warning SUZUKI GRAND VITARA 2002 2.G Service Repair Manual
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Page 403 of 801
YH4
GRAND
VITARA
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
Page 428 of 801
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7B1-26 AUTOMATIC TRANSMISSION (4 A / T)
Operation
VISUAL INSPECTION
Visually check following parts and systems.
INSPECTION ITEM
REFERRING SECTION
A / T fluid ± ± ± ± ± level, leakage, color
A / T fluid hoses ± ± ± ± ± disconnection, looseness, deterioration
Throttle (accelerator) cable ± ± ± ± ± play, installation
A / T throttle cable ± ± ± ± ± play, installation
A / T select cable ± ± ± ± ± installation, operation
Engine oil ± ± ± ± ± level, leakage
Engine coolant ± ± ± ± ± level, leakage
Battery ± ± ± ± ± fluid level, corrosion of terminal
Connectors of electric wire harness ± ± ± ± ± disconnection, friction
Fuses ± ± ± ± ± burning
Parts ± ± ± ± ± installation, damage
Bolt ± ± ± ± ± looseness
Other parts that can be checked visually
Also check following items at engine start, if possible.
ªO / D OFFº lamp
ªPOWERº lamp
Malfunction indicator lamp
Charge warning lamp
Engine oil pressure warning lamp
Engine coolant temp. meter
Other parts that can be checked visually
Section 0B
Section 7B1
Section 6E1 / 6E2
Section 7B1
Section 7B1
Section 0B
Section 0B
Section 6 / 6-1 / 7B1
Section 8
Section 7B1
Section 7B1
Section 6 / 6-1
Section 6H
Section 8 (Section 6A1 / 6A2 /
6A4 for pressure check)
Page 433 of 801
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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.
Page 435 of 801
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VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-33
O / D cut
switchOFF ON
VoltageBattery
voltage0 V
DIAGNOSTIC FLOW TABLE A-2 (NO GEAR SHIFT TO O / D)
SYSTEM DESCRIPTION
PCM does not shift to O / D gear under any of the following conditions.
O / D cut switch: ON
4WD LOW switch: ON
Cruise control module: O / D 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
C51-1-2 (G16 / J20 engines) or C51-1-6 (H25
engine) terminal of PCM coupler and ground,
C51-1-1 terminal of PCM coupler and ground.
O / D cut switch OFF (ªO / D OFFº lamp OFF).
Normal mode in ªDº range.
Transfer ª2Hº position.
Cruise control is not operated (if equipped).
Drive vehicle with 4th gear condition
referring to ªGear shift diagramº in this
section.
Is each voltage about 0 V?Faulty shift solenoid
valve, its circuit or
transmission.ªGº wire or ªG / Rº wire
shorted to power circuit.
If OK, go to Step 4.
4O / D cut switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-33 (G16 / J20 engines) or
E61-14 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 5.Faulty O / D cut switch or
its circuit.
If OK, substitute a known-
good PCM and recheck.
Page 442 of 801
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7B1-40 AUTOMATIC TRANSMISSION (4 A / T)
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
Transmission range switch signal (P, R, N, D, 2 or L)
is not inputted for 25 sec. at 60 km/h (38 mph) or
higher vehicle speed.
or
Multiple signals are inputted simultaneously for 25
sec.
(2 driving cycles detection logic)Transmission range sensor (switch) maladjusted.
Transmission range sensor (switch) or its circuit mal-
function.
PCM
DTC CONFIRMATION PROCEDURE
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC and start engine.
3) Shift A / T selector lever to each of L, 2, D, N, R and P ranges for 30 seconds each.
4) Increase vehicle speed to about 70 km / h (45 mph) in D range.
5) Keep driving above vehicle speed for 30 seconds.
6) Release accelerator pedal, decrease vehicle speed and stop vehicle.
7) Check DTC and / or pending DTC.
Page 444 of 801
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GRAND
VITARA
G16/J20 Engines H25 Engine
G16/J20 Engines
H25 Engine
1. PCM
2. A / T input speed sensor 11 1 0
Bl / Y Bl / G16 8
Bl / Y Bl / G
7B1-42 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0715 (DTC NO.76) INPUT / TURBINE SPEED SENSOR CIRCUIT MALFUNCTION
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
Input speed sensor detected speed is lower than spec-
ification while vehicle running under all of the following
conditions:
at higher than 10 km / h (7 mph) with 1st gear in D
range for 1 sec. or more.
at higher than 20 km / h (13 mph) with 2nd gear in D
range for 2 sec. or more.
at higher than 30 km / h (20 mph) with 3rd gear in D
range for 2 sec. or more.
(2 driving cycles detection logic)Input speed sensor and its circuit
PCM
DTC CONFIRMATION PROCEDURE
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC.
3) Start engine and turn O / D cut switch ON.
4) Shift select lever to D range and start vehicle.
5) Keep vehicle speed at higher than 10 km / h (7 mph) with 1st gear in D range for 2 sec. or more.
6) Increase vehicle speed and keep it at higher than 20 km / h (13 mph) with 2nd gear in D range for 2 sec. or more.
7) Increase vehicle speed and keep it at higher than 30 km / h (20 mph) with 3rd gear in D range for 2 sec. or more.
8) Stop vehicle.
9) Check DTC and / or pending DTC.
