Suzuki Grand Vitara 2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Year: 2002 Codes Chassis Code: FT/GT Series (Second Generation) Engine Code Common: J20A (2.0L Inline-4), H27A (2.7L V6) 👋 Introduction Market Position Segment: Compact SUV / Crossover SUV Key Selling Points: Rugged styling, available V6 engine, capable 4WD system, practical interior, competitive pricing Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Jeep Cherokee (XJ/Liberty) Key Features Body Styles: 5-door SUV, 3-door (short wheelbase) SUV Drivetrain Options: 2WD (Rear-Wheel Drive), 4WD (Four-Wheel Drive with selectable low range on some models) 📋 Manual Details Coverage Areas Market Coverage: Global (North America, Europe, Asia, Oceania) Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, engine control module (ECM), transmission (automatic & manual), driveline, transfer case, differentials Chassis: Suspension (front & rear), steering system, braking system (ABS, EBD), wheel alignment Electrical: Body electrical systems, lighting, power accessories, climate control system, instrument cluster, audio system, wiring diagrams, diagnostic trouble codes (DTCs), fuses, relays Body And Interior: Body panels, doors, glass, seats, upholstery, interior trim, bumpers, safety restraints (airbags) Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication Troubleshooting: Diagnostic procedures, symptom-based troubleshooting charts, electrical diagnostics, mechanical diagnostics Repair: Component removal and installation, disassembly and assembly, repair procedures for all major systems Diagnostics: OBD-II diagnostics, specific diagnostic trouble codes (DTCs), component testing, sensor data interpretation Technical Depth Depth: Comprehensive; covers everything from basic fluid changes to complete engine and transmission rebuilds, including electrical schematics and diagnostic procedures 📊 Manual Specifications File Format Searchability: Searchable text for quick information retrieval Accessibility: Printable pages for on-the-go use Print Quality Image Resolution: High-resolution diagrams, illustrations, and photographs Binding Type Binding: Not applicable (Digital PDF) Paper Type Paper Type: Not applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 1: 2.0L DOHC Inline-4 (J20A) Engine 1 Horsepower: 123 hp @ 5500 rpm Engine 1 Torque: 130 lb-ft @ 3000 rpm Optional Engine Engine 2: 2.7L SOHC V6 (H27A) Engine 2 Horsepower: 170 hp @ 5500 rpm Engine 2 Torque: 178 lb-ft @ 3000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Management ECU: Suzuki Engine Control Module (ECM) 🔧 Transmission Standard Transmission 1: 5-speed Manual Optional Transmission 2: 4-speed Automatic (with overdrive) Features Transfer Case Type: Part-time 4WD system with Hi/Lo range, or Full-time 4WD system (depending on market/trim) Fluid Specifications Automatic Transmission Fluid: Suzuki ATF 5D03 or equivalent Dexron III/Mercon Manual Transmission Fluid: GL-4 SAE 75W-90 Gear Oil Transfer Case Fluid: GL-4 SAE 75W-90 Gear Oil Differential Fluid: GL-5 SAE 80W-90 Gear Oil 📐 Dimensions Exterior Length 5Dr: 175.0 inches (4445 mm) Width: 67.9 inches (1725 mm) Height: 66.7 inches (1695 mm) Wheelbase 5Dr: 104.1 inches (2645 mm) Weights Curb Weight Approx: 3100-3500 lbs (1406-1588 kg) depending on engine/drivetrain Towing Capacity Approx: 1500-3000 lbs (680-1361 kg) depending on market/engine 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 4/5 stars (V6, 4WD models often rated higher due to stability) Active Features ABS: Standard on most models (Anti-lock Braking System) Ebd: Electronic Brake-force Distribution (often integrated with ABS) Passive Features Airbags: Front airbags standard; side airbags optional on some trims Seatbelts: 3-point seatbelts with pretensioners for front occupants 💡 Technology Features Infotainment Audio System: AM/FM Stereo with CD player, 4-6 speakers Navigation: Optional GPS navigation system on higher trims Driver Assistance Cruise Control: Available on most models Keyless Entry: Optional Connectivity Auxiliary Input: Not standard, some aftermarket head units may have it 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles (8,000 km) or 6 months, whichever comes first Air Filter Replacement: Every 15,000 miles (24,000 km) or 12 months Spark Plug Replacement: Every 60,000 miles (96,000 km) for standard plugs, 100,000 miles (160,000 km) for iridium plugs Transmission Fluid Change: Every 30,000 miles (48,000 km) or 24 months Fluid Specifications Engine Oil Type: 5W-30 Synthetic or Conventional (API SJ or higher) Engine Oil Capacity: 4.3 US Quarts (4.1 Liters) with filter (J20A), 5.3 US Quarts (5.0 Liters) with filter (H27A) Coolant Type: Suzuki Super Long Life Coolant (SLLC) or equivalent P-OAT antifreeze Brake Fluid Type: DOT 3 Known Issues Common Problem 1: Power steering pump leaks or noise Common Problem 2: Catalytic converter failure (especially on earlier models) Common Problem 3: CV joint wear and tear (particularly front) Common Problem 4: ABS sensor faults or ABS warning light illumination Common Problem 5: Oil cooler line leaks (on models equipped with an oil cooler) 📚 Vehicle History Brand Heritage Brand Focus: Suzuki is known for its lightweight, capable off-road vehicles and motorcycles, often with a focus on practicality and value. Model Evolution Generation 1 Start: 1998 Generation 2 Start: 2001 Generation 2...
