transfer SUZUKI GRAND VITARA 2005 2.G Service Owner's Guide

YH4
GRAND
VITARA
7B1-34 AUTOMATIC TRANSMISSION (4 A / T)
Transfer gear
positionª4Lº or ªNº ª4Hº or ª2Hº
Voltage 0 VBattery
voltage
STEPACTIONYESNO
54WD LOW 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 6.Faulty 4WD LOW switch
or its circuit.
If OK, substitute a known-
good PCM and recheck.
6Is vehicle equipped with cruise control
system?Go to Step 7.Substitute a known-good
PCM and recheck.
7Cruise 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.

YH4
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.

YH4
GRAND
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.

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-51
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) Shift selector lever in D range and keep it for 10 seconds.
5) Drive vehicle about 30 km / h (20 mph) with 2nd gear in D range for 10 seconds.
6) Increase vehicle speed to about 80 km / h (50 mph) with 4th gear in D range and keep it for 10 seconds.
7) Release accelerator pedal, decrease vehicle speed and stop vehicle.
8) Check DTC and / or pending DTC.
TROUBLESHOOTING (DTC P0753 / P0758)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Is the vehicle equipped with monitor connector?Go to Step 3.Go to Step 4.
3Is DTC NO.61 or 63?Go to Step 4.Go to Step 6.
4Check Shift Solenoid Circuit for Open or Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Check for proper connection to PCM at terminals
C51-1-2 for G16 / J20 (C51-1-6 for H25) or C51-1-1.
3) If OK, then measure resistance between terminal
C51-1-2 for G16 / J20 (C51-1-6 for H25) or C51-1-1
of disconnected PCM connector and ground.
Is it 11 ± 15
at 20C, 68F?Go to Step 5.ªGº or ªG / Rº circuit
open or shorted to
ground.
If wire and
connections are OK,
replace malfunction
shift solenoid.
5Check Shift Solenoid Circuit for Short.
1) Turn ignition switch ON.
2) Measure voltage between terminal C51-1-2 for
G16 / J20 (C51-1-6 for H25) or C51-1-1 of
disconnected PCM connector and ground.
Is it about 0 V?Intermittent trouble or
faulty PCM.
Check for
ªIntermittent and
Poor Connectionº in
Section 0A.ªGº or ªG / Rº circuit
shorted to power
circuit.
6Check Shift Solenoid Circuit for Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Check for proper connection to PCM at terminals
C51-1-2 for G16 / J20 (C51-1-6 for H25) or C51-1-1.
3) If OK, then measure resistance between terminal
C51-1-2 for G16/J20 (C51-1-6 for H25) or C51-1-1
of disconnected PCM connector and ground.
Is it 11 ± 15
at 20C, 68F?Intermittent trouble or
faulty PCM.
Check for
ªIntermittent and
Poor Connectionº in
Section 0A.ªGº or ªG / Rº circuit
shorted to ground.

YH4
GRAND
VITARA
G16 / J20 Engines
H25 Engine
1. PCM
2. 4WD low switch
3. J / C
7B1-52 AUTOMATIC TRANSMISSION (4 A / T)
DTC P1875 4WD LOW SWITCH CIRCUIT MALFUNCTION (if equipped)
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While driving at higher than specified vehicle speed
and with more than specified throttle valve opening,
the following conditions are satisfied for specified time.

Vehicle speed sensed by vehicle speed sensor is
more than 10 km / h higher than that sensed by A / T
output speed sensor.
(2 driving cycles detection logic)
4WD LOW switch 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.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool.
3) Start engine.
4) Increase vehicle speed to about 30 km/h (19 mph) or more in D range and is in 2H position.
5) Keep driving at above vehicle speed for 30 seconds.
6) Stop vehicle and shift transfer lever to 4L position with A/T selector lever is in P range
7) Increase vehicle speed to about 25 km/h (15 mph) or more in D range and is in 4L position.
8) Keep driving at above vehicle speed for 30 seconds.
9) Stop vehicle and check pending DTC and DTC by using scan tool.

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
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.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-75
1. Drain plug
2. Filler and level plug
1. Drain plug
2. Front propeller shaft
1. Match marks
1. Right side transmission stiffener (if equipped)
G16 / J20
ON LIFT
1) Drain transfer oil for 4WD vehicle or A / T fluid for 2WD vehicle.
NOTE:
If 4WD automatic transmission is overhauled later on,
draining A / T fluid at this point will facilitate work.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
2) Before removing propeller shaft, give match marks on joint
flange and propeller shaft as shown in left figure.
3) Remove universal joint flange bolts and take out rear propeller
shaft.
4) Likewise, take out front propeller shaft. (if equipped)
5) Remove nut from the end of select cable and bracket to set
cable free.
6) Remove select cable bracket by removing its 2 bolts.
7) Remove exhaust No.1 and No.2 pipe.
8) Remove transmission stiffener (right side) if equipped.
9) Unclamp and disconnect oil cooler hoses from pipes.
NOTE:
To avoid leakage of transmission fluid, plug open ends of
oil cooler pipes and hoses right after they are discon-
nected.
10) Remove torque converter housing lower plate.
11) Holding drive plate stationary with special tool or the like, re-
move torque converter mounting bolts with wrench.
Special Tool (only for G16 / J20)
(A): 09927-56010