wheel SUZUKI GRAND VITARA 2000 2.G Service Workshop Manual

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-55
Check resultPossible cause
Line pressure higher
than standard level in
each range
Malfunctioning regulator valve

Malfunctioning throttle valve

Maladjusted A / T throttle cable
Line pressure lower than
standard level in each
range
Defective O/D clutch

Defective oil pump

Malfunctioning throttle valve

Malfunctioning regulator value

Maladjusted A / T throttle cable
Line pressure lower than
standard level only in ªDº
range
Fluid leakage from forward clutch

Defective O/D clutch

Leakage from ªDº range fluid pressure cir-
cuit
Line pressure lower than
standard level only in ªRº
range
Fluid leakage from direct clutch

Defective O/D clutch

Fluid leakage from reverse brake

Fluid leakage from ªRº range fluid circuit
Tightening torque of transmission case plug:
17 N.m (1.7 kg-m, 12.0 lb-ft)
STALL TEST
This test is to check overall performance of automatic transmission
and engine by measuring stall speed at ªDº and ªRº ranges. Be sure
to perform this test only when transmission fluid is at normal operat-
ing temperature and its level is between FULL and LOW marks.
CAUTION:

Do not run engine at stall more than 5 seconds continu-
ously, for fluid temperature may rise excessively high.

After performing stall test, be sure to leave engine running
at idle for longer than 30 seconds before another stall test.
1) Apply parking brake and block wheels.
2) Install tachometer.
3) Start engine with select lever shifted to ªPº.
4) Depress brake pedal fully.
5) Shift select lever to ªDº and depress accelerator pedal fully while
watching tachometer. Read engine rpm quickly when it has be-
come constant (stall speed).
6) Release accelerator pedal immediately after stall speed is
checked.
7) In the same way, check stall speed in ªRº range.

YH4
GRAND
VITARA
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

YH4
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.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-79
09925-37810
Oil pressure gauge09927-56010
Gear stopper
(only for G16 / J20)09931-76030
16 / 14 pin DLC
(OBD-II adapter) cable
09931-76011
SUZUKI scan tool (Tech 1A) kit1. Storage case
2. Operator's manual
3. Tech 1A
4. DLC cable
5. Test lead / probe
6. Power source cable
7. DLC cable adapter
8. Self±test adapterMass storage cartridge
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
A / T fluidAn equivalent of DEXRON-III
Automatic transmission

Parts lubrication when installing
Lithium greaseSUZUKI SUPER GREASE A
(99000±25010)
Cable ends
SealantSUZUKI BOND NO.1215
(99000-31110)
Flywheel bolts
SPECIAL TOOLS

YH4
GRAND
VITARA
7C1
CLUTCH 7C1-1
GENERAL DESCRIPTION7C1 - 2 . . . . . . . . . . . . .
DIAGNOSIS7C1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7C1 - 4 . . . . . . . . . . . . . . .
Clutch Pedal Height 7C1 - 4. . . . . . . . . . . . . . . . . .
Clutch Pedal Free Travel 7C1 - 4. . . . . . . . . . . . .
Clutch Fluid Pipe and Hose 7C1 - 4. . . . . . . . . . .
Clutch Master Cylinder 7C1 - 5. . . . . . . . . . . . . . .
Fluid Inspection 7C1 - 6. . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly
Clutch Master Cylinder 7C1 - 7. . . . . . . . . . . . . . Clutch Operating Cylinder 7C1 - 8. . . . . . . . . . . .
UNIT REPAIR7C1-10 . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Cover, Clutch Disc and
Flywheel 7C1 - 10. . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7C1-14 . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7C1-14 . . . . .
SPECIAL TOOLS7C1-14 . . . . . . . . . . . . . . . . . . . . .
SECTION 7C1
CLUTCH
CONTENTS

YH4
GRAND
VITARA
1. Crankshaft
2. Flywheel
3. Clutch disc
4. Pressure plate
5. Clutch cover
6. Diaphragm spring
7. Release bearing
8. Input shaft bearing
9. Input shaft
10. Operating cylinder
11. Clutch housing
12. Release fork
7C1-2 CLUTCH
The clutch is a diaphragm-spring clutch of a dry single
disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part,
with a series of tapered fingers pointing inward.
The disc, carrying torsional coil springs, is positioned
on the transmission input shaft with an involute spline
fit.
The clutch cover is secured to the flywheel, and car-
ries the diaphragm spring in such a way that the pe-
ripheral edge part of the spring pushes on the pres-
sure plate against the flywheel (with the disc in be-
tween), when the clutch release bearing is held back.
This is the engaged condition of the clutch.Depressing the clutch pedal causes the release bear-
ing to advance and pushes on the tips of the tapered
fingers of the diaphragm spring. When this happens,
the diaphragm spring pulls the pressure plate away
from the flywheel, thereby interrupting the flow of
drive from flywheel through clutch disc to transmis-
sion input shaft.
GENERAL DESCRIPTION

YH4
GRAND
VITARA
CLUTCH 7C1-3
DIAGNOSIS
ConditionPossible CauseCorrection
Slipping
Improper clutch pedal free travel.

