2007 Suzuki Grand VITARA JB416/JB420/JB627/JB419 Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Model Code: JB416, JB420, JB627, JB419 Production Year: 2007 👋 Introduction Market Position Positioning: Compact/Mid-size SUV with available 4WD/AWD, positioned as a versatile and capable vehicle for light off-roading and everyday use. Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Nissan X-Trail/Rogue, Ford Escape, Mazda CX-5, Mitsubishi Outlander. Key Features Engine Options: Offered with multiple engine choices to cater to different needs and budgets, including fuel-efficient four-cylinders and a more powerful V6 option. Drivetrain Options: Available in front-wheel drive (FWD) and Suzuki's advanced 4-mode 4x4 system (4WD) enhancing off-road capability. Body Style: Typically offered as a 5-door SUV. Interior Space: Offers a practical interior with decent passenger and cargo space for its segment. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Engine Variants Covered: JB416 (1.6L), JB420 (2.0L), JB627 (2.7L V6), JB419 (1.9L Diesel - likely for specific markets) Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Downloadable Digital File (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, connecting rods, crankshaft, camshafts, valve train, timing system, lubrication system, cooling system, fuel system (including injectors, pumps, lines), intake system, exhaust system. Engine Electrical: Engine Control Module (ECM) diagnosis, ignition system, starting system, charging system (alternator), sensor operations and testing (crankshaft position, camshaft position, MAF, MAP, O2 sensors, etc.). Transmission Manual: Gearbox internal components, clutch system, shift linkage, lubrication, torque specifications. Transmission Automatic: Automatic transmission components, valve body, torque converter, planetary gear sets, hydraulic control system, electronic control unit (TCU) diagnosis, fluid and filter service. Drivetrain 4Wd: Transfer case operation and repair, front and rear drive shafts, constant velocity (CV) joints, differentials (front, rear, center), wheel hub bearings, 4WD system engagement and control. Brakes: Hydraulic system, brake master cylinder, ABS (Anti-lock Braking System) components and diagnosis, electronic brake force distribution (EBD), brake calipers, rotors, pads, parking brake system, bleeding procedures. Suspension: Front suspension (struts, control arms, ball joints, bushings), rear suspension (multi-link or independent setup depending on variant), shock absorbers, coil springs, anti-roll bars, steering knuckle, alignment specifications. Steering: Power steering system (hydraulic or electric assist), steering rack/gearbox, tie rods, steering column, wheel alignment. Body Exterior: Body panel removal and installation, doors, hood, tailgate, bumpers, glass, mirrors, trim pieces, chassis structure. Body Interior: Dashboard, seats, door panels, headliner, carpeting, HVAC controls, interior trim components. Electrical Lighting: Headlights, taillights, interior lighting, fog lights, wiring diagrams for all lighting circuits. Electrical Accessories: Power windows, power locks, sunroof, wipers, horn, audio system, power mirrors, ignition switch, fuse box and relay locations. Climate Control: HVAC system components (compressor, condenser, evaporator, heater core), refrigerant handling, AC operation, climate control module diagnostics. Safety Systems: Airbag system components and SRS module, seat belt mechanisms, ABS, traction control (if equipped). Diagnostics: OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, component testing procedures, wiring diagrams for diagnostic circuits. Procedures Included Scheduled Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant service, brake fluid flush, transmission fluid/filter change, differential fluid change, transfer case fluid change. Engine Repair: Engine tune-up, head gasket replacement, timing belt/chain service, piston and ring replacement, bearing replacement, oil pump replacement, radiator and hose replacement. Transmission Repair: Clutch replacement (manual), transmission rebuild (automatic and manual), torque converter replacement, seal replacement, transmission fluid and filter replacement. Brake Repair: Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS component replacement and bleeding, parking brake adjustment. Suspension Steering Repair: Strut and shock absorber replacement, control arm and ball joint replacement, power steering pump/rack replacement, wheel bearing replacement, tie rod end replacement. Electrical Diagnosis And Repair: Troubleshooting electrical faults, component testing, wiring harness repair, module replacement (ECM, TCM, ABS), battery and charging system diagnostics. Body Work: Door panel removal, tailgate repair, bumper replacement, glass replacement, mirror replacement, minor body panel adjustments. Troubleshooting Guides: Step-by-step diagnostic procedures for common symptoms (e.g., no-start conditions, poor performance, unusual noises). Technical Specifications And Torques: Detailed torque specifications for all major fasteners, fluid capacities, and component clearances. Technical Depth Depth: Comprehensive from basic maintenance to major component overhaul and advanced diagnostics. Diagnostic Focus: Includes detailed diagnostic flowcharts, sensor specifications, and troubleshooting trees. Rebuild Procedures: Detailed instructions for rebuilding major components like engines, transmissions, and differentials. 📊 Manual Specifications File Format Format: PDF Searchability: Likely fully searchable text content for quick information retrieval. Print Quality Quality: Digital reproduction of original factory manual, includes diagrams and schematics. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1 6L: M16A (JB416) Displacement 1 6L: 1.6 liters (1586 cc) Configuration 1 6L: Inline 4-cylinder, DOHC, 16-valve Performance 1 6L Hp: Approx. 105-110 hp @ 5800-6000 rpm (market dependent) Performance 1 6L Torque: Approx. 145-150 Nm @ 4000-4500 rpm (market...

