page 1 SUZUKI GRAND VITARA 2004 2.G Service User Guide

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GRAND
VITARA
7A-6 MANUAL TRANSMISSION (TYPE 1)
3, (a)
1. Coupler
2. Clamp3. 4WD switch
4. Boot No. 2
1. Back up light switch
2. 4WD switch
1. Back up light switch coupler
2. Front propeller shaft
SWITCHES
TRANSFER 4WD SWITCH
1) Remove console box and lift transmission control lever boots
No. 2 and No. 3. (Refer to page 7A-4.)
2) Remove transfer control lever boot No. 2, unclamp wiring on
transfer case to free it and pull off coupler.
3) Replace switch and connect as it was.
Tightening Torque
(a): 20 N
.m (2.0 kg-m, 14.5 lb-ft)
4) Turn ON ignition switch, shift transfer shift control lever to 4WD
position and check that indicator lights. Turn OFF switch after
checking.
NOTE:

When removing and reinstalling switch, use care not to let
dust enter transfer box inside.

Make sure to reset clamp for wiring which is located
where invisible directly.

It is recommended to work on transfer shift control lever
boot No. 1 from underside of vehicle on lift.

Identify this switch by its leg part which is different for that
of back up light switch.
BACK UP LIGHT SWITCH
WARNING:
Refrain from work while exhaust center pipe is hot.
REMOVAL AND INSTALLATION
NOTE:
When replacing switch, use care not to let dust enter transmis-
sion through switch hole.
1) Lift up vehicle.
2) Remove coupler(s) for switch wiring.

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VITARA
1. Transmission
2. Breather clamp
3. Breather hose
4. Wiring harness clamp
5. Intake manifold
MANUAL TRANSMISSION (TYPE 1) 7A-9
DISMOUNTING OF TRANS. UNIT
IN CABIN
Remove transmission shift control lever (refer to page 7A-4) and
transfer shift control lever knob.
IN ENGINE ROOM
1) Disconnect negative (±) cable of battery.
2) Remove breather hose from clamp at the rear end of cylinder
head.
3) Remove starting motor fixing bolts and nut and then remove
starter.
4) Remove transmission fastening bolts.

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GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-21
AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE
Refer to the following pages for the details of each step.
STEP
ACTIONYESNO
1Customer Complaint Analysis
1) Perform customer complaint analysis referring to
the next page.
Was customer complaint analysis performed
according to instruction on the next page?Go to Step 2.Perform customer
complaint analysis.
2Diagnostic Trouble Code (DTC) and Freeze Frame
Data Check, Record and Clearance
1) Check for DTC (including pending DTC) referring
to the next page.
Is there any DTC(s)?1) Print DTC and
freeze frame data
or write them
down and clear
them by referring
to ªDTC
Clearanceº in this
section.
2) Go to Step 3.Go to Step 4.
3Visual Inspection
1) Perform visual inspection referring to the next page.
Is there any faulty condition?1) Repair or replace
malfunction part.
2) Go to Step 11.Go to Step 5.
4Visual Inspection
1) Perform visual inspection referring to the next page.
Is there any faulty condition?Go to Step 8.
5Trouble Symptom Confirmation
1) Confirm trouble symptom referring to the next page.
Is trouble symptom identified?Go to Step 6.Go to Step 7.
6Rechecking and Record of DTC / Freeze Frame Data
1) Recheck for DTC and freeze frame data referring
to ªDTC Checkº in this section.
Is there any DTC(s)?Go to Step 9.Go to Step 8.
7Rechecking and Record of DTC / Freeze Frame Data
1) Recheck for DTC and freeze frame data referring
to ªDTC Checkº in this section.
Is there any DTC(s)?Go to Step 9.Go to Step 10.
8Automatic Transmission Basic Inspection and
Trouble Diagnosis Table
1) Check and repair according to ªA / T Basic Checkº
and ªTrouble Diagnosis Tableº in this section.
Are check and repair complete?Go to Step 11.1) Check and repair
malfunction part(s).
2) Go to Step 11.
9Troubleshooting for DTC
1) Check and repair according to applicable DTC diag.
flow Table.
Are check and repair complete?
10Check for Intermittent Problems
1) Check for intermittent problems referring to the next
page.
Is there any faulty condition?1) Repair or replace
malfunction
part(s).
2) Go to Step 11.Go to Step 11.
11Final Confirmation Test
1) Clear DTC if any.
2) Perform final confirmation test referring to the next
page.
Is there any problem symptom, DTC or abnormal
condition?Go to Step 6.End.

