2002 Suzuki XL-7 Service and Repair Manual

Sold as the Grand Vitara XL-7, the 2002 model was a stretched Grand Vitara with a body-on-frame chassis, optional third-row seating and rear- or four-wheel drive. Power came from the Suzuki-built 2.7L H27A V6, and 2002 marked the model's US sales peak. Trims ran Base, Plus, Touring and Limited. Early XL-7s differ from later ones in trim content and some components, so this factory service and repair manual is matched to 2002, with procedures, specifications, torque values, wiring diagrams, diagnostics and maintenance schedules.

Engines covered

• 2.7L V6 — DOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sport utility

Trims covered

• Base
• Limited
• Plus
• Touring

Known issues on the 2002 XL-7. Four recalls are on federal record. Some windshields may not be properly bonded because of poor paint adhesion; the accelerator cable casing cap at the firewall can crack and fray the cable so it sticks; moisture can freeze in the fuel pressure regulator in extreme cold and leak fuel at start-up; and on vehicles with 16-inch wheels the front brake discs may break under sustained braking on steep grades. Sixty-seven owner complaints are logged with NHTSA. This manual's brake, fuel, throttle and electrical chapters include the torque values, routing views and inspection steps needed for that work.