2002 Suzuki Grand Vitara Service and Repair Manual

A simplified lineup marks the 2002 Grand Vitara: the Plus and SE variants were folded away, leaving two-wheel-drive JLS, four-wheel-drive JLX and the leather-trimmed Limited. The four-door body, ladder frame and 2.5L DOHC V6 carry over, now rated at 165 horsepower, with the XL-7 by then treated as its own model. Year-exact coverage matters because trim content and wiring shifted with the consolidation, and this service and repair manual supplies the 2002 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

• JLS
• JLX
• Limited

Known issues on the 2002 Grand Vitara. Four recalls are on federal record. In one, the windshield may not be properly bonded because of poor adhesion between paint layers, a failure of FMVSS 212. In another, the plastic accelerator cable casing cap on the firewall can crack and fray the inner cable, which may then stick. In a third, moisture can freeze in the fuel pressure regulator below about -25°C, raising pressure at start-up and leaking fuel at the pipe-to-hose joint. In a fourth, 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 53 complaints with NHTSA, most often about the vehicle speed control and the service brakes. Windshield installation, accelerator cable, fuel pressure regulator and front brake procedures in this manual cover every system named in these campaigns.