Suzuki Grand Vitara 1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Year: 1999 Generation: Second Generation (SQ Series) Codes Chassis Code: SQ416, SQ420, SQ625 👋 Introduction Market Position Vehicle Segment: Compact SUV...

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Taper: Car

Distributeur:

UGS: 369459

Mots clés: 1999 Car Cars Grand Vitara Suzuki

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Grand Vitara

Year:

Generation:

Second Generation (SQ Series)

Codes

Chassis Code:

SQ416, SQ420, SQ625

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Sport Utility Vehicle

Target Audience:

DIY enthusiasts, independent repair shops, and Suzuki owners seeking detailed technical information.

Competitive Analysis

Key Competitors 1999:

Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Subaru Forester.

Key Features

Manual Purpose:

To provide comprehensive, step-by-step guidance for the repair and maintenance of the 1999 Suzuki Grand Vitara.

Manual Benefit:

Empowers owners and technicians to perform accurate diagnostics and repairs, reducing reliance on dealerships and saving costs.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF, though not explicitly stated)

Page Count

Page Count:

Estimated 800-1200 pages (typical for a comprehensive factory service manual)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, repair, timing, cooling, lubrication, fuel delivery, emission control.

Engine Performance:

Ignition system, fuel injection system (MPI), engine control module (ECM) diagnostics, sensor data.

Transmission Manual:

Clutch system, gearbox assembly, disassembly, repair, shift mechanism, driveline components (propeller shafts, drive shafts).

Transmission Automatic:

Automatic transmission assembly, disassembly, repair, torque converter, hydraulic control system, electronic control unit (TCU).

Suspension Steering:

Front suspension (independent, strut-based), rear suspension (multi-link, solid axle depending on configuration), steering gear, power steering system.

Brakes:

Front disc brakes, rear disc or drum brakes, parking brake system, ABS (Anti-lock Braking System) diagnostics and repair.

Electrical System:

Wiring diagrams, battery, charging system (alternator, starter), lighting system, horn, ignition system, starter motor.

Body Chassis:

Body construction, exterior panels, interior trim, doors, hood, tailgate, glass, rust prevention, chassis components.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant handling, component testing, controls.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, pipes, hangers, emission control related components.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, evaporative emission control (EVAP).

Diagnostic Troubleshooting:

Diagnostic Trouble Codes (DTCs), symptom-based troubleshooting, electrical component testing, mechanical system diagnostics.

Procedures Included

Scheduled Maintenance:

Detailed procedures for all routine maintenance tasks and service intervals.

Engine Repair:

Complete engine overhaul, piston ring replacement, bearing service, cylinder head repair.

Transmission Overhaul:

Step-by-step instructions for disassembling, inspecting, and reassembling both manual and automatic transmissions.

Brake System Service:

Brake pad and rotor replacement, brake caliper service, bleeding the brake system, ABS component replacement.

Suspension Component Replacement:

Strut replacement, control arm service, ball joint replacement, tie rod end replacement.

Electrical Troubleshooting Repair:

Diagnosing and repairing electrical faults, wiring harness repairs, component replacement.

Body Panel Replacement:

Procedures for removing and installing fenders, doors, bumpers, and other body panels.

HVAC System Repair:

Recharging AC system, replacing evaporator, condenser, or compressor.

Engine Timing Adjustment:

Setting engine timing, replacing timing belt or chain.

Clutch Replacement:

Detailed steps for clutch disc, pressure plate, and release bearing replacement.

Driveline Maintenance:

CV joint inspection and replacement, differential service.

Wheel Alignment Specifications:

Specifications for front and rear wheel alignment.

Tire Pressure Recommendations:

Correct tire pressures for various loads and conditions.

Torque Specifications:

Precise torque values for all critical fasteners.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures including wiring diagrams, sensor data interpretation, and fault code analysis.

Repair Scope:

Covers everything from basic fluid changes and filter replacements to complete engine and transmission rebuilds, and body repair.

Special Tools:

Lists and descriptions of special tools required for specific repair procedures.

Troubleshooting Flowcharts:

Includes diagnostic flowcharts to systematically identify and resolve issues.

📊 Manual Specifications

File Format

File Format:

Digital (PDF recommended for searchability and accessibility)

Searchable Text:

High likelihood of being searchable if a proper PDF

Print Quality

Print Quality:

Variable, dependent on source. Factory manuals generally feature clear diagrams and text.

Binding Type

Binding Type:

N/A (for digital format)

Paper Type

Paper Type:

N/A (for digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1.6L:

Engine Displacement 1.6L:

1.6 Liters (1590 cc)

Engine Configuration 1.6L:

Inline 4-cylinder, DOHC, 16-valve

Horsepower 1.6L:

Approx. 95-100 hp @ 5800-6000 rpm (varies by market)

Torque 1.6L:

Approx. 96-100 lb-ft @ 3500-4000 rpm (varies by market)

Optional Engine

Engine Code 2.0L:

Engine Displacement 2.0L:

2.0 Liters (1998 cc)

Engine Configuration 2.0L:

Inline 4-cylinder, DOHC, 16-valve

Horsepower 2.0L:

Approx. 125-130 hp @ 5500-6000 rpm

Torque 2.0L:

Approx. 130-135 lb-ft @ 3000-4000 rpm

Engine Code 2.5L V6:

Engine Displacement 2.5L V6:

2.5 Liters (2492 cc)

Engine Configuration 2.5L V6:

V6, SOHC, 24-valve

Horsepower 2.5L V6:

Approx. 155-160 hp @ 6200 rpm

Torque 2.5L V6:

Approx. 155-160 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane or higher recommended)

Emission Control:

Catalytic converter, Oxygen sensors, EGR (Exhaust Gas Recirculation) system.

