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

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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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. Back up light switch
2. Exhaust center pipe
1. Ohmmeter
2. Back up light switch or 4WD switch1, (a)
[Type 1]
[Type 2]
MANUAL TRANSMISSION (TYPE 1) 7A-7
3) Replace switch, connect and clamp as they were.
Tightening Torque
(a): 20 N
.m (2.0 kg-m, 14.5 lb-ft) (Type 1)
(a): 45 N
.m (4.5 kg-m, 32.5 lb-ft) (Type 2)
4) When back up light switch has been replaced, check switch for
proper function with ignition switch turned ON and gear shifted
to reverse position. Turn OFF switch after checking its function.
INSPECTION OF 4WD SWITCH AND BACK UP LIGHT
SWITCH
1) Undo clamp and disconnect coupler of back up light switch
and / or 4WD switch.
2) Function of back up light switch can be checked as shown in fig-
ure.
There should be conduction at these terminals only when shift
lever is shifted to reverse position.
3) Function of transfer 4WD switch can be checked in the same
manner as back up light switch.
There should be conduction at these terminals when shift lever
is shifted to 4H, and 4L positions.
Upon completion of check, connect coupler and clamp wiring har-
ness as they were.
NOTE:
When replacing switch(es), use care not to let dust enter trans-
mission through switch hole(s).

YH4
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VITARA
1. Match mark
1. Flange bolt
2. Front propeller shaft
1. Transmission jack
2. Engine rear mounting member
7A-10 MANUAL TRANSMISSION (TYPE 1)
ON LIFT
1) Drain oil from transmission and transfer.
2) Give match marks on joint flange and propeller shaft as shown
in figure. (front and rear)
3) Remove flange bolts of rear propeller shaft universal joint and
pull out propeller shaft.
4) Remove flange bolts of front propeller shaft universal joint and
pull out propeller shaft.
5) Remove clutch operating cylinder from transmission. It is not
necessary to disconnect clutch hose from operating cylinder.
NOTE:

It is not necessary to drain transmission oil when dis-
mounting transmission and transfer for clutch mainte-
nance only.

Work without draining transfer oil is possible if front pro-
peller shaft is dismounted together with transmission and
transfer.
6) Remove clutch housing lower plate.
7) Disconnect couplers from 4WD switch, back up light switch and
speed sensor assembly and release their harness from clamps.
Remove nuts from joint with engine.
8) Apply transmission jack and remove engine rear mounting
member taking off its bolts.
9) After removing mounting member, move rearward transmission
and transfer assemblies placed on jack and then lower them.

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7B1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-1
GENERAL DESCRIPTION7B1- 3 . . . . . . . . . . . . . .
CLUTCH / BRAKE FUNCTIONS 7B1- 5. . . . . . . . .
TABLE OF COMPONENT OPERATION 7B1- 6. . .
ELECTRONIC SHIFT CONTROL
SYSTEM 7B1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSIS7B1-17 . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION IN DIAGNOSING
TROUBLE 7B1-20. . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE 7B1-21. . . . . . . . . .
Customer Problem Inspection Form 7B1-23. . .
Malfunction Indicator lamp (MIL)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
ªO / D OFFº Lamp Check 7B1-24. . . . . . . . . . . . .
ªPOWERº Lamp Check 7B1-24. . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Clearance 7B1-24. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) Table7B1-24 . . .
Fail-Safe Table 7B1-25. . . . . . . . . . . . . . . . . . . . .
Visual Inspection 7B1-26. . . . . . . . . . . . . . . . . . .
A / T Basic Check 7B1-27. . . . . . . . . . . . . . . . . . .
Trouble Diagnosis Table 1 7B1-28. . . . . . . . . . .
Trouble Diagnosis Table 2 7B1-28. . . . . . . . . . . Trouble Diagnosis Table 3 7B1-29. . . . . . . . . . .
Scan Tool Data 7B1-30. . . . . . . . . . . . . . . . . . . . .
Inspection of PCM and Its Circuit 7B1-30. . . . .
Wire Harness and Connectors 7B1-30. . . . . . . .
Diagnostic Flow Table A-1 7B1-31. . . . . . . . . . .
Diagnostic Flow Table A-2 7B1-33. . . . . . . . . . .
Table B-1 ªO / D OFFº Light Circuit
Check 7B1-35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-2 ªO / D OFFº Light Circuit
Check 7B1-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-3 ªPOWERº Light Circuit
Check 7B1-37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-4 ªPOWERº Light Circuit
Check 7B1-38. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0705 Transmission Range
Sensor (Switch) Circuit Malfunction 7B1-39. .
DTC P0715 Input / Turbine Speed
Sensor Circuit Malfunction 7B1-42. . . . . . . . . .
DTC P0720 Output Speed Sensor
Circuit Malfunction 7B1-44. . . . . . . . . . . . . . . . .
DTC P0741 TCC Solenoid Valve
Performance or Stuck Off 7B1-46. . . . . . . . . . .
DTC P0743 TCC Solenoid Electrical 7B1-47. .
DTC P0751 Shift Solenoid Valve-A (#1)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
DTC P0756 Shift Solenoid Valve-B (#2)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
SECTION 7B1
AUTOMATIC TRANSMISSION
(4 A
/
T)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS

