2001 SUZUKI GRAND VITARA torque

CHARGING SYSTEM 6H-1
6H
SECTION 6H
CHARGING SYSTEM
CONTENTS
General Description ....................................... 6H-2
Generator ..................................................... 6H-2
Unit Repair Overhaul ..................................... 6H-3
Generator Assembly .................................... 6H-3
Inspection ................................................. 6H-3Specifications................................................. 6H-6
Battery.......................................................... 6H-6
Generator ..................................................... 6H-6
Tightening Torque Specification .................. 6H-6

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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in Section 10B in order to confirm whether you are performing service on or
near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in Section 10B before performing service on or around the air
bag system components or wiring. Failure to follow WARNINGS could result in unintentional activa-
tion 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
“LOCK” 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.

6H-6 CHARGING SYSTEM
Specifications
Battery
Generator
Tightening Torque Specification
Battery type 55D23L 75D23L 95D26L
Rated capacity AH/5HR, 12 Volts 48 52 66
Electrolyte L (US/Imp.pt) 3.9 (8.24/6.86) 3.9 (8.24/6.86) 4.0 (8.53/7.04)
Electrolyte S.G. 1.28 when fully charged at 20°C (68°F)
Type 105 A type
Rated voltage 12 V
Nominal output 105 A
Permissible max. speed 18000 r/min.
No-load speed 1150 r/min (rpm)
Setting voltage 14.2 to 14.8 V
Permissible ambient temperature–30 to 90 °C (–22 to 194 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Nm kg-m lb-ft
Body ground bolt 8 0.8 6.0
Generator mounting bolts and nut 23 2.3 16.5
“B” terminal inner nut 3.6 0.37 3.0
“B” terminal outer nut 8 0.8 6.0
Generator pulley nut 111 11.2 81.5
Rear end frame nuts 4.5 0.45 3.5
Rear end cover nuts 4.5 0.45 3.5
Stator stud bolts 9.8 1.0 7.0
Drive end bearing plate screws 3.0 0.30 2.2
Rectifier screws 3.0 0.30 2.2
Regulator and brush holder screws 2.0 0.20 1.5
Terminal plate bolt 3.9 0.39 3.0

6K-2 EXHAUST SYSTEM
On-Vehicle Service
Components
TYPE WITH WELD BOLT AT MUFFLER FRONT FLANGE
1-1 Exhaust manifold (without WU-TWC) 4. Heated oxygen sensor-1 (if equipped) 7. Exhaust pipe bolt 11. Muffler tail pipe
1-2 Exhaust manifold (with WU-TWC) 5. Exhaust pipe gasket 8. Muffler 12. Muffler gasket
2. Seal ring 6-1 Exhaust No.2 pipe (without WU-TWC) 8-1. Weld bolt 13. No.1 Exhaust pipe stiffener
3-1 Exhaust No.1 pipe (without WU-TWC) 6-2 Exhaust No.2 pipe (with WU-TWC) 9. Muffler mounting Tightening Torque
3-2 Exhaust No.1 pipe (with WU-TWC) 6-3 Exhaust No.2 pipe (without TWC) 10. Heated oxygen sensor-2
(if equipped)Do not reuse

EXHAUST SYSTEM 6K-3
TYPE WITHOUT WELD BOLT AT MUFFLER FRONT FLANGE
1-1 Exhaust manifold (without WU-TWC) 4. Heated oxygen sensor-1 (if equipped) 7. Exhaust pipe bolt 12. Muffler gasket
1-2 Exhaust manifold (with WU-TWC) 5. Exhaust pipe gasket 8. Muffler 13. No.1 Exhaust pipe stiffener
2. Seal ring 6-1 Exhaust No.2 pipe (without WU-TWC) 9. Muffler mounting Tightening Torque
3-1 Exhaust No.1 pipe (without WU-TWC) 6-2 Exhaust No.2 pipe (with WU-TWC) 10. Heated oxygen sensor-2
(if equipped)Do not reuse
3-2 Exhaust No.1 pipe (with WU-TWC) 6-3 Exhaust No.2 pipe (without TWC) 11. Muffler tail pipe

7B1-2 AUTOMATIC TRANSMISSION (4 A/T)
Stall Test ................................................... 7B1-38
Line Pressure Test .................................... 7B1-39
Road Test ................................................. 7B1-40
Manual Road Test..................................... 7B1-41
Time Lag Test ........................................... 7B1-41
Engine Brake Test .................................... 7B1-42
“P” Range Test.......................................... 7B1-42
On-Vehicle Service ..................................... 7B1-43
Maintenance Service ................................ 7B1-43
Fluid level .............................................. 7B1-43
Fluid change.......................................... 7B1-44
A/T Throttle Cable ..................................... 7B1-45Solenoid Valves (Shift Solenoid Valves
and TCC Solenoid Valve) ......................... 7B1-45
MANUAL SELECTOR ASSEMBLY .......... 7B1-46
SELECT CABLE ....................................... 7B1-48
Unit Repair .................................................. 7B1-49
Sub-Assembly Repair ............................... 7B1-49
Overdrive (case side) ............................ 7B1-49
Forward clutch ...................................... 7B1-50
Front upper valve body ......................... 7B1-54
Unit Assembly ........................................... 7B1-59
Tightening Torque Specification............... 7B1-60
Special Tool ................................................ 7B1-61

