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FAQ's (Frequently Asked Questions) on Parts, Tech Publications + "How-to" links...

Developed to aid in locating the most sought after topics and those of key interest based on the number of thread views.

Please check-in here prior to first time forum posting:

Technical Publications:
Max's FREE Pubs stash. Service, Owner's and more Manuals!
Additional model publications (SideTrack link)
Suzuki Pit Stop (Pubs for purchase)>>

Genuine (OE) parts: With part #'s and diagrams!
Calif Suzuki Car Parts Catalog Online Store
N. Carolina Chevy Tracker Parts> GM Parts Direct: Your direct source for Genuine GM Parts
Arizona + by VIN
New Jersey Genuine OEM Suzuki Automotive Parts
Florida no longer processing new orders :(
U.A.E. (Asia) By VIN too
Caribbean Suzuki Caribbean | Choose Your Country
A worldwide warehousing source

Aftermarket Mail Order: Forum sponsor

Used Parts Sources:
Oregon Trail Tough Used Suzuki Samurai, X90, Sidekick, XL7, and Geo Tracker Parts
Arkansas Universal Auto Sales
UK new OE parts as well.

USA / Canada Wrecker search engines: Auto Parts Market

VEHICLE INFO (general):
Suzuki OBD Trouble Codes –

Cold Air Intake system mods

02 Sensor Replacement

Alternate tire size options:

Engine and transmission removal (manual trans) (2.7L to 2.5L V-6 particulars) (J20a to J23a swap)

Ignition timing setting

Engine noise at start-up.


Which manufacturers Diesel engine do I have?

J20a (2.0L)
Timing Chains and Tensioners (Vitara & Tracker) repair info:

Camshaft Position Sensor (CPS, aka CMP)

Where to buy an oil pan and how to install...

Engine vibration due to motor mount issues? See...

H25a / H27a (2.5L / 2.7L)
Timing Chains & Tensioners (GV, Tracker & early XL-7) repair info...

GM 2.5L OBD Codes Tracker 2.5L.pdf

A/C belt changing / tightening technique with a manual tensioner

Alternator and belt removal tips

Exhaust Smoke. Valve Cover Baffle drainage issues and PCV Info...

Where can I find my Camshaft Position Sensor?

MAF and inlet duct replacement info...

MAF info:

Where are my spark plugs?

Servicing the EGR valve and Intake Plenum gaskets...:

Engine hard to start and fuel "Flooding" symptoms...

Starter removal tips:

Oil pan removal and reseal. Lessons learned + tips

Cooling System:
Radiator Replacement

Finding and fixing coolant leaks...

Conversion: mechanical to 12V thermostatic electric fan

Drive train:
4 Wheel Drive problems to include early (thru '04) XL-7's

Gear Oils:

Stuck transmission, differential or transfer case drain or fill plugs?

Clutch problems...

Loose (manual) shifting mechanism!

Automatic Transmission level checks and transmission oil changing...

Rear Axle Bearing and axle seal servicing:

Front hub (wheel bearing) replacement...

CV joint / seal free play (differential nylon bushing up-grade)

CV Shaft and Boot replacement:

Finicky hydraulic clutch operation?

Heating and Air Conditioning:
A/C system overhaul. Lessons learned:

Cabin Filter. Do I have one? How to change..

Compressor troubleshooting...

Amount of refrigerant charge and compressor replacement...

A/C condenser fan issues & under-hood 25amp fuse blowing...

Heater Core replacement

Frame, Steering and Suspension:
Calmini 2.5" Lift Kit

Rusted out front cross-member

Tightness in steering

Rack and pinion housing, rubber securing mount / bushings...

Brake shoe installation, lessons learned...

Front brake (calipers) dragging...

Starter or battery??

Steering wheel "clock spring" / Multi-function switch and Air Bag light problems?

Ignition (no start) blackout...

Radio removal (1999-2003), HVAC control lighting, dash light dimming, Auto Trans floor shifter light bulb replacement...

How to fix a faulty power window switch

Re-programming the 1999 & 2000 remote door lock system...

Side door panel removal and window operating problems?

Front grille removal

Headlamp / sidelight bulb access...

Replacing the back door handle

Trailer towing capabilities

Flat towing your Zuk

Common Problems of note?

65 Posts
Thanks for doing this writeup, Max!
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