2005-2008 Suzuki Grand Vitara Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Model Years: 2005, 2006, 2007, 2008 Codes Chassis Code: JB419WD, JB420WD, JB632W 👋 Introduction Market Position Segment: Compact/Mid-size SUV, often marketed as a lifestyle or adventure-oriented vehicle. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan X-Trail, Mitsubishi Outlander, Kia Sportage, Hyundai Tucson. Key Features Distinctive Attributes: Available with true body-on-frame construction (early models) and unibody construction (this generation), sophisticated 4x4 systems (e.g., Full-Time 4WD), durable powertrains, and practical interior space. 📋 Manual Details Coverage Areas Regions Covered: Global (specific market variations may exist) Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECU/ECM), transmission (automatic and manual), transfer case, drive shafts, differentials. Chassis: Suspension (front and rear), steering system, braking system (including ABS and ESP), wheels and tires. Electrical: Wiring diagrams, lighting system, audio system, power accessories (windows, mirrors, locks), instrument cluster, HVAC controls, engine control wiring, body control modules (BCM), fuses and relays, battery and charging system. Body And Frame: Body panels, doors, windows, bumpers, interior trim, seating, sunroof, chassis frame (if applicable for this generation), corrosion protection. Procedures Included Maintenance: Oil changes, fluid checks and replacements, filter replacements, spark plug replacement, brake pad replacement, tire rotation. Repair: Engine overhaul, transmission overhaul, suspension component replacement, brake system repair, steering component replacement, electrical component diagnosis and repair, body panel repair. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based troubleshooting, component testing procedures. Special Procedures: Torque specifications for critical fasteners, engine timing procedures, clutch replacement, wheel alignment specifications, diagnostic scan tool usage. Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format Compatibility: Compatible with all PC-based Windows operating systems and Mac. Print Quality Printability: All pages are printable. Binding Type Digital Format: PDF Paper Type Digital Features: Searchable text, hyperlinked sections (typical for high-quality PDFs). ⚙️ Engine Specifications Primary Engine Engine 1.9L Diesel: 1.9L DDiS Turbodiesel (F9Q), Approx. 120 HP, 260 Nm Torque. Not widely available in all markets. Engine 2.0L Petrol: 2.0L J20A DOHC 16-valve I4 Petrol, Approx. 130-140 HP, 180-185 Nm Torque. Engine 2.7L Petrol: 2.7L H27A DOHC 24-valve V6 Petrol (some markets), Approx. 170-180 HP, 230-240 Nm Torque. Performance Fuel Delivery: Multi-point fuel injection (MPFI) for petrol, Common Rail Direct Injection (CRDI) for diesel. Fuel System Emission Controls: Catalytic converter, Oxygen sensors, EGR (for diesel). 🔧 Transmission Standard Manual Transmission: 5-speed manual (typical for 2.0L models). Optional Automatic Transmission: 4-speed automatic (typical for 2.0L and 2.7L V6 models). Features Drivetrain Options: Rear-wheel drive (RWD) or Full-Time 4WD (often with low-range gearing). 📐 Dimensions Exterior Length: Approx. 4,145 mm (163.2 in) Width: Approx. 1,800 mm (70.9 in) Height: Approx. 1,690 mm (66.5 in) Wheelbase: Approx. 2,500 mm (98.4 in) Weights Curb Weight: Approx. 1,450 - 1,650 kg (3,197 - 3,638 lbs) depending on engine and drivetrain. 🛡️ Safety Features Ratings Crash Test Results: Varies by market and testing agency (e.g., NCAP, IIHS). Generally good for its class, but specific ratings should be checked for the target market. Active Features Active Safety: Anti-lock Braking System (ABS), Electronic Stability Program (ESP) / Electronic Stability Control (ESC) (optional or standard on higher trims), Brake Assist. Passive Features Passive Safety: Front airbags, side airbags, curtain airbags (optional or standard on higher trims), seatbelt pretensioners, crumple zones, impact-absorbing steering column. 💡 Technology Features Infotainment Audio System: Factory fitted CD/MP3 player, AM/FM radio. Higher trims may feature a premium audio system and optional satellite navigation. Driver Assistance Advanced Features: Cruise control, Keyless entry and start (on some trims), Automatic climate control (on some trims). Connectivity Auxiliary Input: Auxiliary audio input jack (standard on most models). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first (check manual for specific engine and oil type). Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions. Spark Plug Replacement: Iridium spark plugs typically last 60,000 - 100,000 miles (96,000 - 160,000 km). Fluid Specifications Engine Oil Type: API SN/SP, ILSAC GF-5 or newer. Viscosity typically 5W-30 or 10W-30 (refer to manual for exact specification based on engine and climate). Coolant Type: Suzuki Super Long Life Coolant (SLLC) or equivalent OAT coolant (typically pink or orange). Mixture: 50/50 with distilled water. Transmission Fluid Atf: Suzuki ATF J3 or equivalent Dexron III/Mercon compatible fluid. Capacity varies by model, typically 3-5 quarts for drain and fill. Manual Transmission Fluid: API GL-4 or GL-5 gear oil, SAE 75W-90 viscosity. Capacity typically around 2 liters. Brake Fluid Type: DOT 3 or DOT 4 brake fluid....
