I also have a DA63T and I also poked a hole in the coolant tank so I guess its pretty common on these trucks. I just subscribed and curious to see what you plan to do with that truck. My truck is more off-road oriented so I built front and rear bumpers plus various other upgrades. I also plan to rust-proof the underside. Good video keep them coming!!!
Thanks for sharing Nick, I never imagined I'd encounter someone who'd done the same thing! I'm going to be selling this one as it is but keen to get another and try out some modifications. Have you lifted yours or changed the wheels and tyres? The rust proofing wasn't the most enjoyable job but well worth it IMHO. There are more videos on the way, including changing the clutch.
Do you have the part number to get a tank in the UK? I just picked up a 2008 and it's done exactly the same on me at the weekend. Dealer sent a replacement that's also brittle in the same place!!!
It's in the video: 12:14 If you're struggling to find the part, you can fill in this form and I'll see if I can get one for you. andrewsjapanesecars.com/ask-me-a-question/japanese-import-car-parts/
Fantastic tutorial, I took delivery of a 2003 Suzuki carry DA63T last week and have done literally exactly the same as yourself, went to check the coolant, rubbed the dirt off the tank and thankfully only cracked it, sadly it is still leaking so will need to be replaced. I don't suppose you have had any luck sourcing parts form an official Suzuki dealer by any chance? in any case I will fill in one of your forms as these little tanks seem difficult to get a hold of in the UK. Lastly I don't suppose you are aware of any common issues regarding the blower fans on these little trucks? the one I have seems very intermittent on the first and second speed, sometimes it works on all three, sometimes just on 1 and three and so on, my first guess would be some kind of fan resistor although I will admit, electrics are not my strong point.
It seems like this is quite a common problem! Sourcing parts from Suzuki in the UK is hit and miss and they aren't always able to look up part numbers. About the fan, sorry I'm not aware of the common issues. The resistors are readily available, as are the fan / ac switch unit and the fan motor itself. From what you've described it could be any of those things, although if it's intermittent on full speed that might point to the switch or motor over the resistor.
That bonnet is all plastic apart from the one metal bar below, so no crumple zone whatsoever, I wonder how they do in a crash test, not very well I imagine.
