2004 Suzuki Grand Vitara Service and Repair Manual

New LX and EX badges arrived for 2004, the penultimate year of the first-generation Grand Vitara. LX covers the core four-door with the 2.5L V6, while EX adds upgraded comfort equipment; both keep the body-on-frame layout, selectable four-wheel drive with low range on 4x4 versions, and manual or automatic transmissions. This was also the year the smaller Vitara name moved onto a V6 four-door, so parts catalogs overlap. This service and repair manual keeps the 2004 Grand Vitara procedures, specifications, torque values, wiring diagrams, diagnostics and maintenance schedules straight.

Engines covered

• 2.5L V6 — DOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sport utility

Trims covered

• EX
• LX

Known issues on the 2004 Grand Vitara. Two recalls are on federal record. In one, the plastic accelerator cable casing cap on the firewall can crack and fray the inner cable, which may then stick. In another, 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 eight complaints with NHTSA, most often about the vehicle speed control and the electrical system. This manual's accelerator linkage and front brake procedures cover inspecting and replacing the parts named in both campaigns.