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Grand Vitara

Model Code:

JB416, JB420, JB627, JB419

Production Year:

👋 Introduction

Market Position

Positioning:

Compact/Mid-size SUV with available 4WD/AWD, positioned as a versatile and capable vehicle for light off-roading and everyday use.

Competitive Analysis

Competitors:

Honda CR-V, Toyota RAV4, Nissan X-Trail/Rogue, Ford Escape, Mazda CX-5, Mitsubishi Outlander.

Key Features

Engine Options:

Offered with multiple engine choices to cater to different needs and budgets, including fuel-efficient four-cylinders and a more powerful V6 option.

Drivetrain Options:

Available in front-wheel drive (FWD) and Suzuki's advanced 4-mode 4x4 system (4WD) enhancing off-road capability.

Body Style:

Typically offered as a 5-door SUV.

Interior Space:

Offers a practical interior with decent passenger and cargo space for its segment.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair

Engine Variants Covered:

JB416 (1.6L), JB420 (2.0L), JB627 (2.7L V6), JB419 (1.9L Diesel - likely for specific markets)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Downloadable Digital File (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, connecting rods, crankshaft, camshafts, valve train, timing system, lubrication system, cooling system, fuel system (including injectors, pumps, lines), intake system, exhaust system.

Engine Electrical:

Engine Control Module (ECM) diagnosis, ignition system, starting system, charging system (alternator), sensor operations and testing (crankshaft position, camshaft position, MAF, MAP, O2 sensors, etc.).

Transmission Manual:

Gearbox internal components, clutch system, shift linkage, lubrication, torque specifications.

Transmission Automatic:

Automatic transmission components, valve body, torque converter, planetary gear sets, hydraulic control system, electronic control unit (TCU) diagnosis, fluid and filter service.

Drivetrain 4Wd:

Transfer case operation and repair, front and rear drive shafts, constant velocity (CV) joints, differentials (front, rear, center), wheel hub bearings, 4WD system engagement and control.

Brakes:

Hydraulic system, brake master cylinder, ABS (Anti-lock Braking System) components and diagnosis, electronic brake force distribution (EBD), brake calipers, rotors, pads, parking brake system, bleeding procedures.

Suspension:

Front suspension (struts, control arms, ball joints, bushings), rear suspension (multi-link or independent setup depending on variant), shock absorbers, coil springs, anti-roll bars, steering knuckle, alignment specifications.

Steering:

Power steering system (hydraulic or electric assist), steering rack/gearbox, tie rods, steering column, wheel alignment.

Body Exterior:

Body panel removal and installation, doors, hood, tailgate, bumpers, glass, mirrors, trim pieces, chassis structure.

Body Interior:

Dashboard, seats, door panels, headliner, carpeting, HVAC controls, interior trim components.

Electrical Lighting:

Headlights, taillights, interior lighting, fog lights, wiring diagrams for all lighting circuits.

Electrical Accessories:

Power windows, power locks, sunroof, wipers, horn, audio system, power mirrors, ignition switch, fuse box and relay locations.

Climate Control:

HVAC system components (compressor, condenser, evaporator, heater core), refrigerant handling, AC operation, climate control module diagnostics.

Safety Systems:

Airbag system components and SRS module, seat belt mechanisms, ABS, traction control (if equipped).

Diagnostics:

OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, component testing procedures, wiring diagrams for diagnostic circuits.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant service, brake fluid flush, transmission fluid/filter change, differential fluid change, transfer case fluid change.

Engine Repair:

Engine tune-up, head gasket replacement, timing belt/chain service, piston and ring replacement, bearing replacement, oil pump replacement, radiator and hose replacement.

Transmission Repair:

Clutch replacement (manual), transmission rebuild (automatic and manual), torque converter replacement, seal replacement, transmission fluid and filter replacement.

Brake Repair:

Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS component replacement and bleeding, parking brake adjustment.

Suspension Steering Repair:

Strut and shock absorber replacement, control arm and ball joint replacement, power steering pump/rack replacement, wheel bearing replacement, tie rod end replacement.

