🏷️ Basic Information Identification Make: Suzuki Model: Vitara Year: 1991 Codes Chassis Code: ET/TA Series (First Generation) 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Target Audience: Enthusiasts, DIY mechanics, restoration specialists, and professional repair shops working on first-generation Suzuki Vitaras. Competitive Analysis Contemporaries: Jeep Cherokee (XJ), Toyota RAV4 (later in the generation), Mitsubishi Pajero (Montero), Isuzu Trooper, Nissan Pathfinder (first gen), Ford Bronco II. Key Features Vehicle Strengths: Compact size, impressive off-road capability for its class, rugged construction, relatively simple mechanicals, good fuel economy (for its era), versatility (3-door, 5-door, convertible variants). Manual Value Proposition: The 'complete' nature of this manual ensures that owners and technicians have access to authoritative, factory-level information, crucial for maintaining the longevity and performance of this capable vehicle. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Maintenance, Diagnostics, Troubleshooting, Rebuilding, Refurbishing, Restoration Page Count Estimated Pages: Varies by specific publisher, but typically 800-1200 pages for a comprehensive factory service manual for this era. Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF likely, often searchable) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (4WD System, Differentials, Driveshafts) Chassis: Suspension (Front & Rear), Steering System, Brake System (Front & Rear), Wheels & Tires Electrical: Battery, Charging System, Starting System, Lighting System, Instrumentation, Wiper/Washer System, Audio System, Accessory Circuits, Engine Control Unit (ECU) & Sensors, Wiring Diagrams Body: Body Panels, Doors, Hood, Tailgate, Interior Trim, Seats, Glass, Bumpers, HVAC System (Heating, Ventilation, Air Conditioning) Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks & Replacements, Belt Inspection & Replacement, Spark Plug Service, Brake Pad Replacement Diagnostics: Troubleshooting Guides, Symptom-Based Diagnostics, Fault Code Identification (where applicable), Component Testing Procedures Repair: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Repair, Electrical Component Repair, Body Panel Repair, HVAC System Repair Special Procedures: Timing Belt Replacement (Critical), Clutch Replacement, Differential Service, 4WD System Servicing, Air Conditioning System Servicing (Refrigerant Handling) Technical Depth Depth: Comprehensive, covering everything from basic fluid checks and filter replacements to complete engine and transmission rebuilds. Includes detailed torque specifications, diagnostic flowcharts, and component removal/installation procedures. 📊 Manual Specifications File Format Format: Likely a PDF document, optimized for digital viewing and printing. May be searchable for quick access to specific topics. Print Quality Quality: High-resolution scans or digital originals, ensuring clear diagrams, illustrations, and text. Designed for clarity in a workshop environment. Binding Type Type: N/A (Digital Product) Paper Type Type: N/A (Digital Product) ⚙️ Engine Specifications Primary Engine Engine Code: G16A (Commonly found) Engine Type: Inline 4-cylinder, SOHC (Single Overhead Cam) Displacement: 1.6 Liters (1590 cc) Performance Horsepower: Approx. 80-85 HP @ 5000-5500 RPM (Varies slightly by market and tuning) Torque: Approx. 95-100 lb-ft @ 3000-3500 RPM (Varies slightly by market and tuning) Fuel System Fuel Delivery: Fuel Injection (Multi-Point Fuel Injection - MPFI) or Carbureted (early models/specific markets). Manual will detail both. Recommended Fuel: Unleaded gasoline (Octane rating typically 87 or higher) Engine Management Ignition Type: Distributor-based ignition system with electronic ignition control (ICM/Coil). 🔧 Transmission Standard Type: 5-Speed Manual Transmission Optional Type: 3-Speed Automatic Transmission (Less common, but available) Features Drivetrain Modes: Part-time 4WD system with 2WD (RWD), 4WD High, and 4WD Low (4L) selectable modes. May include a manual locking hub system on front wheels. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or SAE 80W-90 gear oil. Manual will specify exact type and capacity. Automatic Transmission Fluid: Dexron II/III or equivalent. Manual will specify exact type and capacity. Transfer Case Fluid Fluid Type: API GL-4, SAE 75W-90 or SAE 80W-90 gear oil. Manual will specify exact type and capacity. 📐 Dimensions Exterior Wheelbase: Approx. 2030 mm (80 inches) for 3-door models Length: Approx. 3675 mm (145 inches) for 3-door models Width: Approx. 1695 mm (66.7 inches) Height: Approx. 1625 mm (64 inches) Weights Curb Weight: Approx. 970 kg - 1100 kg (2138 lbs - 2425 lbs) depending on configuration. Gross Vehicle Weight Rating: Refer to vehicle's VIN plate for exact specification. Wheels Tires Standard Tire Size: 205/75R15 (Common size, manual will confirm) Wheel Bolt Pattern: 5x139.7 mm (5x5.5 inches) Center Bore: 108 mm 🛡️ Safety Features Ratings Crash Test Data: Limited official crash test data available for this specific model year from modern agencies like NHTSA/IIHS. However, it was designed with a body-on-frame construction for robustness. Active Features Braking System: Front Disc Brakes, Rear Drum Brakes. Manual will detail ABS availability for specific trims/markets (likely optional or absent on base models). Passive Features Restraints: Seat belts (lap and shoulder belts). Airbags were not standard or commonly available on early 1991 models. Manual will confirm. Rollover Protection: Body-on-frame construction offers inherent structural rigidity. Convertible models would have a roll bar for...