Manual transmission SUZUKI GRAND VITARA 2001 2.G Owners Manual

Foreword
This manual contains only different service information of the following applicable model as compared with
SQ416/SQ420/SQ625 SERVICE MANUAL.
Applicable model: GRAND VITARA XL-7
Therefore, whenever servicing the above applicable model, consult this manual first. And for any section, item
or description not found in this manual, refer to the related manual below.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials (lubricant, sealants, etc.) as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
RELATED MANUAL:
© COPYRIGHT SUZUKI MOTOR CORPORATION 2001Manual Name Manual No.
SQ416/SQ420/SQ625 Service Manual 99500-65D10-01E
SQ416/SQ420/SQ625 Unit Repair Manual for Manual Transmis-
sion, Automatic Transmission, Transfer and Differential99501-65D01-01E
GRAND VITARA XL-7 Wiring Diagram Manual 99512-52D00-015

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND
DIFFERENTIAL0A7A1
General Information0A
0B7B1
Maintenance and Lubrication0B
Manual Transmission7A1
7C1
HEATING AND AIR CONDITIONING
Automatic Transmission7B1
1A7D
Heater and Ventilation1A
Clutch7C1
1B7E
Air Conditioning1B
Transfer7D7F
STEERING, SUSPENSION, WHEELS
AND TIRESDifferential (Front)7E
3
Differential (Rear)7F
3A8
Steering, Suspension, Wheels and Tires3 ELECTRICAL SYSTEM3B18A
Front End Alignment3A
Electrical System8
3C18B
Power Steering (P/S) System3B1
Wiring Diagram8A3D8C
Air Bag Steering Wheel and Column3C1
Lightening System8B3E8D
Front Suspension3D
Instrumentation / Driver Information8C
3F8E
Rear Suspension3E
Windows, Mirrors, Security and Lock8D
8G
Wheels and Tires3F
Cruise Control System8E
4A2
DRIVE SHAFT AND PROPELLER SHAFT
Immobilizer control system (if equipped)8G4B9
Front Drive Shaft / Shaft Bearing,
Oil Seal4A2BODY SERVICE
Body Service9
510
Propeller Shaft4B RESTRAINT SYSTEM
5A10A
BRAKE SYSTEM
Restraint System10
5B10B
Brakes5
Seat Belt10A
5C
Brake Pipe / Hose / Master Cylinder5A
Air Bag System10B
5E2
Front Brake5B
Parking and Rear Brake5C
6-1
Antilock Brake System (ABS)5E2
6A2
ENGINE
6B
General Information and
Diagnosis (H27 Engine)6-1
6C
6E2
Engine Mechanical (H27 Engine)6A2
6F2
Engine Cooling6B
6G
Engine Fuel6C
6H
Engine and Emission Control System
(SFI For H27 Engine)6E2
6K
Ignition System (H27 Engines)6F2
Cranking System6G
Charging System6H
Exhaust System6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.

GENERAL INFORMATION 0A-1
0ASECTION 0A
GENERAL INFORMATION
CONTENTS
Precautions......................................................0A-2
Precaution for Vehicles Equipped with A
Supplemental Restraint
(Air Bag) System ........................................... 0A-2
Diagnosis................................................... 0A-2
Servicing and handling .............................. 0A-3Identification Information ............................... 0A-6
Vehicle Identification Number ....................... 0A-6
Engine Identification Number ........................ 0A-7
Transmission Identification Number.............. 0A-7
Warning, Caution and Information Labels.... 0A-8

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this 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.

MANUAL TRANSMISSION 7A1-1
7A1SECTION 7A1
MANUAL TRANSMISSION
CONTENTS
Unit Repair .....................................................7A1-1

Unit Repair
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.
NOTE:
This manual transmission (for H27 engine) is not equipped with C-ring of countershaft rear bearing.
Therefore it is not necessary to disassemble or reassemble this C-ring from or to countershaft rear
bearing. For the descriptions (items) other than mentioned above, refer to the same section of “UNIT
REPAIR MANUAL” mentioned in the FOREWORD of this manual.

