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Suzuki CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Suzuki REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Model
| Aerio | Equator | Esteem | Forenza |
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| SA310 | Samurai | Sidekick | SJ410 |
| SJ413 | Swift | SX4 | Verona |
| Vitara | X-90 | XL-7 |
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Suzuki car and truck
repair procedures including Suzuki engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system
specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Suzuki
automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Suzuki AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Suzuki cars and light trucks from 1990+
Import Compressor Service -> Sanden Compressor -> Precautions -> Product Compatibility
Vehicle: 1999 Suzuki Esteem 1.6 L4 GAS
Product Compatibility
Before replenishing refrigerant or refrigerant oil, en...
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BRAKE SERVICE PROCEDURES FOR Suzuki AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Suzuki cars and light trucks from 1990+.
SUZUKI, POWER BRAKE UNITS -> BRAKE BOOSTER OVERHAUL
Vehicle: 1991 Suzuki Samurai JA 1.3 L4 GAS
Refer to Figs through when performing this procedure.
- Remove piston rod from booster, then push rod clevis and nut.
- Set booster in booster overhaul set No. 09950-88210, Fig.
- Tighten tool bolt clockwise until No. 1 body projecting part and No.2 body depressed part fit each other, Fig. Mark both body parts.
- Remove booster from tool, then separate No. 1 and No. 2 bodies. Hold both bodies carefully to prevent either body from jumping off by spring force.
- Remove piston return spring.
- From No. 2 body, remove boot, air cleaner elements and air cleaner separator.
- On Sidekick models, ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Suzuki AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Suzuki cars and light trucks sold in the U.S. for 1980+.
Suzuki -> Fuel Filter Replacement -> Except Aerio, 1998-02 Swift & 1999-02 Esteem -> Fuel System Pressure Relief -> Removal & Installation -> With Onboard Refueling Vapor Recovery System
Vehicle: 1993 Suzuki Swift GLX 1.6 L4 GAS
With Onboard Refueling Vapor Recovery System
Fuel System Pressure Relief
- Loosen the fuel filler cap to relieve fuel tank pressure.
- Remove the fuel pump relay/fuse from relay or fuse box located in engine compartment.
- Start the engine and allow to stall. Crank the engine for several seconds more to ensure relief of any remaining fuel pressure.
- Disconnect the battery ground cable.
- Install the fuel pump relay/fuse.
Removal & Installation
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flamma...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Suzuki AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Suzuki cars and light trucks from 1990+.
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 2009 Suzuki XL-7 Luxury 3.6 V6 GAS
Disassemble
- Using special tool 09900-06108 or equivalent, remove 2 circlips.
- Using special tool 09926-48010 or equivalent, push spider bearing race out 0.12 - 0.16 in. from shaft yoke race. Before pushing it out, apply penetrate lubricant between bearing race and yoke race.
- Tapping yoke with a hammer, completely remove bearing race.
- Take out bearing race on other side in same way as in Step 2 and 3.
- Push out bearing race on flange yoke side as described in Step 1 and 2, and then, holding bearing race in a vise, tap flange yoke and take out race. Remove bearing race on opp...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Suzuki AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Suzuki cars and light trucks sold in the U.S. from mid 1990's+.
Component Locations
Vehicle: 2009 Suzuki SX4 Sport 2.0 L4 GAS
Refer to F...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Suzuki AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Suzuki cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 2006 Suzuki Aerio Premium 2.3 L4 GAS
- Disconnect battery ground cable.
- Remove air cleaner hose intake clamps, disconnect MAP sensor connector, and remove bolts securing housing assembly.
- Remove power steering return pipe clamp bolt.
- Remove righthand front drive shaft nut and washer.
- Raise vehicle on suitable lift.
- Remove righthand side front wheel nuts then remove wheel.
- Remove transaxle drain plug and drain oil into clean container.
- Remove cotter pin and castle nut from tie rod end.
- Separate tie rod end from steering knuckle by using suitable tool.
- Tap with plastic hammer and drive out shaft joint to release snap ring f...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Suzuki AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Suzuki cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Suzuki -> 2003-05 Grand Vitara & 2003-06 XL-7
Vehicle: 2005 Suzuki XL-7 LX 2.7 V6 GAS
Inspect the cabin air filter every 15,000 miles and replace as required. The cabin air filter should be replaced every 30,000 miles.
- Disconnect the battery ground cable.
- Open the glove box, then remove the screw.
- Remove the glove box assembly.
- Release the cabin air filter access cover tabs, then remove the cabin air...
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MAINTENANCE LAMP RESET PROCEDURES FOR Suzuki AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Suzuki cars and light trucks sold in the U.S. from 1990+.
Suzuki -> Malfunction Indicator Lamp (MIL)/Service Engine Soon Lamp -> 1995-2002 Esteem
Vehicle: 1996 Suzuki Esteem GLX 1.6 L4 GAS
The MIL will be illuminated when the ignition switch is placed in the on position. When the engine is started, the lamp should go out. If it remains lit after engine start-up, the self-diagnostic system has detected a problem and stored a diagnostic trouble code. On models less OBD II, after diagnosis and repair are complete, the self-diagnostic system memory can be cleared by removing the PCM fuse, disconnecting PCM electrical connectors, isolating the battery ground cable for more than 60 seconds. On models eq...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Suzuki AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Suzuki cars and light trucks from 1990+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2002 Suzuki Grand Vitara 2.5 V6 GAS
Lower
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at radiator outlet.
- Remove hose from radiator.
- Reposition hose clamp at thermostat housing.
- Remove hose from thermostat housing.
- Remove hose from vehicle.
- Reverse procedure to...
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SERPENTINE BELT SERVICE PROCEDURES FOR Suzuki AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Suzuki cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 1998 Suzuki Sidekick JS 1.6 L4 GAS
- Disconnect battery ground cable at battery.
- On models with air conditioning, loosen air conditioning drive belt adjusting bolt and ...
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COMPONENT LOCATION DIAGRAMS FOR Suzuki AUTOMOBILES
Component location diagrams for most Suzuki cars and light trucks sold in the U.S. from 1990+.
 Door Components Diagram for 2007 Suzuki Forenza 2.0 L4 GASComponents on diagram: |
 Instrument Panel Diagram for 2002 Suzuki Grand Vitara 2.5 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Suzuki AUTOMOBILES
OEM drawn wiring diagrams for most Suzuki cars and light trucks sold in the U.S.
 1991 Suzuki Swift 1.3 L4 GAS Wiring DiagramComponents on diagram: |
 2007 Suzuki Aerio Premium 2.3 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Suzuki AUTOMOBILES
OEM TSB listings for most Suzuki cars and light trucks sold in the U.S. from 1985+.
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Document: TIRE PRESSURE MONITORING SYSTEM (TPMS) DIAGNOSTIC TIPS Vehicle: 2009 Suzuki Equator RMZ-4 4.0 V6 GAS Auto Systems: |
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Document: SPECIAL TOOLS - BOARDS AVAIL TO ORGANIZE/ARRANGE Vehicle: 1985 Suzuki SJ410 V 1.6 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Suzuki AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Suzuki cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Suzuki cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Suzuki cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Suzuki cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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