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission

Optional

Transmission Type Optional:

4-speed Automatic Transmission (with overdrive)

Features

Drivetrain Options:

2WD (Rear-wheel drive) and 4WD (Four-wheel drive) with available 2-speed transfer case (low range) on some models.

Manual Transmission Fluid Spec:

API GL-4, SAE 75W-90 Gear Oil

Automatic Transmission Fluid Spec:

Dexron III or equivalent

📐 Dimensions

Exterior

Wheelbase:

Approx. 2480 mm (97.6 in) for 4-door models, Approx. 2175 mm (85.6 in) for 2-door models

Length 4 Door:

Approx. 4245 mm (167.1 in)

Width 4 Door:

Approx. 1780 mm (70.1 in)

Height 4 Door:

Approx. 1700 mm (66.9 in)

Weights

Curb Weight Approx:

1350 - 1550 kg (2976 - 3417 lbs) depending on engine and drivetrain

Towing Capacity Approx:

Up to 1500 kg (3300 lbs) with appropriate hitch and braking system (check local regulations)

Wheels Tires

Standard Wheel Size:

15-inch or 16-inch alloy or steel wheels

Standard Tire Size:

215/70R15 or 235/60R16 (varies by trim and options)

Wheel Bolt Pattern:

5x139.7 mm (5x5.5 inches)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Rating:

Not readily available for this specific model year and region, but typical for SUVs of this era.

IIHS Crash Test Performance:

Not readily available for this specific model year and region.

Active Features

Available on higher trims or as an option

Traction Control:

Rarely equipped on this model year, but possible on very late production or specific market variants.

Passive Features

Airbags:

Driver and front passenger airbags standard.

Seatbelts:

Three-point inertia-reel seatbelts for all seating positions.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system typically not standard on this model.

💡 Technology Features

Infotainment

Audio System:

Factory fitted AM/FM radio with cassette player, optional CD player. Basic speaker configuration.

Navigation:

No factory navigation system available for this model year.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Parking Sensors:

Not available.

Connectivity

Bluetooth:

Not available.

Usb Ports:

Not available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first.

Engine Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Approx. 60,000-100,000 miles (96,000-160,000 km) depending on spark plug type (standard vs. iridium).

Coolant Flush Interval:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.

Transmission Fluid Change Manual:

Every 30,000-60,000 miles (48,000-96,000 km).

Transmission Fluid Change Automatic:

Every 30,000-60,000 miles (48,000-96,000 km).

Fluid Specifications

Engine Oil Specification:

SAE 5W-30 or 5W-40, API SG or higher (check owner's manual for exact recommendation)

Engine Oil Capacity 1.6L:

Approx. 3.5 - 4.0 liters (3.7 - 4.2 US quarts) with filter

Engine Oil Capacity 2.0L:

Approx. 3.8 - 4.3 liters (4.0 - 4.5 US quarts) with filter

Engine Oil Capacity 2.5L V6:

Approx. 4.0 - 4.5 liters (4.2 - 4.7 US quarts) with filter

Coolant Type:

Ethylene glycol-based coolant (50/50 mix with distilled water)

Coolant Capacity:

Approx. 7.0 - 8.0 liters (7.4 - 8.5 US quarts)

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Common Engine Issues:

Occasional oil leaks from valve cover or oil pan gaskets, potential for carbon build-up in older engines.

Common Transmission Issues:

Clutch wear in manual transmissions, potential for automatic transmission solenoid issues or wear.

Common Suspension Issues:

Worn ball joints, tie rod ends, and bushings can lead to steering looseness and noise.

Common Electrical Issues:

Corrosion on grounds, failing alternator, or starter motor issues can occur with age.

Common Chassis Issues:

Rust on the frame or body panels, particularly in areas with harsh winter climates.

📚 Vehicle History

Brand Heritage

Suzuki Offroad Legacy:

Suzuki has a long history of producing capable off-road vehicles, notably the Samurai and Sidekick, which influenced the Grand Vitara's design and capability.

Model Evolution

First Generation Vitara Intro:

The original Vitara (also known as Sidekick in North America) debuted in 1988, establishing Suzuki's presence in the compact SUV market.

Grand Vitara Introduction:

The Grand Vitara was introduced in 1998 for the 1999 model year, representing a more substantial and refined offering than its predecessor, with a longer wheelbase and more upscale features.

Production

Production Locations:

Japan (Main Plant), and potentially other global assembly plants depending on market.

Model Years Covered:

Focuses specifically on the 1999 model year, covering all its configurations.

🏆 Awards & Recognition

Recognitions

Offroad Capability Recognition:

Often praised for its off-road prowess relative to its class, especially with the 4WD system and low-range transfer case.

Ratings

Consumer Reviews General:

Generally reviewed positively for reliability, affordability, and off-road capability, though often criticized for interior refinement and fuel economy compared to car-based crossovers.

Certifications

Manufacturer Certification:

Official Factory Service Manual, produced by or for Suzuki Motor Corporation.