7A1-2 MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION (4 A/T) 7B1-1
7B1
SECTION 7B1
AUTOMATIC TRANSMISSION (4 A/T)
CONTENTS
General Description ......................................7B1-3
Electronic Shift Control System ................... 7B1-4
Automatic gear shift diagram................... 7B1-5
Diagnosis .......................................................7B1-7
On-Board Diagnostic System
(Vehicle without monitor connector) ............ 7B1-7
On-Board Diagnostic System
(Vehicle with monitor connector) ................. 7B1-8
Precaution in Diagnosing Trouble ............... 7B1-9
Automatic Transmission Diagnostic Flow
Table ......................................................... 7B1-10
Malfunction Indicator Lamp (MIL) Check... 7B1-13
“O/D OFF” Lamp Check ............................ 7B1-13
“POWER” Lamp Check ............................. 7B1-13
Diagnostic Trouble Code (DTC) Check ..... 7B1-13
Diagnostic Trouble Code Clearance ......... 7B1-13
Diagnostic Trouble Code Table ................. 7B1-14
Fail Safe Table .......................................... 7B1-14
Visual Inspection ....................................... 7B1-14
A/T Basic Check ........................................ 7B1-14
Trouble Diagnosis Table 1 ........................ 7B1-15
Trouble Diagnosis Table 2 ........................ 7B1-15
Trouble Diagnosis Table 3 ........................ 7B1-16
Scan Tool Data ......................................... 7B1-17
Inspection of PCM and Its Circuit .............. 7B1-17Wire Harness and Connectors .................. 7B1-17
Table A-1 : No TCC Lock-Up Occurs ........ 7B1-18
Table A-2 : No Gear Shift to O/D .............. 7B1-20
Table B-1 : “O/D OFF” Light Circuit Check
(“O/D OFF” Light Doesn’t Light at Ignition
Switch ON But Engine Starts Up) ............. 7B1-22
Table B-2 : “O/D OFF” Light Circuit Check
(“O/D OFF” Light Comes ON Steadily) ..... 7B1-23
Table B-3 : “POWER” Light Circuit Check
(“POWER” Light Doesn’t Light at Ignition
Switch ON But Engine Starts Up) ............. 7B1-24
Table B-4 : “POWER” Light Circuit Check
(“POWER” Light Comes ON Steadily) ...... 7B1-25
DTC P0705 (DTC NO.72) - Transmission
Range Sensor (Switch) Circuit Malfunction7B1-26
DTC P0715 (DTC NO.76) - Input/Turbine
Speed Sensor Circuit Malfunction............. 7B1-29
DTC P0720 (DTC NO.75) Output Speed
Sensor Circuit Malfunction ........................ 7B1-32
DTC P0743 (DTC NO.65/66) -
TCC (Lock-Up) Solenoid Electrical ........... 7B1-34
DTC P0753 (DTC NO.61/62)
Shift Solenoid-A (#1) Electrical
DTC P0758 (DTC NO.63/64)
Shift Solenoid-B (#2) Electrical ................. 7B1-36 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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” 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
“LOCK” 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

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) 7B1-9
Precaution in Diagnosing Trouble
•Don’t disconnect couplers from PCM (ECM), battery cable
from battery, PCM ground wire harness from engine or main
fuse before checking the diagnosis information (DTC, freeze
frame data, etc.) stored in PCM memory. Such disconnec-
tion will clear memorized information in PCM memory.
•Using SUZUKI scan tool or also generic scan tool for vehicle
without monitor connector, the diagnostic information stored
in PCM memory can be checked and cleared as well. Before
its use, be sure to read Operator’s (Instruction) Manual sup-
plied with it carefully to have good understanding of its func-
tions and usage.
•Priorities for diagnosing troubles
If two or more diagnostic trouble codes (DTCs) are stored,
proceed to the flow table of the DTC which was detected
earliest in the order and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble
codes according to the following priorities.
–Diagnostic trouble codes (DTCs) other than DTC P0171/
P0172/P0174/P0175 (Fuel system too lean/too rich), DTC
P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire
detected) and DTC P0400 (EGR flow malfunction)
–DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too
rich) and DTC P0400 (EGR flow malfunction)
–DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306
(Misfire detected)
•Be sure to read “PRECAUTIONS FOR ELECTRICAL CIR-
CUIT SERVICE” in Section 0A before inspection and
observe what is written there.
•PCM replacement
When substituting a known-good PCM, check for following
conditions.
Neglecting this check may result in damage to a good PCM.
–All relays and actuators have resistance of specified value.
–MAF sensor, MDP sensor, TP sensor and fuel tank pres-
sure sensor are in good condition. Also, the power circuit of
these sensors is not shorted to the ground.