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Suzuki Carry GA413 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Carry Model Code: GA413 Year: 2002 Vehicle Type: Light Commercial Vehicle / Kei Truck (depending on market variant) Codes Chassis Codes: Common chassis codes include DA51T, DB52T, DA63T (though GA413 specifically refers to the engine/platform variant and may map to one of these chassis types depending on market. 👋 Introduction Market Position Market Segment: Compact utility vehicle, popular in markets requiring economical and versatile small commercial transport. Often used for agricultural, delivery, and light-duty construction tasks. Competitive Analysis Key Competitors: Daihatsu Hijet, Subaru Sambar, Mitsubishi Minicab, Honda Acty (competitors in the kei truck/van segment). Key Features Vehicle Attributes: Compact size, high maneuverability, fuel efficiency, rugged construction, adaptable cargo bed/van space, rear-wheel or four-wheel drive options. Manual Value Target Audience: Professional mechanics, DIY enthusiasts, fleet owners, and anyone seeking in-depth knowledge for maintaining and repairing their Suzuki Carry GA413. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Body, and Maintenance for Suzuki Carry GA413 (2002 Model) Page Count Estimated Pages: Varies by specific edition, typically 800-1200 pages for comprehensive factory manuals. Manual Type Type: Factory Service Repair Manual Language Language: English (typical for factory-translated international manuals) Format Format: Digital (PDF) or Printed 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, repair, cooling system, lubrication system, fuel system (carburetor/injection), emissions control. Engine Electrical: Ignition system, starting system, charging system, engine control unit (ECU), sensors, wiring diagrams. Transmission: Manual transmission (and potentially automatic if applicable to GA413 variant), clutch system, transfer case (if applicable). Drivetrain: Driveshafts, differentials, axles, hubs, wheel bearings. Suspension: Front and rear suspension components (struts, springs, shock absorbers, control arms, leaf springs), alignment specifications. Steering: Steering gear, steering column, tie rods, power steering system (if equipped). Brakes: Brake system components (master cylinder, brake lines, calipers, wheel cylinders, drums, pads, shoes), parking brake, ABS (if equipped). Body Exterior: Body panel removal/installation, doors, hood, tailgate, bumpers, lighting, glass, mirrors. Body Interior: Dashboard, seats, upholstery, trim panels, HVAC system (heating, ventilation, air conditioning). Electrical System: Lighting, wipers, horn, power windows/locks (if equipped), audio system, wiring diagrams for all circuits. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points, tune-up procedures. Troubleshooting: Diagnostic flowcharts, common problem identification, symptom-based troubleshooting guides. Repair: Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Technical Specifications: Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic trouble codes (DTCs). Diagnostics: Component testing, diagnostic trouble code retrieval and interpretation (OBD-I or OBD-II depending on market/variant), circuit testing. Rebuilds: Complete instructions for rebuilding engine, transmission, differentials, and other major mechanical assemblies. Technical Depth Depth: Comprehensive, covering from basic maintenance to major component overhauls and diagnostics. 📊 Manual Specifications File Format Digital Format: PDF (searchable text, hyperlinked sections, high-resolution diagrams) Print Quality Print Quality: High-resolution, clear diagrams and text, suitable for printing. Binding Type Binding: N/A (for digital), Professional (for printed - comb, spiral, or perfect binding) Paper Type Paper Type: N/A (for digital), Durable, high-quality paper stock (for printed) to withstand workshop use. Completeness Manual Completeness: This factory service manual provides complete diagnostic and repair procedures for all systems and components of the vehicle. ⚙️ Engine Specifications Primary Engine Engine Family: Suzuki G13B (commonly found in this generation of Carry) Engine Type: Inline 4-cylinder, SOHC (Single Overhead Camshaft) Displacement: 1.3 Liters (1328 cc) Performance Horsepower: Approximately 65-75 PS (48-56 kW) at 5500-6000 rpm (specifications vary by market and tuning). Torque: Approximately 100-115 Nm (74-85 lb-ft) at 3500-4500 rpm (specifications vary by market and tuning). Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) or Carburetor (depending on market and specific variant). Fuel Type: Unleaded Gasoline Cooling System Coolant Type: Ethylene Glycol based antifreeze/coolant (e.g., Suzuki Genuine Long Life Coolant or equivalent). Lubrication System Oil Type Recommendation: API SG or higher, SAE 10W-30 or 10W-40 (refer to manual for specific ambient temperature viscosity recommendations). Oil Capacity With Filter: Approximately 3.7 Liters (3.9 US Quarts). 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 3-speed Automatic Transmission (less common for GA413, but may exist for certain markets/variants). Features Drivetrain Options: Rear-Wheel Drive (RWD) or Selectable Four-Wheel Drive (4WD). Fluid Specs Manual Transmission Fluid: API GL-4 SAE 75W-90 Gear Oil (refer to manual for exact Suzuki specifications). Automatic Transmission Fluid: Dexron III or equivalent (if automatic is equipped). 📐 Dimensions Exterior Overall Length: Approx. 3,200 - 3,500 mm (varies by body style - flatbed, panel van, high-top). Overall Width: Approx. 1,400 - 1,450 mm (within kei car regulations in Japan). Overall Height: Approx. 1,800 - 1,950 mm (varies by body style, especially high-top variants). Weights Curb Weight: Approx. 750 - 950 kg (depending on configuration and equipment). Gross Vehicle Weight Rating Gvw: Approx. 1,500 - 1,700 kg. 🛡️ Safety Features Ratings Crash Test Data: Limited public crash test data available for this specific model in...
