battery SUZUKI GRAND VITARA 2002 2.G Service Manual PDF

YH4
GRAND
VITARA
1
1. 4WD low switch
AUTOMATIC TRANSMISSION (4 A / T) 7B1-53
TROUBLESHOOTING (DTC P1875)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
24WD low switch and its circuit check:
When using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON.
3) Select ªData listº mode on scan tool.
4) Check 4WD low switch signal (ON or OFF) on
display when shifting transfer lever to each
position.
4H or 2H position : OFF
4L position : ON
Is OFF / ON displayed as described above?
When not using SUZUKI scan tool:
1) Remove PCM cover.
2) Turn ignition switch ON.
3) Check voltage at terminal C51-1-26 for G16 / J20
(C51-1-5 for H25) of PCM connector connected
when shifting transfer lever to each position.
4H or 2H position : 10 ± 14 V
4L position : 0 ± 1 V
Is voltage as specified?Check for poor con-
nection at the termi-
nal of PCM if voltme-
ter is used in Step 2.
If connection is OK,
intermittent trouble
or faulty PCM.
Check for intermittent
referring to ªIntermit-
tent and Poor
Connectionº in
Section 0A.Go to Step 3.
34WD low switch check:
1) Check 4WD low switch for operation referring to
ª4WD Low Switch Inspectionº below.
Is check result satisfactory?ªOr / Wº or ªBº circuit
open or short. If wires
and connections are
OK, substitute a
known-good PCM
and recheck.Replace 4WD low
switch.
4WD Low Switch Inspection
1) Disconnect negative cable at battery.
2) Disconnect 4WD low switch coupler.
3) Check continuity between 4WD low switch terminals.
There should be continuity when transfer lever shifted to 4L posi-
tion and should be infinity when transfer lever shifted to 4H or 2H
positions.
If not, replace 4WD low switch.
4) Connect 4WD low switch coupler and battery negative cable.

YH4
GRAND
VITARA
1. Manual selector assembly
(Select lever assembly)
2. Manual lever assembly
3. Select cable bracket
4. Select indicator
5. Slide cover
6. Select lever knob7. Spring
8. Knob button
9. Shift lock solenoid rod
10. Shift lock solenoid
11. Cover
12. Illumination lamp
13. Interlock cam
1. Interlock cam pin
(only for new selector assembly) Tightening Torque
(a): 18 N
.m (1.8 kg-m, 13.5 lb-ft)1. Manual lever
assembly
2. Select indicator
assembly
3. Illumination lamp
assembly
4. Bulb filter
5. Bulb
6. Knob assembly
7. Shift lock solenoid
Type-1 Type-2
Type-1
7B1-62 AUTOMATIC TRANSMISSION (4 A / T)
MANUAL SELECTOR ASSEMBLY
REMOVAL
1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connector for illumination lamp, shift lock solenoid
and overdrive OFF switch.
4) Disconnect interlock cable from interlock cam of selector as-
sembly.
5) Remove selector assembly mounting bolts.
6) Disconnect select cable from lever of selector assembly.
INSTALLATION
NOTE:
New selector assembly of Type-1 is supplied with held inter-
lock cam at interlock cable connecting position with pin. Re-
move this pin after connecting interlock cable to interlock cam
and tightening cable nut.
Reverse removal procedure to install noting the followings.

Connect interlock cable end to cam referring to steps 2) to 8) of
ªInterlock Cable Installationº section.

Upon completion of installation, confirm that brake (key) interlock
system operates properly.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-65
1. Drain plug
2. Propeller shaft
1. Oiler (with transmission fluid)
2. Solenoid valve
3. BatteryA: Hole (Should be dry)
B: Exhausting fluid Terminal Arrangement of PCM Coupler
(Viewed from harness side)
WITH BATTERY VOLTAGE WITHOUT BATTERY VOLTAGE
H25 Engine
Shift solenoid valve ± A (#1)C51-1-6
Shift solenoid valve ± B (#2)C51-1-1
TCC (Lock-up) solenoid valveC51-1-2
REMOVAL
1) Pull out dipstick and lift up vehicle.
2) With engine cooled, remove drain plug from oil pan and drain
A / T fluid.
3) Install drain plug with gasket.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Remove exhaust pipe bracket and disconnect front propeller
shaft from front differential (if equipped).
5) Remove oil pan bolts.
6) Remove oil pan.
7) Remove oil tubes.
8) Remove solenoid valve No.1 (shift solenoid valve A and B) or so-
lenoid valve No.2 (TCC solenoid valve).
OPERATION CHECK
Whenever shift solenoid valves and TCC (lock-up) solenoid valve
are removed from transmission, verify their valve function physical-
ly before they are reinstalled.
1) Apply oiler to solenoid valve and give compression by hands
and then check to be sure that transmission fluid from oiler does
not come out of holes in solenoid valve when battery voltage is
not conducted.
2) Under the same conditions as above, conduct battery voltage
and then make sure that fluid comes out with vigor.
NOTE:

