2006-2010 Suzuki Grand Vitara JB416 JB419 JB420 JB627 Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Generation: Second Generation (JB) Codes Chassis Codes: JB416, JB419, JB420, JB627 Engine Codes: J20A (2.0L), H27A (2.7L), M16A (1.6L), Z19DTH (1.9L Diesel) 👋 Introduction Market Position Segment: Compact/Mid-size SUV (Sport Utility Vehicle) Orientation: Versatile compact SUV with available all-wheel-drive, suitable for urban driving and light off-roading. Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Ford Escape, Chevrolet Equinox, Kia Sportage, Hyundai Tucson Key Features Platform: Body-on-frame construction (traditional SUV robustness) from 2005 onwards, offering better towing and off-road capability compared to unibody crossovers. Drivetrain: Available in 2WD (Rear Wheel Drive) and 4WD (Four Wheel Drive) configurations, including Suzuki's advanced '3-Mode 4WD System' on some models. 📋 Manual Details Coverage Areas Covered Years: 2006, 2007, 2008, 2009, 2010 Covered Chassis: JB416, JB419, JB420, JB627 Page Count Estimated Pages: Over 2500 Pages (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Electronic (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical (J20A, H27A, M16A, Z19DTH), Engine Performance, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Engine Control System (ECM), Manual Transmission (MT), Automatic Transmission (AT), Transfer Case, Drivetrain (Front/Rear Axles, Driveshafts) Chassis: Suspension System (Front Struts, Rear Multi-link), Steering System, Brake System (ABS, EBD), Wheels, Tires Electrical: Body Electrical Systems, Lighting System, Audio System, Power Windows, Power Locks, Mirrors, Wiper/Washer System, HVAC System, Instrument Panel, Gauges, Warning Indicators, Engine Control Circuits, Transmission Control Circuits, ABS Circuits, SRS (Airbag) Circuits, Immobilizer System, Keyless Entry System Body And Interior: Body Panels, Doors, Hood, Tailgate, Bumpers, Exterior Trim, Interior Trim, Seats, Restraint Systems, HVAC Ducts, Weatherstripping Procedures Included Maintenance: Scheduled Maintenance (Oil Changes, Filter Replacements, Spark Plugs, Belts), Fluid Checks and Replacements (Engine Oil, Transmission Fluid, Coolant, Brake Fluid, Power Steering Fluid, Differential Fluid), Tire Rotation and Inspection, Brake Pad Replacement, Battery Service Repair And Overhaul: Engine Overhaul, Cylinder Head Removal/Installation, Piston and Connecting Rod Service, Crankshaft Service, Valve Train Service, Transmission Rebuild (MT/AT), Transfer Case Overhaul, Differential Service, Suspension Component Replacement (Struts, Shocks, Bushings), Steering Rack Replacement, Brake System Component Replacement (Calipers, Rotors, Lines), Fuel Pump Replacement, Radiator Replacement, Alternator Replacement, Starter Replacement Diagnostics And Troubleshooting: Diagnostic Trouble Codes (DTCs), Symptom-based Troubleshooting Guides, Electrical Schematics, Component Testing Procedures, Engine Performance Diagnosis, Transmission Performance Diagnosis, HVAC System Diagnosis Technical Depth Depth: Comprehensive: Includes detailed specifications, diagnostic procedures, step-by-step repair instructions, torque specifications, wiring diagrams, and exploded views for complete overhauls and diagnostics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable Text (OCR processed for easy keyword searching) Print Quality Printability: Printable (designed for home or professional printing) Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1 Name: J20A Engine 1 Displacement: 2.0 Liters (1998 cc) Engine 1 Configuration: Inline-4 Cylinder, DOHC, 16 Valves Engine 1 Power: Approx. 138-140 hp @ 6000 rpm Engine 1 Torque: Approx. 133-136 lb-ft @ 4000 rpm Optional Engine 1 Engine 2 Name: H27A Engine 2 Displacement: 2.7 Liters (2736 cc) Engine 2 Configuration: V6 Cylinder, DOHC, 24 Valves Engine 2 Power: Approx. 185-190 hp @ 6000 rpm Engine 2 Torque: Approx. 184-189 lb-ft @ 4500 rpm Optional Engine 2 Engine 3 Name: M16A Engine 3 Displacement: 1.6 Liters (1586 cc) Engine 3 Configuration: Inline-4 Cylinder, DOHC, 16 Valves Engine 3 Power: Approx. 101-103 hp @ 6000 rpm Engine 3 Torque: Approx. 103-105 lb-ft @ 4000 rpm Optional Engine 3 Engine 4 Name: Z19DTH (Diesel) Engine 4 Displacement: 1.9 Liters (1910 cc) Engine 4 Configuration: Inline-4 Cylinder, Turbocharged, Common Rail Diesel, DOHC, 16 Valves Engine 4 Power: Approx. 120-129 hp @ 4000 rpm Engine 4 Torque: Approx. 207-210 lb-ft @ 2000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) for gasoline engines; Common Rail Direct Injection (CRDI) for diesel engine. Fuel Type: Unleaded Gasoline (91+ Octane recommended for J20A/H27A), Diesel Fuel (Low Sulfur) 🔧 Transmission Standard Transmission Type J20A: 5-Speed Manual Transmission (M15A) Transmission Type H27A: 5-Speed Automatic Transmission (LA409) Optional Transmission Type J20A Auto: 4-Speed Automatic Transmission (TA41) Transmission Type M16A: 5-Speed Manual Transmission (M15A) Transmission Type M16A Auto: 4-Speed Automatic Transmission (TA41) Transmission Type Z19Dth: 5-Speed Manual Transmission Features Drivetrain Options: 2WD (RWD), 4WD (Full-time 4WD or 2-Mode/3-Mode 4WD with center differential and low-range gearing on select models) 📐 Dimensions Exterior Length: Approx. 4,145 mm (163.2 in) Width: Approx. 1,785 mm (70.3 in) Height: Approx. 1,670 mm (65.7 in) Wheelbase: Approx. 2,500 mm (98.4 in) Weights Curb Weight: Approx. 1,400 - 1,700 kg (3,086 - 3,748 lbs) depending on engine and drivetrain Towing Capacity: Varies by market and configuration, generally around 1,500 - 2,000 kg (3,300 - 4,400 lbs) when properly equipped. 🛡️ Safety Features Ratings NHTSA Rating: Varies by market and testing year,...

