Cover SUZUKI GRAND VITARA 2000 2.G Service Repair Manual

YH4
GRAND
VITARA
7A
MANUAL TRANSMISSION (TYPE 1) 7A-1
TYPE 1
GENERAL DESCRIPTION7A- 1 . . . . . . . . . . . . . .
DIAGNOSIS7A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A- 3 . . . . . . . . . . . . . . . .
Gear Oil 7A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A- 4. . . . . . . . . . . . . . . . . . .
Switches 7A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A- 8. . . . . . . . . . . . . . . .
Dismounting of Trans. Unit 7A- 9. . . . . . . . . . . . .
Remounting of Trans. Unit 7A-12. . . . . . . . . . . . . Extension Case (2WD MODEL) 7A-13. . . . . . . .
Extension Case Oil Seal
(2WD MODEL) 7A-13. . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A-14 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A-14 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A-14 . . . . . .
SPECIAL TOOL7A-14 . . . . . . . . . . . . . . . . . . . . . . .
As the aluminum case is sealed with liquid type gas-
ket, it is necessary to use genuine sealant or its equiv-
alent on its mating surfaces when reassembling it.
Also, the case fastening bolts must be tightened to
specified torque by means of the torque wrench and
tightening over or below the specified torque should
be avoided.
The description under ON-VEHICLE SERVICE in this
section covers a part of the TYPE 2 manual transmis-
sion and the transfer. The transfer is next to the trans-
mission as well, but their gear boxes are independent
and each of them has its own drain and level / filler
plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A
MANUAL TRANSMISSION
(TYPE 1)
CONTENTS
GENERAL DESCRIPTION
The manual transmission consists of the input shaft,
main shaft, countershaft and reverse gear which are
installed in the aluminum case. Its gears are of for-
ward five speeds in synchro mesh and reverse one
speed in constant mesh system.
The main shaft gears are held by the needle bearings
and on them the synchronizer rings and synchronizer
sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.

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GRAND
VITARA
7A-2 MANUAL TRANSMISSION (TYPE 1)
DIAGNOSIS
ConditionPossible CauseCorrection
Gear slipping out of mesh
Worn shift fork shaft

Worn shift fork or synchronizer sleeve

Weak or damaged locating spring

Worn bearings on input shaft or main shaft

Worn chamfered tooth on sleeve or gear

Missing or disengagement of circlip(s)Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Gears refusing to disengage
Weakened or broken synchronizer spring

Distorted shift shaft or shift forkReplace
Replace
Hard shifting
Improper clutch pedal free travel

Distorted or broken clutch disc

Damaged clutch pressure plate

Worn synchronizer ring

Worn chamfered tooth on sleeve or gear

Distorted shift shaftAdjust
Replace
Replace clutch cover
Replace
Replace sleeve and gear
Replace
Noise
Inadequate or insufficient lubricant

Damaged or worn bearing(s)

Damaged or worn gear(s)

Damaged or worn synchronizer ring

Damaged or worn chamfered tooth on
sleeve or gearReplenish
Replace
Replace
Replace
Replace

YH4
GRAND
VITARA
1. Bolt
2. Console box
bracket
3. Boot cover
1. Boot No. 3
2. Boot cover
3. Boot No. 2
4. Control lever
5. Lever case
6. Control case cover
7. Boot No. 1
1. Transmission control
lever locating bolt
2. Transfer control lever
locating bolt
7A-4 MANUAL TRANSMISSION (TYPE 1)
SHIFT CONTROL LEVERS
REMOVAL
1) Remove 4 screws at the front and rear and 2 clips at the center
then take off front and rear center console boxes.
NOTE:
To remove clip, push in its center pin first.
2) Remove console box bracket by removing bolts and lift up boot
cover and boot No. 2.
3) Remove boot clamp and then remove boot No. 1 from transmis-
sion shift lever case.
4) With gear shift control case cover pushed down with fingers, turn
it to counter clockwise and take out shift control lever.
5) Take out transfer shift control lever in similar manner as de-
scribed above.
INSPECTION AND INSTALLATION
1) Check shift control lever lower portion and control lever locating
sheet for excessive wear, and boot for damage. Correct or re-
place if necessary.
2) Apply grease to pivot portions and seat, then install shift control
lever.
ªAº: Grease 99000-25010
3) Perform above steps also for transfer shift control lever.
4) If control lever locating bolts (a) are replaced or retightened,
torque them as specified below.
Replacing of control lever locating bolts requires thread lock ce-
ment.
ªBº: Cement 99000-32020
Tightening Torque
(a): 17 N
.m (1.7 kg-m, 12.5 lb-ft)

