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2004 Suzuki Grand Vitara CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Suzuki REPAIR SHOPS DON'T WANT YOU TO KNOW
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- 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
A/C & HEATER SERVICE PROCEDURES FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Suzuki -> Component Replacement & Adjustment -> Blower Motor Resistor, Replace -> Front -> Rear
Vehicle: 2004 Suzuki Grand Vitara 2.5 V6 GAS
Front
- Remove front blower motor as outlined in "Blower Motor, Replace."
- Disconnect resistor electrical connector.
- Remove resister to HVAC housing retaining screws, then the resistor.
- Reverse procedure ...
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BRAKE SERVICE PROCEDURES FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Suzuki -> Hydraulic Brake Systems -> Diagnosis & Testing -> Brake Fluid Leakage Inspection -> Road Test -> Substandard Or Contaminated Brake Fluid
Vehicle: 2004 Suzuki Grand Vitara 2.5 V6 GAS
Road Test
Brakes should be tested on dry, clean, smooth and reasonable level roadway which is not crowned. Road test brakes by making brake applications with both light and heavy pedal forces at various speeds to determine if vehicle stops evenly and effectively.
Also road test vehicle to see if it pulls to one side without brake application. If it does, inspect tire pressure, front end alignment and front suspension attachments for looseness.
Brake Fluid Leakage Inspection
Inspect master cylinder fluid levels. While a slight drop in reservoir level does result from normal linin...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Suzuki -> Fuel Filter Replacement -> Grand Vitara, Verona, Vitara & XL-7 -> Fuel System Pressure Relief -> Removal & Installation
Vehicle: 2004 Suzuki Grand Vitara XL-7 2.7 V6 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 2004 Suzuki Grand Vitara AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2004 Suzuki Grand Vitara XL-7 2.7 V6 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 c...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Suzuki Grand Vitara XL-7 2.7 V6 GAS
- Disconnect battery ground cable.
- Remove air cleaner outlet hose and air cleaner assembly.
- Remove power steering return line clamp bolt.
- Raise and support vehicle.
- Remove righthand front wheel, then drain transaxle fluid into suitable container.
- Disconnect tie rod end from steering knuckle using suitable tool.
- Drive out drive shaft joint to release snap ring fitting from joint spline at cen...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Cabin Air Filter Service -> Suzuki -> 2003-05 Grand Vitara & 2003-06 XL-7
Vehicle: 2004 Suzuki Grand Vitara XL-7 2.7 V6 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 the battery ground cable.
- Open the glove box, then remove the screw.
- Remove the glove box assembly.
- Release the cabin air filter access cover tabs, then remove the cabin air...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Suzuki -> Anti-Lock Brake System Warning Lamp -> 1999-2009 Grand Vitara
Vehicle: 2004 Suzuki Grand Vitara 2.5 V6 GAS
The Anti-Lock Brake System (ABS) indicator lamp should illuminate for approximately 2 seconds as a bulb check when the ignition Switch is placed in the on position. If the lamp remains illuminated or comes on while driving the vehicle or is blinking, a fault in the ABS has been detected. After diagnosis and repair are completed, the DTCs can be cleared using a suitable scan tool or as follows:
- Place ignition switch in the off positio...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Suzuki Grand Vitara 2.5 V6 GAS
- Drain coolant into suitable container.
- Disconnect automatic transmission cooler lines.
- Loosen cooling fan/clutch mounting nuts.
- Disconnect radiator inlet hose.
- Remove power steering oil ...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Suzuki Grand Vitara 2.5 V6 GAS
- Disconnect battery ground cable at battery.
- Loosen power steering pump drive belt adjusting bolt...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Suzuki Grand Vitara AUTOMOBILES
Component location diagrams for most 2004 Suzuki Grand Vitara cars and light trucks sold in the U.S. from 1990+.
Engine Room Diagram for 2004 Suzuki Grand Vitara XL-7 2.7 V6 GAS Components on diagram: |
Roof Wire Diagram for 2004 Suzuki Grand Vitara 2.5 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 Suzuki Grand Vitara AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Suzuki Grand Vitara cars and light trucks sold in the U.S.
2004 Suzuki Grand Vitara 2.5 V6 GAS Wiring Diagram Components on diagram: |
2004 Suzuki Grand Vitara XL-7 2.7 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Suzuki Grand Vitara AUTOMOBILES
OEM TSB listings for most 2004 Suzuki Grand Vitara cars and light trucks sold in the U.S. from 1985+.
Document: SPECIAL COVERAGE ADJUSTMENT "PQ": CORROSION INSPECTION OF FRONT SUSPENSION FRAME Vehicle: 2004 Suzuki Grand Vitara 2.5 V6 GAS Auto Systems: |
Document: OIL LEAK IDENTIFICATION Vehicle: 2004 Suzuki Grand Vitara 2.5 V6 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Suzuki Grand Vitara AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Suzuki Grand 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 2004 Suzuki Grand 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 2004 Suzuki Grand 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 2004 Suzuki Grand 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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