2001 SUZUKI GRAND VITARA oil level

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-41
INSTALLATION
1) Confirm that vacuum passage on intake manifold is free from
clog.
2) Apply engine oil to O-ring of sensor.
3) Install sensor (1) to intake manifold (2).
4) Connect connector to sensor (1) securely.
Fuel level sensor (sender gauge)
Refer to Section 8C.
Crankshaft position sensor
REMOVAL AND INSTALLATION
Refer to Section 6A4.
INSPECTION
Refer to Section 6-1.
Main relay
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove main relay (1) from its connector.
2. Fuel pump relay
3. Fuse box
4. Instrument panel
[A]: Left-hand steering vehicle
[B]: Right-hand steering vehicle

6F2-10 IGNITION SYSTEM (FOR H27 ENGINE)
CMP Sensor
REMOVAL
1) Disconnect CMP sensor coupler (2).
2) Remove A/T fluid level gauge and filler tube.
3) Remove CMP sensor (1) by removing bolt (3).
INSTALLATION
1) Install a new O-ring (2) with engine oil applied to CMP sen-
sor (1). CAUTION:
Disassembly is prohibited. If anything faulty is found,
replace as an assembly unit.
2
3
1
NOTE:
After installing CMP sensor, adjust ignition timing. (Refer
to “IGNITION TIMING CHECK AND ADJUSTMENT” in this
section).

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.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-39
Line Pressure Test
Purpose of this test is to check operating conditions of each part
by measuring fluid pressure in fluid pressure line. Line pressure
test requires following conditions.
•Automatic fluid is at normal operating temperature (70 to 80
°
C/158 – 176 °F).
•Fluid is filled to proper level (between FULL HOT and LOW
HOT on dipstick).
1) Apply parking brake securely and place checks against
wheels.
2) Attach oil pressure gauge to fluid pressure check hole (1) in
transmission case.
Special tool
(A) : 09925-37811-001
3) Depress foot brake fully, run engine at idle and stall.
4) Check fluid pressure in “D” or “R” range within the following
specification.
Line pressure :
5) If check result is OK, disconnect special tool, then tighten
transmission case plug to specified torque.
Tightening torque
Transmission case plug : 17 N·m (1.7 kg-m, 12.0 lb-ft) CAUTION:
After attaching oil pressure gauge, check that not fluid
leakage exists.
CAUTION:
Do not continue running engine at stall speed longer
than 5 seconds.
“D” range“R” range
Idle speed
4.1 – 4.6 kg/cm
2
58 – 65 psi5.4 – 6.0 kg/cm
2
77 – 85 psi
Stall speed
12.0 – 13.5 kg/cm
2
171 – 192 psi14.6 – 17.1 kg/cm
2
208 – 243 psi

7B1-40 AUTOMATIC TRANSMISSION (4 A/T)
TROUBLESHOOTING
Road Test
This test is to check if upshift and downshift take place at specified speed while actually driving vehicle on a
level road.
1) Warm up engine.
2) With engine running at idle, shift select lever “D”.
3) Accelerate vehicle speed by depressing accelerator pedal gradually.
4) While driving in “D” range, check if gear shift occurs properly as shown in “GEAR SHIFT DIAGRAM” in this
section.
TROUBLESHOOTING
Condition Possible cause
Line pressure higher than standard level in each
range•Malfunctioning regulator valve
•Malfunctioning throttle valve
•Maladjusted A/T throttle cable
Line pressure lower than standard level in each
range•Defective O/D clutch
•Defective oil pump
•Malfunctioning throttle valve
•Malfunctioning regulator value
•Maladjusted A/T throttle cable
Line pressure lower than standard level only in
“D” range•Fluid leakage from forward clutch
•Defective O/D clutch
•Leakage from “D” range fluid pressure circuit
Line pressure lower than standard level only in
“R” range•Fluid leakage from direct clutch
•Defective O/D clutch
•Fluid leakage from reverse brake
•Fluid leakage from “R” range fluid circuit
WARNING:
Carry out test in very little traffic area to prevent an accident.
Test requires 2 persons, a driver and a tester.
Condition Possible cause
When 1 → 2 upshift fails to occur 1–2 shift valve stuck
When 2 → 3 upshift fails to occur 2–3 shift valve stuck
When 3 → O/D upshift fails to occur 3–4 shift valve stuck
When gear shift point is incorrect•Maladjusted throttle cable
•Defective shift solenoid valve -A or -B
•1–2, 2–3 or 3–4 shift valve not operating properly

7B1-44 AUTOMATIC TRANSMISSION (4 A/T)
LEVEL CHECK AT ROOM TEMPERATURE
The fluid level check at room temperature (20 – 30 °C (68 – 86
°F)) performed after repair or fluid change before test driving is
just preparation for level check of normal operating temperature.
The checking procedure itself is the same as that described previ-
ously. If the fluid level is between FULL COLD and LOW COLD,
proceed to test drive. And when the fluid temperature has
reached the normal operating temperature, check fluid level again
and adjust it as necessary.
Fluid change
1) Lift up vehicle.
2) With engine is cool, remove drain plug (1) from oil pan and
drain A/T fluid.
3) Install drain plug (1).
Tightening torque
A/T fluid drain plug (a) :
23 N·m (2.3 kg-m, 17.0 lb-ft)
4) Lower vehicle and fill proper amount of an equivalent of
DEXRON
®-III.
5) Check fluid level referring to “LEVEL CHECK NORMAL
OPERATING TEMPERATURE” of “FLUID LEVEL” in this
section.
Fluid specification :
An equivalent of DEXRON
®-III
Fluid capacity
When draining from drain plug hole:
2.5 liters (5.28/4.40 US/lmp.pt.)
When overhauling:
6.8 liters (14.37/11.97 US/lmp.pt.)

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

DIFFERENTIAL (FRONT) 7E-3
Diagnosis
Differential Assembly Diagnosis Table
4WD Control System Diagnostic Flow Table
Before performing the trouble diagnosis, check that the transfer and front differential are in good condition and
there is no air leakage from air hoses and the actuator. Refer to “4WD CONTROL SYSTEM INSPECTION” in
this section for air leakage.
Notes on system circuit inspection
•Be sure to read “PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE” in Section 0A before circuit
inspection and observe what is written there.
•For system circuit, refer to the figure of “GENERAL DESCRIPTION” in this section.
•For terminal arrangement, refer to “4WD CONTROL CIRCUIT INSPECTION” in this section. Condition Possible Cause Correction
Gear noiseDeteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between bevel pinion and gear Adjust.
Improper tooth contact in the mesh between bevel pinion
and gearAdjust or replace.
Loose bevel gear securing bolts Replace or retighten.
Damaged side gear(s) or side pinion(s) Replace.
Bearing noise(Constant noise) Deteriorated or water mixed lubricant Repair and replenish.
(Constant noise) Inadequate or insufficientlubricant Repair and replenish.
(Noise while coasting) Damaged bearing(s) of bevel pinion Replace.
(Noise while turning) Damaged differential side bearing(s)
or axle bearing(s)Replace.
Oil leakageWorn or damaged oil seal Replace.
Excessive oil Adjust oil level.
Loose differential carrier bolts Replace or retighten.
2WD/4WD
switching errorDefective actuator Replace.
Abnormality in 4WD control system Inspect referring to “4WD
CONTROL SYSTEM DIAG-
NOSTIC FLOW TABLE”.