Electrical Diagnosis And Repair:

Troubleshooting electrical faults, component testing, wiring harness repair, module replacement (ECM, TCM, ABS), battery and charging system diagnostics.

Body Work:

Door panel removal, tailgate repair, bumper replacement, glass replacement, mirror replacement, minor body panel adjustments.

Troubleshooting Guides:

Step-by-step diagnostic procedures for common symptoms (e.g., no-start conditions, poor performance, unusual noises).

Technical Specifications And Torques:

Detailed torque specifications for all major fasteners, fluid capacities, and component clearances.

Technical Depth

Depth:

Comprehensive from basic maintenance to major component overhaul and advanced diagnostics.

Diagnostic Focus:

Includes detailed diagnostic flowcharts, sensor specifications, and troubleshooting trees.

Rebuild Procedures:

Detailed instructions for rebuilding major components like engines, transmissions, and differentials.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely fully searchable text content for quick information retrieval.

Print Quality

Quality:

Digital reproduction of original factory manual, includes diagrams and schematics.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1 6L:

M16A (JB416)

Displacement 1 6L:

1.6 liters (1586 cc)

Configuration 1 6L:

Inline 4-cylinder, DOHC, 16-valve

Performance 1 6L Hp:

Approx. 105-110 hp @ 5800-6000 rpm (market dependent)

Performance 1 6L Torque:

Approx. 145-150 Nm @ 4000-4500 rpm (market dependent)

Engine Code 2 0L:

J20A (JB420)

Displacement 2 0L:

2.0 liters (1998 cc)

Configuration 2 0L:

Inline 4-cylinder, DOHC, 16-valve

Performance 2 0L Hp:

Approx. 138-140 hp @ 5900-6000 rpm (market dependent)

Performance 2 0L Torque:

Approx. 183-185 Nm @ 4000-4500 rpm (market dependent)

Engine Code 2 7L V6:

H27A (JB627)

Displacement 2 7L V6:

2.7 liters (2736 cc)

Configuration 2 7L V6:

V6, DOHC, 24-valve

Performance 2 7L V6 Hp:

Approx. 185-190 hp @ 6000 rpm

Performance 2 7L V6 Torque:

Approx. 250 Nm @ 3000-3500 rpm

Engine Code 1 9L Diesel:

F9Q (JB419 - likely Renault-Nissan sourced)

Displacement 1 9L Diesel:

1.9 liters (1870 cc)

Configuration 1 9L Diesel:

Inline 4-cylinder, Turbocharged, Common Rail Diesel

Performance 1 9L Diesel Hp:

Approx. 120-130 hp (market dependent)

Performance 1 9L Diesel Torque:

Approx. 280-300 Nm (market dependent)

Fuel System

Fuel Delivery Gasoline:

Electronic Fuel Injection (EFI)

Fuel Delivery Diesel:

Common Rail Direct Injection (CRDI)

Recommended Fuel Gasoline:

Unleaded Gasoline (Octane rating specified by market)

Recommended Fuel Diesel:

Low sulfur Diesel Fuel

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission (MT) often standard on lower engine variants.

Optional

Optional Transmission:

4-speed Automatic Transmission (AT) often available on 2.0L and standard on 2.7L V6 models.

Features

4Wd System:

Suzuki's 4-mode 4x4 system (e.g., 2H, 4H, 4H Lock, 4L Lock) allowing driver selection for various terrain conditions. This system is a key differentiator.

Gear Ratios:

Specific gear ratios for manual and automatic transmissions are detailed within the manual.

Clutch Type:

Hydraulically actuated dry single-plate clutch for manual transmissions.

Fluid Specifications

Manual Transmission Fluid:

Refer to manual for specific API GL-4 or GL-5 gear oil viscosity (e.g., 75W-90).

Automatic Transmission Fluid:

Refer to manual for specific ATF type (e.g., Dexron III/VI or equivalent).

📐 Dimensions

Exterior

Length:

Approx. 4145-4150 mm (depending on market/variant)

Width:

Approx. 1780-1800 mm

Height:

Approx. 1680-1690 mm

Wheelbase:

Approx. 2500 mm

Ground Clearance:

Approx. 190-200 mm (depending on variant/tire size)

Interior

Seating Capacity:

5 Passengers

Cargo

Cargo Volume:

Approx. 396 liters (rear seats up), expandable with seats folded.

Weights

Curb Weight:

Approx. 1350-1550 kg (depending on engine and drivetrain)

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle's VIN plate or manual for specific GVWR.

Towing Capacity:

Refer to market-specific regulations and manual; typically rated for lighter loads.

🛡️ Safety Features

Ratings

Crash Test Results:

Refer to NHTSA (US) or Euro NCAP (Europe) for specific crash test ratings for the 2007 model year. Results varied by region and testing agency.

Active Features

Standard Anti-lock Braking System (ABS) across most trims.

Traction Control:

Electronic Stability Program (ESP) or Traction Control System (TCS) often available, especially on higher trims or 4WD models.

Electronic Brake-force Distribution (EBD) integrated with ABS.

Passive Features

Airbags:

Front driver and passenger airbags standard. Side curtain airbags and front side airbags may be optional or standard on higher trims.

Seatbelts:

3-point seat belts with pretensioners for front occupants, 3-point belts for rear passengers.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system compliant.

💡 Technology Features

Infotainment

Audio System:

Standard CD player with AM/FM radio, auxiliary input. Higher trims might feature upgraded audio systems and potentially a CD changer.

Navigation:

Optional factory-installed navigation system available on some higher trim levels.

Display Type:

Basic LCD screen for audio and climate controls, with a separate screen for navigation if equipped.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Keyless Entry:

Available keyless entry and ignition on higher trims.

Connectivity

Bluetooth:

Bluetooth connectivity was not widely standard in 2007 and would likely be an aftermarket addition or part of a higher-spec trim/option package.

Usb Port:

USB ports were not common in 2007 infotainment systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 6-12 months, depending on driving conditions and oil type used (synthetic recommended).

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Cabin Air Filter Replacement:

Inspect/replace annually or every 15,000 miles (24,000 km).

Spark Plug Replacement Gasoline:

Typically around 60,000-100,000 miles (96,000-160,000 km) depending on plug type (e.g., iridium plugs).

Coolant Flush:

Initial flush around 100,000 miles (160,000 km), then every 50,000-60,000 miles (80,000-100,000 km) or 4-5 years thereafter.

Transmission Fluid Change Atf:

Refer to manual. Often recommended every 30,000-60,000 miles (48,000-96,000 km) for normal use, sooner for severe use. Filter replacement often done at the same time.

Differential Fluid Change:

Typically every 30,000-50,000 miles (48,000-80,000 km).

Fluid Specifications

Engine Oil Type Gasoline:

Refer to manual. Commonly 5W-30 or 5W-40 synthetic or synthetic blend.

Engine Oil Capacity 2 0L:

Approx. 4.0-4.2 liters (4.2-4.4 US quarts) with filter change.

Engine Oil Capacity 2 7L V6:

Approx. 4.8-5.0 liters (5.1-5.3 US quarts) with filter change.

Coolant Type:

Sufficiently المضاد للتجمد (antifreeze) coolant meeting specified standards (e.g., ethylene glycol based).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Refer to manual; typically ATF Dexron II/III or specific power steering fluid.

Known Issues

Catalytic Converter:

Some early models may have experienced catalytic converter issues, especially with the 2.7L V6.

ABS Sensor Failures:

Wheel speed sensors for the ABS system can be prone to failure over time, especially in areas with road salt and dirt.

Exhaust Manifold Cracks:

Cracks in the exhaust manifold, particularly on the 2.7L V6, have been reported, leading to exhaust leaks and noise.

Power Steering Pump Leaks:

Occasional leaks from the power steering pump or hoses.

Interior Rattles:

As with many vehicles of this age, interior trim pieces can develop rattles and squeaks.

Timing Chain Stretch:

While generally reliable, some engines might experience minor timing chain stretch over high mileage, though less common than in some other brands.

📚 Vehicle History

Brand Heritage

Suzuki Offroad Legacy:

Suzuki has a long-standing reputation for building rugged, capable off-road vehicles like the Samurai, Jimny, and Vitara lineage, instilling confidence in the Grand Vitara's 4WD capabilities.

Model Evolution

Generation:

This 2007 model represents the second generation (JT) of the Grand Vitara, which debuted in 2005. This generation moved to a unibody construction with integrated body-frame for improved on-road manners while retaining significant off-road prowess, particularly with its optional 4-mode 4x4 system.

Previous Generation:

The first generation (SQ) was known for its body-on-frame construction and more traditional SUV feel.

Production

Production Locations:

Manufactured in Japan and various other international locations depending on the target market.

Production Years Jt Generation:

2005-2015 (with facelifts and updates)

🏆 Awards & Recognition

Recognitions

4X4 Capability Recognition:

The Grand Vitara's integrated body-frame and sophisticated 4-mode 4x4 system often earned it praise in off-road reviews for its class.

Value Proposition:

Often cited for offering a good balance of capability, features, and value for money in the compact SUV segment.

Ratings

Consumer Satisfaction Reports:

Refer to historical consumer satisfaction reports from organizations like Consumer Reports for specific model year ratings, which varied.