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VITARA
1. Boot No. 1
2. Boot clamp
3. Boot cover
4. Boot No. 2
1. Transfer boot No. 1
2. Boot clamp
1. Console box
bracket
2. Boot cover
3. Boot No. 3
MANUAL TRANSMISSION (TYPE 1) 7A-5
5) Install transmission boot No. 1 from inside of cabin and clamp
it with a new clamp securely.
6) Install transfer boot No. 1 securely on lift and clamp it by using
a new clamp.
7) Tighten transmission boot No. 2 with boot cover and console box
bracket.
Tightening Torque
(a): 6 N
.m (0.6 kg-m, 4.0 lb-ft)
8) Install console box.
NOTE:
Be sure that flare end of transmission boot No. 3 is engaged
with console box.

YH4
GRAND
VITARA
7A-14 MANUAL TRANSMISSION (TYPE 1)
09951-16060
Oil seal installer
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Oil filler / level and drain plugs232.317.0
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back up light switch (Type 1)202.014.5
Back up light switch (Type 2)454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts and nut505.036.5
Exhaust center pipe to manifold nuts505.036.5
Muffler to exhaust center pipe bolts505.036.5
Universal joint flange bolts505.036.5
Select return spring bolts232.317.0
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever.

Select return springs, bolts and guides.
Thread lock cementTHREAD LOCK CEMENT
SUPER 1333B (99000-32020)
Shift control lever locating bolts.
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil Drain and filler / level plugs.
SPECIAL TOOL

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GRAND
VITARA
7A1
MANUAL TRANSMISSION (TYPE 2) 7A1-1
TYPE 2
GENERAL DESCRIPTION7A1-1 . . . . . . . . . . . . . .
DIAGNOSIS7A1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A1-3 . . . . . . . . . . . . . . . .
Gear Oil 7A1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A1-4. . . . . . . . . . . . . . . . . . .
Switches 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A1-4. . . . . . . . . . . . . . . . Dismounting / Remounting of
Trans. Unit 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A1-4 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A1-5 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A1-5 . . . . . .
The manual transmission consists of the input shaft,
main shaft, counter shaft and reverse gear which are
installed in the aluminum and castings cases. Its
gears are of forward five speeds in synchro mesh and
reverse one speed in sliding idler gear arrangement
system.
The main shaft gears are held by the needle bear-
ings and on them the synchronizer rings and syn-
chronizer sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.As the aluminum and castings cases are sealed with
liquid type gasket, it is necessary to use genuine seal-
ant or its equivalent on its mating surfaces when reas-
sembling them. Also, the case fastening bolts must be
tightened to specified torque by means of the torque
wrench and tightening over or below the specified
torque should be avoided.
The description under ON-VEHICLE SERVICE in this
section covers the transfer partially which is next to
the transmission as well, but their gear boxes are in-
dependent and each of them has its own drain and
level / filler plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A1
MANUAL TRANSMISSION
(TYPE 2)
CONTENTS
GENERAL DESCRIPTION

YH4
GRAND
VITARA
7A1-2 MANUAL TRANSMISSION (TYPE 2)
DIAGNOSIS
ConditionPossible CauseCorrection
Gear slipping out of mesh
Worn shift fork shaft

Worn shift fork or synchronizer sleeve

Weak or damaged locating spring

Worn bearings on input shaft or main shaft

Worn chamfered tooth on sleeve or gear

Missing or disengagement of circlip(s)Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Gears refusing to disengage
Weakened or broken synchronizer spring

Distorted shift shaft or shift forkReplace
Replace
Hard shifting
Improper clutch pedal free travel

Distorted or broken clutch disc

Damaged clutch pressure plate

Worn synchronizer ring

Worn chamfered tooth on sleeve or gear

Distorted shift shaftAdjust
Replace
Replace clutch cover
Replace
Replace sleeve and gear
Replace
Noise
Inadequate or insufficient lubricant

Damaged or worn bearing(s)

Damaged or worn gear(s)

Damaged or worn synchronizer ring

Damaged or worn chamfered tooth on
sleeve or gearReplenish
Replace
Replace
Replace
Replace