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VITARA
7B1-28 AUTOMATIC TRANSMISSION (4 A / T)
Transmission fluid Running condition Running condition Gear shift
TROUBLE DIAGNOSIS TABLE 1
ConditionPossible CauseCorrection
TCC does not operate
Brake pedal (stop lamp) switch or its
circuit faulty (H25 engine only)

4WD low switch or its circuit faulty

Engine coolant temp. sensor or its
circuit faulty

Cruise control signal circuit faulty
(if equipped)DIAGNOSTIC FLOW TABLE A-1
Gear does not change
to 4th
O / D cut switch or its circuit faulty

4WD low switch or its circuit faulty

Engine coolant temp. sensor or its
circuit faulty

Cruise control signal circuit faulty
(if equipped)DIAGNOSTIC FLOW TABLE A-2
TROUBLE DIAGNOSIS TABLE 2
ConditionPossible CauseCorrection
Low fluid pressure
Clogged oil pump strainer

Malfunction of pressure regulator valveWash strainer.
Overhaul valve body.
High fluid pressure
Pressure regulator valveOverhaul valve body.
Unable to run in all
range
Regulator valve stickReplace.

Clogged oil strainerWash strainer.

Seized or broken planetary gearRepair or replace.

Faulty manual valveReplace.
Poor 1st speed run-
ning or excessive
slippage in ªDº or
ª2º
Faulty 1±2 shift valveReplace.
Poor 1±2 shift, ex-
ili

Regulator valve stickingReplace.
cessive slippage
1±2 shift valve stickingReplace.

Shift solenoid valve-B stickingReplace.

Intermediate coast modulator valve stick-
ingReplace.
Poor 2±3 shift, ex-
ili

2±3 shift valve stickingReplace.
cessive slippage
Shift solenoid valve-A stickingReplace.
Poor start or surg-
ing in ªDº range
Regulator valve stickingReplace.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-29
Gear shift Transmission fluid Running condition
ConditionPossible CauseCorrection
Poor 3±4 shift, ex-
3±4 shift valve stickingReplace.
cessive slippage
Shift solenoid valve-B stickingReplace.
Excessive shock on
Regulator valve stickingReplace.
1±2 shift
Faulty accumulator, second brake pistonReplace.
Excessive shock on
Regulator valve stickingReplace.
2±3 shift
Faulty accumulator, direct clutch pistonReplace.
Excessive shock on
3±4 shift
Regulator valve stickingReplace.
Non operate lock-
TCC (Lock-up) control valve stickingReplace.
up system
Solenoid valve No.2 (TCC solenoid valve)
stickingReplace.
TROUBLE DIAGNOSIS TABLE 3
ConditionPossible CauseCorrection
Low fluid pressure
Leakage from oil pressure circuitOverhaul.
Unable to run in all
range
Wear in oil pumpReplace.

Seizure in oil pumpReplace.

Fluid pressure leakage to over drive clutch
due to wear of oil pump bushingReplace.

Faulty in torque converterReplace.

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VITARA
7B1-30 AUTOMATIC TRANSMISSION (4 A / T)
Running condition Gear shift Abnormal
noise
ConditionPossible CauseCorrection
Poor 1st speed run-
ning or excessive
slippage in ªDº or ª2º
Fluid pressure leakage from forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Overdrive clutch slippingReplace.
Unable to run or ex-
cessive slippage in
ªLº range
Fluid pressure leakage of forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Reverse brake disc slippingReplace.

Broken brake piston O-ringReplace.
Unable to run or ex-
cessive slippage in
ªRº range
Fluid pressure leakage to direct clutch due
to wear or breakage of center support seal
ringReplace.

Worn direct clutchReplace.
Poor 1±2 shift, ex-
cessive slippage
Fluid pressure leakage to overdrive clutch
due to wear or breakage of O/D case seal
ringReplace.

Faulty second brakeReplace.

Broken O-ring of second brake pistonReplace.

Faulty second coast brake (in ª2º range)Replace.
Poor 2±3 shift, ex-
cessive slippage
Fluid pressure leakage to overdrive clutch
due to wear or breakage of O/D case seal
ringReplace.

Worn direct clutch bushingReplace.

Direct clutch slippingReplace.

Foreign material caught in direct clutch pis-
ton check ballReplace.
Poor start or surging
in ªDº range
Fluid pressure leakage of forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Malfunction of forward clutchReplace.
Poor 3±4 shift, ex-
ili

Faulty overdrive brakeReplace.
cessive slippage
Faulty overdrive clutchReplace.
Poor start or judder-
ing in ªRº range
Fluid pressure leakage of direct clutch due
to wear or breakage of oil center support
seal ringReplace.

Worn direct clutchReplace.
Excessive shock on
1± 2 shift
Faulty one-way clutchReplace.
Non operate lock-up
system
Faulty torque converterReplace.
Abnormal noise in
ªPº or ªNº range
Worn oil pumpReplace.
SCAN TOOL DATA-Refer to SECTION 6 / 6-1.
INSPECTION OF PCM AND ITS CIRCUIT-Refer to SECTION 6 / 6-1.
WIRE HARNESS AND CONNECTORS-Refer to SECTION 6 / 6-1.

