1999 Suzuki Grand Vitara Service and Repair Manual

Suzuki's compact SUV moved upmarket for 1999 with the debut of the Grand Vitara, a four-door sport utility that kept a ladder frame and low-range transfer case while adding a 2.5L DOHC V6. Buyers chose two-wheel-drive JS or four-wheel-drive JLX, each also offered in better-equipped Plus form, with a five-speed manual or four-speed automatic. Because this was the launch year, many parts and wiring details differ from later builds, and this factory service and repair manual gives the 1999-specific procedures, specifications, torque values, wiring diagrams, diagnostics and maintenance schedules.

Engines covered

• 2.5L V6 — DOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sport utility

Trims covered

• JLX
• JLX Plus
• JS
• JS Plus

Known issues on the 1999 Grand Vitara. Five recalls are on federal record. In one, steel replacement wheels (part 4310-665D21-27S) built in mid-2000 have metal too thin near the rim weld and can crack and slowly lose air. In another, moisture can freeze in the fuel pressure regulator below about -25°C, spiking pressure at start-up and leaking fuel at the pipe-to-hose joint. In a third, the plastic accelerator cable casing cap on the firewall can crack and fray the inner cable, which may then stick. In a fourth, a later campaign (04V427) addressed the same cold-weather fuel leak at start-up. Beyond those, front brake discs on models with 16-inch wheels can break when the brakes are held on long, very steep paved descents. Owners have filed 117 complaints with NHTSA, most often about the fuel system and the engine and engine cooling. The fuel system, throttle linkage, brake and wheel sections of this manual detail the inspection and replacement work each of these campaigns involves.