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Suzuki Carry 1991-1999 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Suzuki Model: Carry Model Designation: Various, typically a microvan/kei truck platform Generation Generation Code: DA51T/DB51T/DA52T/DB52T (depending on specific sub-models and regions) Codes Chassis Codes: Primarily F6A and K6A engines, associated with chassis codes like DA51, DB51, DA52, DB52 👋 Introduction Market Position Vehicle Segment: Kei truck/van segment, known for utility, fuel efficiency, and compact size, popular in commercial and rural applications Competitive Analysis Competitors: Competes with other Japanese manufacturers' kei vehicles such as the Honda Acty, Subaru Sambar, and Mitsubishi Minicab Key Features Utility: Designed for practicality and cargo hauling, often featuring a flatbed or enclosed van body Compact Size: Benefits from Kei car regulations in Japan, offering maneuverability in tight spaces and lower running costs Manual Value Proposition Benefit To Owner: Empowers owners and technicians to perform comprehensive maintenance, diagnostics, and repairs, extending vehicle life and ensuring optimal performance 📋 Manual Details Coverage Areas Applicable Years: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Page Count Total Pages: 1246 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, assembly, repair, and adjustment of all internal engine components (pistons, rings, bearings, crankshaft, camshaft, valves, etc.) Engine Management: Fuel injection system, ignition system, emissions control, ECU diagnostics, sensor testing and replacement Transmission Manual: Removal, installation, disassembly, assembly, and adjustment of manual transmissions, including clutch system Transmission Automatic: Removal, installation, disassembly, assembly, and adjustment of automatic transmissions (if applicable to specific models within the year range) Drivetrain: Driveshafts, differentials, axles, hubs, and wheel bearings Suspension: Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings Steering: Steering column, steering rack/gearbox, tie rods, power steering system (if equipped) Brakes: Brake system diagnosis, front and rear brake components (discs, drums, calipers, pads, shoes), hydraulic system, parking brake Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting system, fuses, relays, control modules Body And Chassis: Body panel removal/installation, doors, hoods, bumpers, interior trim, chassis component inspection Heating And Air Conditioning: HVAC system components, refrigerant circuits, blower motor, controls Body Electrical Comfort Features: Power windows, door locks, wipers, washers, horn, instrumentation Procedures Included Maintenance: Regular maintenance procedures, fluid changes, filter replacements, spark plug replacement, brake checks, tire rotation Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides, fault code interpretation Repair: Detailed step-by-step instructions for repairing and replacing all vehicle components Disassembly Assembly: Comprehensive guides for dismantling and reassembling all major systems and components Adjustments: Precise instructions for adjusting critical components such as engine idle speed, ignition timing, brake adjustments, clutch free play Technical Depth Depth: Comprehensive, bumper-to-bumper coverage suitable for both professional mechanics and experienced DIY enthusiasts Detail Level: Includes detailed illustrations, exploded diagrams, pictorial diagrams, and specific service tool references Specifications: Provides essential service data, factory specifications, allowable limits, and tightening torques for all components 📊 Manual Specifications File Format Readability: High-resolution PDF, allowing for zooming and clear viewing of diagrams and text Print Quality Printable: Yes, all 1246 pages are printable for convenient reference Binding Type Digital Binding: Instant Download PDF Paper Type Digital Paper Simulation: N/A (Digital PDF) Software Requirements Required Software: Adobe Reader or compatible PDF viewer Compatibility Operating Systems: Compatible with Windows, Mac OS, and Linux operating systems ⚙️ Engine Specifications Primary Engine Engine Code Typical: F6A (657cc, 3-cylinder, SOHC, naturally aspirated or turbocharged) Engine Code Alternative: K6A (658cc, 3-cylinder, DOHC, VVT, naturally aspirated or turbocharged) - introduced later in the generation Performance Horsepower Range Na: Approx. 40-50 HP for naturally aspirated variants Horsepower Range Turbo: Approx. 55-65 HP for turbocharged variants Torque Range: Approx. 50-60 lb-ft for naturally aspirated, up to 70-80 lb-ft for turbocharged Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Cooling System Cooling Method: Liquid-cooled Lubrication System Oil Type Specification: API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact specifications) Engine Codes Detailed F6A Features: Compact design, reliable, available in naturally aspirated and turbocharged versions, often with intercooler for turbo variants 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 3-speed Automatic Transmission (less common on some utility variants) Features Drive Layout: Rear-Wheel Drive (RWD) standard, with optional 4-Wheel Drive (4WD) available on many models Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or 80W-90 gear oil (refer to manual for specific fill levels and types) Automatic Transmission Fluid: Dexron III or equivalent (if equipped with automatic transmission) 📐 Dimensions Exterior Length: Varies by body style, typically around 3,200-3,400 mm for utility variants (within Kei regulations) Width: Varies by body style, typically around 1,400-1,500 mm (within Kei regulations) Height: Varies by body style, typically around 1,800-1,900 mm for van variants Weights Curb Weight: Approx. 700-900 kg, depending on configuration (2WD/4WD, van/truck) Gross Vehicle Weight Rating Gvw: Typically...
