Servicing Imports: 2002 Suzuki Vitara/Grand Vitara - - Search Auto Parts | Automotive News

Servicing Imports: 2002 Suzuki Vitara/Grand Vitara
Publish date: Dec 1, 2004
By:  Jacques Gordon
Source: Motor Age

CHEAT SHEET

Production run: 1999-2005
Model variants: JLS, JLX, Limited
Engines: 1.6L (G16), 2.0L (J20), 2.5L (H25)
(Photo: Suzuki)
2002 Suzuki Vitara/Grand Vitara

Though equipment and trim levels vary, the Vitara and Grand Vitara have been the same full-frame truck since the Grand Vitara was introduced in 1999.

Chassis specs given here apply to all models, but wheel speed sensor resistance on vehicles with Type 1 ABS (separate proportioning valve) is 800 ohms to 1,600 ohms. Vehicles with Type 2 ABS have Electronic Brake force Distribution (EBD), and wheel speed sensor resistance is 1,200 ohms to 1,600 ohms. 

BELT POSITIONS: 
H25 ENGINE

1. Crankshaft Pulley
2. P/S Pump Pulley
3. A/C Compressor Pulley (if equipped)
4. Tension Pulley
(Motor Age graphic. Source: Suzuki)

There is no timing belt, so while the maintenance chart calls for relatively frequent attention, maintenance should be easy.

TSBs were issued for a faulty timing chain tensioner and oil leaks at the timing chain cover and rear main seal. A recall was issued to replace a sticking accelerator cable.

The transfer case's low range makes this a capable off-road vehicle, so if that's how your customer uses the truck, put it on the lift and check carefully for damage underneath.

KEY SPECS2002 SUZUKI VITARA/
GRAND VITARA

H25 ENGINE SPECS
Type: 

Displacement:
Bore x stroke: 
Horsepower: 
Torque: 
Compression ratio: 
Emission controls: 
Fuel system:  
Fuel pressure: 
Fuel injectors: 
Oil pressure: 
Valve clearance: 
Spark plug gap: 
Firing order: 

Ignition timing: 
Base idle speed: 

ELECTRICAL SYSTEM
Battery: 
Alternator: 
Ignition: 

CAPACITIES
Oil/filter change: 
Automatic trans: 
Manual trans:
Transfer case: 
Differential

Fuel tank: 
Cooling system: 
Refrigerant: 
Compressor:
 
LUBRICANTS
Brake fluid: 
Engine oil: 
Automatic trans: 
Differential: 
Transfer case:
Manual trans: 
Power steering:
Refrigerant: 
Compressor: 

MAINTENANCE
Oil and filter: 
Auto trans: 
Spark plugs: 
Fuel filter:
Fuel tank cap:
Brake fluid: 
Manual trans oil:
Automatic trans fluid:
Transfer case oil:
Differential oil:

CHASSIS SPECS 
Drivetrain: 



Brake system: 
WS sensors: 
Front disc thickness: 
Rear disc thickness: 

SUSPENSION SYSTEM
Front: 

Rear: 

Lug nut torque: 
Front axle nut torque: 

FRONT ALIGNMENT
Toe: 
Camber:
Caster:  

FRONT ALIGNMENT
Toe: 
Camber: 
Caster:


V6, 2.5L, chain-driven DOHC, four-valve, aluminum block and heads
2495cc (152 cid)
84.1 x 74.9mm (3.31 x 2.95 in.)
155 hp @ 6,500 rpm
160 ft.-lbs. @ 4,000 rpm
9.5:1
EGR, EVAP
MPFI
30-37 psi @ idle; 38-44 psi unregulated
10-14 ohms
55-67 psi @ 4,000 rpm
Hydraulic
0.039-0.043 in. (1.0-1.1mm)
1-6-5-4-3-2 (Odd numbers on left bank)
4-6° BTDC @ idle 
625-725 rpm, 10-50 percent duty cycle


12V, min 36AH
60, 70 or 80 amp
Direct


5.2 qt. (5.0L)
7.5 qt. (7.1L)
2.9 qt. (2.7L)
1.8 qt. (1.7L)
Front, 1.1 qt. (1.0L): Rear, 2.3 qt. (2.2L)
16.8 gal. (64L)
8.0 qt. (7.9L)
17.6 oz (500g)
8.2 oz (250cc) total system


DOT 3
API SG or newer, SAE 5W-30
Dexron III 
Hypoid, API GL-5, SAE 75W-90
API GL-4, SAE 75W-90
API GL-4, SAE 75W-90
Dexron III
R134a
PAG ND-OIL8


7,500 miles
60,000 milesl
30,000 miles
60,000 miles
60,000 miles
60,000 miles
30,000 miles
100,000 miles
45,000 miles
135,000 miles


RWD or part-time 4WD with two-speed transfer case, five-speed manual or electronic four-speed automatic transmission with overdrive (O/D)
Disc/drum with three-channel ABS
See Technical Notes.
0.787 in. (20mm) minimum
8.740 in (222.1mm) maximum


MacPherson struts, lower A-arms, stabilizer bar
Solid axle, coil springs, two trailing links per side, Panhard rod
73 ft.-lbs. (100 Nm)
156 ft.-lbs. (216 Nm)


0° ± 10'
-0°36' ± 20'
1°50' ± 30'


0 ± 2 mm (0 ± 0.080 in.)
0° ± 1°
2°40' ± 1°

(Information source: Suzuki)

About the Author

Jacques Gordon

Technical Editor

Jacques Gordon, technical editor, joined the Motor Age team in April 1998 with almost 30 years of automotive experience. He worked for 10 years in dealerships and independent repair shops, specializing in European cars. He later moved to a dyno-lab environment with companies such as Fel-Pro, Robert Bosch, and Johnson-Matthey Catalyst Systems Division. From there, Jacques joined Chilton Book Co, writing diagnostic and repair procedures before joining Motor Age. Articles by Jacques Gordon

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Source: Motor Age, 12/1/2004
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