2001 SUZUKI GRAND VITARA brake

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-15
Idle Speed/Idle Air Control (IAC) Duty Inspec-
tion
Before idle speed/IAC duty check, make sure of the following.
•Lead wires and hoses of engine/emission control systems
are connected securely.
•Accelerator cable is adjusted.
•Ignition timing is within specification.
•All accessories (wipers, heater, lights, A/C, etc.) are out of
service.
•Air cleaner has been properly installed and is in good condi-
tion.
•ECM (PCM) does not detect any malfunction DTC.
After above items are all confirmed, check idle speed and IAC
duty as follows.
[Using SUZUKI scan tool]
1) Connect SUZUKI scan tool to DLC with ignition switch OFF.
Special tool
(A) : SUZUKI scan tool
2) Warm up engine to normal operating temperature.
3) Check IAC duty and idle speed by using “Data List” mode of
SUZUKI scan tool.
Engine idle speed:
A/C OFF: 700 ± 50 r/min.
A/C ON: 750 ± 50 r/min.
IAC duty at specified idle speed:
5 – 40 % (at A/C OFF)
4) If duty and/or idle speed is out of specifications, check idle
air control system referring to “DIAG. FLOW TABLE B-4” in
Section 6-1.
5) Check that specified engine idle speed is obtained with A/C
ON if vehicle is equipped with A/C. If not, check A/C ON sig-
nal circuit and idle air control system. NOTE:
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
vehicle), and set parking brake and block drive wheels.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-39
HEATER INSPECTION
Refer to “HEATED OXYGEN SENSOR (SENSOR 1) HEATER
INSPECTION”
Vehicle speed sensor (VSS)
ON-VEHICLE INSPECTION
1) Hoist vehicle.
2) Release parking brake lever, set transmission in neutral and
transfer in “2H”.
3) Remove ECM (PCM) cover.
4) Connector voltmeter between VSS terminal C51-3-1 of ECM
(PCM) connector and body ground.
5) Turn ignition switch ON and turn rear right tire slowly with
rear left tire locked.
Voltmeter should indicate deflection between 0 – 1 V and 8 –
14 V a few times while tire (1) is turned one revolution.
If check result is not satisfactory, proceed to flow table of
“DTC P0500” in Section 6-1.
REMOVAL, INSPECTION AND INSTALLATION
Refer to “VSS Removal, Inspection or Installation” in Section 7D.
Manifold absolute pressure sensor
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from manifold absolute pressure sen-
sor.
3) Remove manifold absolute pressure sensor from intake
manifold.
[A]: Terminal arrangement of ECM (PCM) coupler
(viewed from harness side)
1. VSS

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-43
Fuel cut operation
INSPECTION
1) Warm up engine to normal operating temperature.
2) While listening to sound of injector by using sound scope (1)
or such, increase engine speed to higher than 3,000 r/min.
3) Check to make sure that sound to indicate operation of injec-
tor stops when throttle valve is closed instantly and it is
heard again when engine speed is reduced to less than
about 2,000 r/min. NOTE:
Before inspection, check to make sure that gear shift
lever is in Neutral position (with A/T model, selector lever
in “P” range) and that parking brake lever is pulled all the
way up.

6F2-6 IGNITION SYSTEM (FOR H27 ENGINE)
Ignition Spark Check
1) Remove surge tank cover.
2) Disconnect injector coupler (1).
3) Remove spark plug and check it for condition and type, refer-
ring to “SPARK PLUG” in this section.
4) If OK, connect ignition coil coupler to ignition coil assembly
and connect spark plug to ignition coil assembly. Ground
spark plug.
5) Crank engine and check if each spark plug sparks.
If no spark is emitted, inspect the related parts as described
under “DIAGNOSIS” in this section.
6) After checking, install spark plug, referring to “SPARK PLUG”
in this section.
7) Connect injector coupler (1).
8) Install surge tank cover.
Ignition Timing Check and Adjustment
1) Start engine and warm it up to normal operating tempera-
ture.
2) Make sure that all of electrical loads except ignition are
switched off.
3) Check to be sure that idle speed is within specification.
Refer to Section 6E2.
4) Connect SUZUKI scan tool to DLC (1) with ignition switch
OFF, restart engine and fix ignition timing by using fixed
spark mode of SUZUKI scan tool.
Special tool
(A) : SUZUKI scan tool WARNING:
Without disconnection of injector coupler, combustible
gas may come out from spark plug holes during this test
and may get ignited in engine room.
NOTE:
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
model), and set parking brake.

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

AUTOMATIC TRANSMISSION (4 A/T) 7B1-15
Trouble Diagnosis Table 1
Trouble Diagnosis Table 2
TRANSMISSION FLUID
RUNNING CONDITION
4 Perform stall test, time rag test, line pressure test,
engine brake test and “P” range test referring to
“STALL TEST”, “LINE PRESSURE TEST”, “ENGINE
BRAKE TEST” and ““P” RANGE TEST” in this section.
Are the test results satisfactory?Go to Step 5. Proceed to “TROUBLE
DIAGNOSIS TABLE 3” in
this section.
5 Proceed to “TROUBLE DIAGNOSIS TABLE 2” in this
section.
Is trouble identified?Repair or replace
defective parts.Proceed to “TROUBLE
DIAGNOSIS TABLE 3” in
this section. Step Action Yes No
Condition Possible Cause Correction
TCC does not operateBrake pedal (stop lamp) switch or its circuit
faulty (H25 engine only)Refer to “DIAGNOSTIC FLOW
TABLE A-1” in this section.
4WD low switch or its circuit faulty
Engine coolant temp. sensor or its circuit faulty
Cruise control signal circuit faulty (if equipped)
Gear does not change
to 4thO/D off switch or its circuit faulty Refer to “DIAGNOSTIC FLOW
TABLE A-2” in this section.
4WD low switch or its circuit faulty
Engine coolant temp. sensor or its circuit faulty
Cruise control signal circuit faulty (if equipped)
Condition Possible Cause Correction
Low fluid pressureClogged oil pump strainer Wash strainer.
Malfunction of pressure regulator valve Overhaul valve body.
High fluid pressurePressure regulator valve Overhaul valve body.
Condition Possible Cause Correction
Unable to run in all
rangeRegulator valve stick Replace.
Clogged oil strainer Wash strainer.
Seized or broken planetary gear Repair or replace.
Faulty manual valve Replace.
Poor 1st speed run-
ning or excessive slip-
page in “D” or “2”Faulty 1–2 shift valve Replace.

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.