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Tipo: Truck
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Sku: 423998
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Suzuki Carry 1991-1999 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
Carry
Model Designation:
Various, typically a microvan/kei truck platform
Generation
Generation Code:
DA51T/DB51T/DA52T/DB52T (depending on specific sub-models and regions)
Codes
Chassis Codes:
Primarily F6A and K6A engines, associated with chassis codes like DA51, DB51, DA52, DB52
👋 Introduction
Market Position
Vehicle Segment:
Kei truck/van segment, known for utility, fuel efficiency, and compact size, popular in commercial and rural applications
Competitive Analysis
Competitors:
Competes with other Japanese manufacturers' kei vehicles such as the Honda Acty, Subaru Sambar, and Mitsubishi Minicab
Key Features
Utility:
Designed for practicality and cargo hauling, often featuring a flatbed or enclosed van body
Compact Size:
Benefits from Kei car regulations in Japan, offering maneuverability in tight spaces and lower running costs
Manual Value Proposition
Benefit To Owner:
Empowers owners and technicians to perform comprehensive maintenance, diagnostics, and repairs, extending vehicle life and ensuring optimal performance
📋 Manual Details
Coverage Areas
Applicable Years:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Page Count
Total Pages:
1246
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, assembly, repair, and adjustment of all internal engine components (pistons, rings, bearings, crankshaft, camshaft, valves, etc.)
Engine Management:
Fuel injection system, ignition system, emissions control, ECU diagnostics, sensor testing and replacement
Transmission Manual:
Removal, installation, disassembly, assembly, and adjustment of manual transmissions, including clutch system
Transmission Automatic:
Removal, installation, disassembly, assembly, and adjustment of automatic transmissions (if applicable to specific models within the year range)
Drivetrain:
Driveshafts, differentials, axles, hubs, and wheel bearings
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings
Steering:
Steering column, steering rack/gearbox, tie rods, power steering system (if equipped)
Brakes:
Brake system diagnosis, front and rear brake components (discs, drums, calipers, pads, shoes), hydraulic system, parking brake
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting system, fuses, relays, control modules
Body And Chassis:
Body panel removal/installation, doors, hoods, bumpers, interior trim, chassis component inspection
Heating And Air Conditioning:
HVAC system components, refrigerant circuits, blower motor, controls
Body Electrical
Comfort Features:
Power windows, door locks, wipers, washers, horn, instrumentation
Procedures Included
Maintenance:
Regular maintenance procedures, fluid changes, filter replacements, spark plug replacement, brake checks, tire rotation
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides, fault code interpretation
Repair:
Detailed step-by-step instructions for repairing and replacing all vehicle components
Disassembly Assembly:
Comprehensive guides for dismantling and reassembling all major systems and components
Adjustments:
Precise instructions for adjusting critical components such as engine idle speed, ignition timing, brake adjustments, clutch free play
Technical Depth
Depth:
Comprehensive, bumper-to-bumper coverage suitable for both professional mechanics and experienced DIY enthusiasts
Detail Level:
Includes detailed illustrations, exploded diagrams, pictorial diagrams, and specific service tool references
Specifications:
Provides essential service data, factory specifications, allowable limits, and tightening torques for all components
📊 Manual Specifications
File Format
Readability:
High-resolution PDF, allowing for zooming and clear viewing of diagrams and text
Print Quality
Printable:
Yes, all 1246 pages are printable for convenient reference
Binding Type
Digital Binding:
Instant Download PDF
Paper Type
Digital Paper Simulation:
N/A (Digital PDF)
Software Requirements
Required Software:
Adobe Reader or compatible PDF viewer
Compatibility
Operating Systems:
Compatible with Windows, Mac OS, and Linux operating systems
⚙️ Engine Specifications
Primary Engine
Engine Code Typical:
