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2005-2012 Suzuki Grand VITARA Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Generation: Second Generation (JB) Codes Model Years Covered: 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Chassis Codes: JB416, JB419WD, JB420,...
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Distributeur:
UGS: 321952
2005-2012 Suzuki Grand VITARA Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
Grand Vitara
Generation:
Second Generation (JB)
Codes
Model Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Chassis Codes:
JB416, JB419WD, JB420, JB627W, JB424
Engine Codes Gasoline:
J20A (2.0L), J24B (2.4L), M16A (1.6L), H27A (2.7L V6 - Note: Manual description lists 1.6L and 2.0L gasoline, but common for this generation to include 2.4L and 2.7L V6. Confirming manual coverage for these specific engines is key.)
Transmission Types Covered:
Automatic, Manual
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV
Key Competitors:
Honda CR-V, Toyota RAV4, Nissan X-Trail, Ford Escape, Mazda CX-5.
Competitive Analysis
Unique Selling Points:
Often praised for its rugged styling, available true four-wheel-drive system (4WD) with low-range gearing in some configurations, and relatively affordable pricing compared to some rivals.
Key Features
Body Styles:
Primarily offered as a 5-door SUV. A 3-door version was also available in some markets.
Drivetrain Options:
Front-wheel drive (FWD) and four-wheel drive (4WD) were commonly available. The 4WD system often included a lockable center differential and a low-range gear for off-road capability.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Language:
English
Format:
PDF
Compatibility:
All Versions of Windows & Mac
Download Type:
Instant Download
Printability:
All pages are printable
📖 Manual Coverage
Systems Covered
General Information:
Vehicle identification, general precautions, safety, torque specifications, lubrication.
Engine:
Engine mechanical systems (J20A, M16A, J24B, H27A - if covered), cooling system, lubrication system, fuel system, ignition system, emission control systems, starting system, charging system.
Driveline Axle:
Front axle, rear axle, drive shafts, constant velocity joints, differentials.
Transmission:
Manual transmission (operation, disassembly, assembly, diagnostics), Automatic transmission (operation, internal components, hydraulic control, diagnostics, service).
Suspension:
Front suspension (struts, control arms, bushings), rear suspension (multi-link system, coil springs), shock absorbers, wheel alignment.
Brakes:
Front and rear brake systems (discs), Anti-lock Braking System (ABS), hydraulic system, parking brake.
Steering:
Power steering system (hydraulic pump, steering rack, power steering fluid), steering column, steering wheel.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant circuit, blower motor, climate control unit.
Restraint:
Airbag system (SRS), seat belts, pre-tensioners.
Body Cab Accessories:
Body panels, doors, windows, interior trim, exterior trim, bumpers, lights, wipers, locks, power accessories, chassis components.
Control Systems:
Electronic control modules (ECU), powertrain control module (PCM), body control module (BCM), diagnostic trouble codes (DTCs), on-board diagnostics (OBD-II).
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, brake pad replacement, spark plug replacement.
Repair Procedures:
Engine tune-ups, cylinder head repair, transmission overhaul, brake caliper replacement, suspension component replacement, steering rack rebuild.
Diagnostic Procedures:
Troubleshooting engine performance issues, diagnosing transmission faults, identifying brake system problems, electrical system diagnostics.
Assembly Disassembly:
Step-by-step instructions for disassembling and reassembling major vehicle components.
Technical Depth
Depth Of Information:
Factory level detail, including detailed diagrams, exploded views, torque specifications, and step-by-step instructions for a wide range of repairs.
Information Source:
Represents the same type of information used by authorized Suzuki dealerships and professional mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Software Requirements:
Adobe PDF Reader
Print Quality
Output Quality:
High-resolution, suitable for professional printing.
Binding Type
Binding Method:
Digital (Not Applicable, but printable for binding)
Paper Type
Paper Recommendation:
Standard copier paper (8.5" x 11" or A4) recommended for printing.
⚙️ Engine Specifications
Primary Engine
Engine 1 6L M16A:
1.6L inline-4, DOHC, 16 valves. Power: Approx. 100-105 hp. Torque: Approx. 105-110 lb-ft. Fuel System: Multi-point fuel injection.
Engine 2 0L J20A:
2.0L inline-4, DOHC, 16 valves. Power: Approx. 140-145 hp. Torque: Approx. 130-135 lb-ft. Fuel System: Multi-point fuel injection.