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Suzuki Carry GA413 2002 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
Carry
Model Code:
GA413
Year:
2002
Vehicle Type:
Light Commercial Vehicle / Kei Truck (depending on market variant)
Codes
Chassis Codes:
Common chassis codes include DA51T, DB52T, DA63T (though GA413 specifically refers to the engine/platform variant and may map to one of these chassis types depending on market.
👋 Introduction
Market Position
Market Segment:
Compact utility vehicle, popular in markets requiring economical and versatile small commercial transport. Often used for agricultural, delivery, and light-duty construction tasks.
Competitive Analysis
Key Competitors:
Daihatsu Hijet, Subaru Sambar, Mitsubishi Minicab, Honda Acty (competitors in the kei truck/van segment).
Key Features
Vehicle Attributes:
Compact size, high maneuverability, fuel efficiency, rugged construction, adaptable cargo bed/van space, rear-wheel or four-wheel drive options.
Manual Value
Target Audience:
Professional mechanics, DIY enthusiasts, fleet owners, and anyone seeking in-depth knowledge for maintaining and repairing their Suzuki Carry GA413.
📋 Manual Details
Coverage Areas
Primary Coverage:
Mechanical, Electrical, Body, and Maintenance for Suzuki Carry GA413 (2002 Model)
Page Count
Estimated Pages:
Varies by specific edition, typically 800-1200 pages for comprehensive factory manuals.
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (typical for factory-translated international manuals)
Format
Format:
Digital (PDF) or Printed
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, repair, cooling system, lubrication system, fuel system (carburetor/injection), emissions control.
Engine Electrical:
Ignition system, starting system, charging system, engine control unit (ECU), sensors, wiring diagrams.
Transmission:
Manual transmission (and potentially automatic if applicable to GA413 variant), clutch system, transfer case (if applicable).
Drivetrain:
Driveshafts, differentials, axles, hubs, wheel bearings.
Suspension:
Front and rear suspension components (struts, springs, shock absorbers, control arms, leaf springs), alignment specifications.
Steering:
Steering gear, steering column, tie rods, power steering system (if equipped).
Brakes:
Brake system components (master cylinder, brake lines, calipers, wheel cylinders, drums, pads, shoes), parking brake, ABS (if equipped).
Body Exterior:
Body panel removal/installation, doors, hood, tailgate, bumpers, lighting, glass, mirrors.
Body Interior:
Dashboard, seats, upholstery, trim panels, HVAC system (heating, ventilation, air conditioning).
Electrical System:
Lighting, wipers, horn, power windows/locks (if equipped), audio system, wiring diagrams for all circuits.
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points, tune-up procedures.
Troubleshooting:
Diagnostic flowcharts, common problem identification, symptom-based troubleshooting guides.
Repair:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic trouble codes (DTCs).
Diagnostics:
Component testing, diagnostic trouble code retrieval and interpretation (OBD-I or OBD-II depending on market/variant), circuit testing.
Rebuilds:
Complete instructions for rebuilding engine, transmission, differentials, and other major mechanical assemblies.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to major component overhauls and diagnostics.
📊 Manual Specifications
File Format
Digital Format:
PDF (searchable text, hyperlinked sections, high-resolution diagrams)
Print Quality
Print Quality:
High-resolution, clear diagrams and text, suitable for printing.
