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Suzuki Grand Vitara 1998-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Grand Vitara Generation: First Generation (SQ Series) Codes Chassis Code: SQ416/SQ420/SQ625 👋 Introduction Market Position Segment: Compact SUV / Off-road capable vehicle. Competitive...
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Type: Car
Vendor:
Sku: 414201
Suzuki Grand Vitara 1998-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
Grand Vitara
Generation:
First Generation (SQ Series)
Codes
Chassis Code:
SQ416/SQ420/SQ625
👋 Introduction
Market Position
Segment:
Compact SUV / Off-road capable vehicle.
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Mitsubishi Montero Sport, Jeep Cherokee (XJ).
Key Features
Attributes:
Body-on-frame construction, available 4WD, robust and reliable powertrain options, good off-road capability for its class.
📋 Manual Details
Coverage Areas
Covered Years:
1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnosis, tuning, cooling, lubrication, emissions control, timing systems.
Transmission:
Manual and automatic transmission removal, installation, overhaul, diagnosis, fluid changes.
Drivetrain:
Front/rear differentials, transfer case, driveshafts, CV joints, 4WD system operation and repair.
Suspension:
Front strut/coil spring, rear multi-link/coil spring, shock absorbers, bushings, wheel alignment procedures.
Steering:
Power steering system diagnosis, pump, rack and pinion repair, tie rod ends.
Brakes:
Front and rear disc brake systems, ABS diagnosis, hydraulic components, bleeding procedures.
Electrical:
Complete wiring diagrams, starter, alternator, battery, lighting system, fuses, relays, ECU diagnosis.
Body:
Body panel removal/installation, interior trim, glass replacement, door mechanisms, exterior components.
Climate Control:
HVAC system diagnosis, refrigerant handling, compressor, evaporator, heater core.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection/replacement.
Diagnostics:
Troubleshooting guides for common drivability issues, electrical faults, and mechanical problems using symptoms and causes.
Repair:
Step-by-step instructions for component removal, installation, and rebuilding for all major systems.
Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, engine timing settings.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including electrical system diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval.
Printability:
Printable pages for physical reference.
Print Quality
Image Resolution:
High-resolution diagrams and illustrations.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine 1:
G16A 1.6L SOHC I4 (1590cc)
Engine 1 Power:
92 hp @ 5500 rpm
Engine 1 Torque:
98 lb-ft @ 3500 rpm
Engine 2:
J20A 2.0L DOHC I4 (1998cc)
Engine 2 Power:
128 hp @ 6000 rpm
Engine 2 Torque:
134 lb-ft @ 3000 rpm
Engine 3:
H25A 2.5L DOHC V6 (2492cc)
Engine 3 Power:
157 hp @ 6000 rpm
Engine 3 Torque:
160 lb-ft @ 3500 rpm
Performance
Compression Ratio G16A:
9.5:1
Compression Ratio J20A:
9.8:1
Compression Ratio H25A:
9.3:1
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Engine Control Unit (ECU) - specific models may vary, refer to manual for details.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
4Wd System:
Part-time 4WD system (selectable 2WD, 4WD High, 4WD Low) standard on most models. Full-time 4WD (with center differential) available on V6 models.
📐 Dimensions
Exterior
Wheelbase Short Body:
2,280 mm (89.8 in)
Wheelbase Long Body:
2,695 mm (106.1 in)
Length Short Body:
4,045 mm (159.3 in)
Length Long Body:
4,510 mm (177.6 in)
Width:
1,780 mm (70.1 in)
Height:
1,670 mm (65.7 in)
Cargo
Cargo Volume Short Body:
Approx. 400-600 Liters (seats up, varies by configuration)
Weights
Curb Weight Approx:
1,300 - 1,600 kg (2,866 - 3,527 lbs) depending on engine and drivetrain
🛡️ Safety Features
Ratings
NHTSA Ratings:
Variable across model years and regions. Early models generally had lower ratings compared to modern vehicles. Specific reports are model-year dependent and often regional.
Active Features
Active Safety:
Anti-lock Braking System (ABS) - standard on most models from 2001 onwards, optional on earlier models.
Passive Features
Passive Safety:
Front airbags, 3-point seat belts with pretensioners, reinforced body structure.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium sound systems. Basic functionality, limited connectivity by modern standards.
Driver Assistance
Driver Aids:
Primarily ABS on later models. Limited electronic driver aids compared to contemporary SUVs.
Connectivity
Connectivity Options:
No Bluetooth or USB connectivity from the factory. Aftermarket solutions may be available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 miles (12,000 km) or 6 months, whichever comes first. Consult manual for specific engine and oil type.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Varies by spark plug type. Iridium plugs typically 60,000-100,000 miles. Consult manual for specific recommendations.
Timing Belt Replacement:
For J20A and H25A engines, typically every 60,000-90,000 miles (96,000-144,000 km). G16A may have a timing chain. CRITICAL TO VERIFY IN MANUAL.
Fluid Specifications
Engine Oil Type:
API SG, SH, or SJ classification. Viscosity typically SAE 10W-30 or 10W-40. Check manual for specific recommendations.
Coolant Type:
Ethylene glycol based coolant, pre-diluted or concentrate (mix 50/50 with distilled water).
Transmission Fluid Manual:
API GL-4 SAE 75W-90 gear oil.
Transmission Fluid Automatic:
Dexron II or equivalent.
Brake Fluid Type:
DOT 3
Known Issues
Common Problems:
Rust on frame and body panels (especially in salt-belt regions), potential for head gasket issues on older engines, starter motor failure, minor electrical gremlins.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Suzuki Motor Corporation, Japan.
Model Evolution
Introduction Year:
1998
Generation Change:
This manual covers the first generation (SQ series), which was produced until 2005. A significant redesign occurred with the second generation (SQ625/JB series) starting in 2006.
Production
Manufacturing Locations:
Primarily Japan; assembly also occurred in other locations depending on market.
🏆 Awards & Recognition
Recognitions
Awards List:
While not a consistent recipient of major automotive awards, the Grand Vitara was generally praised for its off-road capability and value in its segment during its production run. Specific awards are scarce.
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