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2002 Suzuki Grand Vitara Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Year: 2002 Codes Chassis Code: JT 👋 Introduction Market Position Segment: Compact SUV / Crossover Usp: Body-on-frame construction offering traditional SUV capabilities in a compact package, available with a V6 engine. Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Jeep Cherokee (XJ) Key Features Platform: Body-on-frame chassis, rear-wheel drive bias with available 4WD. Engine Options: Reliable V6 engines offering good power for its class. Off Road Capability: Higher ground clearance and robust construction compared to unibody competitors. 📋 Manual Details Coverage Areas Engine Coverage: 2.5L V6 (H25A), 2.7L V6 (H27A) Drivetrain Coverage: 4-speed automatic transmission (430), 5-speed manual transmission (5M-41), 4WD system (including transfer case and differentials) Chassis Coverage: Suspension (front MacPherson strut, rear multi-link), Steering (power rack and pinion), Brakes (front ventilated discs, rear discs) Electrical Coverage: Engine control systems, lighting, body control modules, power accessories, audio system, diagnostic trouble codes (DTCs) Body Coverage: Body panels, interior trim, doors, windows, bumpers, ventilation, heating, air conditioning (HVAC) Page Count Estimated Pages: 1500+ Manual Type Type: Service and Repair Manual Software Language Language: English Format Format: Digital Software (e.g., PDF, proprietary executable) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication, cooling, fuel injection Engine Electrical: Ignition system, starting system, charging system, ECU, sensors, actuators, wiring diagrams Transmission Drivetrain: Manual and automatic transmission overhaul, clutch, drive shafts, differentials, transfer case Suspension Steering: Front and rear suspension component replacement, wheel alignment, power steering system repair Brakes: Brake system diagnostics, component replacement (discs, pads, calipers, lines), ABS system HVAC: Air conditioning system service, heater core replacement, blower motor service Body Interior: Door lock mechanisms, window regulators, seat removal, interior paneling, weatherstripping Diagnostics Troubleshooting: Symptom-based troubleshooting guides, diagnostic procedures, OBD-II scanning and interpretation Procedures Included Preventative Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspection and replacement Engine Repair: Head gasket replacement, timing belt/chain service, piston ring replacement, valve adjustment Transmission Repair: Clutch replacement (manual), transmission fluid and filter service (automatic), internal component repair Brake Service: Brake pad and rotor replacement, brake caliper service, brake fluid flush Electrical Diagnostics: Wiring harness repair, sensor testing and replacement, starter and alternator testing Suspension Wheel Alignment: Strut and shock absorber replacement, ball joint replacement, tie rod end replacement, wheel bearing replacement, wheel alignment procedures Body Repair: Door panel removal, bumper cover replacement, glass replacement, seal inspection and replacement Technical Depth Depth: Comprehensive, from basic maintenance to full engine and transmission rebuilds Diagnostic Capability: Advanced diagnostic procedures, component testing, and troubleshooting charts 📊 Manual Specifications File Format File Type: Proprietary Software / PDF Searchability: Text-searchable for quick information retrieval Print Quality Print Capability: Printable pages for workshop use Binding Type Binding: N/A (Software) Paper Type Paper Quality: N/A (Software) ⚙️ Engine Specifications Primary Engine Engine Code 1: H25A Engine Description 1: 2.5L (2492 cc) V6, DOHC, 24 valves Horsepower 1: 155 hp @ 6000 rpm Torque 1: 160 lb-ft @ 3500 rpm Optional Engine Engine Code 2: H27A Engine Description 2: 2.7L (2736 cc) V6, DOHC, 24 valves Horsepower 2: 185 hp @ 6000 rpm Torque 2: 184 lb-ft @ 3400 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 octane recommended) 🔧 Transmission Standard Transmission Type 1: 5-speed Manual Transmission Transmission Code 1: 5M-41 Optional Transmission Type 2: 4-speed Automatic Transmission Transmission Code 2: 430 Features Drivetrain Options: RWD (standard on some trims), 4WD (part-time or full-time, depending on trim) 📐 Dimensions Exterior Wheelbase: 103.1 inches (2619 mm) Length: 178.7 inches (4539 mm) Width: 70.5 inches (1791 mm) Height: 66.7 inches (1694 mm) (without roof rack) Interior Passenger Volume: Approx. 