2004 SUZUKI GRAND VITARA 2.0 TD

(this vehicle has now been sold and so I will not be adding any further to this site)

Current fuel mileage:
CITY 29.1 mpg(US), 34.3 mpg(IMP), 8.3 L/100km
HIGHWAY 34.2 mpg(US), 40.3 mpg(IMP), 7.04 L/100km

Maintenance and Mod Pages

1. Engine Oil Change 9. Clean / Replace the HVAC Cabin Filter
2. Toe-in Adjustment 10. Replacing Engine Coolant
3. Fuel Filter Water Drain 11. Replacing Gear Oils
4. Fixing a minor hose routing issue 12. Flush / Replace Power Steering Fluid
5. Protective Mesh for Front Grill 13. Installing Manual Locking Hubs
6. Brake Light Mod 14.  Removing the Radio (2003+ GV/XL-7)
7. Misc minor mods 15.  Mitigating Rattles
8. Brake and Clutch Fluid Flush

Factory service manuals in CD form for the DIESEL VERSIONS can be obtained off ebay.co.uk  You will need to be persistent but they do show up now and again.  Look for genuine Suzuki CDs with "RHZ" (single cam) or "RHW" (twin cam) "diesel supplement" or similar wording.  The older Mazda diesel is termed "RF."  Also be aware that (a) the RHW manual has the two previous diesels included and (b) these manuals are copyrighted material.

Engine Technical Stuff

The engine is coded RHW type DW10ATED4 and is a Peugeot 2.0 L 4-cylinder 16-valve DOHC normally found in older 806, 807s, and the Expert van.  Turbocharged to 1.0 bar and intercooled, it has a 1350 bar (19,580 psi) common-rail injection system under Bosch EDC15C2 control with liquid-cooled and throttle-assisted EGR. It also has actively-controlled swirl-inducing butterflies in the intake ports.

The RHW was clearly derived from the earlier single overhead cam RHZ which used a toothed-belt cam drive. The exhaust cam is driven directly of the toothed belt (from the crankshaft) while the intake cam is driven by a short chain from the exhaust cam.

The oil filter is a spin-on type and a semi-synthetic 10W-40 ACEA B3-98 oil is specified. The engine spec is very similar to the BMW 320D but the RHWs 109 hp is not even close to the BMW's 150 hp. The bimmer also has balance shafts which make it turbine-smooth.

The engine is a tight fit in the Grand Vitara yet the plumbing is very tidy considering it's a transplant. A north-south orientation of course, yet there is no mechanical fan as is usually found in rear-wheel drive vehicles. Now presumably this is due to the engine being designed for east-west front-wheel drive applications but there is no room in any case. The radiator is fitted with three electric fans, one on the front and two behind. There are two serpentine belts on the engine, one driving the alternator, PS pump, and water pump, the other driving the AC compressor. The injection pump is included in the camshaft toothed belt path no doubt due to the much higher power draw (up to 3.5 kW.) The intake plumbing is very tidy and short as the intercooler is mounted directly on top of the engine. The Garrett GT15 ball-bearing turbo with conventional wastegate hangs off the exhaust manifold and feeds primary and secondary catalytic converters.

The fuel filter is situated right next to the intake manifold as part of the engine and has a sensor of some sort on top, probably temperature. There is a conventional water drain underneath with a plastic finger-tightened valve.