Generation Code:
DF51V (likely chassis code for this era, specific to user manual context)
Model Years Covered:
1985, 1986, 1987, 1988, 1989, 1990, 1991
Chassis Codes:
Likely variations of DA/DB/DE51V series depending on specific configuration and market. Manual covers the range.
Market Position:
The Suzuki Carry is a highly versatile and durable Kei truck/van, renowned for its utilitarian capabilities and compact size, often used for commercial purposes, light hauling, and as a practical vehicle in various global markets.
Competitors:
Competed with other Japanese manufacturers' compact commercial vehicles, such as the Daihatsu Hijet, Honda Acty, and Subaru Sambar of the same era.
Key Features:
Compact dimensions, rear-engine, rear-wheel drive or 4WD options, durable construction, fuel efficiency, and simple mechanicals making it easy to maintain.
Value Proposition:
Provides comprehensive, dealer-level service information to enable owners and technicians to maintain, diagnose, and repair the Suzuki Carry, potentially saving significant costs on professional servicing.
Systems Covered:
Engine, Transmission, Fuel System, Ignition System, Lubrication System, Exhaust System, Electrical System, Bodywork, Brakes, Steering, Suspension, Cooling System, Clutch, HVAC (if applicable), Diagnostics, Routine Maintenance, Overhaul Procedures, Component Removal and Installation.
Manual Type:
Workshop Repair Service Manual
Engine Coverage:
Detailed disassembly, assembly, troubleshooting, and repair of engine components including cylinder head, block, pistons, crankshaft, camshaft, timing, and associated systems.
Transmission Coverage:
Covers both manual and potential automatic transmission variants (depending on specific market configurations for the Carry), including removal, disassembly, inspection, repair, and installation. Clutch system also detailed.
Fuel System Coverage:
Covers carburetor (likely for most models in this range) or potential early fuel injection systems, fuel pump, fuel lines, filters, and related diagnostics.
Electrical System Coverage:
Wiring diagrams, troubleshooting guides for lighting, ignition, starting, charging systems, instrument cluster, and accessories.
Brake System Coverage:
Detailed procedures for hydraulic system (master cylinder, wheel cylinders/calipers, lines), drum and disc brake service, parking brake.
Suspension And Steering Coverage:
Front and rear suspension components, steering gear, tie rods, alignment specifications, and troubleshooting.
Body And Chassis Coverage:
Body panel removal and installation, interior trim, door mechanisms, glass replacement, and chassis component inspection/repair.
Routine Maintenance:
Covers oil changes, filter replacements, spark plug checks, fluid level checks and top-ups, belt adjustments, and general inspections.
Troubleshooting:
Provides diagnostic procedures for common problems across various systems, including symptom-based troubleshooting and flowcharts.
Major Repairs:
Includes comprehensive procedures for engine and transmission disassembly, overhaul, and reassembly, as well as suspension, brake, and steering component rebuilding.
Technical Specifications:
Contains essential specifications such as torque values, clearances, fluid types and capacities, tire pressures, and alignment angles.
Technical Depth:
Advanced diagnostics and complete rebuilds for engine, transmission, and other major mechanical and electrical systems, suitable for professional technicians and experienced DIY mechanics.
Engine Type:
Likely naturally aspirated, multi-point fuel injection or carburetor-fed gasoline engines. Common displacements for this era and model include 657cc and 800cc variants.
Horsepower Range:
Typically in the range of 30-50 hp, depending on engine displacement and specific tuning for the model year.
Torque Range:
Torque figures would be modest, appropriate for its class, likely in the 40-60 lb-ft range.
Fuel Delivery:
Primarily carburetor-fed, with potential for early electronic fuel injection (EFI) systems in later models within this range. Manual covers specific fuel system configurations.
Cooling Type:
Liquid-cooled, with radiator, fan, water pump, and thermostat.
Ignition Type:
Distributor-based ignition system with coil, spark plugs, and potentially electronic ignition control in later years.
Overall Length:
Varies by body style (e.g., pickup truck vs. van), but typically compact, around 3,200-3,400 mm for truck variants.
Overall Width:
Designed to meet Kei vehicle regulations, so typically around 1,400-1,450 mm.
Overall Height:
Also compact, usually around 1,800-1,900 mm, allowing for good cargo volume within its footprint.
Curb Weight:
Typically in the range of 700-900 kg, depending on configuration and equipment.
Gross Vehicle Weight Rating:
Would be specified by Suzuki, designed for light commercial loads, likely around 1,300-1,500 kg.
Crash Test Ratings:
Information on crash safety ratings for this specific era might be limited or not directly comparable to modern standards. The manual likely details structural components and safety features as designed by Suzuki.
Active Safety Features:
Focus on mechanical integrity. Disc front brakes and drum rear brakes were common. ABS was not standard or common on these models.
Passive Safety Features:
Seat belts, reinforced body structure, and crumple zones (as designed for the era). The manual will detail the correct installation and adjustment of safety-related components.
Infotainment Features:
Basic factory fitted radio (AM/FM), possibly with cassette player. Manual will cover radio removal, installation, and speaker wiring.
Driver Assistance Features:
Minimal by modern standards. Focus is on the mechanical and electrical systems of the vehicle.
Connectivity Features:
None by modern definition (no Bluetooth, USB, etc.). Manual covers basic electrical connections.
Oil Change Interval:
Typically every 5,000-7,500 km or 3-6 months, depending on operating conditions. Manual will specify precise intervals and oil types.
Air Filter Replacement:
Recommended at intervals such as 15,000-30,000 km, or more frequently under dusty conditions. Manual provides specific guidance.
Spark Plug Replacement:
Intervals can vary, but typically around 30,000-50,000 km. Manual will list correct spark plug types and gap settings.
Engine Oil Specification:
Likely API SF or SG category, viscosity typically 10W-30 or 10W-40. Manual will confirm exact specification.
Coolant Specification:
Ethylene glycol-based antifreeze, mixed with distilled water in a 50/50 ratio. Manual will specify type and capacity.
Transmission Fluid Specification:
For manual transmissions, a GL-4 gear oil, typically SAE 75W-90 or 80W-90. For automatics, Dexron-II or equivalent. Manual will specify precisely.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid. Manual will specify.
Common Issues:
Rust and corrosion, particularly on the chassis and body panels, is common for vehicles of this age. Engine overheating due to aging cooling system components, clutch wear, and electrical component failure (e.g., grounds, relays) can also occur. The manual aids in diagnosing and repairing these.
Brand Heritage:
Suzuki has a long history of producing reliable and innovative small vehicles, motorcycles, and off-road vehicles, with the Carry line being a cornerstone of their commercial vehicle offerings.
Model Evolution Summary:
The Suzuki Carry has undergone numerous generations, evolving from basic utility vehicles to more refined, albeit still compact, commercial transporters. This 1985-1991 period likely represents a specific generation (e.g., the fifth or sixth generation, depending on exact market classification) that saw updates in styling, engine technology, and chassis design.
Production Locations:
Primarily manufactured in Japan, with potential for assembly in other international locations under license or through partnerships.