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Tags: 2006 2007 2008 2009 2010 Car Grand Vitara JB416 Grand Vitara JB419 Grand Vitara JB420 Grand Vitara JB627 Misc Motorcycles Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Grand Vitara

Generation:

Second Generation (JB)

Codes

Chassis Codes:

JB416, JB419, JB420, JB627

Engine Codes:

J20A (2.0L), H27A (2.7L), M16A (1.6L), Z19DTH (1.9L Diesel)

👋 Introduction

Market Position

Segment:

Compact/Mid-size SUV (Sport Utility Vehicle)

Orientation:

Versatile compact SUV with available all-wheel-drive, suitable for urban driving and light off-roading.

Competitive Analysis

Competitors:

Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Ford Escape, Chevrolet Equinox, Kia Sportage, Hyundai Tucson

Key Features

Platform:

Body-on-frame construction (traditional SUV robustness) from 2005 onwards, offering better towing and off-road capability compared to unibody crossovers.

Drivetrain:

Available in 2WD (Rear Wheel Drive) and 4WD (Four Wheel Drive) configurations, including Suzuki's advanced '3-Mode 4WD System' on some models.

📋 Manual Details

Coverage Areas

Covered Years:

2006, 2007, 2008, 2009, 2010

Covered Chassis:

JB416, JB419, JB420, JB627

Page Count

Estimated Pages:

Over 2500 Pages (typical for comprehensive factory service manuals)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Electronic (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical (J20A, H27A, M16A, Z19DTH), Engine Performance, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Engine Control System (ECM), Manual Transmission (MT), Automatic Transmission (AT), Transfer Case, Drivetrain (Front/Rear Axles, Driveshafts)

Chassis:

Suspension System (Front Struts, Rear Multi-link), Steering System, Brake System (ABS, EBD), Wheels, Tires

Electrical:

Body Electrical Systems, Lighting System, Audio System, Power Windows, Power Locks, Mirrors, Wiper/Washer System, HVAC System, Instrument Panel, Gauges, Warning Indicators, Engine Control Circuits, Transmission Control Circuits, ABS Circuits, SRS (Airbag) Circuits, Immobilizer System, Keyless Entry System

