G16 SUZUKI GRAND VITARA 2002 2.G Service Owner's Manual

YH4
GRAND
VITARA
3B1-26 POWER STEERING (P / S) SYSTEM
09915-77420
Oil pressure gauge
attachment and hose set09915-77410
Oil pressure gauge09943-55010
Boot clamp plier
TIGHTENING TORQUE SPECIFICATION
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Gear box mounting bolts555.540.0
Gear box cylinder pipe flare nuts292.921.0
Gear box low pressure pipe union bolt404.029.0
Gear box high pressure pipe union bolt353.525.5
Tie-rod end lock nut656.547.0
G16 Type engine555.540.0
Pump bracket boltJ20 Type engine252.518.5
H25 Type engine454.532.5
Pump union bolt606.043.5
Oil pump mount bolts252.518.5
Pipe clamp bolt / Reservoir bracket bolt111.18.0
Steering shaft joint bolt252.518.0
High pressure flare nuts404.029.0
Pump cover bolts232.317.0
Plug606.043.5
Pressure switch (Terminal)282.820
Suction connector bolt101.07.5
Tie-rod end nut484.835.0
Tie-rod (for canvas top LH model only)858.561.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUPER GREASE (A)
(99000-25010)
Oil seal lip of P / S pump pulley shaft
Power steering fluidAn equivalent of DEXRON
-III or
DEXRON
-II

To fill P / S fluid reservoir

Parts lubrication when installing
SPECIAL TOOL

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GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Drive shaft flange
bolts and nuts
1. Oil seal
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3
ON-VEHICLE SERVICE
DRIVE SHAFT
REMOVAL (LEFT SIDE)
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange.
3) Remove drive shaft circlip and front spindle thrust washer.
4) Remove drive shaft flange bolts and nuts.
5) Remove drive shaft assembly to differential side as shown in left
figure.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
6) Remove drive shaft thrust washer (vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.

YH4
GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Differential side joint
2. Tire lever
3. Front differential assembly
1. Oil seal 2
1
4A2-4 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
REMOVAL (RIGHT SIDE)
1) Hoist vehicle and remove wheel.
2) Drain differential gear oil.
3) Remove axle shaft drive flange.
4) Remove circlip and front spindle thrust washer.
5) Remove knuckle and wheel hub comp, refer to steps 5) to 7) and
9) to 14) of item COIL SPRING REMOVAL in Section 3D.
6) Remove drive shaft assembly.
To detach snap ring fitted on the spline of differential side joint
(inboard joint) from differential side gear, pull inboard joint by us-
ing a tire lever.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
7) Remove drive shaft thrust washer (to vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.

YH4
GRAND
VITARA
1. Drive shaft oil seal
1. Drive shaft flange bolt and nut
2. Front spindle thrust washer
3. Axle shaft drive flange
ªAº
1. Drive shaft joint
2. Oil seal
3. Pipe
4. Thrust washer4
4A2-8 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
INSTALLATION
Install drive shaft assembly by reversing removal procedure and
noting following points.

Clean front drive shaft oil seal and then apply lithium grease to oil
seal and DOJ shaft.
ªAº: Grease 99000-25010

Check oil seal for breakage or deterioration.
Replace it as necessary.

Drive in oil seal until its end contacts stepped surface of drive
shaft joint by using a pipe whose inner diameter is 76 mm (2.992
in.) or more and outer diameter is 80 mm (3.150 in.) or less.
Diameter ªaº: 76 mm (2.992 in.) or more
Diameter ªbº: 80 mm (3.150 in.) or less

Drive in drive shaft thrust washer (Vehicle with G16 or J20 en-
gine).

RH Side
Push differential side joint by hand until it is positioned by snap
ring fitted to its spline.
LH Side
Connect drive shaft flange bolts and nuts.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

Apply grease to front spindle thrust washer and front spindle part
of drive shaft.
ªAº: Grease 99000-25010

When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.
ªBº: Sealant 99000-31090
Tightening Torque
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
CAUTION:

To prevent breakage of boots (wheel side and differen-
tial side), be careful not to bring them into contact with
other parts when installing drive shaft assembly.