Worn or oily clutch disc facing.

Warped disc, pressure plate or flywheel
surface.

Weakened diaphragm spring.

Master cylinder piston or seal cup not returning.Bleed air or replace master
cylinder.
Replace disc.
Replace disc, clutch cover or
flywheel.
Replace clutch cover.
Repair master cylinder.
Dragging clutch
Improper clutch pedal free travel.

Weakened diaphragm spring, or worn spring tip.

Rusted input shaft splines.

Damaged or worn splines of transmission
input shaft.

Excessively wobbly clutch disc.

Clutch facings broken or dirty with oil.

Fluid leakage.Bleed air or replace master
cylinder.
Replace clutch cover.
Lubricate.
Replace input shaft.
Replace disc.
Replace disc.
Repair or replace.
Clutch vibration
Glazed (glass-like) clutch facings.

Clutch facings dirty with oil.

Release bearing slides unsmoothly on input
shaft bearing retainer.

Wobbly clutch disc, or poor facing contact.

Weakened torsion springs in clutch disc.

Clutch disc rivets loose.

Distorted pressure plate or flywheel surface.

Weakened or loosened engine mounting
bolt or nut.Repair or replace disc.
Replace disc.
Lubricate or replace input
shaft bearing retainer.
Replace disc.
Replace disc.
Replace disc.
Replace clutch cover or flywheel.
Retighten or replace mounting.
Noisy clutch
Worn or broken release bearing.

Input shaft front bearing worn down.

Excessive rattle of clutch disc hub.

Cracked clutch disc.

Pressure plate and diaphragm spring rattling.Replace release bearing.
Replace input shaft bearing.
Replace disc.
Replace disc.
Replace clutch cover.
Grabbing clutch
Clutch disc facings soaked with oil.

Clutch disc facings excessively worn.

Rivet heads showing out of facing.

Weakened torsion springs.Replace disc.
Replace disc.
Replace disc.
Replace disc.

YH4
GRAND
VITARA
7C1-10 CLUTCH
(B)1
12
(A)
1. Input shaft bearing
2. Flywheel
3. Clutch disc
4. Clutch cover
5. Bolt
6. Release bearing
7. Clutch release fork
8. Boot
9. Clip
10. Clutch release fork support
1. Bolt
2. Clutch cover
1. Input shaft bearing
UNIT REPAIR
CLUTCH COVER, CLUTCH DISC AND FLYWHEEL
DISMOUNTING / REMOUNTING
Refer to SECTION 7A ªDismounting / Remounting of Trans Unitº.
REMOVAL
1) Hold flywheel stationary with special tool (A) and remove clutch
cover bolts, clutch cover and clutch disc.
Special Tool
(A): 09924-17810
2) Pull out input shaft bearing by using special tool (B) and wrench.
Special Tool
(B): 09917-58010 (G16 engine)
(B): 09923-73210 (J20 and H25 engines)
3) Remove release bearing and release fork.

YH4
GRAND
VITARA
CLUTCH 7C1-11
INSPECTION
Input Shaft Bearing and Release Bearing
Check bearing for smooth rotation and replace it if abnormality is
found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance between rivet
head and facing surface. If depression is found to have reached
service limit at any of holes, replace disc assembly.
Rivet head depth
Standard: 1.6 mm (0.06 in.)
Service limit: 0.5 mm (0.02 in.)
Clutch Cover
1) Check diaphragm spring for abnormal wear or damage.
2) Inspect pressure plate for wear or heat spots.
3) If abnormality is found, replace it as assembly. Do not disas-
semble it into diaphragm and pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear or heat
spots. Replace or repair as required.

YH4
GRAND
VITARA
7C1-12 CLUTCH
(C)
1
ªAº, (a)1
2
1. Flywheel
2. Bolt
1. Clutch cover
INSTALLATION
NOTE:
Before assembling, make sure that flywheel surface and pres-
sure plate surface have been cleaned and dried thoroughly.
1) Install flywheel to crankshaft and tighten bolts to which sealant
is applied to specification.
Special Tool
(A): 09924-17810
ªAº: Sealant 99000-31110
Tightening Torque
(a): 78 N
.m (7.8 kg-m, 56.5 lb-ft) (G16 engine)
(a): 70 N
.m (7.0 kg-m, 50.5 lb-ft) (J20 and H25 engines)
2) Using special tool (B), install input shaft bearing to flywheel.
Special Tool
(B): 09925-98210
3) Aligning clutch disc to flywheel center by using special tool (C),
install clutch cover and bolts. Then tighten bolts to specification.
NOTE:

While tightening clutch cover bolts, compress clutch disc
with special tool (C) by hand so that disc centered.

Tighten cover bolts little by little evenly in diagonal order.
Special Tools
(A): 09924-17810
(C): 09923-36330 (G16 engine)
(C): 09923-36320 (J20 and H25 engines)
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 16.5 lb-ft)