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Suzuki · Known Issues

2002 Suzuki Grand Vitara Problems: 1 Known Issue

2002 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Suzuki Grand Vitara has 1 documented issue, with 1 rated critical. The most serious is V6 (H25A/H27A) Timing Chain Tensioner Rattle ($800-$2,500 repair). Across all issues with published estimates, repair costs range from $800 to $2,500. DIY maintenance guides at au7o.io.

In This Article

  • Grand Vitara Engine1
  • Recalls10
  • FAQ
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In This Article

  • Engine1
  • Recalls10
  • FAQ

All 1 Known Issue

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On the 1999-2006 Suzuki Grand Vitara, the 2.5L and 2.7L V6 engines (and the related 2.0L/2.7L used in the XL-7) are widely documented to develop a rattling/ticking noise from the front of the engine on cold start, originating from the No. 1 timing chain tensioner failing to maintain proper chain tension. Suzuki's own technical bulletin acknowledges the noise and a brief rattle (under ~5 seconds) is considered acceptable, but persistent rattle indicates a worn tensioner and often worn chain/guides. Because these are interference engines, a chain that jumps a tooth can bend valves, so owners are advised not to ignore the noise.

Common Symptoms

  • Rattling or ticking noise from front of engine on cold start
  • Noise loudest when engine is cold
  • Metallic chain rattle that may persist after warm-up in worn cases
  • Possible rough running if chain jumps a tooth

How to Fix

Replace the No. 1 timing chain tensioner per the Suzuki TSB; if any wear is evident on the chain, sprockets or guides, replace the full timing chain kit (chain, sprockets, guides/dampers and tensioners) as an assembly. The job requires removing the front of the engine/timing cover and is labor-intensive (roughly 8+ hours flat-rate). Use an OEM or quality timing kit and set timing precisely to avoid valve-to-piston contact.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Evergreen H25A/H27A Multi-Chain Timing Set

    matched chain/guide/tensioner set only when system-wide wear is proven Fitment/availability: 1999-2005 Grand Vitara 2.5L H25A and listed 2001-2006 XL-7/Grand Vitara 2.7L H27A branches; without gear, oil pump or water pump, confirm VIN an…

    Spark Automotive

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$800 - $2,500

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Jun 2026
NHTSA Recalls10 recalls

STEERING:HYDRAULIC POWER ASSIST SYSTEM

Suzuki Motor of America, Inc. (Suzuki) is recalling certain 2006 Suzuki Grand Vitara vehicles. The power steering pump belt tension adjuster pulley has an outer portion that is made of plastic. Repeated heat stress can cause the plastic material to deteriorate, causing pieces of the pulley to break off.

Campaign #18V66700025/09/2018

SEATS

Suzuki Motor of America, Inc. (Suzuki) is recalling certain 2010-2013 Kizashi and 2006-2013 Grand Vitara vehicles. The front passenger leather seat may shrink due to high humidity and high temperature. As a result, the occupant classification system (OCS) sensor mat may not accurately detect if an adult or child is occupying the seat.

Campaign #19V18700007/03/2019

AIR BAGS

Suzuki Motor of America, Inc. (Suzuki) is recalling certain model year 2006-2011 Grand Vitara and 2007-2011 SX4 vehicles. In the affected vehicles, over time, the OCS sensor mat installed in the front passenger seat may fail due to repeated flexing of the mat from use of the seat. As a result, during a crash necessitating deployment, the air bag will deploy regardless of whether the front seat occupant is an adult or a child.

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Other Suzuki Models

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Frequently Asked Questions

What are the most common Suzuki Grand Vitara problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Suzuki Grand Vitara has 1 documented issue. The documented issue is: V6 (H25A/H27A) Timing Chain Tensioner Rattle. Of these, 1 is rated critical and should be addressed promptly.

Is the Suzuki Grand Vitara reliable?

The 2002 Suzuki Grand Vitara has 1 known issue compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: V6 (H25A/H27A) Timing Chain Tensioner Rattle. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Suzuki Grand Vitara problems?

Repair costs for known Suzuki Grand Vitara issues range from $800 to $2,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, V6 (H25A/H27A) Timing Chain Tensioner Rattle, typically costs $800-$2,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 1999-2006 Suzuki Grand Vitara V6 (H25A/H27A) Timing Chain Tensioner Rattle?

The 2.5L and 2.7L V6 engines (and the related 2.0L/2.7L used in the XL-7) are widely documented to develop a rattling/ticking noise from the front of the engine on cold start, originating from the No. 1 timing chain tensioner failing to maintain proper chain tension. Suzuki's own… Repairs typically run $800-$2,500. Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

Campaign #13V40500006/09/2013

STEERING:HYDRAULIC POWER ASSIST:PUMP

SUZUKI IS RECALLING CERTAIN MODEL YEAR MODEL YEAR 2006 GRAND VITARA AND MODEL YEAR 2005-2006 XL-7 VEHICLES. THE TENSION ADJUSTER PULLEY FOR THE DRIVE BELT THAT OPERATES THE POWER STEERING PUMP AND AIR CONDITIONER COMPRESSOR (IF EQUIPPED) HAS AN OUTER PORTION THAT IS MADE OF PLASTIC. REPEATED HEAT STRESS CAN CAUSE THE PLASTIC MATERIAL TO DETERIORATE AND PIECES OF THE PULLEY CAN BREAK OFF.

Campaign #10V25000009/06/2010

POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT

CERTAIN VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 114, 'THEFT PROTECTION. ' THE AUTOMATIC TRANSMISSION SELECTOR LEVER "PARK" LOCK FUNCTION MAY BE INOPERATIVE DUE TO A STICKING SHIFT LOCK ARM. THE SHIFT LEVER MAY BE ABLE TO BE SHIFTED OUT OF "PARK" WITH THE KEY REMOVED AND WITHOUT DEPRESSING THE BRAKE PEDAL.

Campaign #07V55400007/12/2007

+ 5 more recalls. Check all on NHTSA.gov

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