1999 SUZUKI GRAND VITARA tightening torque

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.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-63
1. Select lever assembly
2. Bolt
3. Select cable
4. Cable bracket
5. Bolt
6. Blank
7. Washer
8. Clip
9. Nut
10. Manual select lever
11. Lock washer
12. Nut
13. Select cable joint
14. Bush
15. Washer
16. E-ring
17. Transmission range switch assembly
18. Bolt
1. Transmission range
sensor (switch)
2. Select cable
3. Manual shift lever
4. Select cable joint
1. Select cable joint
A. Align with cable joint
B. Tighten with wrench
Tightening Torque
(a): 13 N.m (1.3 kg-m, 9.5 lb-ft)
(b): 7 N.m (0.7 kg-m, 5.5 lb-ft)
INSPECTION
Check select lever for smooth and clear-cut movement and position
indicator for correct indication.
For operation of select lever, refer to left figure.
SELECT CABLE
ADJUSTMENT
1) Before tightening cable end nut, shift select lever to ªNº.
2) Also shift manual shift lever to ªNº.
NOTE:

Make sure that nut and cable joint have clearance under
above conditions.

If select cable has been moved, push it in arrow C direc-
tion as shown in figure at the left till it stops and then con-
firm that select lever is in ªNº position.
3) Turn nut A by hand till it contacts manual select cable joint.
Then tighten nut B with wrench.
4) After select cable was installed, check for the following.

Push vehicle with select lever shifted to ªPº.
Vehicle should not move.

Vehicle can not be driven in ªNº.

Vehicle can be driven in ªDº, ª2º, and ªLº.

Vehicle can be backed in ªRº.

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-67
1. Oil cooler pipes
2. Union gaskets
3. Pipe bolt
OIL COOLER PIPES
REMOVAL
1) Lift up vehicle.
2) Make sure to wash dirt off from around pipe joints.
3) With engine is cool, loosen oil cooler pipe union bolts with oil out-
let union locked and remove oil cooler pipes from oil outlet
unions and hoses.
NOTE:
To avoid fluid leakage, plug open ends of oil outlet unions
and hoses right after they are disconnected.
INSTALLATION
1) Use new union gaskets and connect oil cooler pipes to oil outlet
unions.
2) Connect hoses to pipes and clamp them securely.
3) Tighten union bolts to specified torque with oil outlet union
locked.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
4) Tighten pipe bolt securely.
5) Check A / T fluid level according to procedure described in ªFluid
Levelº section.
Add if necessary.
6) Check for fluid leakage after warming up A / T.

YH4
GRAND
VITARA
1. Ignition switch assembly
2. Clamp screw
3. Outer end
1. Interlock cable
2. Steering column
3. Steering column
holder
Type-1
1. Interlock cam
2. Lever plate
3. Interlock cable
4. Pin with 4 mm (0.15 in.) dia.
7B1-72 AUTOMATIC TRANSMISSION (4 A / T)
Installation
1) Shift select lever to ªNº range and turn ignition key to ªACCº
position.
2) Connect inner end of interlock cable to key interlock lever (Igni-
tion switch side).
3) Install outer end bracket of interlock cable to ignition switch as-
sembly, and tighten screw to specified torque.
Tightening Torque
(a): 2.2 N
.m (0.22 kg-m, 1.5 lb-ft)
4) Pass and connect interlock cable as shown at the left figure.
TYPE-1
5) Fix interlock cam by inserting pin with about 4 mm (0.15 in.) dia.
into holes of cam and lever plate.
6) Install cable end to interlock cam and stud bolt and after making
sure that cable outer is pushed in arrow direction B by leaf
spring, tighten mounting nut to specified torque. Remove pin.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
7) Turn ignition key to ªACCº position and shift select lever to ªNº
range, and check for the followings.
a. When select lever is shifted at ªPº range with knob button
depressed, ignition key can not be turned from ªACCº to
ªLOCKº position.
b. When knob button is released, ignition key can be turned to
ªLOCKº position.
c. When ignition key is at ªLOCKº position, select lever can not
be shifted from ªPº to any other range.
8) Install console box.
9) Install steering column cover.
10) Adjust steering column or tighten steering column bolts.
11) Install steering column hole cover.
12) If equipped with air bag system, enable air bag system.
Refer to ªEnabling Air bag Systemº in Section 10B.

YH4
GRAND
VITARA
1. Inner end of interlock cable
2. Key release cam
1. Key release cam
2. Cable outer(a)
Type-2
Type-2
AUTOMATIC TRANSMISSION (4 A / T) 7B1-73
TYPE-2
5) With key release cam set as shown at the left figure, connect
inner end of interlock cable to key release cam. (Select lever
side.)
6) Move key release cam so that it is set at such angle as shown
at the left figure and with special tool inserted in hole A , fix key
release cam.
Special Tool
(A): 09925-78210 (6 mm)
7) With key release cam fixed with special tool, install cable outer
to bracket and after making sure that cable outer is pushed in
arrow direction B by leaf spring, tighten mounting nut to speci-
fied torque. Remove special tool.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
8) Turn ignition key to ªACCº position and shift select lever to ªNº
range, and check for the followings.
a. When select lever is shifted at ªPº range with knob button
depressed, ignition key can not be turned from ªACCº to
ªLOCKº position.
b. When knob button is released, ignition key can be turned to
ªLOCKº position.
c. When ignition key is at ªLOCKº position, select lever can not
be shifted from ªPº to any other range.
9) Install console box.
10) Install steering column cover.
11) Adjust steering column or tighten steering column bolts.
12) Install steering column hole cover.
13) If equipped with air bag system, enable air bag system.
Refer to ªEnabling Air bag Systemº in Section 10B.

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

YH4
GRAND
VITARA
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.