Page 446 of 801
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GRAND
VITARA
G16/J20 Engines H25 Engine
G16/J20 Engines
H25 Engine
1. PCM
2. A / T output speed sensor 23
22
WOr10 9
WOr
7B1-44 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0720 (DTC NO.75) OUTPUT SPEED SENSOR CIRCUIT MALFUNCTION
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
With 4WD LOW switch OFF, no output speed sensor
signal is inputted while vehicle speed sensor signal
are inputted.
or
With 4WD LOW switch OFF, no output speed sensor
signal is inputted while engine running at higher than
specified engine speed with ªDº range.
(2 driving cycles detection logic)A / T output speed sensor or its circuit
PCM
DTC CONFIRMATION PROCEDURE
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC.
3) Start engine and shift transfer lever to ª2Hº or ª4Hº range.
4) Drive vehicle at 40 km / h (25 mph) or more for longer than 10 sec. (or higher than 3500 rpm engine speed with
D range for longer than 10 sec.)
5) Stop vehicle and check DTC and / or pending DTC.
Page 448 of 801
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VITARA
7B1-46 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0741 TCC (LOCK-UP) SOLENOID VALVE PERFORMANCE OR STUCK OFF
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While running in 2nd or 4th gear, D range, TCC control
of PCM does not agree with actual operation of trans-
mission TCC even though solenoid valve is electrically
in good condition.
(2 driving cycles detection logic)TCC (lock-up) solenoid valve stuck
TCC control valve stuck
Valve body fluid passage clogged
TCC faulty
DTC CONFIRMATION PROCEDURE
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool and check fuel level meter
indication is 1/4 or more.
3) Start engine, warm it up to normal operating temperature and shift transfer lever to ª2Hº or ª4Hº range.
4) Increase vehicle speed with D range, and check that gear position changes from 1st to 2nd and keep driving
about 20 mph, 30 km/h in 2nd of ªDº range for 10 seconds. (Throttle valve should be not at idle position and
the opening should be kept constant in this step.)
5) Keep driving about 50 mph, 80 km/h in 4th of ªDº range for 10 seconds.
6) Release accelerator pedal, decrease vehicle speed and stop vehicle.
7) Check pending DTC and DTC by using scan tool.
TROUBLESHOOTING
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2TCC solenoid valve operation check:
1) Check TCC solenoid valve operation referring to
ªSolenoid Valves Operation Checkº in this section.
Is it in good condition?Go to Step 3.Faulty TCC solenoid
valve.
3Valve body check:
1) Check valve body referring to ªUnit Repairº in this
section.
Is it in good condition?Faulty torque
converter.Faulty valve body.
Page 449 of 801
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G16/J20 Engines H25 Engine
G16/J20 Engines
H25 Engine
1. PCM
2. Shift solenoid-A
3. Shift solenoid-B
4. TCC solenoid
AUTOMATIC TRANSMISSION (4 A / T) 7B1-47
DTC P0743 (DTC NO.65 / 66) TCC (LOCK-UP) SOLENOID ELECTRICAL
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
Voltage at terminal C51-1-8 for G16 / J20 (C51-1-2 for
H25) of PCM is high while TCC solenoid OFF is com-
manded or low while TCC solenoid ON is comman-
ded.TCC (lock-up) solenoid valve
TCC (lock-up) solenoid valve circuit
PCM
DTC CONFIRMATION PROCEDURE
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC.
3) Start engine, warm it up to normal operating temperature and shift transfer lever to ª2Hº or ª4Hº range.
4) Shift selector lever in D range and keep it there for 10 seconds.
5) Increase vehicle speed to about 80 km / h (50 mph) in 4th gear and in D range.
6) Keep driving at above speed for 20 seconds.
7) Release accelerator pedal, decrease vehicle speed and stop vehicle.
8) Check DTC and / or pending DTC.
Page 451 of 801
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AUTOMATIC TRANSMISSION (4 A / T) 7B1-49
DTC P0751 SHIFT SOLENOID VALVE-A (#1) PERFORMANCE OR STUCK OFF
DTC P0756 SHIFT SOLENOID VALVE-B (#2) PERFORMANCE OR STUCK OFF
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While running in D range, gear change control from
PCM to A / T does not agree with actual A / T gear posi-
tion even though solenoid valve is electrically in good
condition.
(A / T gear position is calculated based on engine
speed signal and vehicle speed sensor signal.)
(2 driving cycles detection logic)DTC P0751:
Shift solenoid valve-A stuck or leakage.
2-3 shift valve stuck.
Valve body fluid passage clogged.
Mechanical malfunction in transmission.
(Direct clutch malfunction)
DTC P0756:
Shift solenoid valve-B stuck or leakage.
1-2 shift valve stuck.
3-4 shift valve stuck.
Valve body fluid passage clogged.
Mechanical malfunction in transmission.
(2nd brake malfunction)
DTC CONFIRMATION PROCEDURE
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool and check fuel level meter
indication is 1 / 4 or more.
3) Start engine, warm it up to normal operating temperature and shift transfer lever to ª2Hº or ª4Hº range.
4) Increase vehicle speed with D range, and check that gear position changes from 1st to 2nd, 3rd and 4th in that
order as vehicle speed increases, referring to ªGear Shift Diagramº in this section.
5) Stop vehicle and check pending DTC and DTC by using scan tool.
TROUBLESHOOTING
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Shift solenoid valve-A or -B operation check:
1) Check shift solenoid valve-A or -B for operation
referring to ªSolenoid Valves Operation Checkº
section.
Is it in good condition?Go to Step 3.Faulty shift solenoid
valve-A or -B.
3Valve body check:
1) Check valve body and its passage referring to
ªUnit Repairº section.
Are they in good condition?Overhaul and repair
automatic transmis-
sion.Faulty valve body.