior panels, interior trim, seats, climate control system, safety restraint systems (SRS) Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement Repair Rebuild: Engine overhaul, transmission overhaul, brake system repair, suspension component replacement, electrical component diagnosis and repair Troubleshooting: Diagnostic procedures, fault code interpretation, common problem diagnosis and solutions Technical Depth Depth: Comprehensive, covering everything from basic maintenance to in-depth mechanical and electrical diagnostics and repairs 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Quality: High-resolution, clear images and text, suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Searchability Text Search: Searchable PDF text ⚙️ Engine Specifications Primary Engine Engine Code 1: K6A (658cc, DOHC, 3-cylinder, turbocharged and naturally aspirated variants) Engine Code 2: F6A (657cc, SOHC, 3-cylinder, naturally aspirated variants - primarily older models within the range) Performance Horsepower Range: 45-64 PS (33-47 kW) depending on engine and aspiration Torque Range: 50-80 Nm (37-59 lb-ft) depending on engine and aspiration Fuel System Induction Type: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (RON 91 or higher recommended) Lubrication Oil Type: API SG, SH, SJ or ILSAC GF-II or higher (e.g., 0W-20, 5W-30, 10W-30 depending on climate and specific engine) Oil Capacity: Approx. 2.7-3.0 Liters (with filter change) 🔧 Transmission Standard Transmission Type Standard: 4-speed Automatic Transmission (AT) Optional Transmission Type Optional: Continuously Variable Transmission (CVT), 5-speed Manual Transmission (MT) Features Drivetrain Options: Front-Wheel Drive (FWD), All-Wheel Drive (AWD) Fluid Specifications Atf Type: Dexron III equivalent or specific Suzuki AT fluid (consult manual for exact type) Fluid Capacity Atf Capacity: Approx. 3.0-3.5 Liters (for AT, drain and fill) 📐 Dimensions Exterior Length: Approx. 3,395 mm (JDM regulations) Width: Approx. 1,475 mm (JDM regulations) Height: Approx. 1,600 - 1,640 mm (depending on suspension/roof options) Weights Curb Weight: Approx. 700-850 kg (depending on drivetrain and equipment) Cargo Cargo Volume: Highly flexible due to folding rear seats, typically around 200-300 liters with seats up 🛡️ Safety Features Ratings Jncsa Ratings: Various safety ratings depending on market and year, often achieving 4-5 stars in local crash tests (e.g., JNCAP) Active Features ABS: Available on higher trims/later models E Brake Assist: May be available on certain higher-spec models Passive Features Airbags: Driver and passenger airbags standard on many models, side airbags optional/available on higher trims Seatbelts: 3-point ELR seatbelts with pretensioners for front occupants Iso Fix: Available on rear seats for child seat installation on some models 💡 Technology Features Infotainment Audio System: Base models may have a simple AM/FM radio and CD player. Higher trims could feature upgraded audio systems with more speakers. Navigation: Optional factory-installed navigation systems were available on higher-spec models, often integrated into the dashboard. Driver Assistance Parking Sensors: Optional rear parking sensors were available on some trims. Connectivity Aux Input: Not common on base models; may be present on aftermarket or higher-spec factory units. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil used (refer to manual for specific recommendations) Air Filter Replacement: Every 20,000-40,000 km or as needed based on inspection Spark Plug Replacement: Every 40,000-80,000 km, depending on plug type (standard vs. iridium) Timing Belt Or Chain: K6A engine uses a timing chain, generally maintenance-free unless wear is present. F6A may use a belt requiring replacement around 80,000-100,000 km (verify engine code in manual). Fluid Specifications Coolant Type: Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Use HOAT or OAT coolant suitable for Japanese vehicles. Brake Fluid Type:...
Dexron III equivalent or specific Suzuki AT fluid (consult manual for exact type)
Fluid Capacity
Atf Capacity:
Approx. 3.0-3.5 Liters (for AT, drain and fill)
📐 Dimensions
Exterior
Length:
Approx. 3,395 mm (JDM regulations)
Width:
Approx. 1,475 mm (JDM regulations)
Height:
Approx. 1,600 - 1,640 mm (depending on suspension/roof options)
Weights
Curb Weight:
Approx. 700-850 kg (depending on drivetrain and equipment)
Cargo
Cargo Volume:
Highly flexible due to folding rear seats, typically around 200-300 liters with seats up
🛡️ Safety Features
Ratings
Jncsa Ratings:
Various safety ratings depending on market and year, often achieving 4-5 stars in local crash tests (e.g., JNCAP)
Active Features
ABS:
Available on higher trims/later models
E Brake Assist:
May be available on certain higher-spec models
Passive Features
Airbags:
Driver and passenger airbags standard on many models, side airbags optional/available on higher trims
Seatbelts:
3-point ELR seatbelts with pretensioners for front occupants
Iso Fix:
Available on rear seats for child seat installation on some models
💡 Technology Features
Infotainment
Audio System:
Base models may have a simple AM/FM radio and CD player. Higher trims could feature upgraded audio systems with more speakers.
Navigation:
Optional factory-installed navigation systems were available on higher-spec models, often integrated into the dashboard.
Driver Assistance
Parking Sensors:
Optional rear parking sensors were available on some trims.
Connectivity
Aux Input:
Not common on base models; may be present on aftermarket or higher-spec factory units.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil used (refer to manual for specific recommendations)
Air Filter Replacement:
Every 20,000-40,000 km or as needed based on inspection
Spark Plug Replacement:
Every 40,000-80,000 km, depending on plug type (standard vs. iridium)
Timing Belt Or Chain:
K6A engine uses a timing chain, generally maintenance-free unless wear is present. F6A may use a belt requiring replacement around 80,000-100,000 km (verify engine code in manual).
Fluid Specifications
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Use HOAT or OAT coolant suitable for Japanese vehicles.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Power Steering Fluid:
Typically ATF Dexron II/III equivalent or specific power steering fluid (check manual)
Known Issues
Common Wear Items:
Suspension bushings, engine mounts, exhaust system components, catalytic converter (especially on high-mileage vehicles)
Transmission Hesitation:
CVT or older ATs can sometimes exhibit hesitant shifting or slipping, often related to fluid degradation or electronic control unit issues.
Ignition Coils:
Ignition coil packs (especially on K6A engines) can be a point of failure, leading to misfires.
📚 Vehicle History
Brand Heritage
Suzuki Specialty:
Suzuki is renowned for its small, efficient, and often capable vehicles, particularly in the kei car segment
Model Evolution
Wagon R Concept:
Evolved from the original Wagon R concept, focusing on maximizing interior space ('tall wagon') within strict kei car regulations
Production
Manufacturing Location:
Primarily Japan, with some production or assembly in other markets
Second Gen Introduction:
Launched in 2003, featuring a more modern design and improved aerodynamics over the first generation
🏆 Awards & Recognition
Recognitions
Kei Car Segment Success:
Consistently one of the best-selling kei cars in Japan, lauded for its practicality and value.
Ratings
Fuel Efficiency:
Highly rated for fuel economy, making it an economical choice for urban driving. Specific MPG figures vary by engine and transmission.
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