SuzukiXL-72002Overview/suzuki/xl-7/2002/base/

2002 Suzuki XL-7

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 XL-7.

Body SUVTransmission Automatic 4-spd

The 2002 Suzuki XL-7 is a conventional SUV of its era, pairing a four-speed automatic transmission with EPA fuel economy ratings of 15 city, 18 highway, and 17 combined mpg that placed it squarely in the mid-pack for its class at the turn of the millennium. Its reliability record, however, marks this as a model year worth approaching with caution: 67 total owner complaints and four recalls are documented, with vehicle speed control emerging as the most frequently cited problem area. For researchers evaluating where this year sits in the XL-7's overall history, those figures point to a notably troubled point in the model's timeline, meaning any assessment of the 2002 should weigh the complaint and recall data heavily before reaching a verdict on its long-term durability.

Model year2006200420032002

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Lug nut torque73 ft-lbsOEM · verified
EPA fuel economy15/18/17 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

Tail / brake / turnOFFOEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length180.3 in
Overall width70.1 in
Overall height68.1 in
Wheelbase110.2 in
Curb weight3726 lb
Track (front / rear)59.1 / 59.1 in
Weight distribution (front / rear)54/46

Ratings & economy EPA / vPIC

EPA city / highway / combined15 / 18 / 17 mpg
DrivetrainRear-Wheel Drive
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

Torque lug nuts to 73 ft-lbs.

Lubricants & capacities

Power Steering FluidATF

Chassis torques

Lug Nuts73 ft-lbs
Transfer Case Fill Plug17.0 ft-lbs
Transfer Case Drain Plug17.0 ft-lbs

Ignition

Spark Plug ManufacturerDenso
Spark Plug Gap0.039-0.0.043 in
Spark Plug Torque18.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant CapacitySingle A/C, .99-1.21; dual A/C, 1.54-1.76. lbs
Oil GroupPAG
Oil Type46
Oil Capacity8.43 oz

Service checks

Pressure Test16 psi
Radiator Cap Pressure Relief16 psi
Thermostat Opening Temperature179 °F
Engine Oil Pressure10 psi @ Idle, 20 psi @ 2000 rpm psi
Intake Valve LashHydraulic in
Exhaust Valve LashHydraulic in

Brakes

Torque Caliper to Bracket36.5 ft-lbs
Torque to Knuckle61.5 ft-lbs
Minimum Pad ThicknessFront: 0.275; Rear: 0.275 specification
Minimum Shoe Thickness.140 in
Rotor Runout Limit0.0059 in
Rotor Minimum Machining0.866 in
Rotor Finish0.787 μin
Drum Maximum Machining10 in

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 5 stages

Prep Large hex head bolts:

138.5 ft. lbs.38.5 ft. lbs
261 ft. lbs.61 ft. lbs
3Loosen
438.5 ft. lbs.38.5 ft. lbs
576 ft. lbs.; Small hex head bolt: 7.576 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 30,000 mi; coolant every 30,000 mi. The big-interval services (every 30,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

At 7,500 miDrive Axle Assembly (drain & refill)
Every 7,500 miEngine Oil (drain & refill) · Engine Oil Filter (replace)
Every 15,000 miBrake Drum Assembly (inspect)
Every 30,000 miCabin Air Filter (replace) · Differential (inspect fluid level) · Engine Air Filter Element (replace) · Engine Coolant System (drain, flush & refill) · Fuel Filter (replace) · Spark Plugs (replace)
Every 60,000 miBrake Hydraulic System (drain, refill & bleed) · Drive Belt (replace) · Fuel Tank Filler Cap (replace)
Every 90,000 miTransfer Case Assembly (drain & refill)
At 120,000 miFuel Evaporative Canister (replace) · Fuel Evaporative Canister Filter (replace)
At 142,500 miDrive Axle Assembly (drain & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

Owner complaints about the 2002 Suzuki XL-7 lead in one area — the vehicle speed control, 12 of 67 reports (18%), well ahead of the next concern. None of this vehicle's 1 recall campaigns target the vehicle speed control, so those reports read as owner-reported wear-and-tear rather than an acknowledged defect. 8 of the reports describe a crash and 3 a fire — a small share of the total, but worth weighing against the vehicle speed control pattern above. These are tallies of what owners actually reported to the federal government, not an editorial score — and higher-selling models naturally rack up more reports.

4
Open recalls
NHTSA campaigns
5
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
67
Owner complaints
8 involved a crash · 3 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★

Owner complaints filed with NHTSA, by component

All 67 complaints on record, top 8 components.

Vehicle Speed Control12
Engine & Engine Cooling6
Tires6
Service Brakes, Hydraulic5
Power Train5
Suspension4
Electrical System4
Fuel System, Gasoline4

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 1 of 1 campaigns on record for this vehicle.

04V427000Fuel System, GasolineReported 30/08/2004

ON CERTAIN PASSENGER VEHICLES, UNDER AMBIENT TEMPERATURES BELOW -25 DEGREES CELSIUS, MOISTURE CAN FREEZE IN THE FUEL PRESSURE REGULATOR. AS A RESULT, FUEL SYSTEM PRESSURE MAY INCREASE AT THE TIME OF ENGINE START UP… Remedy: DEALERS WILL REPLACE THE FUEL PRESSURE REGULATOR, THE FUEL DELIVER HOSE AND REPLACE THE HOSE CLAMP WITH AN IMPROVED CLAMP. THE RECALL BEGAN ON SEPTEMBER 29, 2004. OWNERS SHOULD…

Technical service bulletins NHTSA · verified

Showing 5 of 5 bulletins on record with NHTSA.

BulletinDateComponentSummary
SUZ_0160082022-07-08SuspensionReminder of the importance to conduct safety inspections for rust damage to suspension…
N-Q-G-0452018-11-20SuspensionThis Service Bulletin was sent by Suzuki Motor Corporation to its authorized Suzuki…
PIC3278F2015-01-14EquipmentTHIS PRELIMINARY INFORMATION COMMUNICATION PROVIDES INFORMATION TO THE TECHNICIAN THE…
0602244R22004-01-01Engine And Engine CoolingOIL LEAKING FROM LEFT FRONT OF ENGINE. *TT
1405175Engine And Engine CoolingMODIFICATION OF MAIN BEARING OIL CLEARANCE AND THE BEARING SELECTION PROCEDURE. 1999-2005…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific XL-7. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

Does the 2002 XL-7 have open recalls?

NHTSA lists 4 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the XL-7 get?

EPA figures are 15 city / 18 highway / 17 combined mpg.