If fluid does not come out with vigor in above step 2 in-
spection, do not re-use that solenoid valve.

Figure at the left shows shift solenoid valve check.
Check TCC solenoid valve also in the same way.

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VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-71
Ignition switch side
1. Ignition switch assembly
2. Clamp screw
3. Interlock cable
Select lever side
Type-1
1. Inner end of interlock cable
2. Interlock cam (or key release cam)
3. Stud bolt4. Cam boss
5. Claw
Select lever side
Type-2
KEY INTERLOCK CABLE
NOTE:
Don't bend interlock cable excessively when removing and
installing it, or system will not operate correctly.
Removal
1) Disconnect negative (±) cable from battery.
2) If equipped with air bag system, disable air bag system.
Refer to ªDisabling Air bag Systemº in Section 10B.
3) Remove steering column hole cover.
4) Tilt steering column if steering column is adjustable.
If no adjustable, loosen steering column bolts.
5) Remove steering column cover.
6) Remove interlock cable clamp screw located at ignition switch
assembly.
7) Disconnect interlock cable inner end.
(Ignition switch side.)
8) With console box removed, take out interlock cable by loosening
lock nuts.
9) Detach cable end from interlock cam (or key release cam) while
pressing claws of interlock cam boss. At this time, be careful not
to cause damage to its claws.

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VITARA
7B1-74 AUTOMATIC TRANSMISSION (4 A / T)
1. Boot No.2
2. Boot cover
1. Boot clamp
2. Boot No.1
3. Gear shift control lever
1. Boot No.2
2. Transfer shift control
lever
3. Transfer shift lever case4. Transfer shift control
case cover
5. Boot No.1
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
G16 / J20 H25
DISMOUNTING OF TRANSMISSION (WITH
TRANSFER IF EQUIPPED)
IN CABIN
1) Remove console box.
NOTE:
To remove clip, push in its center pin first.
2) Remove boot cover and boot No.2. (if equipped)
3) Remove boot clamp and then remove boot No.1 from transfer
gear shift lever case. (if equipped)
4) With transfer shift control case cover pushed down with fingers,
turn it to counterclockwise and take out shift control lever. (if
equipped)
IN ENGINE ROOM
1) Remove battery, dipstick and oil filler tube.
2) Disconnect A
/
T throttle cable from throttle cam and bracket.
3) Remove starter motor. But don't disconnect its wiring harness.
4) Remove transmission to engine bolt and nut.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-77
ªAº, (d)
1. Drive plate
2. Torque converter
3. Case right stiffener (if equipped)
4. Automatic transmissionTightening torque
(a): 50 N´m
5.0 kg-m
36.5 lb-ft
(b): 65 N´m
6.5 kg-m
47.0 lb-ft
(c): 85 N´m
8.5 kg-m
61.5 lb-ft
(d): 78 N´m
7.8 kg-m
56.5 lb-ft
1. Automatic transmission
2. Transfer (4WD)
3. Engine rear mounting
4. Engine rear mounting member Tightening torque
(a): 50 N´m (5.0 kg-m, 36.5 lb-ft) ªAº: Sealant 99000-31110
REMOUNTING
WARNING:
When moving transmission assembly with torque convert-
er equipped in it, be sure to keep it horizontal. Tilting it with
its front facing down may allow converter to fall off. Where-
by an injury may result.
For remounting, reverse dismounting procedure. Use specified
torque as given below and left.
Tightening torque
N.mkg-mlb-ft
Exhaust No.1 pipe to manifold
bolts or nuts505.036.5
Muffler to exhaust No.2 pipe
nuts606.043.5
Universal joint flange bolts and
nuts505.036.5

Oil filler tube bolts

Select cable bracket bolts232.317.0

Clamp wiring harness and hoses securely.

Refer to ªSelect Cableº section for adjusting procedure of select
cable.