Component removal and installation, disassembly and assembly, repair procedures for all major systems
Diagnostics:
OBD-II diagnostics, specific diagnostic trouble codes (DTCs), component testing, sensor data interpretation
Technical Depth
Depth:
Comprehensive; covers everything from basic fluid changes to complete engine and transmission rebuilds, including electrical schematics and diagnostic procedures
📊 Manual Specifications
File Format
Searchability:
Searchable text for quick information retrieval
Accessibility:
Printable pages for on-the-go use
Print Quality
Image Resolution:
High-resolution diagrams, illustrations, and photographs
Binding Type
Binding:
Not applicable (Digital PDF)
Paper Type
Paper Type:
Not applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.0L DOHC Inline-4 (J20A)
Engine 1 Horsepower:
123 hp @ 5500 rpm
Engine 1 Torque:
130 lb-ft @ 3000 rpm
Optional Engine
Engine 2:
2.7L SOHC V6 (H27A)
Engine 2 Horsepower:
170 hp @ 5500 rpm
Engine 2 Torque:
178 lb-ft @ 3000 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU:
Suzuki Engine Control Module (ECM)
🔧 Transmission
Standard
Transmission 1:
5-speed Manual
Optional
Transmission 2:
4-speed Automatic (with overdrive)
Features
Transfer Case Type:
Part-time 4WD system with Hi/Lo range, or Full-time 4WD system (depending on market/trim)
Fluid Specifications
Automatic Transmission Fluid:
Suzuki ATF 5D03 or equivalent Dexron III/Mercon
Manual Transmission Fluid:
GL-4 SAE 75W-90 Gear Oil
Transfer Case Fluid:
GL-4 SAE 75W-90 Gear Oil
Differential Fluid:
GL-5 SAE 80W-90 Gear Oil
📐 Dimensions
Exterior
Length 5Dr:
175.0 inches (4445 mm)
Width:
67.9 inches (1725 mm)
Height:
66.7 inches (1695 mm)
Wheelbase 5Dr:
104.1 inches (2645 mm)
Weights
Curb Weight Approx:
3100-3500 lbs (1406-1588 kg) depending on engine/drivetrain
Towing Capacity Approx:
1500-3000 lbs (680-1361 kg) depending on market/engine
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
4/5 stars (V6, 4WD models often rated higher due to stability)
Active Features
ABS:
Standard on most models (Anti-lock Braking System)
Ebd:
Electronic Brake-force Distribution (often integrated with ABS)
Passive Features
Airbags:
Front airbags standard; side airbags optional on some trims
Seatbelts:
3-point seatbelts with pretensioners for front occupants
💡 Technology Features
Infotainment
Audio System:
AM/FM Stereo with CD player, 4-6 speakers
Navigation:
Optional GPS navigation system on higher trims
Driver Assistance
Cruise Control:
Available on most models
Keyless Entry:
Optional
Connectivity
Auxiliary Input:
Not standard, some aftermarket head units may have it
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for standard plugs, 100,000 miles (160,000 km) for iridium plugs
Transmission Fluid Change:
Every 30,000 miles (48,000 km) or 24 months
Fluid Specifications
Engine Oil Type:
5W-30 Synthetic or Conventional (API SJ or higher)
Engine Oil Capacity:
4.3 US Quarts (4.1 Liters) with filter (J20A), 5.3 US Quarts (5.0 Liters) with filter (H27A)
Coolant Type:
Suzuki Super Long Life Coolant (SLLC) or equivalent P-OAT antifreeze
Brake Fluid Type:
DOT 3
Known Issues
Common Problem 1:
Power steering pump leaks or noise
Common Problem 2:
Catalytic converter failure (especially on earlier models)
Common Problem 3:
CV joint wear and tear (particularly front)
Common Problem 4:
ABS sensor faults or ABS warning light illumination
Common Problem 5:
Oil cooler line leaks (on models equipped with an oil cooler)
📚 Vehicle History
Brand Heritage
Brand Focus:
Suzuki is known for its lightweight, capable off-road vehicles and motorcycles, often with a focus on practicality and value.
Model Evolution
Generation 1 Start:
1998
Generation 2 Start:
2001
Generation 2 End:
2005
Production
Manufacturing Location:
Japan, Canada, and various international plants
🏆 Awards & Recognition
Recognitions
Award 1:
Often praised for its off-road capability relative to its segment competitors.
Award 2:
Recognized for its value proposition and rugged design.
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