2001 SUZUKI GRAND VITARA ig meter

AUTOMATIC TRANSMISSION (4 A/T) 7B1-7
Diagnosis
This vehicle is equipped with an electronic transmission control system, which control the automatic shift up and
shift down timing, TCC operation, etc. suitably to vehicle driving conditions.
PCM (ECM) has an On-Board Diagnosis system which detects a malfunction in this system and abnormality of
those parts that influence the engine exhaust emission.
When diagnosing a trouble in the transmission including this system, be sure to have full understanding of the
outline of “ON-BOARD DIAGNOSTIC SYSTEM” and each item in “PRECAUTION IN DIAGNOSING TROUBLE”
and execute diagnosis according to “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE” to obtain
correct result smoothly.
On-Board Diagnostic System (Vehicle without
monitor connector)
For automatic transmission control system, PCM (ECM) has fol-
lowing functions. Refer to Section 6-1 for details.
•When the ignition switch is turned ON with the engine at a
stop, malfunction indicator lamp (MIL) (1) turns ON to check
the bulb of the MIL.
•When PCM detects a malfunction in A/T control system
(and/or a malfunction which gives an adverse effect to vehi-
cle emission) while the engine is running, it makes the mal-
function indicator lamp in the meter cluster of the instrument
panel turn ON and stores the malfunction area.
(If it detects that continuously 3 driving cycles are normal
after detecting a malfunction, however, it makes MIL (1) turn
OFF although DTC stored in its memory will remain.)
•It is possible to communicate through DLC (3) by using not
only SUZUKI scan tool (2). (Diagnostic information can be
accessed by using a scan tool (2).)
2 DRIVING CYCLE DETECTION LOGIC
Refer to Section 6-1 for details.
PENDING DTC
Refer to Section 6-1 for details.
FREEZE FRAME DATA
Refer to Section 6-1 for details.

7B1-14 AUTOMATIC TRANSMISSION (4 A/T)
Diagnostic Trouble Code Table
Refer to the same item in Section 6-1.
Fail Safe Table
Refer to the same item in Section 6-1.
Visual Inspection
Visually check following parts and systems.
A/T Basic Check
This inspection is important for troubleshooting when PCM (ECM) has detected no DTC and no abnormality has
been noted in visual inspection. Follow flow table carefully.INSPECTION ITEM REFERRING SECTION
•A/T fluid - - - - - level, leakage, color SECTION 0B
•A/T fluid hoses - - - - - disconnection, looseness, deterioration SECTION 7B1
•Throttle (accelerator) cable - - - - - play, installation SECTION 6E2
•A/T throttle cable - - - - - play, installation SECTION 7B1
•A/T select cable - - - - - installation, operation SECTION 7B1
•Engine oil - - - - - level, leakage SECTION 0B
•Engine coolant - - - - - level, leakage SECTION 0B
•Battery - - - - - fluid level, corrosion of terminal
•Connectors of electric wire harness - - - - - disconnection, friction Section 6-1 or 7B1
•Fuses - - - - - burning SECTION 8
•Parts - - - - - installation, damage
•bolt - - - - - looseness
•Other parts that can be checked visually
•Also check following items at engine start, if possible.
–“O/D OFF” lamp - - - - - Operation SECTION 7B1
–“POWER” lamp - - - - - Operation SECTION 7B1
–Malfunction indicator lamp (“SERVICE ENGINE SOON” lamp) - -
- - - OperationSection 6-1
–Charge warning lamp - - - - - Operation SECTION 6H
–Engine oil pressure warning lamp - - - - - Operation SECTION 8C (SECTION 6A2 for pres-
sure check)
–Engine coolant temp. meter - - - - - Operation
–Other parts that can be checked visually
Step Action Yes No
1Was “AUTOMATIC TRANSMISSION DIAGNOSTIC
FLOW TABLE” performed?Go to Step 2. Go to “AUTOMATIC
TRANSMISSION DIAG-
NOSTIC FLOW TABLE”.
2Perform “MANUAL ROAD TEST” in this section.
Is it OK?Go to Step 3. Go to Step 4.
3Proceed to “TROUBLE DIAGNOSIS TABLE 1” in this
section.
Is trouble identified?Repair or replace
defective parts.Go to Step 5.

7B1-38 AUTOMATIC TRANSMISSION (4 A/T)
Stall Test
This test is to check overall performance of automatic transmission and engine by measuring stall speed at “D”
and “R” ranges. Be sure to perform this test only when transmission fluid is at normal operating temperature and
its level is between FULL and LOW marks.
1) Apply parking brake and block wheels.
2) Install tachometer.
3) Start engine with select lever shifted to “P”.
4) Depress brake pedal fully.
5) Shift select lever to “D” and depress accelerator pedal fully while watching tachometer. Read engine rpm
quickly when it has become constant (stall speed).
6) Release accelerator pedal immediately after stall speed is checked.
7) In the same way, check stall speed in “R” range.
8) Stall speed should be within the following specification.
Stall speed :
2,460 – 2,760 r/min.
TROUBLESHOOTING
CAUTION:
Do not run engine at stall more than 5 seconds continuously, for fluid temperature may rise exces-
sively high.
After performing stall test, be sure to leave engine running at idle for longer than 30 seconds before
another stall test.
Condition Possible cause
Lower than standard level•Faulty engine output
•Defective torque converter
Higher than standard level in “D” range•Slippery O/D clutch
•Slippery forward clutch
•Malfunctioning O/D one-way clutch
•Malfunctioning one-way clutch No. 2
•Low line pressure
Higher than standard level in “R” range•Slippery direct clutch
•Slippery reverse brake
•Low fluid pressure
•Slippery O/D clutch
•Defective O/D one-way clutch

AUTOMATIC TRANSMISSION (4 A/T) 7B1-43
On-Vehicle Service
Maintenance Service
Fluid level
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal oper-
ating temperature (70 – 80 °C (158 – 176 °F)). As a guide to
check fluid temperature, warm up engine till engine coolant
temperature meter indicated around 1 unit above “C” point.
5) Keep engine idling and shift selector slowly to “L” and back
to “P” position.
6) With engine idling, pull out dipstick, wipe it off with a clean
cloth and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it.
Fluid level should be between FULL HOT and LOW HOT. if it
is below LOW HOT, add an equivalent of DEXRON
®-III up to
FULL HOT.
Fluid specification :
An equivalent of DEXRON
®-III
[A] : Shift the select lever with its button pushed in.
[B] : Shift the select lever without pushing its button.
NOTE:
DO NOT RACE ENGINE while checking fluid level, even
after the engine start.
DO NOT OVERFILL. Overfilling can causes foaming
and loss of fluid through breather. Then slippage and
transmission failure can result.
Bringing the level from LOW HOT to FULL HOT
requires 0.3 liters (0.64/0.53 US/lmp.pt).
If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour
after it is stopped.

7B1-54 AUTOMATIC TRANSMISSION (4 A/T)
6) Install direct clutch cylinder to center support.
Remove direct clutch piston by blowing air into the second
hole from the left as shown in the figure. Also, remove direct
clutch inner piston by blowing air into hole at the extreme
right. And then remove O-rings from pistons.
Front upper valve body
ASSEMBLY
Assemble each component by reversing disassembly procedure
and noting the following points.
•Coil outer diameter and free length of each valve spring
should be as listed below. Be sure to use each one of correct
size.
Coil outer diameter and free length of each valve spring
•Install as many throttle valve compensating rings as written
down when disassembled.
•Tighten throttle cam bolt (1) to specified torque.
Tightening torque
Throttle cam bolt (a) : 7.5 N·m (0.75 kg-m, 5.5 lb-ft)
•Tighten pressure relief valve bolts (1) to specified torque.
Tightening torque
Pressure relief valve bolt (b) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
Name of spring Outer diameter Free length
Secondary regulator
valve spring17.43 mm
(0.681 in.)71.27 mm
(2.806 in.)
Cut back valve spring 6.85 mm
(0.259 in.)23.0 mm
(0.906 in.)
Throttle valve
secondary spring8.56 mm
(0.337 in.)18.86 mm
(0.743 in.)
Throttle valve
primary spring10.90 mm
(0.429 in.)39.55 mm
(1.557 in.)

7B1-58 AUTOMATIC TRANSMISSION (4 A/T)
ASSEMBLY
Assemble each component by reversing disassembly procedure
and noting the following points.
•Coil outer diameter and free length of each valve spring
should be as listed below. Be sure to use each one of correct
size.
Coil outer diameter and free length of each valve spring :
•Install primary regulator valve sleeve so that its tip is posi-
tioned as it was before disassembly.
•Use new TCC (lock-up) control valve gasket, solenoid gas-
ket and lower valve body plate gasket.
•Tighten shift solenoid valve bolt to specified torque.
Tightening torque
Shift solenoid valve bolt : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Name of spring Outer diameter Free length
Pressure relief valve spring 13.14 mm (0.517 in.) 32.14 mm (1.265 in.)
TCC (Lock-up) control valve
spring11.40 mm (0.449 in.) 32.60 mm (1.283 in.)
Valve damping spring 4.95 mm (0.195 in.) 20.00 mm (0.787 in.)
Low coast modulator valve spring 10.00 mm (0.394 in.) 42.35 mm (1.667 in.)
Inter coast modulator valve
spring9.04 mm (0.356 in.)
(G16 and J20 engines)27.26 mm (1.073 in.)
(G16 and J20 engines)
10.00 mm (0.394 in.)
(H25 and H27 engine)25.60 mm (1.008 in.)
(H25 and H27 engine)
Ball valve spring 10.5 mm (0.413 in.) 13.7 mm (0.539 in.)
Bypass valve spring 13.82 mm (0.544 in.) 28.90 mm (1.138 in.)
Primary regulator valve spring 17.02 mm (0.670 in.) 50.28 mm (1.980 in.)
1. Solenoid valve No. 1 (Shift solenoid valve)
2. Low coast modulator valve spring
3. Inter coast modulator valve spring
4. Intermediate coast modulator valve
5. Low coast modulator valve

7B1-60 AUTOMATIC TRANSMISSION (4 A/T)
Accumulator piston and spring specification :
Tightening Torque Specification
Used forPiston outer
diameter “a”Spring free length “b”
Direct clutch accumulator (2)31.80 – 31.85 mm
(1.252 – 1.254 in.)Upper spring 43.56 mm (1.715 in.)
Lower spring 30.00 mm (1.181 in.)
Forward clutch accumulator (1)31.80 – 31.85 mm
(1.252 – 1.254 in.)Upper spring 57.18 mm (2.251 in.)
Lower spring 30.50 mm (1.201 in.)
Second brake accumulator (3)34.80 – 34.85 mm
(1.370 – 1.372 in.)Upper spring 56.16 mm (2.211 in.)
Lower spring 18.5 mm (0.728 in.)
Fastening partTightening torque
Nm kg-m lb-ft
Automatic transmission fluid drain plug 23 2.3 17.0
Transfer oil level/filler and drain plugs 23 2.3 17.0
Transmission case plug 17 1.7 12.5
Manual select lever nut 13 1.3 9.5
Manual select cable nut 7 0.7 5.5
Manual selector assembly bolts 18 1.8 13.5
Transmission to engine bolts and nuts 85 8.5 61.5
Engine rear mounting bolts
Engine rear mounting member bolts50 5.0 36.5
Universal joint flange bolts and nuts 50 5.0 36.5
Torque converter mounting bolts 65 6.5 47.0
Adapter case or extension case bolts 42 4.2 30.0
Transmission range switch lock bolt 5.5 0.55 4.0
Oil pipe union bolts 35 3.5 22.5
Drive plate bolts 78 7.8 56.5
Interlock cable clamp screw 2.2 0.22 1.5
Interlock cable outer mounting nut 13 1.3 9.5

7E-4 DIFFERENTIAL (FRONT)
Flow table
Step Action Yes No
1 Turn ON ignition switch (but engine at stop) and
check malfunction indicator lamp.
Does lamp light up?Go to step 2. A trouble has occurred
at some place. Repair
it referring to
MALFUNCTION INDI-
CATOR LAMP
(“CHECK ENGINE”
LAMP) CHECK in
DIAGNOSIS of Sec-
tion 6.
2 Check 4WD switch circuit.
Turn ignition switch ON and check that voltage
between terminal C51-3-7 and terminal C51-3-17
(ground) is as follows.
 When transfer shift lever is in N or 2H : 10 – 14 V
 When transfer shift lever is in 4L or 4H : 0 – 1 V
Is the check result satisfactory?Go to step 3. Check 4WD switch
(refer to Section 7A),
“BLK/ORN” and “BLK”
circuits of 4WD switch.
If OK, substitute a
known-good ECM
(PCM) and recheck.
3 Check power supply.
1) Turn ignition switch ON.
2) Check voltage between C51-1-9 and C51-3-17
(ground). The check results should be as follows.
 When transfer shift lever is in N or 2H : 0 – 1 V
 When transfer shift lever is in 4L or 4H : 10 – 14 V
Is the check result satisfactory?Go to step 4. Check “RED” circuit. If
it is OK, substitute a
known-good ECM
(PCM) and recheck.
4 Check air pump assembly circuit.
1) Check for proper connection to air pump assem-
bly at all terminals.
2) Turn ignition switch ON.
3) Check voltage between C51-3-18 and C51-3-17
(ground). The check result should be as follows.
 When transfer shift lever is in 2H or N : 0 – 1 V
 When transfer shift lever is in 4L or 4H (more than
4 seconds after shifted to 4L or 4H) : 10 – 14 V
Is the check result satisfactory?Go to step 5. Check air pump
assembly referring to
“ON-VEHICLE SER-
VICE”, and then
“PNK” circuit.
If OK, substitute a
known-good ECM
(PCM) and recheck.
5 Check 4WD indicator lamp circuit.
1) Turn ignition switch ON.
2) Check voltage between E61-19 and C51-3-17
(ground). The check result should be as follows.
 When transfer shift lever is in 2H or N : 10 – 14 V
 When transfer shift lever is in 4L or 4H : 0 – 1 V
Is the check result satisfactory?4WD control system is
in good condition.Check “ORN/BLK” cir-
cuit (including indica-
tor lamp and
combination meter).
If OK, substitute a
known-good ECM
(PCM) and recheck.