2001 SUZUKI GRAND VITARA Lock

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) 7B1-45
A/T Throttle Cable
ADJUSTMENT
1) Pull inner cable (3) by force of 2 N (0.2 kg, 0.45 lb) or less to
be no slack of inner cable with A/T throttle cable (1) curved
as shown in the figure.
2) Fix stopper (2) to inner cable (3) with clearance “c”.
A/T throttle cable adjusting position (clearance “c”) :
0.8 – 1.5 mm (0.03 – 0.06 in.)
3) Warm up engine and transmission to normal operating tem-
perature.
4) Make sure that accelerator cable is adjusted as specified.
5) With throttle valve closed, check clearance “c”, which should
be within the following specification, of A/T throttle cable (1).
If it is out of specification, adjust it by turning cable adjusting
nut (2).
A/T throttle cable adjusting position (clearance “c”) :
0.8 – 1.5 mm (0.03 – 0.06 in.)
6) Tighten lock nut (3) securely.
Solenoid Valves (Shift Solenoid Valves and
TCC Solenoid Valve)
INSPECTION
With PCM couplers disconnected and using service wire as
shown in the figure, check each solenoid valve for clicking sound.
Shift solenoid valve - A (#1) C51-1-2
Shift solenoid valve - B (#2) C51-1-1
TCC (Lock-up) solenoid valve C51-1-8

7B1-46 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 sole-
noid (if equipped) and overdrive OFF switch (if equipped).
4) Remove selector assembly mounting bolts.
5) Disconnect selector cable (1) from manual selector assem-
bly (2) expanding selector cable clip (3).
INSTALLATION
Reverse removal procedure to install manual selector assembly
noting the following instructions.
•Make sure that selector cable clip (3) hold selector cable (1)
on manual selector assembly (2) securely.
•Tighten manual selector assembly mounting bolts as speci-
fied torque.
Tightening Torque
Manual selector assembly mounting bolts :
18 N·m (1.8 kg-m, 13.5 lb-ft)
•Connect interlock cable end to cam referring to step 2) to 8)
of “Interlock cable installation” of the service manual men-
tioned in FOREWORD of this manual, if necessary.
•Confirm that brake (key) interlock system operates properly
(if equipped).
1. Manual lever assembly 4. Bulb filter 7. Shift lock solenoid (if equipped)
2. Select indicator assembly 5. Bulb 8. Manual selector assembly mounting bolt
3. Illumination assembly 6. knob assembly Tightening torque

7B1-48 AUTOMATIC TRANSMISSION (4 A/T)
SELECT CABLE
ADJUSTMENT
1) Loosen manual shift lever (select cable side) nut (1).
2) Shift select lever to “N” range.
3) Align center line (2) on manual valve shaft (3) to “N” refer-
ence line (4) as shown.
4) Tighten manual shift lever nut (selector cable side) (1) as
specified torque.
Tightening torque
Manual shift lever nut (a) :
23 N·m (2.3 kg-m, 17.0 lb-ft)
5) After select cable was installed, check for the following.
•Push vehicle with selector lever shifted to “P” range.
Vehicle should not move.
•Vehicle can not be driven in “N” range.
•Vehicle can be driven in “D”, “2” and “L” ranges.
•Vehicle can be backed in “R” range.
1. Selector lever assembly 6. Washer 11. Transmission range switch assembly
2. Selector lever assembly mounting bolt 7. Clip 12. Transmission range switch mounting bolt
3. Selector cable 8. Manual select lever nut (transmission range switch side) 13. Manual select lever nut (selector cable side)
4. Cable bracket 9. Lock washer 14. Selector cable clip
5. Cable bracket mounting bolt 10. Manual select lever Tightening Torque
24
3
1, (a)

AUTOMATIC TRANSMISSION (4 A/T) 7B1-55
LOWER VALVE BODY
1. Lower valve body 7. TCC (Lock-up) control valve plate 13. Primary regulator valve sleeve
2. Spring 8. TCC (Lock-up) control valve gasket 14. Primary regulator valve plunger
3. Pressure relief valve ball 9. TCC (Lock-up) control sleeve 15. Primary regulator valve
4. Pressure relief valve retainer 10. TCC (Lock-up) control valve 16. Spacer
5. Lower valve body plate 11. Pin
6. Lower valve body gasket 12. Retainer

7B1-56 AUTOMATIC TRANSMISSION (4 A/T)
DISASSEMBLY
1) Remove bypass valve (1), bypass valve spring, check ball
valve damping spring, valve body ball (2) and ball valve
spring.
2) Remove lower valve body plate (1) and lower valve body
plate gasket.
3) Remove TCC (lock-up) control valve plate (2) and TCC
(lock-up) control valve gasket.
4) With pressure relief valve retainer (1) pressed with finger,
remove pressure relief valve bolt and then remove pressure
relief valve retainer (1), pressure relief valve spring and pres-
sure relief valve ball.
5) Remove TCC (lock-up) solenoid valve (1) and Then remove
O-ring (2) from TCC solenoid valve (1).
3. Check ball
4. Primary regulator valve sleeve retainer
5. Locating pin

AUTOMATIC TRANSMISSION (4 A/T) 7B1-57
6) After removing shift solenoid valve (A & B) (1), remove sole-
noid valve gasket, low coast modulator valve spring (2), inter
coast modulator valve spring (3) and 2 intermediate coast
modulator valves (4).
7) Pressing TCC (lock-up) control sleeve with finger and using
magnet (1), remove locating pin and then remove TCC (lock-
up) control sleeve, TCC (lock-up) control valve and TCC
(lock-up) control valve spring.
8) Check which step of primary regulator valve sleeve (1) (how
many steps down from its tip) contacts primary regulator
valve sleeve retainer (2).
9) Pressing primary regulator valve sleeve (1) with finger and
using magnet, remove primary regulator valve sleeve
retainer and then remove primary regulator valve sleeve (1),
spacer (2), primary regulator valve plunger (3), primary regu-
lator valve spring (4) and primary regulator valve (5).

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