Secondary Engines Potential Coverage
Engine 2 4L J24B:
2.4L inline-4, DOHC, 16 valves. Power: Approx. 160-170 hp. Torque: Approx. 165-170 lb-ft. Fuel System: Multi-point fuel injection.
Engine 2 7L H27A V6:
2.7L V6, DOHC, 24 valves. Power: Approx. 185-190 hp. Torque: Approx. 190-195 lb-ft. Fuel System: Multi-point fuel injection.
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
🔧 Transmission
Standard
Manual Transmission:
5-speed manual transmission (common with 1.6L and 2.0L engines)
Optional
Automatic Transmission:
4-speed automatic transmission (common with 2.0L, 2.4L engines), 5-speed automatic transmission (sometimes found with 2.7L V6).
Features
Gear Ratios:
Specific gear ratios for each transmission and engine combination would be detailed within the manual.
Transmission Fluid Type:
Specific Suzuki-approved ATF for automatics (e.g., Suzuki ATF 5D03 or equivalent) and gear oil for manuals (e.g., SAE 75W-90 GL-4 or GL-5).
📐 Dimensions
Exterior
Wheelbase:
Approx. 2,640 mm (103.9 inches) for 5-door models.
Length:
Approx. 4,145 mm (163.2 inches) for 5-door models (may vary slightly by year/trim).
Width:
Approx. 1,810 mm (71.3 inches) for 5-door models.
Height:
Approx. 1,680 mm (66.1 inches) for 5-door models (without roof rails).
Weights
Curb Weight:
Ranges from approximately 1,400 kg to 1,700 kg (3,086 lbs to 3,748 lbs) depending on engine, drivetrain, and trim.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Variable by year and specific testing. Early models may have lower ratings compared to later ones. Reviewing specific model year NHTSA reports is recommended.
IIHS Ratings:
Similarly, ratings vary by year and testing criteria. Check IIHS archives for specific model year evaluations.
Active Features
ABS:
Standard Anti-lock Braking System.
Electronic Stability Control:
Often available or standard on higher trims, known as ESP or ESC.
Passive Features
Airbags:
Frontal airbags for driver and front passenger, side-impact airbags, and curtain airbags were available on many trims.
Seat Belts:
3-point seat belts with pre-tensioners and load limiters for front occupants. ISOFIX child seat anchors.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player with speaker system. Higher trims may feature upgraded audio systems, Bluetooth connectivity, and steering wheel audio controls.
Navigation:
Optional factory-installed navigation system was available on some models and trims.
Driver Assistance
Cruise Control:
Standard on most trims.
Rear View Camera:
Available on later model years or higher trim levels.
Connectivity
Usb Aux Input:
May be available on later models or as an aftermarket addition, typically not standard on early models.
🔧 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. Consult the manual for precise recommendations.
Air Filter Replacement:
Recommended every 15,000 - 30,000 miles (24,000 - 48,000 km) or as per manual. Cabin air filter typically annually or bi-annually.
Spark Plug Replacement:
Varies by plug type. Iridium plugs can last 60,000 - 100,000 miles (96,000 - 160,000 km). Consult the manual for specific plug part numbers and intervals.
Fluid Specifications
Engine Oil Grade:
Typically SAE 0W-20 or 5W-30 synthetic oil, depending on engine and climate. Always verify with the manual for the specific engine.
Coolant Type:
Suzuki Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with the correct silicate and organic acid technology (OAT) formulation. Typically a pink or red color.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Complaints:
Some owners report issues with catalytic converters, minor electrical gremlins (e.g., window regulators, sensors), and occasional front suspension component wear (bushings, ball joints) due to its off-road oriented design. Clutch wear on manual transmissions is also a possibility with high mileage.
📚 Vehicle History
Brand Heritage
Suzuki SUVs:
Suzuki has a long history of producing capable off-road and compact SUVs, with predecessors like the Suzuki Samurai and Vitara laying the groundwork for the Grand Vitara's blend of utility and everyday drivability.
Model Evolution
Second Generation Launch:
The second generation (JB) was launched for the 2006 model year, evolving from the previous generation with a unibody construction for improved on-road manners while retaining available robust 4WD systems and optional V6 engines.
Production
Manufacturing Locations:
Produced in Japan and at various international assembly plants.
🏆 Awards & Recognition
Recognitions
Segment Performance:
While not a consistent award winner like some competitors, the Grand Vitara was often recognized for its off-road capability and value proposition within the compact SUV segment.
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