Do not pull housing of differential side joint.
If housing is pulled, it may be detached from drive shaft.

Fill specified differential gear oil into differential case to specified
level.

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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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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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GRAND
VITARA
Gear Shift Diagram
TCC Lock-up Diagram
Vehicle speedUpshift
Downshift
Throttle valve opening
Vehicle speed
Throttle valve opening
TCC ON
TCC OFF 4th
gear
3rd
gear(km / h)
(km / h)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-11
AUTOMATIC GEAR SHIFT DIAGRAM
Automatic shift schedule as a result of shift control is shown below. In case that select lever is shifted to L at a higher
than 52 km / h or 33 mile / h speed for G16 engine (45 km / h or 28 mile / h for J20 engine, 55 km / h or 34 mile / h for
H25 engine), 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower than that. No up shift is
available in L.
The same as, the select lever is shifted to 2 at a higher than 102 km/h (64 mile/h) speed for G16/J20 engines (105
km / h or 65 mile / h for H25 engine), 3rd gear is operated and then down shifts to 2nd at a speed lower than that.
Power Mode For G16 EngineUnit: km / h
(mile/h)
Shift
Throttle opening
1
22
33
44
33
22
1
Full throttle49
(30)94
(58)153
(95)124
(77)85
(53)43
(27)
Closed throttle18
(11)36
(23)48
(30)40
(25)29
(18)7
(4)

YH4
GRAND
VITARA
Gear Shift Diagram
TCC Lock-up Diagram
Vehicle speedUpshift
Downshift
Throttle valve opening
Vehicle speed
Throttle valve opening
TCC ON
TCC OFF 4th
gear3rd
gear(km / h)
(km / h)
7B1-12 AUTOMATIC TRANSMISSION (4 A / T)
Normal Mode For G16 EngineUnit: km / h
(mile/h)
Shift
Throttle opening
1
22
33
44
33
22
1
Full throttle45
(28)94
(58)136
(85)124
(77)74
(46)39
(24)
Closed throttle14
(9)32
(20)45
(28)35
(22)29
(18)7
(4)

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GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-31
Brake pedal Released Depressed
Voltage 0 VBattery
voltage
DIAGNOSTIC FLOW TABLE A-1 (NO TCC LOCK-UP OCCURS)
SYSTEM DESCRIPTION
PCM turns TCC solenoid OFF under any of the following conditions.

Brake pedal switch: ON

4WD LOW switch: ON

Cruise control module: TCC OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

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

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor, its
circuit or engine cooling
system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-8 (G16 / J20 engines) or C51-1-2 (H25
engine) terminal of PCM coupler and ground.

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Brake pedal released.

Drive vehicle with TCC ON condition
referring to ªTCC lock-up diagramº in
this section.
Is it battery voltage?Faulty TCC solenoid
valve, its circuit or
transmission.Go to Step 4.
4Is vehicle equipped with H25 engine?Go to Step 5.Go to Step 6.
5Brake switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-31 terminal of PCM coupler
terminal and ground.
Is the result as specified?Go to Step 6.Faulty brake pedal switch
or its circuit.
If OK, substitute a known-
good PCM and recheck.

YH4
GRAND
VITARA
7B1-32 AUTOMATIC TRANSMISSION (4 A / T)
Transfer gear
positionª4Lº or ªNº ª4Hº or ª2Hº
Voltage 0 VBattery
voltage
STEPACTIONYESNO
6ª4WD LOWº switch signal inspection:
(1) With ignition switch ON, check voltage
between C51-1-26 (G16 / J20 engines) or
C51-1-5 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 7.Faulty ª4WD LOWº
switch or its circuit.
If OK, substitute a known-
good PCM and recheck.
7Is vehicle equipped with cruise control
system?Go to Step 8.Substitute a known-good
PCM and recheck.
8Cruise control signal inspection:
(1) With ignition switch ON, check voltage
between E61-35 (G16 / J20 engines) or
E61-3 (H25 engine) terminal of PCM
coupler and ground.
Is it battery voltage?Substitute a known-good
PCM and recheck.Faulty cruise control
module or its circuit.
If OK, substitute a known-
good PCM and recheck.