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GRAND
VITARA
MANUAL TRANSMISSION (TYPE 2) 7A1-5
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN´mkg-mlb-ft
Transfer oil filler / level and drain plugs232.317.0
Transmission oil filler / level and drain plugs383.827.5
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back-up light switch454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts505.036.5
Muffler to exhaust No. 2 pipe nuts505.036.5
Universal joint flange bolts505.036.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever
Thread lock cement
THREAD LOCK CEMENT
SUPER 1333B
(99000-32020)

Shift control lever locating bolts
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil drain and filler / level plugs

YH4
GRAND
VITARA
Oscilloscope waveforms
2V/Div.
Waveforms at specified idle
speed in ªPº range5ms / Div.
AUTOMATIC TRANSMISSION (4 A / T) 7B1-43
TROUBLESHOOTING (DTC P0715)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Input speed sensor circuit check:
1) Remove PCM cover.
2) With ignition switch OFF, disconnect PCM
connectors.
3) Check for proper connection to input speed sensor
at C51-1-10 and C51-1-11 terminals for G16/J20
(at C51-1-8 and C51-1-16 terminals for H25)
4) If OK, check resistance of sensor circuit.
Resistance between C51-1-10
and C51-1-11 for G16 / J20
(C51-1-8 and C51-1-16 for H25):530 ± 650
at
20C, 68F
Resistance between C51-1-10 /
C51-1-11 for G16 / J20 (C51-1-8 /
C51-1-16 for H25) and ground: 1 M
or more
Are check results satisfactory?Go to Step 4.Go to Step 3.
3Input speed sensor check:
1) With ignition switch OFF, disconnect input speed
sensor connector.
2) Check for proper connection to input speed sensor
at each terminals.
3) If OK, then check resistance of input speed sensor.
Are measured values as specified in Step 2?ªBl / Gº or ªBl / Yº wire
open or shorted to
ground.Replace input speed
sensor.
4Check visually input speed sensor and overdrive clutch
drum for the followings.

No damage

No foreign material attached

Correct installation
Are they in good condition?Intermittent trouble
or faulty PCM.
Check for intermittent
referring to
ªIntermittent and
Poor Connectionº in
Section 0A.Clean, repair or
replace.
Reference
Connect oscilloscope between C51-1-11 (+) and C51-1-10 (±) for
G16 / J20 (C51-1-16 (+) and C51-1-8 (±) for H25) of PCM connector
connected to PCM and check input speed sensor signal.

YH4
GRAND
VITARA
Oscilloscope waveforms
2 V/Div.
5 ms / Div.
Waveforms at about 25 mph, 40 km / h
AUTOMATIC TRANSMISSION (4 A / T) 7B1-45
TROUBLESHOOTING (DTC P0720)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Output speed sensor circuit check:
1) Remove PCM cover.
2) With ignition switch OFF, disconnect PCM
connectors.
3) Check for proper connection to output speed sensor
at C51-1-22 and C51-1-23 terminals for G16 / J20
(at C51-1-9 and C51-1-10 terminals for H25).
4) If OK, check resistance of sensor circuit.
Resistance between C51-1-22
and C51-1-23 for G16 / J20
(C51-1-9 and C51-1-10 for H25): 387 ± 473
at
20 C, 68 F
Resistance between C51-1-22 /
C51-1-23 for G16/J20 (C51-1-9 /
C51-1-10 for H25) and ground: 1 M
or more
Are check results satisfactory?Go to Step 4.Go to Step 3.
3Output speed sensor check:
1) With ignition switch OFF, disconnect output speed
sensor connector.
2) Check for proper connection to output speed sensor
at each terminals.
3) If OK, then check resistance of output speed sensor.
Are measured values as specified in Step 2?ªOrº or ªWº wire
open or shorted to
ground.Replace output
speed sensor.
4Check visually output speed sensor and sensor rotor
for the followings.

No damage

No foreign material attached

Correct installation
Are they in good condition?Intermittent trouble
or faulty PCM.
Check for intermittent
referring to
ªIntermittent and
Poor Connectionº in
Section 0A.Clean, repair or
replace.
Reference
Connect oscilloscope between C51-1-23 (+) and C51-1-22 (±) for
G16/J20 (C51-1-10 (+) and C51-1-9 (±) for H25) of PCM connector
connected to PCM and check output speed sensor signal.