Od off SUZUKI GRAND VITARA 2000 2.G Service Workshop Manual

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VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-51
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC.
3) Start engine and shift transfer lever to ª2Hº or ª4Hº range.
4) Shift selector lever in D range and keep it for 10 seconds.
5) Drive vehicle about 30 km / h (20 mph) with 2nd gear in D range for 10 seconds.
6) Increase vehicle speed to about 80 km / h (50 mph) with 4th gear in D range and keep it for 10 seconds.
7) Release accelerator pedal, decrease vehicle speed and stop vehicle.
8) Check DTC and / or pending DTC.
TROUBLESHOOTING (DTC P0753 / P0758)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Is the vehicle equipped with monitor connector?Go to Step 3.Go to Step 4.
3Is DTC NO.61 or 63?Go to Step 4.Go to Step 6.
4Check Shift Solenoid Circuit for Open or Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Check for proper connection to PCM at terminals
C51-1-2 for G16 / J20 (C51-1-6 for H25) or C51-1-1.
3) If OK, then measure resistance between terminal
C51-1-2 for G16 / J20 (C51-1-6 for H25) or C51-1-1
of disconnected PCM connector and ground.
Is it 11 ± 15
at 20C, 68F?Go to Step 5.ªGº or ªG / Rº circuit
open or shorted to
ground.
If wire and
connections are OK,
replace malfunction
shift solenoid.
5Check Shift Solenoid Circuit for Short.
1) Turn ignition switch ON.
2) Measure voltage between terminal C51-1-2 for
G16 / J20 (C51-1-6 for H25) or C51-1-1 of
disconnected PCM connector and ground.
Is it about 0 V?Intermittent trouble or
faulty PCM.
Check for
ªIntermittent and
Poor Connectionº in
Section 0A.ªGº or ªG / Rº circuit
shorted to power
circuit.
6Check Shift Solenoid Circuit for Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Check for proper connection to PCM at terminals
C51-1-2 for G16 / J20 (C51-1-6 for H25) or C51-1-1.
3) If OK, then measure resistance between terminal
C51-1-2 for G16/J20 (C51-1-6 for H25) or C51-1-1
of disconnected PCM connector and ground.
Is it 11 ± 15
at 20C, 68F?Intermittent trouble or
faulty PCM.
Check for
ªIntermittent and
Poor Connectionº in
Section 0A.ªGº or ªG / Rº circuit
shorted to ground.

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G16 / J20 Engines
H25 Engine
1. PCM
2. 4WD low switch
3. J / C
7B1-52 AUTOMATIC TRANSMISSION (4 A / T)
DTC P1875 4WD LOW SWITCH CIRCUIT MALFUNCTION (if equipped)
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While driving at higher than specified vehicle speed
and with more than specified throttle valve opening,
the following conditions are satisfied for specified time.

Vehicle speed sensed by vehicle speed sensor is
more than 10 km / h higher than that sensed by A / T
output speed sensor.
(2 driving cycles detection logic)
4WD LOW switch or its circuit

PCM
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool.
3) Start engine.
4) Increase vehicle speed to about 30 km/h (19 mph) or more in D range and is in 2H position.
5) Keep driving at above vehicle speed for 30 seconds.
6) Stop vehicle and shift transfer lever to 4L position with A/T selector lever is in P range
7) Increase vehicle speed to about 25 km/h (15 mph) or more in D range and is in 4L position.
8) Keep driving at above vehicle speed for 30 seconds.
9) Stop vehicle and check pending DTC and DTC by using scan tool.