Binding Type
Binding:
N/A (for digital), Professional (for printed - comb, spiral, or perfect binding)
Paper Type
Paper Type:
N/A (for digital), Durable, high-quality paper stock (for printed) to withstand workshop use.
Completeness
Manual Completeness:
This factory service manual provides complete diagnostic and repair procedures for all systems and components of the vehicle.
⚙️ Engine Specifications
Primary Engine
Engine Family:
Suzuki G13B (commonly found in this generation of Carry)
Engine Type:
Inline 4-cylinder, SOHC (Single Overhead Camshaft)
Displacement:
1.3 Liters (1328 cc)
Performance
Horsepower:
Approximately 65-75 PS (48-56 kW) at 5500-6000 rpm (specifications vary by market and tuning).
Torque:
Approximately 100-115 Nm (74-85 lb-ft) at 3500-4500 rpm (specifications vary by market and tuning).
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) or Carburetor (depending on market and specific variant).
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Type:
Ethylene Glycol based antifreeze/coolant (e.g., Suzuki Genuine Long Life Coolant or equivalent).
Lubrication System
Oil Type Recommendation:
API SG or higher, SAE 10W-30 or 10W-40 (refer to manual for specific ambient temperature viscosity recommendations).
Oil Capacity With Filter:
Approximately 3.7 Liters (3.9 US Quarts).
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
3-speed Automatic Transmission (less common for GA413, but may exist for certain markets/variants).
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) or Selectable Four-Wheel Drive (4WD).
Fluid Specs
Manual Transmission Fluid:
API GL-4 SAE 75W-90 Gear Oil (refer to manual for exact Suzuki specifications).
Automatic Transmission Fluid:
Dexron III or equivalent (if automatic is equipped).
📐 Dimensions
Exterior
Overall Length:
Approx. 3,200 - 3,500 mm (varies by body style - flatbed, panel van, high-top).
Overall Width:
Approx. 1,400 - 1,450 mm (within kei car regulations in Japan).
Overall Height:
Approx. 1,800 - 1,950 mm (varies by body style, especially high-top variants).
Weights
Curb Weight:
Approx. 750 - 950 kg (depending on configuration and equipment).
Gross Vehicle Weight Rating Gvw:
Approx. 1,500 - 1,700 kg.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited public crash test data available for this specific model in international markets; emphasis on structural integrity for its class.
Active Features
Active Safety:
Standard safety features typical for the era: hazard warning lights, backup lights.
Passive Features
Passive Safety:
Seat belts (front), reinforced cabin structure, side impact beams (in later/export models).
💡 Technology Features
Infotainment
Audio System:
Typically a basic AM/FM radio with cassette or CD player. Speaker placement is usually minimal.
Driver Assistance
Advanced Features:
Limited advanced driver assistance systems. Focus is on mechanical reliability and basic functionality.
Connectivity
Connectivity Options:
Basic (e.g., 12V power outlet). No modern connectivity features like Bluetooth or USB ports unless aftermarket installed.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, whichever comes first (refer to manual for precise interval based on usage).
Air Filter Replacement:
Every 20,000 - 30,000 km (12,000 - 18,000 miles) or as needed based on operating conditions.
Spark Plug Replacement:
Every 30,000 - 40,000 km (18,000 - 24,000 miles), depending on plug type (standard or platinum).
Fluid Specifications
Coolant Capacity:
Approximately 4.0 - 4.5 Liters (4.2 - 4.8 US Quarts) for the entire cooling system.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
If equipped, consult manual for specific type (often ATF Dexron III or a dedicated power steering fluid).
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, exhaust system components, starter motor, alternator, and brake components due to commercial use.
Rust Susceptibility:
Prone to rust in certain areas (e.g., chassis, wheel wells, cargo bed) in humid or corrosive environments, especially with regular exposure to salt.
📚 Vehicle History
Brand Heritage
Suzuki Utility Vehicles:
Suzuki has a long-standing reputation for producing reliable and compact utility vehicles, dating back to early micro-trucks and vans.
Model Evolution
Carry Generations:
The Carry line has seen numerous generations and platform updates. The GA413 falls into the latter part of the 1990s/early 2000s generation, succeeding earlier models and preceding the DB52T/DA63T platforms.
Production
Manufacturing Locations:
Primarily manufactured in Japan by Suzuki Motor Corporation, with potential for CKD assembly in other markets.
🏆 Awards & Recognition
Recognitions
Market Reputation:
Recognized for its durability, affordability, and suitability for light commercial tasks in many global markets.
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