🏷️ Basic Information

Make:

Suzuki

Model:

Grand Vitara XL-7

Model Variant:

Grand Vitara XL-7

Generation:

First Generation (JT)

Chassis Codes:

JT

👋 Introduction

Segment:

Compact SUV / Crossover Utility Vehicle

Target Audience:

DIY mechanics, independent repair shops, owners seeking to maintain or repair their vehicle.

Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Jeep Cherokee (XJ/Liberty).

Xl7 Advantage:

Offered a longer wheelbase and optional third-row seating, differentiating it from many compact SUV competitors of its era.

Manual Value Proposition:

Provides comprehensive technical data essential for servicing, repair, and restoration, empowering owners and technicians.

📋 Manual Details

Years Covered:

2001, 2002, 2003, 2004, 2005, 2006

Estimated Page Count:

Hundreds (specific number not provided, but indicates extensive detail)

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Engine diagnosis, overhaul, lubrication system, cooling system, fuel system, emission control system, ignition system, engine electrical system, components, specifications.

Transmission Drivetrain:

Manual transmission, automatic transmission, transfer case, drive shafts, differentials (front, center, rear), propeller shafts, axles, hubs, CV joints.

Suspension Steering:

Front suspension (independent), rear suspension (multi-link), shock absorbers, springs, control arms, stabilizer bars, steering gear, power steering system, steering column, wheel alignment specifications.

Brakes:

Front disc brakes, rear drum brakes (or disc depending on trim), parking brake, hydraulic system, ABS (Anti-lock Braking System) diagnosis and components, brake pad replacement, caliper service, brake fluid specifications.

Electrical Electronics:

Battery, starting system, charging system, lighting system, ignition system, dashboard instruments, switches, relays, fuses, wiring diagrams for all systems, body control module (BCM), power windows, power locks, audio system, HVAC controls.

Body Chassis:

Body construction, exterior panels, doors, hood, tailgate, bumpers, interior trim, seats, roof rack, chassis frame inspection and repair, corrosion protection.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system diagnosis, refrigerant handling, component replacement (compressor, condenser, evaporator, blower motor), cabin air filter replacement.

Safety Systems:

Airbag system diagnosis and component replacement, seat belt mechanisms, SRS (Supplemental Restraint System) precautions.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection and replacement.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification and solutions for engine, transmission, electrical, and other systems.

Repair Rebuild:

Detailed step-by-step instructions for component removal, installation, overhaul, and repair of all major vehicle systems, including engine rebuilds, transmission overhauls, brake caliper servicing, and more.

Diagnostics:

On-board diagnostics (OBD-II) system interpretation, fault code retrieval, sensor testing, actuator testing, pressure tests, electrical continuity testing.

Depth:

Comprehensive coverage from basic maintenance to advanced engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures for all factory-equipped systems.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High resolution, optimized for digital viewing and printing.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Code And Displacement:

J25A - 2.5L V6 DOHC (2493 cc)

Cylinder Configuration:

V6

Valvetrain:

DOHC (Dual Overhead Camshafts), 24 Valves (4 per cylinder)

Horsepower Approx:

155-160 hp @ 6000 rpm (varies slightly by year/region)

Torque Approx:

170-175 lb-ft @ 3500-4000 rpm (varies slightly by year/region)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Bore X Stroke:

84.0 mm x 75.4 mm (approximate)

Compression Ratio:

9.7:1 (approximate)

🔧 Transmission

Transmission Type:

4-speed Automatic Transmission

Transmission Type:

5-speed Manual Transmission

Drivetrain Options:

2WD (Rear-Wheel Drive), 4WD (Four-Wheel Drive) with low range transfer case.

