Suzuki Grand Vitara 2004 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Year: 2004 Generation Generation Designation: Second Generation (JT) Codes Chassis Code: JT 👋 Introduction Market Position Segment: Compact SUV / Crossover SUV Key Selling Points: Versatile 4x4 capability, compact footprint, reliable powertrain options, practical interior. Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Jeep Cherokee. Key Features Vehicle Type: Sport Utility Vehicle (SUV) Body Styles: 2-door (XL-7 derivative) and 4-door configurations. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Full coverage including disassembly, assembly, inspection, and repair of all engine components. Engine Management: Detailed information on fuel injection, ignition system, sensors, actuators, and ECU diagnostics. Transmission Manual: Complete overhaul and repair procedures for the manual transmission. Transmission Automatic: Detailed diagnosis, repair, and overhaul for the automatic transmission. Drivetrain 4Wd: In-depth coverage of the 4x4 system, transfer case, drive shafts, differentials, and CV joints. Brakes: Diagnosis, repair, and servicing of ABS, EBD, brake lines, calipers, rotors, and master cylinder. Suspension: Detailed procedures for front and rear suspension components, including struts, shocks, control arms, and bushings. Steering: Repair and maintenance of power steering system, rack and pinion, and steering column. Electrical System: Comprehensive wiring diagrams, diagnostic procedures, and repair information for all electrical components. HVAC: Service and repair of the heating, ventilation, and air conditioning system. Body Exterior: Information on body panel removal/installation, trim, glass, and exterior lighting. Body Interior: Procedures for interior trim, seating, dashboard, and headliner removal/installation. Restraints: Airbag system diagnostics and repair, seat belt mechanisms. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, spark plug replacement. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides. Repair: Step-by-step instructions for component removal, installation, and adjustment. Overhaul: Detailed procedures for complete engine and transmission rebuilds. Diagnostics: OBD-II codes, sensor data interpretation, and component testing. Technical Depth Depth: Factory-level technical detail suitable for professional technicians and advanced DIYers. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval. Resolution: High-resolution scans ensuring clarity of diagrams and text. Print Quality Printability: Printable pages for convenient workshop use. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline 1: J20A Engine Description Gasoline 1: 2.0L Inline-4 DOHC 16-valve Displacement Gasoline 1: 1995 cc (121.7 cu in) Horsepower Gasoline 1: 123-135 hp @ 5500-6000 rpm (varies by market/tune) Torque Gasoline 1: 133-138 lb-ft @ 3000-3500 rpm (varies by market/tune) Fuel System Gasoline 1: Electronic Multi-Port Fuel Injection (MPI) Compression Ratio Gasoline 1: 9.7:1 Bore X Stroke Gasoline 1: 84.0 mm x 90.0 mm Alternative Engine Gasoline Engine Code Gasoline 2: J27A Engine Description Gasoline 2: 2.7L V6 DOHC 24-valve (North American market primarily) Displacement Gasoline 2: 2736 cc (167 cu in) Horsepower Gasoline 2: 185 hp @ 6000 rpm Torque Gasoline 2: 184 lb-ft @ 3000 rpm Fuel System Fuel Type: Unleaded Gasoline Fuel Octane Rating: 87 Octane (minimum) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission (4EAT) Features Drivetrain Options: Available in Rear-Wheel Drive (RWD) and All-Wheel Drive (AWD) configurations. AWD System: Full-time 4x4 system with viscous coupling center differential. 📐 Dimensions Exterior Length: 4,470 mm (176.0 in) for 4-door model Width: 1,810 mm (71.3 in) Height: 1,695 mm (66.7 in) without roof rails Wheelbase: 2,635 mm (103.7 in) Ground Clearance: Approx. 200 mm (7.9 in) Weights Curb Weight Min: Approx. 1,500 kg (3,307 lbs) for 2.0L RWD manual Curb Weight Max: Approx. 1,750 kg (3,858 lbs) for 2.7L AWD automatic Cargo Cargo Volume Behind Rear Seats: Approx. 735 liters (25.9 cu ft) Cargo Volume With Rear Seats Folded: Approx. 1,717 liters (60.6 cu ft) 🛡️ Safety Features Ratings NHTSA Frontal Crash Rating Driver: 4 Stars (2004 Model Year) NHTSA Frontal Crash Rating Passenger: 4 Stars (2004 Model Year) NHTSA Side Impact Crash Rating Front Driver: 4 Stars (2004 Model Year) NHTSA Side Impact Crash Rating Front Passenger: 5 Stars (2004 Model Year) NHTSA Side Impact Crash Rating Rear Driver: 5 Stars (2004 Model Year) NHTSA Rollover Rating: 4 Stars (2004 Model Year) Active Features ABS: Standard (4-wheel disc brakes on most models) Ebd: Electronic Brake-force Distribution (Standard) Passive Features Airbags: Front dual-stage airbags, optional front side-impact airbags. Seatbelts: 3-point height-adjustable front seatbelts with pretensioners and load limiters. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player with optional premium audio system and steering wheel controls on higher trims. Navigation: Optional factory-installed GPS navigation system on select models. Driver Assistance Cruise Control: Standard cruise control system. Connectivity Auxiliary Input: Typically no standard auxiliary audio input; aftermarket solutions may be available. 🔧 Maintenance Service Intervals Oil Change...
Diagnostic flowcharts and symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, installation, and adjustment.
Overhaul:
Detailed procedures for complete engine and transmission rebuilds.
Diagnostics:
OBD-II codes, sensor data interpretation, and component testing.
Technical Depth
Depth:
Factory-level technical detail suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval.
Resolution:
High-resolution scans ensuring clarity of diagrams and text.
