Pressure SUZUKI GRAND VITARA 2001 2.G Owners Manual

6E2-40 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
INSPECTION
1) Check sensor O-ring (1) for damage and deterioration.
Replace as necessary.
2) Arrange 3 new 1.5 V batteries (2) in series and connect its
positive terminal to “Vin” terminal of MAP sensor (1) and
negative terminal to “Ground” terminal. Then check voltage
between “Vout” and “Ground”.
Also, check if voltage reduces when vacuum is slowly
applied up to 400 mmHg by using vacuum pump (3).
If check result is not satisfactory, replace manifold absolute
pressure sensor.
MAP sensor output voltage (Vin voltage 4.5 – 5.5 V, ambi-
ent temp. 20 – 30°C (68 – 86°F))
CAUTION:
As connection to wrong terminal will cause damage to
manifold absolute pressure sensor, make absolutely sure
to connect properly as shown in the figure.
ALTITUDE
(Reference)BAROMETRIC
PRESSUREOUTPUT
VOLTAGE
(ft) (m) (mmHg) (kPa) (V)
0
–
20000
–
610760
–
707100 – 94 3.3 – 4.3
2001
–
5000611
–
1524Under 707
over 63494 – 85 3.0 – 4.1
5001
–
80001525
–
2438Under 634
over 56785 – 76 2.7 – 3.7
8001
–
100002439
–
3048Under 567
over 52676 – 70 2.5 – 3.3

6E2-46 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
1) Disconnect vacuum hoses from EVAP canister and remove
EVAP canister.
2) When air is blown into tank pipe, there should be no restric-
tion of flow through purge pipe and air pipe.
If operation differs from above description, EVAP canister
must be replaced.
3) Install EVAP canister and connect hoses to canister.
Vacuum passage
INSPECTION
Start engine and run it at idle speed. Disconnect vacuum hose
from EVAP canister purge valve. With finger placed against hose
disconnected, check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.
TANK PRESSURE CONTROL VALVE INSPECTION
1) Remove tank pressure control valve installed around EVAP
canister.
2) Air should pass through valve smoothly from black side (3) of
tank pressure control valve (1) to orange side (2) when
blown hard.
3) From orange side, even when blown softly, air should come
out of black side.
4) If air doesn’t pass through valve in Step 2) or hard blow is
required in Step 3), replace tank pressure control valve.
5) Plug orange nozzle and apply 26 kPa (20 cmHg) vacuum to
black nozzle. Check that vacuum is held at that level (there is
no leakage).
If vacuum leaks, replace.
6) Install tank pressure control valve.
1. Tank pipe
2. Purge pipe
3. Air pipe
4. Blow air
WARNING:
DO NOT SUCK air through tank pressure control valve.
Fuel vapor inside the valve is harmful.
4. To canister
5. From fuel tank

6E2-48 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
PCV system
PCV HOSE
Check hoses for connection, leakage, clog, and deterioration.
Replace as necessary.
Tightening Torque Specification
Special Tool
NOTE:
Be sure to check that there is no obstruction in PCV
valve or its hoses (6) before checking engine idle speed/
IAC duty for obstructed PCV valve or hose hampers its
accurate checking.
1. EVAP canister purge valve 4. EGR pipe
2. EVAP canister purge valve hose 5. EGR valve
3. Breather hose 6. PCV hose
Fastening partTightening torque
Nm kg-m lb-ft
Heated oxygen sensor 45 4.5 32.5
Fuel pressure regulator bolts 10 1.0 7.5
Fuel pipe union bolts 30 3.0 22.0
Engine coolant temp. sensor 15 1.5 11.0
09912-58441 09912-58431 09912-58490 09912-58421
Pressure gauge Pressure hose 3-way joint & hose Checking tool set
(See NOTE “A”.)

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

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.

7B1-38 AUTOMATIC TRANSMISSION (4 A/T)
Stall Test
This test is to check overall performance of automatic transmission and engine by measuring stall speed at “D”
and “R” ranges. Be sure to perform this test only when transmission fluid is at normal operating temperature and
its level is between FULL and LOW marks.
1) Apply parking brake and block wheels.
2) Install tachometer.
3) Start engine with select lever shifted to “P”.
4) Depress brake pedal fully.
5) Shift select lever to “D” and depress accelerator pedal fully while watching tachometer. Read engine rpm
quickly when it has become constant (stall speed).
6) Release accelerator pedal immediately after stall speed is checked.
7) In the same way, check stall speed in “R” range.
8) Stall speed should be within the following specification.
Stall speed :
2,460 – 2,760 r/min.
TROUBLESHOOTING
CAUTION:
Do not run engine at stall more than 5 seconds continuously, for fluid temperature may rise exces-
sively high.
After performing stall test, be sure to leave engine running at idle for longer than 30 seconds before
another stall test.
Condition Possible cause
Lower than standard level•Faulty engine output
•Defective torque converter
Higher than standard level in “D” range•Slippery O/D clutch
•Slippery forward clutch
•Malfunctioning O/D one-way clutch
•Malfunctioning one-way clutch No. 2
•Low line pressure
Higher than standard level in “R” range•Slippery direct clutch
•Slippery reverse brake
•Low fluid pressure
•Slippery O/D clutch
•Defective O/D one-way clutch

AUTOMATIC TRANSMISSION (4 A/T) 7B1-39
Line Pressure Test
Purpose of this test is to check operating conditions of each part
by measuring fluid pressure in fluid pressure line. Line pressure
test requires following conditions.
•Automatic fluid is at normal operating temperature (70 to 80
°
C/158 – 176 °F).
•Fluid is filled to proper level (between FULL HOT and LOW
HOT on dipstick).
1) Apply parking brake securely and place checks against
wheels.
2) Attach oil pressure gauge to fluid pressure check hole (1) in
transmission case.
Special tool
(A) : 09925-37811-001
3) Depress foot brake fully, run engine at idle and stall.
4) Check fluid pressure in “D” or “R” range within the following
specification.
Line pressure :
5) If check result is OK, disconnect special tool, then tighten
transmission case plug to specified torque.
Tightening torque
Transmission case plug : 17 N·m (1.7 kg-m, 12.0 lb-ft) CAUTION:
After attaching oil pressure gauge, check that not fluid
leakage exists.
CAUTION:
Do not continue running engine at stall speed longer
than 5 seconds.
“D” range“R” range
Idle speed
4.1 – 4.6 kg/cm
2
58 – 65 psi5.4 – 6.0 kg/cm
2
77 – 85 psi
Stall speed
12.0 – 13.5 kg/cm
2
171 – 192 psi14.6 – 17.1 kg/cm
2
208 – 243 psi