F6A (657cc, 3-cylinder, SOHC, naturally aspirated or turbocharged)
Engine Code Alternative:
K6A (658cc, 3-cylinder, DOHC, VVT, naturally aspirated or turbocharged) - introduced later in the generation
Performance
Horsepower Range Na:
Approx. 40-50 HP for naturally aspirated variants
Horsepower Range Turbo:
Approx. 55-65 HP for turbocharged variants
Torque Range:
Approx. 50-60 lb-ft for naturally aspirated, up to 70-80 lb-ft for turbocharged
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Oil Type Specification:
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact specifications)
Engine Codes Detailed
F6A Features:
Compact design, reliable, available in naturally aspirated and turbocharged versions, often with intercooler for turbo variants
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
3-speed Automatic Transmission (less common on some utility variants)
Features
Drive Layout:
Rear-Wheel Drive (RWD) standard, with optional 4-Wheel Drive (4WD) available on many models
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90 gear oil (refer to manual for specific fill levels and types)
Automatic Transmission Fluid:
Dexron III or equivalent (if equipped with automatic transmission)
📐 Dimensions
Exterior
Length:
Varies by body style, typically around 3,200-3,400 mm for utility variants (within Kei regulations)
Width:
Varies by body style, typically around 1,400-1,500 mm (within Kei regulations)
Height:
Varies by body style, typically around 1,800-1,900 mm for van variants
Weights
Curb Weight:
Approx. 700-900 kg, depending on configuration (2WD/4WD, van/truck)
Gross Vehicle Weight Rating Gvw:
Typically around 1,500-1,800 kg
🛡️ Safety Features
Ratings
Crash Test Performance:
As a Kei vehicle from this era, official crash test ratings comparable to larger vehicles may be limited; focus is on occupant protection within its class
Active Features
Braking System:
Front disc brakes, rear drum brakes standard. ABS not commonly available on this generation.
Passive Features
Seatbelts:
Three-point seatbelts in front, lap belts in rear (if equipped)
Body Structure:
Reinforced cabin structure for occupant protection within Kei vehicle standards
💡 Technology Features
Infotainment
Entertainment Systems:
Basic AM/FM radio, cassette player, or CD player (optional) depending on trim level and market
Driver Assistance
Assistance Features:
Limited driver assistance features on this generation; focus on mechanical systems.
Connectivity
Connectivity Options:
No advanced connectivity features (e.g., Bluetooth, smartphone integration) on this generation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km or 6-12 months, depending on driving conditions (refer to manual)
Air Filter Replacement:
Every 20,000-30,000 km or as needed based on inspection
Spark Plug Replacement:
Every 30,000-60,000 km (depending on plug type, check manual)
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant, pre-mixed or concentrate (refer to manual for specific type and mixture ratio)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific type)
Fluid Capacities
Engine Oil Capacity:
Approx. 2.7 - 3.2 liters (including filter, refer to manual)
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, exhaust system corrosion, engine mounts, ignition components (distributor cap/rotor on older models)
Common Electrical:
Corrosion on electrical connectors, aging wiring harness components
Preventative Maintenance
Importance Of Routine:
Adherence to the periodic maintenance chart in the manual is crucial for maximizing longevity and reliability
📚 Vehicle History
Brand Heritage
Suzuki History:
Suzuki has a long history in producing compact and efficient vehicles, particularly in the Kei car segment
Model Evolution
Carry Legacy:
The Carry nameplate has been in continuous production for decades, evolving through numerous generations, known for its robust utility and reliability
Production
Manufacturing Locations:
Primarily Japan, with production and assembly also occurring in other countries for various markets
🏆 Awards & Recognition
Recognitions
Market Recognition:
Widely recognized for its utility, affordability, and durability in its segment, especially in export markets
Ratings
Reliability Ratings:
Generally considered reliable, with many units serving commercial purposes for extended periods with proper maintenance
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