Automatic Transmission Fluid:

Suzuki ATF D-II or equivalent (check manual for specific part number and capacity)

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (check manual for specific part number and capacity)

Transfer Case Fluid:

API GL-4 or GL-5, SAE 75W-90 (check manual for specific part number and capacity)

📐 Dimensions

Wheelbase:

2715 mm (106.9 inches)

Length:

4520 mm (178.0 inches)

Width:

1780 mm (70.1 inches)

Height:

1735 mm (68.3 inches)

Seating Capacity:

5-7 passengers (depending on configuration)

Cargo Volume Behind Second Row:

Approx. 30.4 cubic feet (varies)

Curb Weight Approx:

1700-1900 kg (3748-4189 lbs) depending on configuration (2WD/4WD, 5/7 seat)

🛡️ Safety Features

NHTSA Front Crash Test:

4-star driver, 4-star passenger (for 2003 model year, results may vary by year)

ABS:

Standard on most models/trims, check specific vehicle.

Traction Control:

Available on some models.

Airbags:

Front airbags standard. Side airbags often optional or standard on higher trims.

Seatbelts:

3-point seatbelts with pretensioners for front occupants.

💡 Technology Features

Audio System:

Factory AM/FM/CD player, with available premium audio systems. Aux input or Bluetooth connectivity typically not standard.

Cruise Control:

Standard on most models.

Keyless Entry:

Available on higher trim levels.

Power Outlets:

12V accessory power outlets in the cabin.

🔧 Maintenance

Engine Oil Change Interval:

Every 3,750 to 5,000 miles or 6 months (whichever comes first), depending on driving conditions and oil type used (consult manual for precise recommendation).

Engine Air Filter Replacement:

Every 15,000 to 30,000 miles or annually.

Spark Plug Replacement:

Platinum or Iridium plugs typically recommended for 60,000 to 100,000-mile intervals. Check manual for specific plug type and gap.

Transmission Fluid Change:

Automatic: Every 30,000-50,000 miles. Manual: Every 30,000-60,000 miles. Heavy use may require more frequent changes.

Engine Oil Type And Capacity:

SAE 5W-30 Synthetic or Synthetic Blend recommended. Capacity approx. 4.5-5.0 US quarts (4.3-4.8 Liters) with filter. Consult manual for exact specification.

Coolant Type:

Asian Green or Long-Life Antifreeze/Coolant (ethylene glycol based), typically a 50/50 mix with distilled water. Capacity approx. 7.5-8.0 US quarts (7.1-7.6 Liters). Consult manual for specific type and capacity.

Brake Fluid Type:

DOT 3 or DOT 4 (check reservoir cap or manual for exact specification).

Power Steering Fluid:

ATF Dexron III or equivalent (check manual).

Engine Vibration:

Some owners report engine vibration, potentially related to engine mounts or balance shafts in the V6.

Transmission Harsh Shifting:

Occasional reports of harsh shifting in the automatic transmission, often rectifiable with fluid service or solenoid replacement.

Rear Differential Noise:

Potential for whining or clunking noise from the rear differential, may require fluid change or bearing inspection.

Cv Joint Wear:

Wear and tear on front CV joints, especially with off-road use, leading to clicking noises during turns.

Exhaust Manifold Cracks:

Some V6 models may experience exhaust manifold cracks due to heat cycles.

📚 Vehicle History

Suzuki Offroad Legacy:

Suzuki has a long history of producing capable off-road vehicles, starting with the original Jimny and Samurai, influencing the Grand Vitara's rugged appeal.

Xl7 Introduction:

The XL-7 was introduced in 2001 as an extended-wheelbase version of the Grand Vitara, designed to compete in the growing mid-size SUV segment and offer third-row seating.

Platform Sharing:

Shared its platform and many mechanical components with the shorter wheelbase Grand Vitara (Grand Vitara SQ).

Production Years Global:

2001-2006 (First Generation)

Assembly Locations:

Primarily assembled in Japan, with some production or assembly potentially occurring in other Suzuki facilities globally.

🏆 Awards & Recognition

Automotive Journal Reviews:

While specific major awards for this model year are not widely cited, it was generally well-received for its value, capability, and practicality in its segment during its production run.