4wd SUZUKI GRAND VITARA 2003 2.G Service Owner's Manual

YH4
GRAND
VITARA
1. Back up light switch
2. Exhaust center pipe
1. Ohmmeter
2. Back up light switch or 4WD switch1, (a)
[Type 1]
[Type 2]
MANUAL TRANSMISSION (TYPE 1) 7A-7
3) Replace switch, connect and clamp as they were.
Tightening Torque
(a): 20 N
.m (2.0 kg-m, 14.5 lb-ft) (Type 1)
(a): 45 N
.m (4.5 kg-m, 32.5 lb-ft) (Type 2)
4) When back up light switch has been replaced, check switch for
proper function with ignition switch turned ON and gear shifted
to reverse position. Turn OFF switch after checking its function.
INSPECTION OF 4WD SWITCH AND BACK UP LIGHT
SWITCH
1) Undo clamp and disconnect coupler of back up light switch
and / or 4WD switch.
2) Function of back up light switch can be checked as shown in fig-
ure.
There should be conduction at these terminals only when shift
lever is shifted to reverse position.
3) Function of transfer 4WD switch can be checked in the same
manner as back up light switch.
There should be conduction at these terminals when shift lever
is shifted to 4H, and 4L positions.
Upon completion of check, connect coupler and clamp wiring har-
ness as they were.
NOTE:
When replacing switch(es), use care not to let dust enter trans-
mission through switch hole(s).

YH4
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VITARA
1. Match mark
1. Flange bolt
2. Front propeller shaft
1. Transmission jack
2. Engine rear mounting member
7A-10 MANUAL TRANSMISSION (TYPE 1)
ON LIFT
1) Drain oil from transmission and transfer.
2) Give match marks on joint flange and propeller shaft as shown
in figure. (front and rear)
3) Remove flange bolts of rear propeller shaft universal joint and
pull out propeller shaft.
4) Remove flange bolts of front propeller shaft universal joint and
pull out propeller shaft.
5) Remove clutch operating cylinder from transmission. It is not
necessary to disconnect clutch hose from operating cylinder.
NOTE:

It is not necessary to drain transmission oil when dis-
mounting transmission and transfer for clutch mainte-
nance only.

Work without draining transfer oil is possible if front pro-
peller shaft is dismounted together with transmission and
transfer.
6) Remove clutch housing lower plate.
7) Disconnect couplers from 4WD switch, back up light switch and
speed sensor assembly and release their harness from clamps.
Remove nuts from joint with engine.
8) Apply transmission jack and remove engine rear mounting
member taking off its bolts.
9) After removing mounting member, move rearward transmission
and transfer assemblies placed on jack and then lower them.

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VITARA
7A-14 MANUAL TRANSMISSION (TYPE 1)
09951-16060
Oil seal installer
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Oil filler / level and drain plugs232.317.0
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back up light switch (Type 1)202.014.5
Back up light switch (Type 2)454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts and nut505.036.5
Exhaust center pipe to manifold nuts505.036.5
Muffler to exhaust center pipe bolts505.036.5
Universal joint flange bolts505.036.5
Select return spring bolts232.317.0
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever.

Select return springs, bolts and guides.
Thread lock cementTHREAD LOCK CEMENT
SUPER 1333B (99000-32020)
Shift control lever locating bolts.
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil Drain and filler / level plugs.
SPECIAL TOOL

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VITARA
MANUAL TRANSMISSION (TYPE 2) 7A1-5
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN´mkg-mlb-ft
Transfer oil filler / level and drain plugs232.317.0
Transmission oil filler / level and drain plugs383.827.5
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back-up light switch454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts505.036.5
Muffler to exhaust No. 2 pipe nuts505.036.5
Universal joint flange bolts505.036.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever
Thread lock cement
THREAD LOCK CEMENT
SUPER 1333B
(99000-32020)

Shift control lever locating bolts
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil drain and filler / level plugs

