transmission fluid SUZUKI GRAND VITARA 1999 2.G Owners Manual

MAINTENANCE AND LUBRICATION 0B-3
IntervalKm (× 1,000) 153045607590
Miles (× 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
CHASSIS AND BODY
6-1. Clutch (pedal and fluid level)–I–I–I
6-2.Brake discs and pads (thickness, wear, damage) IIIIII
Brake drums and shoes (wear, damage)–I–I–I
6-3. Brake hoses and pipes (leakage, damage, clamp)–I–I–I
6-4. Brake fluid–R–R–R
6-5. Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles)
only
6-6.Tires (wear, damage, rotation) IIIIII
6-7.Wheel discs (damage) IIIIII
6-8. Suspension system (tighteness, damage, rattle, breakage)–I–I–I
6-9. Propeller shafts and drive shafts––I––I
6-10. Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I–R––R
6-11. Automatic transmission Fluid level –I–I–I
Fluid change Replace every 165,000 km (99,000
miles)
Fluid hose–––R––
6-12. Transfer oil (leakage, level) I–I–I–
6-13. Differential oil (leakage, level) (R: 1st 15,000 km only) R or I–I–I–
6-14. Steering system (tighteness, damage, breakage, rattle)–I–I–I
6-15.Power steering (if equipped) IIIIII
6-16. All latches, hinges and locks–I–I–I
6-17. Air conditioning filter (if equipped)–IR–IR
NOTE:
 “R”: Replace or change
 “I”: Inspect and correct, replace or lubricate if necessary

0B-4 MAINTENANCE AND LUBRICATION
Maintenance Recommended under Severe Driving Conditions
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the
chart below.
Severe condition code :
A: Repeated short trips E: Repeated short trips in extremely cold weather
B: Driving on rough and/or muddy roads F: Leaded fuel use
C: Driving on dusty roads G: – – – – – –
– –
D: Driving in extremely cold weather
and/or salted roadsH: Trailer towing (if admitted)
Severe
Condition CodeMaintenanceMaintenance
OperationMaintenance Interval
– B CD – – –ITEM 1-1
Drive belt (V-rib belt)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
A – CDEF – HITEM 1-4
Engine oil and oil filterREvery 5,000 km
(3,000 miles) or 4 months
– B– – – – – –ITEM 1-6
Exhaust pipe mountingsIEvery 15,000 km
(9,000 miles) or 12 months
– – C – – – – – ITEM 3-1
Air cleaner filter *1IEvery 2,500 km
(1,5000 miles)
REvery 30,000 km
(18,000 miles) or 24 months
ABC–EF–HITEM 2-1
Spark plugsNickel plug REvery 10,000 km
(6,000 miles) or 8 months
Iridium plug REvery 30,000 km
(18,000 miles) or 24 months
– B – D E – – HITEM 6-9
Propeller shafts and drive shafts IEvery 15,000 km
(9,000 miles) or 12 months
– B – – E – – HITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oilREvery 30,000 km
(18,000 miles) or 24 months
– B – – E – – HITEM 6-11
Automatic transmission fluid REvery 30,000 km
(18,000 miles) or 24 months
– B – – – – – – ITEM 6-8
Suspension bolts and nutsTEvery 15,000 km
(9,000 miles) or 12 months
– B C D – – – HITEM 6-7
Wheel bearingIEvery 15,000 km
(9,000 miles) or 12 months
– – CD – – – –ITEM 6-17
Air conditioning filter *2
(if equipped)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
NOTE:
“I”: Inspect and correct, replace or lubricate if necessary
”R”: Replace or change
”T”: Tighten to the specified torque
*1: Inspect or replace more frequently if necessary.
*2: Clean or replace more frequently if the air from the air conditioning decreases.

6A2-28 ENGINE MECHANICAL (H27 ENGINE)
24) Remove A/T fluid hose clamps (1) from engine mounting
bracket (2). (for A/T vehicle)
25) Remove clutch housing lower plate.
26) Remove torque converter bolts (for A/T vehicle).
27) Remove starter motor.
28) Lower vehicle.
29) Support transmission. For A/T vehicle, don’t jack under A/T
oil pan to support transmission.
30) Remove bolts and nuts fastening cylinder block and trans-
mission.
31) Install lifting device.
32) Disconnect engine side mounting brackets (1) to engine
mountings.
33) Before lifting engine, check to ensure all hoses, wires and
cables are disconnected from engine.
34) Remove engine assembly from chassis and transmission by
sliding toward front, and then, carefully hoist engine assem-
bly.
INSTALLATION
Reverse removal procedure for installation, noting the following
points.
1) Lower engine assembly into engine compartment. Connect
engine to transmission and engine side mounting brackets to
engine mountings.
2) Tighten nuts fastening engine side mounting brackets and
engine mountings.
Tightening torque
Engine side mounting bracket nut (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)

ENGINE MECHANICAL (H27 ENGINE) 6A2-29
3) Tighten bolts and nuts fastening cylinder block and transmis-
sion to specified torque.
Tightening torque
Transmission to cylinder block bolt and nut (b) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
4) Remove lifting device
5) Tighten torque converter bolts to specified torque (for A/T
vehicle).
Tightening torque
Torque converter bolt (c) :
65 N·m (6.5 kg-m, 47.0 lb-ft)
6) Tighten bolts and nuts of exhaust No.1 pipe (1) to specified
torque.
Tightening torque
Exhaust No.1 pipe bolt and nut (d) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
7) Install front differential housing with differential to chassis if
removed. Refer to “REMOUNTING” in Section 7E.
8) Install steering shaft lower assembly. Refer to “STEERING
LOWER SHAFT ASSEMBLY” in Section 3C1.
9) Install A/C compressor assembly. Refer to “COMPRESSOR
ASSEMBLY” in Section 1B.
10) Install P/S pump assembly. Refer to “POWER STEERING
PUMP” in Section 3B1.
11) Connect hoses, cables and electric wires.
12) Adjust accelerator cable play and A/T throttle cable play (for
A/T vehicle). Refer to “ACCELERATOR CABLE ADJUST-
MENT” and “A/T THROTTLE CABLE ADJUSTMENT (A/T
VEHICLE)” in Section 6E2.
13) Refill engine with engine oil referring to “ENGINE OIL
CHANGE” in Section 0B.
14) Refill cooling system, referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
15) Check to ensure that all fasteners and clamps are tightened.
16) Upon completion of installation, verify that there is no fuel
leakage, coolant leakage, P/S fluid leakage or exhaust gas
leakage at each connection.
1. Bolt (short)
2. Bolt (Long)

7B1-2 AUTOMATIC TRANSMISSION (4 A/T)
Stall Test ................................................... 7B1-38
Line Pressure Test .................................... 7B1-39
Road Test ................................................. 7B1-40
Manual Road Test..................................... 7B1-41
Time Lag Test ........................................... 7B1-41
Engine Brake Test .................................... 7B1-42
“P” Range Test.......................................... 7B1-42
On-Vehicle Service ..................................... 7B1-43
Maintenance Service ................................ 7B1-43
Fluid level .............................................. 7B1-43
Fluid change.......................................... 7B1-44
A/T Throttle Cable ..................................... 7B1-45Solenoid Valves (Shift Solenoid Valves
and TCC Solenoid Valve) ......................... 7B1-45
MANUAL SELECTOR ASSEMBLY .......... 7B1-46
SELECT CABLE ....................................... 7B1-48
Unit Repair .................................................. 7B1-49
Sub-Assembly Repair ............................... 7B1-49
Overdrive (case side) ............................ 7B1-49
Forward clutch ...................................... 7B1-50
Front upper valve body ......................... 7B1-54
Unit Assembly ........................................... 7B1-59
Tightening Torque Specification............... 7B1-60
Special Tool ................................................ 7B1-61

AUTOMATIC TRANSMISSION (4 A/T) 7B1-3
General Description
Item Specifications
Torque
converterType 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism)
Stall torque ratio 2.0
Oil pump Type Trochoid type oil pump
Drive system Engine driven
Gear
change
deviceType Forward 4-step, reverse 1-step planetary gear type
Shift position“P” range Gear in neutral, output shaft fixed, engine start
“R” range Reverse
“N” range Gear in neutral, engine start
“D” range
(O/D ON)Forward 1st ↔ 2nd ↔ 3rd ↔ 4th (O/D)
automatic gear change
“D” range
(O/D OFF)Forward 1st ↔ 2nd ↔ 3rd
automatic gear change
“2” range (Normal mode) Forward 1st ↔ 2nd ← 3rd auto-
matic gear change
(Power mode) Forward 2nd ← 3rd automatic gear
change and fixed at 2nd gear
“L” range Forward 1st ← 2nd ← 3rd reduction, and fixed at
1st gear
Gear
ratio1st
(low gear)2.826
2nd
(second gear)1.493
3rd
(top gear)1.000
4th
(overdrive gear)0.689
Reverse
(reverse gear2.703
Control elements Wet type multi-disc clutch ... 3 sets
Wet type multi-disc brake ... 4 sets
One-way clutch ... 3 sets
Transfer Hi : 1.000
Lo : 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used
An equivalent of DEXRON
III

7B1-14 AUTOMATIC TRANSMISSION (4 A/T)
Diagnostic Trouble Code Table
Refer to the same item in Section 6-1.
Fail Safe Table
Refer to the same item in Section 6-1.
Visual Inspection
Visually check following parts and systems.
A/T Basic Check
This inspection is important for troubleshooting when PCM (ECM) has detected no DTC and no abnormality has
been noted in visual inspection. Follow flow table carefully.INSPECTION ITEM REFERRING SECTION
•A/T fluid - - - - - level, leakage, color SECTION 0B
•A/T fluid hoses - - - - - disconnection, looseness, deterioration SECTION 7B1
•Throttle (accelerator) cable - - - - - play, installation SECTION 6E2
•A/T throttle cable - - - - - play, installation SECTION 7B1
•A/T select cable - - - - - installation, operation SECTION 7B1
•Engine oil - - - - - level, leakage SECTION 0B
•Engine coolant - - - - - level, leakage SECTION 0B
•Battery - - - - - fluid level, corrosion of terminal
•Connectors of electric wire harness - - - - - disconnection, friction Section 6-1 or 7B1
•Fuses - - - - - burning SECTION 8
•Parts - - - - - installation, damage
•bolt - - - - - looseness
•Other parts that can be checked visually
•Also check following items at engine start, if possible.
–“O/D OFF” lamp - - - - - Operation SECTION 7B1
–“POWER” lamp - - - - - Operation SECTION 7B1
–Malfunction indicator lamp (“SERVICE ENGINE SOON” lamp) - -
- - - OperationSection 6-1
–Charge warning lamp - - - - - Operation SECTION 6H
–Engine oil pressure warning lamp - - - - - Operation SECTION 8C (SECTION 6A2 for pres-
sure check)
–Engine coolant temp. meter - - - - - Operation
–Other parts that can be checked visually
Step Action Yes No
1Was “AUTOMATIC TRANSMISSION DIAGNOSTIC
FLOW TABLE” performed?Go to Step 2. Go to “AUTOMATIC
TRANSMISSION DIAG-
NOSTIC FLOW TABLE”.
2Perform “MANUAL ROAD TEST” in this section.
Is it OK?Go to Step 3. Go to Step 4.
3Proceed to “TROUBLE DIAGNOSIS TABLE 1” in this
section.
Is trouble identified?Repair or replace
defective parts.Go to Step 5.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-15
Trouble Diagnosis Table 1
Trouble Diagnosis Table 2
TRANSMISSION FLUID
RUNNING CONDITION
4 Perform stall test, time rag test, line pressure test,
engine brake test and “P” range test referring to
“STALL TEST”, “LINE PRESSURE TEST”, “ENGINE
BRAKE TEST” and ““P” RANGE TEST” in this section.
Are the test results satisfactory?Go to Step 5. Proceed to “TROUBLE
DIAGNOSIS TABLE 3” in
this section.
5 Proceed to “TROUBLE DIAGNOSIS TABLE 2” in this
section.
Is trouble identified?Repair or replace
defective parts.Proceed to “TROUBLE
DIAGNOSIS TABLE 3” in
this section. Step Action Yes No
Condition Possible Cause Correction
TCC does not operateBrake pedal (stop lamp) switch or its circuit
faulty (H25 engine only)Refer to “DIAGNOSTIC FLOW
TABLE A-1” in this section.
4WD low switch or its circuit faulty
Engine coolant temp. sensor or its circuit faulty
Cruise control signal circuit faulty (if equipped)
Gear does not change
to 4thO/D off switch or its circuit faulty Refer to “DIAGNOSTIC FLOW
TABLE A-2” in this section.
4WD low switch or its circuit faulty
Engine coolant temp. sensor or its circuit faulty
Cruise control signal circuit faulty (if equipped)
Condition Possible Cause Correction
Low fluid pressureClogged oil pump strainer Wash strainer.
Malfunction of pressure regulator valve Overhaul valve body.
High fluid pressurePressure regulator valve Overhaul valve body.
Condition Possible Cause Correction
Unable to run in all
rangeRegulator valve stick Replace.
Clogged oil strainer Wash strainer.
Seized or broken planetary gear Repair or replace.
Faulty manual valve Replace.
Poor 1st speed run-
ning or excessive slip-
page in “D” or “2”Faulty 1–2 shift valve Replace.

7B1-16 AUTOMATIC TRANSMISSION (4 A/T)
GEAR SHIFT
Trouble Diagnosis Table 3
TRANSMISSION FLUID
RUNNING CONDITION
Condition Possible Cause Correction
Poor 1–2 shift, exces-
sive slippageRegulator valve sticking Replace.
1–2 shift valve sticking Replace.
Shift solenoid valve-B sticking Replace.
Intermediate coast modulator valve sticking Replace.
Poor 2–3 shift, exces-
sive slippage2–3 shift valve sticking Replace.
Shift solenoid valve-A sticking Replace.
Poor start or surging
in “D” rangeRegulator valve sticking Replace.
Poor 3-4 shift, exces-
sive slippage3–4 shift valve sticking Replace.
Shift solenoid valve-B sticking Replace.
Excessive shock on
1–2 shiftRegulator valve sticking Replace.
Faulty accumulator, second brake piston Replace.
Excessive shock on
2–3 shiftRegulator valve sticking Replace.
Faulty accumulator, direct clutch piston Replace.
Excessive shock on
3–4 shiftRegulator valve sticking Replace.
Non operate lock-up
systemTCC (Lock-up) control valve sticking Replace.
Solenoid valve No.2 (TCC solenoid valve) stick-
ingReplace.
Condition Possible Cause Correction
Low fluid pressureLeakage from oil pressure circuit Overhaul.
Condition Possible Cause Correction
Unable to run in all
rangeWear in oil pump Replace.
Seizure in oil pump Replace.
Fluid pressure leakage to over drive clutch due
to wear of oil pump bushingReplace.
Faulty in torque converter Replace.
Poor 1st speed run-
ning or excessive slip-
page in “D” or “2”Fluid pressure leakage from forward clutch due
to wear or breakage of O/D case seal ringReplace.
Overdrive clutch slipping Replace.
Unable to run or
excessive slippage in
“L” rangeFluid pressure leakage of forward clutch due to
wear or breakage of O/D case seal ringReplace.
Reverse brake disc slipping Replace.
Broken brake piston O-ring Replace.
Unable to run or
excessive slippage in
“R” rangeFluid pressure leakage to direct clutch due to
wear or breakage of center support seal ringReplace.
Worn direct clutch Replace.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-17
GEAR SHIFT
ABNORMAL NOISE
Scan Tool Data
Refer to Section 6-1.
Inspection of PCM and Its Circuit
Refer to Section 6-1.
Wire Harness and Connectors
Refer to Section 6-1.Condition Possible Cause Correction
Poor 1–2 shift, exces-
sive slippageFluid pressure leakage to overdrive clutch due
to wear or breakage of O/D case seal ringReplace.
Faulty second brake Replace.
Broken O-ring of second brake piston Replace.
Faulty second coast brake (in “2” range) Replace.
Poor 2–3 shift, exces-
sive slippageFluid pressure leakage to overdrive clutch due
to wear or breakage of O/D case seal ringReplace.
Worn direct clutch bushing Replace.
Direct clutch slipping Replace.
Foreign material caught in direct clutch piston
check ballReplace.
Poor start or surging
in “D” rangeFluid pressure leakage of forward clutch due to
wear or breakage of O/D case seal ringReplace.
Malfunction of forward clutch Replace.
Poor 3–4 shift, exces-
sive slippageFaulty overdrive brake Replace.
Faulty overdrive clutch Replace.
Poor start or juddering
in “R” rangeFluid pressure leakage of direct clutch due to
wear or breakage of oil center support seal ringReplace.
Worn direct clutch Replace.
Excessive shock on
1– 2 shiftFaulty one-way clutch Replace.
Non operate lock-up
systemFaulty torque converter Replace.
Condition Possible Cause Correction
Abnormal noise in “P”
or “N” rangeWorn oil pump Replace.