97.3 cu ft (2755 L) Cargo Cargo Volume Behind Rear Seats: Approx. 32.9 cu ft (932 L) Cargo Volume With Rear Seats Folded: Approx. 66.7 cu ft (1889 L) Weights Curb Weight Min: 3649 lbs (1655 kg) (2.5L RWD Manual) Curb Weight Max: 3982 lbs (1806 kg) (2.7L 4WD Automatic) 🛡️ Safety Features Ratings NHTSA Rollover Rating: 4-star (for 2002 models) Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Available on some 4WD models Passive Features Airbags: Driver and front passenger airbags Seatbelts: Front 3-point height-adjustable seatbelts with pretensioners, rear 3-point seatbelts 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, optional premium audio with cassette and/or CD changer. Display: Basic dashboard display for audio, climate controls, and warning lights. Driver Assistance Cruise Control: Standard on most trims. Connectivity OBD Ii: Standard OBD-II diagnostic port for engine and emissions monitoring. 🔧 Maintenance Service Intervals Engine Oil Change: Every 7,500 miles (12,000 km) or 6 months Engine Oil Filter Replacement: With every oil change Spark Plug Replacement: Every 60,000 miles (96,000 km) (Iridium plugs) Automatic Transmission Fluid Change: Every 30,000 miles (48,000 km) or 24 months Manual...
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2002 Suzuki Grand Vitara Service & Repair Manual Software
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
Grand Vitara
Year:
2002
Codes
Chassis Code:
JT
👋 Introduction
Market Position
Segment:
Compact SUV / Crossover
Usp:
Body-on-frame construction offering traditional SUV capabilities in a compact package, available with a V6 engine.
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Jeep Cherokee (XJ)
Key Features
Platform:
Body-on-frame chassis, rear-wheel drive bias with available 4WD.
Engine Options:
Reliable V6 engines offering good power for its class.
Off Road Capability:
Higher ground clearance and robust construction compared to unibody competitors.
📋 Manual Details
Coverage Areas
Engine Coverage:
2.5L V6 (H25A), 2.7L V6 (H27A)
Drivetrain Coverage:
4-speed automatic transmission (430), 5-speed manual transmission (5M-41), 4WD system (including transfer case and differentials)
Chassis Coverage:
Suspension (front MacPherson strut, rear multi-link), Steering (power rack and pinion), Brakes (front ventilated discs, rear discs)
Electrical Coverage:
Engine control systems, lighting, body control modules, power accessories, audio system, diagnostic trouble codes (DTCs)
Body Coverage:
Body panels, interior trim, doors, windows, bumpers, ventilation, heating, air conditioning (HVAC)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Service and Repair Manual Software
Language
Language:
English
Format
Format:
Digital Software (e.g., PDF, proprietary executable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication, cooling, fuel injection
Engine Electrical:
Ignition system, starting system, charging system, ECU, sensors, actuators, wiring diagrams
Transmission Drivetrain:
Manual and automatic transmission overhaul, clutch, drive shafts, differentials, transfer case
Suspension Steering:
Front and rear suspension component replacement, wheel alignment, power steering system repair
Brakes:
Brake system diagnostics, component replacement (discs, pads, calipers, lines), ABS system
HVAC:
Air conditioning system service, heater core replacement, blower motor service
Body Interior:
Door lock mechanisms, window regulators, seat removal, interior paneling, weatherstripping
Diagnostics Troubleshooting:
Symptom-based troubleshooting guides, diagnostic procedures, OBD-II scanning and interpretation
Procedures Included
Preventative Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspection and replacement
Engine Repair:
Head gasket replacement, timing belt/chain service, piston ring replacement, valve adjustment
Transmission Repair:
Clutch replacement (manual), transmission fluid and filter service (automatic), internal component repair
Brake Service:
Brake pad and rotor replacement, brake caliper service, brake fluid flush
Electrical Diagnostics:
Wiring harness repair, sensor testing and replacement, starter and alternator testing
Suspension Wheel Alignment:
Strut and shock absorber replacement, ball joint replacement, tie rod end replacement, wheel bearing replacement, wheel alignment procedures
Body Repair:
Door panel removal, bumper cover replacement, glass replacement, seal inspection and replacement
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine and transmission rebuilds
Diagnostic Capability:
Advanced diagnostic procedures, component testing, and troubleshooting charts
📊 Manual Specifications
File Format
File Type:
Proprietary Software / PDF
Searchability:
Text-searchable for quick information retrieval
Print Quality
Print Capability:
Printable pages for workshop use
Binding Type
Binding:
N/A (Software)
Paper Type
Paper Quality:
N/A (Software)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
H25A
Engine Description 1:
2.5L (2492 cc) V6, DOHC, 24 valves
Horsepower 1:
155 hp @ 6000 rpm
Torque 1:
160 lb-ft @ 3500 rpm
Optional Engine
Engine Code 2:
H27A
Engine Description 2:
2.7L (2736 cc) V6, DOHC, 24 valves
Horsepower 2:
185 hp @ 6000 rpm
Torque 2:
184 lb-ft @ 3400 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
🔧 Transmission
Standard
Transmission Type 1:
5-speed Manual Transmission
Transmission Code 1:
5M-41
Optional
Transmission Type 2:
4-speed Automatic Transmission
Transmission Code 2:
430
Features
Drivetrain Options:
RWD (standard on some trims), 4WD (part-time or full-time, depending on trim)
📐 Dimensions
Exterior
Wheelbase:
103.1 inches (2619 mm)
Length:
178.7 inches (4539 mm)
Width:
70.5 inches (1791 mm)
Height:
66.7 inches (1694 mm) (without roof rack)
Interior
Passenger Volume:
Approx. 97.3 cu ft (2755 L)
Cargo
Cargo Volume Behind Rear Seats:
Approx. 32.9 cu ft (932 L)
Cargo Volume With Rear Seats Folded:
Approx. 66.7 cu ft (1889 L)
Weights
Curb Weight Min:
3649 lbs (1655 kg) (2.5L RWD Manual)
Curb Weight Max:
3982 lbs (1806 kg) (2.7L 4WD Automatic)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4-star (for 2002 models)
Active Features
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Available on some 4WD models
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
Front 3-point height-adjustable seatbelts with pretensioners, rear 3-point seatbelts
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional premium audio with cassette and/or CD changer.
Display:
Basic dashboard display for audio, climate controls, and warning lights.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
OBD Ii:
Standard OBD-II diagnostic port for engine and emissions monitoring.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 7,500 miles (12,000 km) or 6 months
Engine Oil Filter Replacement:
With every oil change
Spark Plug Replacement:
Every 60,000 miles (96,000 km) (Iridium plugs)
Automatic Transmission Fluid Change:
Every 30,000 miles (48,000 km) or 24 months
Manual Transmission Fluid Change:
Every 45,000 miles (72,000 km) or 36 months
Coolant Flush:
Every 30,000 miles (48,000 km) or 24 months
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SG/SH/SJ or ILSAC GF-2)
Engine Oil Capacity 2.5L:
4.4 US quarts (4.2 L) with filter
Engine Oil Capacity 2.7L:
4.4 US quarts (4.2 L) with filter
Automatic Transmission Fluid Type:
Dexron III/Mercon
Manual Transmission Fluid Type:
GL-4 SAE 75W-90
Transfer Case Fluid Type:
API GL-4 SAE 75W-90
Differential Fluid Type Front Rear:
API GL-5 SAE 80W-90
Coolant Type:
Ethylene glycol based coolant (50/50 mix with distilled water)
Known Issues
Engine Oil Consumption:
Some V6 engines may exhibit oil consumption; regular checks are advised.
Rear Main Seal Leaks:
Can occur over time, often identified during transmission service.
Suspension Wear:
Ball joints and bushings can wear, leading to clunks and alignment issues.
HVAC Blower Motor Failure:
Blower motor resistor or motor itself can fail.
📚 Vehicle History
Brand Heritage
Suzuki SUV History:
Suzuki has a long history of producing capable and compact off-road vehicles, beginning with models like the SJ/Samurai.
Model Evolution
Generation 1 Start:
1998
Generation 1 End:
2005
Major Updates 2002:
Introduction of the larger 2.7L V6 engine for improved performance.
Production
Manufacturing Location:
Kosai, Shizuoka, Japan
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