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VITARA
7B1-2 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0753 Shift Solenoid-A (#1)
Electrical 7B1-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0758 Shift Solenoid-B (#2)
Electrical 7B1-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1875 4WD Low Switch Circuit
Malfunction 7B1-52. . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Test 7B1-54. . . . . . . . . . . . . . . . . .
Stall Test 7B1-55. . . . . . . . . . . . . . . . . . . . . . . . . .
Road Test 7B1-56. . . . . . . . . . . . . . . . . . . . . . . . .
Manual Road Test 7B1-57. . . . . . . . . . . . . . . . . .
Time Lag Test 7B1-57. . . . . . . . . . . . . . . . . . . . . .
Engine Brake Test 7B1-58. . . . . . . . . . . . . . . . . .
ªPº Range Test 7B1-58. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7B1-59 . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE 7B1-59. . . . . . . . . . . .
Fluid Level 7B1-59. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Change 7B1-60. . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Hoses 7B1-61. . . . . . . . . . . . . . . . . . .
A / T THROTTLE CABLE 7B1-61. . . . . . . . . . . . . . .
MANUAL SELECTOR ASSEMBLY 7B1-62. . . . .
SELECT CABLE 7B1-63. . . . . . . . . . . . . . . . . . . . . TRANSMISSION RANGE SWITCH 7B1-64. . . . .
A
/
T OUTPUT SPEED SENSOR 7B1-64. . . . . . . .
O / D CUT SWITCH 7B1-64. . . . . . . . . . . . . . . . . . .
SOLENOID VALVES 7B1-64. . . . . . . . . . . . . . . . . .
THROTTLE POSITION SENSOR 7B1-66. . . . . . .
POWER / NORMAL CHANGE SWITCH 7B1-66. .
OIL COOLER PIPES 7B1-67. . . . . . . . . . . . . . . . . .
BRAKE INTERLOCK SYSTEM 7B1-68. . . . . . . . .
Shift Lock Solenoid Control 7B1-68. . . . . . . . . .
Shift Lock Solenoid Control Operations 7B1-68
Shift Lock (Solenoid) Manual Release 7B1-69.
System Inspection 7B1-69. . . . . . . . . . . . . . . . . .
KEY INTERLOCK CABLE 7B1-71. . . . . . . . . . . . .
DISMOUNTING OF TRANSMISSION
(WITH TRANSFER IF EQUIPPED) 7B1-74. . . .
REMOUNTING 7B1-77. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7B1-78 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7B1-78 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7B1-79 . . . . . .
SPECIAL TOOLS7B1-79 . . . . . . . . . . . . . . . . . . . . . .

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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
AUTOMATIC TRANSMISSION (4 A / T) 7B1-9
H25 Engine
1. PCM (ECM)
2. VSS
3. CMP sensor
4. TP sensor
5. ECT sensor
6. Brake pedal switch
7. A / T input speed sensor
8. A / T output speed sensor9. Transmission range switch
10. Shift solenoid-A
11. Shift solenoid-B
12. TCC solenoid
13. Data link connector
14. Cruise control module
15. ªPOWERº lamp
16. ªO / D OFFº lamp17. MIL
18. O / D cut switch
19. P / N change switch
20. 4WD low switch
21. Main relay
22. Ignition switch
23. Battery
24. PCM (ECM) connector terminal
(viewed from harness side) Bl / Y
Bl / G
W
OrC51-1-16
C51-1-8
C51-1-10
C51-1-9
12V

