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2002 Suzuki Vitara CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Suzuki REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 Suzuki Vitara car and truck
repair procedures including Suzuki engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Suzuki Vitara automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
Suzuki -> Diagnosis & Testing -> A/C System Diagnosis & Testing -> A/C System Performance Test
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
A/C System Performance Test
- Connect manifold gauge set to high and low sides of system.
- Start engine and allow to run at 1500 RPM, then activate air conditioner.
- Set blower switch to "HI," and temperature lever to "COOL."
- Open all windows and doors, then position dry bulb thermometer in cool air outlet and psychrometer (combination dry/wet bulb thermometer) near evaporator inlet.
- On Esteem and Swift models, ensure high pressure gauge reading is between 200-227 psi.
- On Grand Vitara and Vitara models, ensure high pressure gauge...
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BRAKE SERVICE PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
Hydraulic Brake Systems -> Brake System Bleed -> Esteem & Swift -> Grand Vitara, Sidekick, Vitara & X-90 -> Master Cylinder -> System Bleed
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface.
System Bleed
Esteem & Swift
The hydraulic lines of the brake system are based on a diagonal split system. When a brake line or hose is disconnected, bleeding operation must be performed at both ends of the line disconnected.
- Fill master cylinder reservoir. Reservoir should be kept at least half full during bleeding operation.
- Remove bleeder plug cap, then attach vinyl tube to bleeder plug of component to be bled. Insert other ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
Suzuki -> Fuel Filter Replacement -> Grand Vitara, Verona, Vitara & XL-7 -> Fuel System Pressure Relief -> Removal & Installation
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
Fuel System Pressure Relief
- Loosen the fuel filler cap to relieve fuel tank pressure.
- Remove the fuel pump relay/fuse from relay or fuse box located in engine compartment.
- Start the engine and allow to stall. Crank the engine for several seconds more to ensure relief of any remaining fuel pressure.
- Disconnect the battery ground cable.
- Install the fuel pump relay/fuse.
Removal & Installation
Do not smoke or allow an open flame of any type when working on or near any fuel system related componen...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
- Raise and support vehicle, then remove wheel and tire assembly.
- Remove axle shaft drive flange or hub cap.
- On models equipped with ABS, remove wheel speed sensor from knuckle and harness clamp from strut.
- Remove caliper bolt, then suspend caliper.
- Remove brake disc.
- Remove front wheel bearing lock washer by loosening four screws.
- Remove front wheel bearing lock nut using special tool No. 09951-16050, or equivalent.
- Remove front wheel bearing washer.
- Remove wheel hub ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
Starter, Replace
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
- Disconnect battery ground cable.
- Disconnect solenoid electrical connector and battery cable fr...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
Cabin Air Filter Service -> Suzuki -> 1999-2002 Grand Vitara, 1999-2004 Vitara & 2001-02 XL-7
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
Inspect the cabin air filter every 15,000 miles and replace as required. The cabin air filter should be replaced every 30,000 miles.
- Disconnect and isolate the battery ground cable. Wait at least 90 seconds for the air bag system back-up power supply to discharge.
- Remove the air bag fuse from the fuse panel located at the lower lefthand side of the instrument panel.
- From under the lefthand side of the instrument panel, disconnect the yellow air bag system contact coil electrical connector, Fig. . Lift up the connector locking lever, then disc...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
Suzuki -> Malfunction Indicator Lamp (MIL)/Service Engine Soon Lamp -> 1999-2004 Vitara
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
The MIL will be illuminated when the ignition switch is placed in the on position. When the engine is started, the lamp should go out. If it remains lit after engine start-up, the self-diagnostic system has detected a problem and stored a diagnostic trouble code. After diagnosis and repair are complete, the self-diagnostic system memory can be cleared using a suitable scan t...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
Inlet
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at heater core.
- Remove hose from heater core.
- Reposition hose clamp at water outlet on cylinder head.
- Remove hose from water outlet.
- Remove hose from vehicle.
- Reverse procedu...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Suzuki Vitara AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS
- Disconnect battery ground cable at battery.
- Use a wrench to turn tensioner bolt clockwise, compressing te...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Suzuki Vitara AUTOMOBILES
Component location diagrams for most 2002 Suzuki Vitara cars and light trucks sold in the U.S. from 1990+.
 Front Wiper And Washer Diagram for 2002 Suzuki Vitara 2.0 L4 GASComponents on diagram: |
 HVAC Components Diagram for 2002 Suzuki Vitara 2.0 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 Suzuki Vitara AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Suzuki Vitara cars and light trucks sold in the U.S.
 2002 Suzuki Vitara 2.0 L4 GAS Wiring DiagramComponents on diagram: |
 2002 Suzuki Vitara 2.0 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Suzuki Vitara AUTOMOBILES
OEM TSB listings for most 2002 Suzuki Vitara cars and light trucks sold in the U.S. from 1985+.
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Document: SPECIAL COVERAGE ADJUSTMENT "PQ": CORROSION INSPECTION OF FRONT SUSPENSION FRAME Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS Auto Systems: |
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Document: OIL LEAK IDENTIFICATION Vehicle: 2002 Suzuki Vitara 2.0 L4 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Suzuki Vitara AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 Suzuki Vitara cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2002 Suzuki Vitara cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2002 Suzuki Vitara cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2002 Suzuki Vitara cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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