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GRAND
VITARA
1. Dipstick (G16 / J20)
2. Dipstick (H25)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-59
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
FLUID LEVEL
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal operating
temperature (70 ± 80C / 158 ± 176F). As a guide to check fluid
temperature, warm up engine till engine coolant temperature
meter indicated around 1 unit above ªCº point.
5) Keep engine idling and shift selector slowly to L and back to P
position.
6) With engine idling, pull out dipstick, wipe it off with a clean cloth
and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it. Fluid
level should be between FULL HOT and LOW HOT. If it is below
LOW HOT, add an equivalent of DEXRON-III up to FULL HOT.
Fluid specification
An equivalent of DEXRON-III
NOTE:

DO NOT RACE ENGINE while checking fluid level, even af-
ter the engine start.

DO NOT OVERFILL. Overfilling can causes foaming and
loss of fluid through breather. Then slippage and trans-
mission failure can result.

Bringing the level from LOW HOT to FULL HOT requires
0.3 liters (0.64/0.53 US/lmp.pt).

If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour af-
ter it is stopped.

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VITARA
8G-6 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
1. Immobilizer diagnostic coupler
DIAGNOSIS
ECM / PCM and Immobilizer Control Module have on-board diag-
nostic system (a system self-diagnosis function) as described pre-
viously.
Investigate where the trouble is by referring to ªDiagnostic Flow
Tableº and ªDiagnostic Trouble Code Tableº on later pages.
PRECAUTIONS IN DIAGNOSING TROUBLES
[PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE]
ECM / PCM
<Vehicle equipped with monitor coupler>

Before identifying diagnostic trouble code indicated by malfunc-
tion indicator lamp, don't disconnect couplers from ECM / PCM,
battery cable from battery, ECM / PCM ground wire harness from
engine.
Such disconnection will clear trouble codes for electronic fuel in-
jection system stored in memory of ECM / PCM.

If abnormality or malfunction lies in two or more areas, malfunc-
tion indicator lamp indicates applicable codes three times each.
And flashing of these codes is repeated as long as diagnosis ter-
minal is grounded and ignition switch is held at ON position.

When ECM / PCM detects a trouble in both electronic fuel injec-
tion system and immobilizer control system, malfunction indicator
lamp indicates trouble codes of both systems alternately while the
ignition switch is turned ON and the diagnosis terminal is
grounded.

Take a note of diagnostic trouble code indicated first.
<Vehicle not equipped with monitor coupler>

Before identifying diagnostic trouble code indicated through Su-
zuki scan tool, don't disconnect couplers from ECM / PCM, bat-
tery cable from battery, ECM / PCM ground wire harness from en-
gine.
Such disconnection will clear trouble codes for electronic fuel in-
jection system stored in memory of ECM / PCM.

Take a note of diagnostic trouble code indicated first.
Immobilizer Control Module

Take a note of diagnostic trouble code indicated first.

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GRAND
VITARA
10A-6 SEAT BELT
1. Upper anchor
2. Lower anchor
3. Retractor assembly
4. Buckle: If equipped* *
REAR SEAT BELT
WARNING:
Be sure to read ªService Precautionsº before starting to work and observe every precaution during
work.
REMOVAL
Refer to the figure below to remove rear seat belts.
INSPECTION
Check the rear seat belt in the same way as when inspecting front seat belt. (Refer to page 10A-4.)
INSTALLATION
Install the rear seat belt observing the same precautions as when installing front seat belt. (Refer to page 10A-5.)
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Upper and lower anchor bolt353.525.5
Retractor assembly bolt353.525.5
Retractor assembly screw5.50.554.0
Buckle bolt353.525.5

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VITARA
10B-14 AIR BAG SYSTEM
DIAGNOSTIC TROUBLE CODE TABLE (Page 1 of 2)
EXAMPLE: WHEN DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH (CODE NO.21) IS SET
Turn ON
Turn OFF
0.30.3 1.0 3.0 3.0 Malfunction indicator lamp
(ªAIR BAGº warning lamp)Code No. 21 Code No. 21 Code No. 21
Time (sec.)
DIAGNOSTIC TROUBLE CODEDIAGNOSISNO.MODEDIAGNOSIS
12Normal±±±±±
15Resistance high
16Passenger
air bag
Resistance low
18
air bag
circuitShort to ground
19Short to power circuit
21Resistance high
Diagnose trouble
according to ªDiagnos-
tic Flow Tableºcorre-
22
Driver air bag
Resistance low
tic Flow Table corre-
sponding to each code
No.
24
g
circuitShort to ground
25Short to power circuit
31Power
source
Too high
32
source
voltageToo low