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VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-25
DIAGNOSTIC TROUBLE CODE (DTC) TABLE (A / T RELATED CODE) (cont'd)
DTC NO.MIL
Using
scan toolNot using
scan toolDETECTED ITEMDETECTING CONDITION
Vehicle
without
monitor
connectorVehicle
with
monitor
connector
*1
P0756
Not
applicableShift solenoid B (#2)
performance or stuck
offGear change control from PCM to
A / T does not agree with actual gear
position of A / T.2 driving
cyclesNot
applicable
P075863
64Shift solenoid B (#2)
electricalMonitor signal OFF is detected
when shift solenoid B (#2) is ON or
monitor signal ON is detected when
it is OFF.1 driving
cycleNot
applicable
*1
P1875
Not
applicable4WD low switch circuit
malfunctionDifference between vehicle speed
detected by VSS and vehicle speed
detected by output speed sensor
and compensated by 4WD low
switch is larger than specification.2 driving
cyclesNot
applicable
NOTE:
*1: Applicable to vehicle without monitor connector only.
FAIL-SAFE TABLE
When any of the following DTC is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues
to exist but that mode is canceled when ECM detects normal condition after that.
DTC NO.
Using
scan toolNot using
scan toolTROUBLE AREAFAIL SAFE OPERATION
P0177
P011814
15ECT SENSOR
Each control except 4-A / T is permitted on the basis of
30.1C engine coolant temp.

4-A / T control is performed assuming 31C (engine warmed
up) or higher after 15 min. from engine start.
P0122
P012321
22TP SENSOR
Each control except 4-A / T is performed on the basis of 124
throttle valve opening.

4-A / T control is performed on the basis of 0 throttle valve
opening.
P070572TR SWITCHA / T control is performed in priority order of L, 2, N, D, R
and P.
P072075OUTPUT SPEED
SENSOR CIRCUIT
MALFUNCTIONA / T control is performed by using signal from VSS.
P075361
62SHIFT SOLENOID
A (#1)
A / T control using 3rd gear is performed when D range, 1st
or 2nd gear is used.

TCC solenoid OFF.
P075863
64SHIFT SOLENOID
B (#2)
A / T control using 4th gear is performed when D range 2nd
or 3rd gear is used.

When both shift solenoid A (#1) and B (#2) failed
simultaneously, A / T control using 4th gear is always
performed in D range.

TCC solenoid OFF.
P074365
66TCC (Lock-up)
SOLENOIDTCC (lock-up) solenoid OFF.

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VITARA
7B1-28 AUTOMATIC TRANSMISSION (4 A / T)
Transmission fluid Running condition Running condition Gear shift
TROUBLE DIAGNOSIS TABLE 1
ConditionPossible CauseCorrection
TCC does not operate
Brake pedal (stop lamp) switch or its
circuit faulty (H25 engine only)

4WD low switch or its circuit faulty

Engine coolant temp. sensor or its
circuit faulty

Cruise control signal circuit faulty
(if equipped)DIAGNOSTIC FLOW TABLE A-1
Gear does not change
to 4th
O / D cut switch or its circuit faulty

4WD low switch or its circuit faulty

Engine coolant temp. sensor or its
circuit faulty

Cruise control signal circuit faulty
(if equipped)DIAGNOSTIC FLOW TABLE A-2
TROUBLE DIAGNOSIS TABLE 2
ConditionPossible CauseCorrection
Low fluid pressure
Clogged oil pump strainer

Malfunction of pressure regulator valveWash strainer.
Overhaul valve body.
High fluid pressure
Pressure regulator valveOverhaul valve body.
Unable to run in all
range
Regulator valve stickReplace.

Clogged oil strainerWash strainer.

Seized or broken planetary gearRepair or replace.

Faulty manual valveReplace.
Poor 1st speed run-
ning or excessive
slippage in ªDº or
ª2º
Faulty 1±2 shift valveReplace.
Poor 1±2 shift, ex-
ili

Regulator valve stickingReplace.
cessive slippage
1±2 shift valve stickingReplace.

Shift solenoid valve-B stickingReplace.

Intermediate coast modulator valve stick-
ingReplace.
Poor 2±3 shift, ex-
ili

2±3 shift valve stickingReplace.
cessive slippage
Shift solenoid valve-A stickingReplace.
Poor start or surg-
ing in ªDº range
Regulator valve stickingReplace.