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1
1. 4WD low switch
AUTOMATIC TRANSMISSION (4 A / T) 7B1-53
TROUBLESHOOTING (DTC P1875)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
24WD low switch and its circuit check:
When using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON.
3) Select ªData listº mode on scan tool.
4) Check 4WD low switch signal (ON or OFF) on
display when shifting transfer lever to each
position.
4H or 2H position : OFF
4L position : ON
Is OFF / ON displayed as described above?
When not using SUZUKI scan tool:
1) Remove PCM cover.
2) Turn ignition switch ON.
3) Check voltage at terminal C51-1-26 for G16 / J20
(C51-1-5 for H25) of PCM connector connected
when shifting transfer lever to each position.
4H or 2H position : 10 ± 14 V
4L position : 0 ± 1 V
Is voltage as specified?Check for poor con-
nection at the termi-
nal of PCM if voltme-
ter is used in Step 2.
If connection is OK,
intermittent trouble
or faulty PCM.
Check for intermittent
referring to ªIntermit-
tent and Poor
Connectionº in
Section 0A.Go to Step 3.
34WD low switch check:
1) Check 4WD low switch for operation referring to
ª4WD Low Switch Inspectionº below.
Is check result satisfactory?ªOr / Wº or ªBº circuit
open or short. If wires
and connections are
OK, substitute a
known-good PCM
and recheck.Replace 4WD low
switch.
4WD Low Switch Inspection
1) Disconnect negative cable at battery.
2) Disconnect 4WD low switch coupler.
3) Check continuity between 4WD low switch terminals.
There should be continuity when transfer lever shifted to 4L posi-
tion and should be infinity when transfer lever shifted to 4H or 2H
positions.
If not, replace 4WD low switch.
4) Connect 4WD low switch coupler and battery negative cable.

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1
1. Shift solenoids connector
AUTOMATIC TRANSMISSION (4 A / T) 7B1-57
MANUAL ROAD TEST
This test check the gear being used in ªLº, ª2º or ªDº range when
driven with unoperated gear shift control system. Test drive vehicle
on a level road.
NOTE:
Before this test, check diagnostic trouble code (DTC).
1) Disconnect coupler of shift solenoid valves on transmission.
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when disconnecting shift solenoid
valves coupler.
2) With select lever in ªPº, start engine and warm it up.
3) With select lever in ªLº range, start vehicle and accelerate to 20
km/h (12.5 mile/h). Check in this state that 1st gear is being
used.
4) At 20 km/h (12.5 mile/h), shift select lever to 2 range and acceler-
ate to 40 km/h (25 mile/h). Check in this state that 3rd gear is
being used.
5) At 40 km/h (25 mile/h), shift select lever to D range and check
that O/D gear is used when speed is higher than 40 km/h (25
mile/h).
6) After above checks, stop vehicle then engine, and connect shift
solenoids coupler with ignition switch OFF.
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when connecting shift solenoid valves
coupler.
7) Clear DTC with scan tool.
TIME LAG TEST
This test is to check conditions of clutch, reverse brake and fluid
pressure. ªTime lagº means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels re-
spectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from ªNº to ªDº range
and measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from ªNº to ªRº
range.
Specification for ªNº
ªDºLess than 1.2 sec.
time lagªNº
ªRºLess than 1.5 sec.
NOTE:

When repeating this test, be sure to wait at least minute
after select lever is shifted back to ªNº range.

Engine should be warmed up fully for this test.
Test resultPossible causes
When ªNº
ªDº time lag
exceeds specification
Low line pressure

Worn forward clutch
When ªNº
ªRº time lag
exceeds specification
Low line pressure

Worn direct clutch

Worn reverse brake

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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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1. Manual selector assembly
(Select lever assembly)
2. Manual lever assembly
3. Select cable bracket
4. Select indicator
5. Slide cover
6. Select lever knob7. Spring
8. Knob button
9. Shift lock solenoid rod
10. Shift lock solenoid
11. Cover
12. Illumination lamp
13. Interlock cam
1. Interlock cam pin
(only for new selector assembly) Tightening Torque
(a): 18 N
.m (1.8 kg-m, 13.5 lb-ft)1. Manual lever
assembly
2. Select indicator
assembly
3. Illumination lamp
assembly
4. Bulb filter
5. Bulb
6. Knob assembly
7. Shift lock solenoid
Type-1 Type-2
Type-1
7B1-62 AUTOMATIC TRANSMISSION (4 A / T)
MANUAL SELECTOR ASSEMBLY
REMOVAL
1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connector for illumination lamp, shift lock solenoid
and overdrive OFF switch.
4) Disconnect interlock cable from interlock cam of selector as-
sembly.
5) Remove selector assembly mounting bolts.
6) Disconnect select cable from lever of selector assembly.
INSTALLATION
NOTE:
New selector assembly of Type-1 is supplied with held inter-
lock cam at interlock cable connecting position with pin. Re-
move this pin after connecting interlock cable to interlock cam
and tightening cable nut.
Reverse removal procedure to install noting the followings.

Connect interlock cable end to cam referring to steps 2) to 8) of
ªInterlock Cable Installationº section.