YH4
GRAND
VITARA
7B1-4 AUTOMATIC TRANSMISSION (4 A / T)
ItemSpecifications
Torque
conver-
terType
Stall torque ratio3-element, 1-step, 2-phase type (with TCC (lock-up)
mechanism)
2.4 (G16 engine) 2.0 (J20 engine) 1.9 (H25 engine)
Oil
pumpType
Drive systemTrochoid type oil pump
Engine driven
TypeForward 4-step, reverse 1-step planetary gear type
Shift position
ªPº range Gear in neutral, output shaft fixed,engine start
ªRº range Reverse
ªNº range Gear in neutral, engine start
ªDº range Forward 1st
2nd
3rd
4th (O / D)
(O / D ON) automatic gear change
ªDº range Forward 1st
2nd
3rd
(O / D OFF) automatic gear change
ª2º range (Normal mode) Forward 1st
2nd  3rd automatic gear
change
(Power mode) Forward 2nd  3rd automatic gear
change and fixed at 2nd gear
ªLº range Forward 1st  2nd  3rd reduction, and fixed at 1st gear
GearEngine typeG16 engineJ20 / H25 engines
change
device1st (low gear)2.8262.826device2nd (second gear)1.4931.493
Gear3rd (top gear)1.0001.000Gear
ratio4th (overdrive
4th gear)0.7300.689
Reverse (reverse
Reverse gear)2.7032.703
Control elements
Wet type multi-disc clutch 3 sets. . . . . . . . . .
Wet type multi-disc brake 4 sets. . . . . . . . . .
One-way clutch 3 sets. . . . . . . . . . . . . . . . . . .
TransferHi: 1.000 Lo: 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125 (G16 engine) 4.875 (J20 / H25 engines)
Lubrica-
tionLubrication systemForce feed system by oil pump
CoolingCooling systemRadiator assisted cooling (water-cooled)
Fluid usedAn equivalent of DEXRON
III

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GRAND
VITARA
7B1-6 AUTOMATIC TRANSMISSION (4 A / T)
Element
Shift
position
TABLE OF COMPONENT OPERATION
SolenoidSolenoidO/DForwardDirect clutchO/DSecondSecondReverse brakeO/DOne-wayOne-wayvalve
No. 1±Avalve
No. 1±BO/DclutchForwardclutchInner
pistonOuter
pistonO/Dbrakecoast
brakeSecondbrakeInner
pistonOuter
pistonone-way
clutchyclutch
No. 1yclutch
No. 2
P
X
±±±±±±±±
±±
R
X
±

±±±


±±
N
X
±±±±±±±±
±±
1st gear
X

±±±±±±±
±

D2nd gear



±±±±
±±

±D3rd gearX


±
±±
±±
±±
O/DXX±
±

±
±±±±±
1st gear
X

±±±±±±±
±

22nd gear



±±±

±±
±±2
3rd gear
(Fail safe)X


±
±±
±±
±±
1st gear
X

±±±±±


±±
L2nd gear
(Fail safe)



±±±

±±
±±

: ON, X: OFF

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GRAND
VITARA
Engine
Vehicle speed
sensor
Throttle position
sensor
ECT sensor
Cruise control
module
(if equipped)Torque converter Planetary gear
Final gear
reduction unit
Oil pump
Shift and TCC
solenoid valvesClutch and brake
Control valve
ªO / D OFFº lamp
ªPOWERº lamp
MILTransmission range
switch
O / D cut switch
P / N change switch
Transfer 4L switch
(if equipped)
CMP sensor Powertrain (engine) control module
Power transmission
Fluid pressure circuit
Electric signalInput speed sensor Brake pedal switch
Output speed sensor
AUTOMATIC TRANSMISSION (4 A / T) 7B1-7
ELECTRONIC SHIFT CONTROL SYSTEM
The gear ratio change in ªDº or ª2º range and torque converter clutch operation are controlled by Powertrain (En-
gine) Control Module.

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GRAND
VITARA
7B1-8 AUTOMATIC TRANSMISSION (4 A / T)
G16 / J20 Engines
1. PCM (ECM)
2. VSS
3. CMP sensor
4. TP sensor
5. ECT sensor
6. A / T input speed sensor
7. A / T output speed sensor
8. Transmission range switch9. Shift solenoid-A
10. Shift solenoid-B
11. TCC solenoid
12. Data link connector
13. Cruise control module
14. ªPOWERº lamp
15. ªO / D OFFº lamp
16. MIL17. O / D cut switch
18. P / N change switch
19. 4WD low switch
20. Main relay
21. Ignition switch
22. Battery
23. PCM (ECM) connector terminal
(viewed from harness side) Bl / Y
Bl / G
W
OrC51-1-11
C51-1-10
C51-1-23
C51-1-22
12V

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VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-9
H25 Engine
1. PCM (ECM)
2. VSS
3. CMP sensor
4. TP sensor
5. ECT sensor
6. Brake pedal switch
7. A / T input speed sensor
8. A / T output speed sensor9. Transmission range switch
10. Shift solenoid-A
11. Shift solenoid-B
12. TCC solenoid
13. Data link connector
14. Cruise control module
15. ªPOWERº lamp
16. ªO / D OFFº lamp17. MIL
18. O / D cut switch
19. P / N change switch
20. 4WD low switch
21. Main relay
22. Ignition switch
23. Battery
24. PCM (ECM) connector terminal
(viewed from harness side) Bl / Y
Bl / G
W
OrC51-1-16
C51-1-8
C51-1-10
C51-1-9
12V