AUTOMATIC TRANSMISSION (4 A/T) 7B1-3
General Description
Item Specifications
Torque
converterType 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism)
Stall torque ratio 2.0
Oil pump Type Trochoid type oil pump
Drive system Engine driven
Gear
change
deviceType Forward 4-step, reverse 1-step planetary gear type
Shift position“P” range Gear in neutral, output shaft fixed, engine start
“R” range Reverse
“N” range Gear in neutral, engine start
“D” range
(O/D ON)Forward 1st ↔ 2nd ↔ 3rd ↔ 4th (O/D)
automatic gear change
“D” range
(O/D OFF)Forward 1st ↔ 2nd ↔ 3rd
automatic gear change
“2” range (Normal mode) Forward 1st ↔ 2nd ← 3rd auto-
matic gear change
(Power mode) Forward 2nd ← 3rd automatic gear
change and fixed at 2nd gear
“L” range Forward 1st ← 2nd ← 3rd reduction, and fixed at
1st gear
Gear
ratio1st
(low gear)2.826
2nd
(second gear)1.493
3rd
(top gear)1.000
4th
(overdrive gear)0.689
Reverse
(reverse gear2.703
Control elements Wet type multi-disc clutch ... 3 sets
Wet type multi-disc brake ... 4 sets
One-way clutch ... 3 sets
Transfer Hi : 1.000
Lo : 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used
An equivalent of DEXRON
III

7B1-16 AUTOMATIC TRANSMISSION (4 A/T)
GEAR SHIFT
Trouble Diagnosis Table 3
TRANSMISSION FLUID
RUNNING CONDITION
Condition Possible Cause Correction
Poor 1–2 shift, exces-
sive slippageRegulator valve sticking Replace.
1–2 shift valve sticking Replace.
Shift solenoid valve-B sticking Replace.
Intermediate coast modulator valve sticking Replace.
Poor 2–3 shift, exces-
sive slippage2–3 shift valve sticking Replace.
Shift solenoid valve-A sticking Replace.
Poor start or surging
in “D” rangeRegulator valve sticking Replace.
Poor 3-4 shift, exces-
sive slippage3–4 shift valve sticking Replace.
Shift solenoid valve-B sticking Replace.
Excessive shock on
1–2 shiftRegulator valve sticking Replace.
Faulty accumulator, second brake piston Replace.
Excessive shock on
2–3 shiftRegulator valve sticking Replace.
Faulty accumulator, direct clutch piston Replace.
Excessive shock on
3–4 shiftRegulator valve sticking Replace.
Non operate lock-up
systemTCC (Lock-up) control valve sticking Replace.
Solenoid valve No.2 (TCC solenoid valve) stick-
ingReplace.
Condition Possible Cause Correction
Low fluid pressureLeakage from oil pressure circuit Overhaul.
Condition Possible Cause Correction
Unable to run in all
rangeWear in oil pump Replace.
Seizure in oil pump Replace.
Fluid pressure leakage to over drive clutch due
to wear of oil pump bushingReplace.
Faulty in torque converter Replace.
Poor 1st speed run-
ning or excessive slip-
page in “D” or “2”Fluid pressure leakage from forward clutch due
to wear or breakage of O/D case seal ringReplace.
Overdrive clutch slipping Replace.
Unable to run or
excessive slippage in
“L” rangeFluid pressure leakage of forward clutch due to
wear or breakage of O/D case seal ringReplace.
Reverse brake disc slipping Replace.
Broken brake piston O-ring Replace.
Unable to run or
excessive slippage in
“R” rangeFluid pressure leakage to direct clutch due to
wear or breakage of center support seal ringReplace.
Worn direct clutch Replace.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-17
GEAR SHIFT
ABNORMAL NOISE
Scan Tool Data
Refer to Section 6-1.
Inspection of PCM and Its Circuit
Refer to Section 6-1.
Wire Harness and Connectors
Refer to Section 6-1.Condition Possible Cause Correction
Poor 1–2 shift, exces-
sive slippageFluid pressure leakage to overdrive clutch due
to wear or breakage of O/D case seal ringReplace.
Faulty second brake Replace.
Broken O-ring of second brake piston Replace.
Faulty second coast brake (in “2” range) Replace.
Poor 2–3 shift, exces-
sive slippageFluid pressure leakage to overdrive clutch due
to wear or breakage of O/D case seal ringReplace.
Worn direct clutch bushing Replace.
Direct clutch slipping Replace.
Foreign material caught in direct clutch piston
check ballReplace.
Poor start or surging
in “D” rangeFluid pressure leakage of forward clutch due to
wear or breakage of O/D case seal ringReplace.
Malfunction of forward clutch Replace.
Poor 3–4 shift, exces-
sive slippageFaulty overdrive brake Replace.
Faulty overdrive clutch Replace.
Poor start or juddering
in “R” rangeFluid pressure leakage of direct clutch due to
wear or breakage of oil center support seal ringReplace.
Worn direct clutch Replace.
Excessive shock on
1– 2 shiftFaulty one-way clutch Replace.
Non operate lock-up
systemFaulty torque converter Replace.
Condition Possible Cause Correction
Abnormal noise in “P”
or “N” rangeWorn oil pump Replace.