Compact/Mid-size SUV, often marketed as a lifestyle or adventure-oriented vehicle.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan X-Trail, Mitsubishi Outlander, Kia Sportage, Hyundai Tucson.
Key Features
Distinctive Attributes:
Available with true body-on-frame construction (early models) and unibody construction (this generation), sophisticated 4x4 systems (e.g., Full-Time 4WD), durable powertrains, and practical interior space.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (specific market variations may exist)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECU/ECM), transmission (automatic and manual), transfer case, drive shafts, differentials.
Chassis:
Suspension (front and rear), steering system, braking system (including ABS and ESP), wheels and tires.
Electrical:
Wiring diagrams, lighting system, audio system, power accessories (windows, mirrors, locks), instrument cluster, HVAC controls, engine control wiring, body control modules (BCM), fuses and relays, battery and charging system.
Body And Frame:
Body panels, doors, windows, bumpers, interior trim, seating, sunroof, chassis frame (if applicable for this generation), corrosion protection.
Procedures Included
Maintenance:
Oil changes, fluid checks and replacements, filter replacements, spark plug replacement, brake pad replacement, tire rotation.
Repair:
Engine overhaul, transmission overhaul, suspension component replacement, brake system repair, steering component replacement, electrical component diagnosis and repair, body panel repair.
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all PC-based Windows operating systems and Mac.
Print Quality
Printability:
All pages are printable.
Binding Type
Digital Format:
PDF
Paper Type
Digital Features:
Searchable text, hyperlinked sections (typical for high-quality PDFs).
⚙️ Engine Specifications
Primary Engine
Engine 1.9L Diesel:
1.9L DDiS Turbodiesel (F9Q), Approx. 120 HP, 260 Nm Torque. Not widely available in all markets.
4-speed automatic (typical for 2.0L and 2.7L V6 models).
Features
Drivetrain Options:
Rear-wheel drive (RWD) or Full-Time 4WD (often with low-range gearing).
📐 Dimensions
Exterior
Length:
Approx. 4,145 mm (163.2 in)
Width:
Approx. 1,800 mm (70.9 in)
Height:
Approx. 1,690 mm (66.5 in)
Wheelbase:
Approx. 2,500 mm (98.4 in)
Weights
Curb Weight:
Approx. 1,450 - 1,650 kg (3,197 - 3,638 lbs) depending on engine and drivetrain.
🛡️ Safety Features
Ratings
Crash Test Results:
Varies by market and testing agency (e.g., NCAP, IIHS). Generally good for its class, but specific ratings should be checked for the target market.
Active Features
Active Safety:
Anti-lock Braking System (ABS), Electronic Stability Program (ESP) / Electronic Stability Control (ESC) (optional or standard on higher trims), Brake Assist.
Passive Features
Passive Safety:
Front airbags, side airbags, curtain airbags (optional or standard on higher trims), seatbelt pretensioners, crumple zones, impact-absorbing steering column.
💡 Technology Features
Infotainment
Audio System:
Factory fitted CD/MP3 player, AM/FM radio. Higher trims may feature a premium audio system and optional satellite navigation.
Driver Assistance
Advanced Features:
Cruise control, Keyless entry and start (on some trims), Automatic climate control (on some trims).
Connectivity
Auxiliary Input:
Auxiliary audio input jack (standard on most models).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first (check manual for specific engine and oil type).
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Iridium spark plugs typically last 60,000 - 100,000 miles (96,000 - 160,000 km).
Fluid Specifications
Engine Oil Type:
API SN/SP, ILSAC GF-5 or newer. Viscosity typically 5W-30 or 10W-30 (refer to manual for exact specification based on engine and climate).
Coolant Type:
Suzuki Super Long Life Coolant (SLLC) or equivalent OAT coolant (typically pink or orange). Mixture: 50/50 with distilled water.
Transmission Fluid Atf:
Suzuki ATF J3 or equivalent Dexron III/Mercon compatible fluid. Capacity varies by model, typically 3-5 quarts for drain and fill.
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, SAE 75W-90 viscosity. Capacity typically around 2 liters.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Complaints:
Catalytic converter failure (especially on higher mileage vehicles), minor electrical gremlins, occasional issues with ABS sensors, some reports of timing chain noise on early J20A engines if oil maintenance is neglected.
📚 Vehicle History
Brand Heritage
Suzuki SUV Legacy:
Suzuki has a long history with capable off-road vehicles and SUVs, including the popular Samurai and Vitara (first generation).
Model Evolution
Generation Details:
This is the second generation Grand Vitara (often referred to as the 'Escudo' in Japan). It transitioned from body-on-frame construction (previous generation) to a unibody platform, offering improved on-road comfort and handling while retaining respectable off-road capability, especially with the 4WD system.
Production
Manufacturing Locations:
Primarily manufactured in Japan (Kosai Plant) and also produced in other global locations for various markets.
🏆 Awards & Recognition
Recognitions
Segment Awards:
While specific awards might vary, the Grand Vitara consistently received praise for its off-road capability relative to its segment and its durability. (Specific awards not detailed in provided product info, general reputation applies).
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