Body And Interior:

Body Panels, Doors, Hood, Tailgate, Bumpers, Exterior Trim, Interior Trim, Seats, Restraint Systems, HVAC Ducts, Weatherstripping

Procedures Included

Maintenance:

Scheduled Maintenance (Oil Changes, Filter Replacements, Spark Plugs, Belts), Fluid Checks and Replacements (Engine Oil, Transmission Fluid, Coolant, Brake Fluid, Power Steering Fluid, Differential Fluid), Tire Rotation and Inspection, Brake Pad Replacement, Battery Service

Repair And Overhaul:

Engine Overhaul, Cylinder Head Removal/Installation, Piston and Connecting Rod Service, Crankshaft Service, Valve Train Service, Transmission Rebuild (MT/AT), Transfer Case Overhaul, Differential Service, Suspension Component Replacement (Struts, Shocks, Bushings), Steering Rack Replacement, Brake System Component Replacement (Calipers, Rotors, Lines), Fuel Pump Replacement, Radiator Replacement, Alternator Replacement, Starter Replacement

Diagnostics And Troubleshooting:

Diagnostic Trouble Codes (DTCs), Symptom-based Troubleshooting Guides, Electrical Schematics, Component Testing Procedures, Engine Performance Diagnosis, Transmission Performance Diagnosis, HVAC System Diagnosis

Technical Depth

Depth:

Comprehensive: Includes detailed specifications, diagnostic procedures, step-by-step repair instructions, torque specifications, wiring diagrams, and exploded views for complete overhauls and diagnostics.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable Text (OCR processed for easy keyword searching)

Print Quality

Printability:

Printable (designed for home or professional printing)

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Name:

Engine 1 Displacement:

2.0 Liters (1998 cc)

Engine 1 Configuration:

Inline-4 Cylinder, DOHC, 16 Valves

Engine 1 Power:

Approx. 138-140 hp @ 6000 rpm

Engine 1 Torque:

Approx. 133-136 lb-ft @ 4000 rpm

Optional Engine 1

Engine 2 Name:

Engine 2 Displacement:

2.7 Liters (2736 cc)

Engine 2 Configuration:

V6 Cylinder, DOHC, 24 Valves

Engine 2 Power:

Approx. 185-190 hp @ 6000 rpm

Engine 2 Torque:

Approx. 184-189 lb-ft @ 4500 rpm

Optional Engine 2

Engine 3 Name:

Engine 3 Displacement:

1.6 Liters (1586 cc)

Engine 3 Configuration:

Inline-4 Cylinder, DOHC, 16 Valves

Engine 3 Power:

Approx. 101-103 hp @ 6000 rpm

Engine 3 Torque:

Approx. 103-105 lb-ft @ 4000 rpm

Optional Engine 3

Engine 4 Name:

Z19DTH (Diesel)

Engine 4 Displacement:

1.9 Liters (1910 cc)

Engine 4 Configuration:

Inline-4 Cylinder, Turbocharged, Common Rail Diesel, DOHC, 16 Valves

Engine 4 Power:

Approx. 120-129 hp @ 4000 rpm

Engine 4 Torque:

Approx. 207-210 lb-ft @ 2000 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) for gasoline engines; Common Rail Direct Injection (CRDI) for diesel engine.

Fuel Type:

Unleaded Gasoline (91+ Octane recommended for J20A/H27A), Diesel Fuel (Low Sulfur)

🔧 Transmission

Standard

Transmission Type J20A:

5-Speed Manual Transmission (M15A)

Transmission Type H27A:

5-Speed Automatic Transmission (LA409)

Optional

Transmission Type J20A Auto:

4-Speed Automatic Transmission (TA41)

Transmission Type M16A:

5-Speed Manual Transmission (M15A)

Transmission Type M16A Auto:

4-Speed Automatic Transmission (TA41)

Transmission Type Z19Dth:

5-Speed Manual Transmission

Features

Drivetrain Options:

2WD (RWD), 4WD (Full-time 4WD or 2-Mode/3-Mode 4WD with center differential and low-range gearing on select models)

📐 Dimensions

Exterior

Length:

Approx. 4,145 mm (163.2 in)

Width:

Approx. 1,785 mm (70.3 in)

Height:

Approx. 1,670 mm (65.7 in)

Wheelbase:

Approx. 2,500 mm (98.4 in)

Weights

Curb Weight:

Approx. 1,400 - 1,700 kg (3,086 - 3,748 lbs) depending on engine and drivetrain

Towing Capacity:

Varies by market and configuration, generally around 1,500 - 2,000 kg (3,300 - 4,400 lbs) when properly equipped.

🛡️ Safety Features

Ratings

NHTSA Rating:

Varies by market and testing year, generally good for its class during its production run. Refer to specific market NHTSA reports for precise ratings.

Active Features

Standard Anti-lock Braking System (ABS)

Electronic Brakeforce Distribution (EBD)

Traction Control:

Available Traction Control System (TCS)

Available Electronic Stability Program (ESP)

Passive Features

Airbags:

Front Driver and Passenger Airbags, Available Side Curtain Airbags

Seatbelts:

3-point front seatbelts with pretensioners and load limiters, 3-point rear seatbelts

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, often with auxiliary input. Higher trims may feature premium audio systems, and/or in-dash CD changer.

Navigation:

Optional factory-installed GPS navigation system on higher trim levels.

Driver Assistance

Cruise Control:

Standard on most trims, allowing for consistent speed on highways.

Connectivity

Connectivity Options:

Auxiliary audio input jack. Some models may offer Bluetooth connectivity for hands-free calling and audio streaming.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type used. Consult owner's manual for specific recommendations.

Air Filter Replacement:

Typically every 15,000 - 30,000 miles (24,000 - 48,000 km).

Spark Plug Replacement:

Iridium spark plugs typically last 60,000 - 100,000 miles (96,000 - 160,000 km). Refer to specific engine requirements.

Fluid Specifications

Engine Oil J20A:

SAE 0W-20 or 5W-30 (API SM/SN or ILSAC GF-4/GF-5), Capacity: Approx. 4.1 US quarts (3.9 L) with filter change.

Engine Oil H27A:

SAE 5W-30 (API SM/SN or ILSAC GF-4/GF-5), Capacity: Approx. 4.8 US quarts (4.5 L) with filter change.

Coolant:

Suzuki Super Long Life Coolant (SLLC) or equivalent silicate-free, long-life coolant (Pink/Red color). Capacity: Approx. 6.0 - 7.0 US quarts (5.7 - 6.6 L) depending on engine.

Transmission Fluid Auto:

Suzuki ATF 5D06, JWS 3309, or equivalent. Capacity: Approx. 3.6 - 4.3 US quarts (3.4 - 4.1 L) for drain and fill.

Transmission Fluid Manual:

API GL-4, SAE 75W-90 Synthetic Gear Oil. Capacity: Approx. 2.0 - 2.2 US quarts (1.9 - 2.1 L).

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

Dexron III or equivalent ATF.

Known Issues

Common Problems Early Models:

Some reports of premature wear in suspension components (bushings, ball joints) on earlier models, especially those with heavier usage. Potential for catalytic converter failure on some high-mileage vehicles. Minor electrical gremlins can occur over time.

Common Problems Powertrain:

The 2.7L V6, while generally robust, can be susceptible to oil leaks from valve cover gaskets. The 1.9L diesel (Z19DTH) can experience issues with the diesel particulate filter (DPF) or EGR system if not properly maintained or driven regularly on short trips.

Common Problems 4Wd System:

While the 4WD system is generally reliable, periodic inspection of CV joints and driveshaft U-joints is recommended for off-road use. Ensure proper maintenance of transfer case and differential fluids.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Suzuki has a long history in compact and off-road vehicles, known for producing rugged and reliable vehicles like the Samurai and Jimny.

Model Evolution

Generation Context:

The JB generation Grand Vitara, launched in 2005, marked a significant shift to a unibody construction for most global markets, but retained body-on-frame construction for some specific markets, including North America until 2008. This manual covers the period where this platform was widely sold.

Production

Production Years Generation:

2005-2015 (global), with specific models and engines varying by market and year.

🏆 Awards & Recognition

Recognitions

General Reputation:

The Suzuki Grand Vitara in this generation was generally praised for its capable 4WD system, respectable off-road ability for its class, and robust build quality, often appealing to buyers seeking a more traditional SUV experience.