Upon completion of installation, confirm that brake (key) interlock
system operates properly.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-67
1. Oil cooler pipes
2. Union gaskets
3. Pipe bolt
OIL COOLER PIPES
REMOVAL
1) Lift up vehicle.
2) Make sure to wash dirt off from around pipe joints.
3) With engine is cool, loosen oil cooler pipe union bolts with oil out-
let union locked and remove oil cooler pipes from oil outlet
unions and hoses.
NOTE:
To avoid fluid leakage, plug open ends of oil outlet unions
and hoses right after they are disconnected.
INSTALLATION
1) Use new union gaskets and connect oil cooler pipes to oil outlet
unions.
2) Connect hoses to pipes and clamp them securely.
3) Tighten union bolts to specified torque with oil outlet union
locked.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
4) Tighten pipe bolt securely.
5) Check A / T fluid level according to procedure described in ªFluid
Levelº section.
Add if necessary.
6) Check for fluid leakage after warming up A / T.

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7B1-76 AUTOMATIC TRANSMISSION (4 A / T)
12) Remove engine to transmission nuts.
13) Disconnect connectors from VSS, output speed sensor, input
speed sensor, TR switch, shift & TCC solenoid valves and oth-
er electrical parts, and release their wire harness from clamps.
14) Apply transmission jack and take off rear mounting member by
removing its bolts.
15) With transmission (and transfer if equipped) assembly held up
on jack, move them to the rear and lower them including torque
converter.
WARNING:
Transmission (and transfer if equipped) assembly may
tilt rearward on jack. It is recommended to use an auxil-
iary arm of jack for the purpose of safety.
AFTER DISMOUNTING
WARNING:
Be sure to keep transmission (and transfer if equipped) as-
sembly horizontal throughout the work. Should they be
tilted, torque converter may fall off and cause personal inju-
ry and A / T fluid may flow out.
1) Remove breather hoses.
2) Remove transfer by removing its bolts, if equipped.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-77
ªAº, (d)
1. Drive plate
2. Torque converter
3. Case right stiffener (if equipped)
4. Automatic transmissionTightening torque
(a): 50 N´m
5.0 kg-m
36.5 lb-ft
(b): 65 N´m
6.5 kg-m
47.0 lb-ft
(c): 85 N´m
8.5 kg-m
61.5 lb-ft
(d): 78 N´m
7.8 kg-m
56.5 lb-ft
1. Automatic transmission
2. Transfer (4WD)
3. Engine rear mounting
4. Engine rear mounting member Tightening torque
(a): 50 N´m (5.0 kg-m, 36.5 lb-ft) ªAº: Sealant 99000-31110
REMOUNTING
WARNING:
When moving transmission assembly with torque convert-
er equipped in it, be sure to keep it horizontal. Tilting it with
its front facing down may allow converter to fall off. Where-
by an injury may result.
For remounting, reverse dismounting procedure. Use specified
torque as given below and left.
Tightening torque
N.mkg-mlb-ft
Exhaust No.1 pipe to manifold
bolts or nuts505.036.5
Muffler to exhaust No.2 pipe
nuts606.043.5
Universal joint flange bolts and
nuts505.036.5

Oil filler tube bolts

Select cable bracket bolts232.317.0

Clamp wiring harness and hoses securely.

Refer to ªSelect Cableº section for adjusting procedure of select
cable.

Refer to ªA / T Throttle Cableº section for tuning of A / T throttle
cable.

Follow fluid level check procedure for refilling automatic transmis-
sion fluid and its level adjusting.

Connect battery, and confirm that engine and transmission func-
tion acceptably.

When remounting drive plate, use specified bolts.

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1. Speed sensor assembly
2. Transfer
7D-4 TRANSFER
SPEEDOMETER DRIVEN GEAR
REMOVAL
1) Lift up vehicle horizontally or rear up.
2) Disconnect speed sensor coupler at transfer case.
3) Remove bolt and take off speed sensor from transfer.
INSTALLATION
1) Make sure that O-ring and speed sensor have not been dam-
aged.
2) Inspect speedometer driven gear for abnormal wear of gear
teeth or bend of shaft portion and replace it if necessary.
3) Make sure its smooth rotation.
4) Install speed sensor assembly to transfer and connect coupler
as it was.
Tightening Torque
(a): 6 N
.m (0.6 kg-m, 4.5 lb-ft)
ENGINE REAR MOUNTING
Refer to ªON-VEHICLE SERVICEº of Section 7A.