Print Quality
Printability:
Printable pages for convenient workshop use.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline 1:
J20A
Engine Description Gasoline 1:
2.0L Inline-4 DOHC 16-valve
Displacement Gasoline 1:
1995 cc (121.7 cu in)
Horsepower Gasoline 1:
123-135 hp @ 5500-6000 rpm (varies by market/tune)
Torque Gasoline 1:
133-138 lb-ft @ 3000-3500 rpm (varies by market/tune)
Fuel System Gasoline 1:
Electronic Multi-Port Fuel Injection (MPI)
Compression Ratio Gasoline 1:
9.7:1
Bore X Stroke Gasoline 1:
84.0 mm x 90.0 mm
Alternative Engine Gasoline
Engine Code Gasoline 2:
J27A
Engine Description Gasoline 2:
2.7L V6 DOHC 24-valve (North American market primarily)
Displacement Gasoline 2:
2736 cc (167 cu in)
Horsepower Gasoline 2:
185 hp @ 6000 rpm
Torque Gasoline 2:
184 lb-ft @ 3000 rpm
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Octane Rating:
87 Octane (minimum)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (4EAT)
Features
Drivetrain Options:
Available in Rear-Wheel Drive (RWD) and All-Wheel Drive (AWD) configurations.
AWD System:
Full-time 4x4 system with viscous coupling center differential.
📐 Dimensions
Exterior
Length:
4,470 mm (176.0 in) for 4-door model
Width:
1,810 mm (71.3 in)
Height:
1,695 mm (66.7 in) without roof rails
Wheelbase:
2,635 mm (103.7 in)
Ground Clearance:
Approx. 200 mm (7.9 in)
Weights
Curb Weight Min:
Approx. 1,500 kg (3,307 lbs) for 2.0L RWD manual
Curb Weight Max:
Approx. 1,750 kg (3,858 lbs) for 2.7L AWD automatic
Cargo
Cargo Volume Behind Rear Seats:
Approx. 735 liters (25.9 cu ft)
Cargo Volume With Rear Seats Folded:
Approx. 1,717 liters (60.6 cu ft)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Rating Driver:
4 Stars (2004 Model Year)
NHTSA Frontal Crash Rating Passenger:
4 Stars (2004 Model Year)
NHTSA Side Impact Crash Rating Front Driver:
4 Stars (2004 Model Year)
NHTSA Side Impact Crash Rating Front Passenger:
5 Stars (2004 Model Year)
NHTSA Side Impact Crash Rating Rear Driver:
5 Stars (2004 Model Year)
NHTSA Rollover Rating:
4 Stars (2004 Model Year)
Active Features
ABS:
Standard (4-wheel disc brakes on most models)
Ebd:
Electronic Brake-force Distribution (Standard)
Passive Features
Airbags:
Front dual-stage airbags, optional front side-impact airbags.
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player with optional premium audio system and steering wheel controls on higher trims.
Navigation:
Optional factory-installed GPS navigation system on select models.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Auxiliary Input:
Typically no standard auxiliary audio input; aftermarket solutions may be available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Air Filter Replacement Interval:
Every 30,000 miles (48,000 km).
Spark Plug Replacement Interval 2.0L:
Every 60,000 miles (96,000 km) (Iridium type recommended).
Spark Plug Replacement Interval 2.7L V6:
Every 100,000 miles (160,000 km) (Iridium type recommended).
Transmission Fluid Change Interval Auto:
Every 60,000 miles (96,000 km) under normal driving conditions.
Transmission Fluid Change Interval Manual:
Every 60,000 miles (96,000 km).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SM/SN or ILSAC GF-4/GF-5)
Engine Oil Capacity 2.0L:
4.2 Liters (4.4 US Quarts) with filter
Engine Oil Capacity 2.7L V6:
4.9 Liters (5.2 US Quarts) with filter
Coolant Type:
Suzuki Super Long Life Coolant (Green) or equivalent HOAT (Hybrid Organic Acid Technology) antifreeze.
Automatic Transmission Fluid Type:
Suzuki ATF 3317 or equivalent DEXRON-III/MERCON
Manual Transmission Fluid Type:
Suzuki Manual Transmission Oil (GL-4) SAE 75W-90
Power Steering Fluid Type:
ATF DEXRON-II or equivalent
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
CV joints, wheel bearings, front sway bar links, exhaust system components.
Engine Considerations 2.7L:
Potential for oil consumption on higher mileage engines, timing chain system (though generally robust).
Transmission Considerations:
Automatic transmission can occasionally develop delayed engagement or shifting issues, often related to fluid condition or valve body wear.
Electrical Considerations:
Window regulators, power lock actuators, and alternator issues can occur with age and mileage.
📚 Vehicle History
Brand Heritage
Suzuki SUV Legacy:
Suzuki has a long history of producing capable off-road vehicles, starting with the Suzuki Samurai and Sidekick.
Model Evolution
First Generation Grand Vitara:
Introduced as the Grand Vitara in 1998 (as a 1999 model in some markets), succeeding the Sidekick/Vitara lineage.
Second Generation Transition:
The 2004 model marks the introduction of the second generation, featuring a unibody construction for improved ride comfort and a more car-like driving experience, a significant departure from the body-on-frame previous generation.
Production
Production Start Year:
1998 (First Generation)
Production Period Second Gen:
2005-2015 (Model years often differ by market, with 2004 sometimes referring to the very first models of the second generation globally).
Manufacturing Locations:
Japan, Hungary, India (different variants).
🏆 Awards & Recognition
Recognitions
Off Road Capability Awards:
While not a hardcore off-roader, the Grand Vitara consistently received praise for its competent 4x4 system and trail capability within its segment.
Ratings
Konsumen Reports Reliability Rating:
Varies by year and specific engine, generally rated as average to below average by some consumer reporting agencies for this generation.
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