Refer to ªA / T Throttle Cableº section for tuning of A / T throttle
cable.

Follow fluid level check procedure for refilling automatic transmis-
sion fluid and its level adjusting.

Connect battery, and confirm that engine and transmission func-
tion acceptably.

When remounting drive plate, use specified bolts.

YH4
GRAND
VITARA
1. Wood block
2. Dash panel
t: 45 mm / 1.8 in.
H: 200 mm / 8 in.
W: 100 ± 150 mm / 4 ± 6 in.
1. Transmission jack
2. Engine rear mounting member
3. Gear shift lever case
4. Bolt
TRANSFER 7D-5
TRANSFER ASSEMBLY
Dismounting and remounting of transfer and transmission together
as a unit is described in Section 7A for Manual Transmission or 7B1
for Automatic Transmission, but it is also possible to dismount and
remount transfer assembly by itself as described below.
DISMOUNTING
IN ENGINE ROOM
1) Disconnect negative (±) cable from battery.
2) Remove distributor assembly (if equipped).
3) Place wood block between engine and dash panel so that it
serves as stopper when engine, transmission and transfer unit
hangs down as rear mounting member is removed.
CAUTION:
Make sure to use wood block to prevent contact which
may occur between dash panel and CMP sensor case
(G16), CMP sensor (J20) or intake manifold (H25), and fan
and shroud.
IN CABIN
1) Remove console box.
2) Remove shift lever of transmission and transfer.
ON LIFT
1) Drain transfer oil.
2) Remove rear propeller shaft.
3) Remove front propeller shaft.
4) Disconnect exhaust center pipe.
5) Disconnect speed sensor coupler.
6) Place transmission jack and remove mounting member.
7) Lower transmission jack gradually and check to ensure that
wood block serves as stopper between engine and dash panel.
8) Remove bolts for gear shift lever case.
9) Pull off breather hose.

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VITARA
1. Bolt
2. Transfer assembly
1. Bolt
2. Engine rear mounting3. Transfer assembly
1. Bolt
2. Transfer assembly
3. Transmission jack
7D-6 TRANSFER
IN CABIN
Remove gear shift lever case and then remove transfer center case
bolt.
ON LIFT
1) Remove transfer mounting (engine rear mounting) by removing
bolts.
2) Apply transmission jack to transfer to support it.
3) Remove couplers for 4WD / 4WD-LOW switches lead.
4) Remove transfer front case bolts.
5) With transfer assembly supported with transmission jack, slide
it rearward and when it is apart from transmission, lower it.
REMOUNTING
For remounting, reverse dismounting procedure described above,
noting following.

Be sure to use specified torque for tightening.

Clamp wiring and breather hose securely.

Clamp shift lever boot securely.

Fill specified gear oil by specified amount.

Connect battery and check for function.

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VITARA
7E-12 DIFFERENTIAL (FRONT)
1. Pump assembly
Air Pump Assembly
Removal / Installation
1) Disconnect air hoses and coupler from air pump assembly.
2) Remove pump assembly by removing bolts.
3) Reverse removal procedure for installation.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
Inspection
1) Install special tool, voltmeter and battery to pump assembly as
shown in figure.
2) Tighten adjusting screw of special tool as far as it stops and
close its air check side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
3) Check that motor starts to run (a sound can be heard) when bat-
tery is connected and it stops when specified pressure is ob-
tained.
Check also for air leakage.
Specified pressure: 30.0 ± 45.0 kPa
(0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that value indicated on voltmeter is within specification
shown below.
When motor is running: 0 ± 1 V
When motor has stopped running: 10 ± 14 V
CAUTION:
Do not run motor more than 10 seconds continuously to
prevent motor breakage.

YH4
GRAND
VITARA
8
BODY ELECTRICAL SYSTEM 8-1
SECTION 8
BODY ELECTRICAL SYSTEM
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).
WIRING SYSTEM
(Harnesses, Connectors, Fuses, Relay, Switches, Grounds, System Circuit Diagram)Section 8A . . . . . . .
LIGHTING SYSTEMSection 8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENTATION AND DRIVER INFORMATIONSection 8C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDOWS, MIRRORS, SECURITY AND LOCKSSection 8D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMMOBILIZER CONTROL SYSTEMSection 8F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS
GENERAL DESCRIPTION8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions in Servicing8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and Marks8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Color Symbols8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Diagram8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .