2001 SUZUKI GRAND VITARA Section 8a

MANUAL TRANSMISSION 7A1-1
7A1SECTION 7A1
MANUAL TRANSMISSION
CONTENTS
Unit Repair .....................................................7A1-1

Unit Repair
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.
NOTE:
This manual transmission (for H27 engine) is not equipped with C-ring of countershaft rear bearing.
Therefore it is not necessary to disassemble or reassemble this C-ring from or to countershaft rear
bearing. For the descriptions (items) other than mentioned above, refer to the same section of “UNIT
REPAIR MANUAL” mentioned in the FOREWORD of this manual.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-1
7B1
SECTION 7B1
AUTOMATIC TRANSMISSION (4 A/T)
CONTENTS
General Description ......................................7B1-3
Electronic Shift Control System ................... 7B1-4
Automatic gear shift diagram................... 7B1-5
Diagnosis .......................................................7B1-7
On-Board Diagnostic System
(Vehicle without monitor connector) ............ 7B1-7
On-Board Diagnostic System
(Vehicle with monitor connector) ................. 7B1-8
Precaution in Diagnosing Trouble ............... 7B1-9
Automatic Transmission Diagnostic Flow
Table ......................................................... 7B1-10
Malfunction Indicator Lamp (MIL) Check... 7B1-13
“O/D OFF” Lamp Check ............................ 7B1-13
“POWER” Lamp Check ............................. 7B1-13
Diagnostic Trouble Code (DTC) Check ..... 7B1-13
Diagnostic Trouble Code Clearance ......... 7B1-13
Diagnostic Trouble Code Table ................. 7B1-14
Fail Safe Table .......................................... 7B1-14
Visual Inspection ....................................... 7B1-14
A/T Basic Check ........................................ 7B1-14
Trouble Diagnosis Table 1 ........................ 7B1-15
Trouble Diagnosis Table 2 ........................ 7B1-15
Trouble Diagnosis Table 3 ........................ 7B1-16
Scan Tool Data ......................................... 7B1-17
Inspection of PCM and Its Circuit .............. 7B1-17Wire Harness and Connectors .................. 7B1-17
Table A-1 : No TCC Lock-Up Occurs ........ 7B1-18
Table A-2 : No Gear Shift to O/D .............. 7B1-20
Table B-1 : “O/D OFF” Light Circuit Check
(“O/D OFF” Light Doesn’t Light at Ignition
Switch ON But Engine Starts Up) ............. 7B1-22
Table B-2 : “O/D OFF” Light Circuit Check
(“O/D OFF” Light Comes ON Steadily) ..... 7B1-23
Table B-3 : “POWER” Light Circuit Check
(“POWER” Light Doesn’t Light at Ignition
Switch ON But Engine Starts Up) ............. 7B1-24
Table B-4 : “POWER” Light Circuit Check
(“POWER” Light Comes ON Steadily) ...... 7B1-25
DTC P0705 (DTC NO.72) - Transmission
Range Sensor (Switch) Circuit Malfunction7B1-26
DTC P0715 (DTC NO.76) - Input/Turbine
Speed Sensor Circuit Malfunction............. 7B1-29
DTC P0720 (DTC NO.75) Output Speed
Sensor Circuit Malfunction ........................ 7B1-32
DTC P0743 (DTC NO.65/66) -
TCC (Lock-Up) Solenoid Electrical ........... 7B1-34
DTC P0753 (DTC NO.61/62)
Shift Solenoid-A (#1) Electrical
DTC P0758 (DTC NO.63/64)
Shift Solenoid-B (#2) Electrical ................. 7B1-36 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 air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation 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 FOREWORD of this manual.

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.

7B1-8 AUTOMATIC TRANSMISSION (4 A/T)
On-Board Diagnostic System (Vehicle with
monitor connector)
For automatic transmission control system, PCM (ECM) has fol-
lowing functions. Refer to Section 6/6-1 for details.
•When the ignition switch is turned ON with the engine at a
stop, malfunction indicator lamp (MIL) turns ON to check the
bulb of the MIL.
•When PCM detects a trouble in electronic shift control sys-
tem, it stores its trouble code in ECM back-up memory. (The
memory is kept as it is even if the trouble was only tempo-
rary and disappeared immediately. And it is not erased
unless the power to PCM is shut off for 30 seconds or
longer.)
•It is possible to communicate through DLC by using not only
SUZUKI scan tool (2) but also generic scan tool. (Diagnostic
information can be accessed by using a scan tool.)
•ECM also indicates trouble area in memory by means of
flashing of malfunction indicator lamp (1) at the time of
inspection. (i.e. when diagnosis switch terminal (3) is con-
nected to ground terminal (4) with a service wire (5) and igni-
tion switch is turned ON.)

AUTOMATIC TRANSMISSION (4 A/T) 7B1-9
Precaution in Diagnosing Trouble
•Don’t disconnect couplers from PCM (ECM), battery cable
from battery, PCM ground wire harness from engine or main
fuse before checking the diagnosis information (DTC, freeze
frame data, etc.) stored in PCM memory. Such disconnec-
tion will clear memorized information in PCM memory.
•Using SUZUKI scan tool or also generic scan tool for vehicle
without monitor connector, the diagnostic information stored
in PCM memory can be checked and cleared as well. Before
its use, be sure to read Operator’s (Instruction) Manual sup-
plied with it carefully to have good understanding of its func-
tions and usage.
•Priorities for diagnosing troubles
If two or more diagnostic trouble codes (DTCs) are stored,
proceed to the flow table of the DTC which was detected
earliest in the order and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble
codes according to the following priorities.
–Diagnostic trouble codes (DTCs) other than DTC P0171/
P0172/P0174/P0175 (Fuel system too lean/too rich), DTC
P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire
detected) and DTC P0400 (EGR flow malfunction)
–DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too
rich) and DTC P0400 (EGR flow malfunction)
–DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306
(Misfire detected)
•Be sure to read “PRECAUTIONS FOR ELECTRICAL CIR-
CUIT SERVICE” in Section 0A before inspection and
observe what is written there.
•PCM replacement
When substituting a known-good PCM, check for following
conditions.
Neglecting this check may result in damage to a good PCM.
–All relays and actuators have resistance of specified value.
–MAF sensor, MDP sensor, TP sensor and fuel tank pres-
sure sensor are in good condition. Also, the power circuit of
these sensors is not shorted to the ground.

7B1-10 AUTOMATIC TRANSMISSION (4 A/T)
Automatic Transmission Diagnostic Flow Table
Refer to the following pages for the details of each step.
Step Action Yes No
1 Customer Complaint Analysis
1) Perform customer complaint analysis refer-
ring to the next page.
Was customer complaint analysis performed
according to instruction?Go to Step 2. Perform customer com-
plaint analysis.
2 Diagnostic Trouble Code (DTC) and Freeze
Frame Data Check, Record and Clearance
1) Check for DTC (including pending DTC)
Is there any DTC(s)?Print DTC and freeze
frame data or write them
down and clear them by
referring to “DTC CLEAR-
ANCE” in this section
Go to Step 3.Go to Step 4.
3 Visual Inspection
1) Perform visual inspection referring to the
next page.
Is there any faulty condition?Repair or replace mal-
function part.
Go to Step 11.Go to Step 5.
4 Visual Inspection
1) Perform visual inspection referring to the
next page.
Is there any faulty condition?Go to Step 8.
5 Trouble Symptom Confirmation
1) Confirm trouble symptom referring to the
next page.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6 Rechecking and Record of DTC/Freeze Frame
Data
1) Recheck for DTC and freeze frame data
referring to “DTC Check” in this section.
Is there any DTC(s)?Go to Step 9. Go to Step 8.
7 Rechecking and Record of DTC/Freeze Frame
Data
1) Recheck for DTC and freeze frame data
referring to “DTC Check” in this section.
Is there any DTC(s)?Go to Step 9. Go to Step 10.
8 Automatic Transmission Basic Inspection and
Trouble Diagnosis Table
1) Check and repair according to “A/T Basic
Check” and “Trouble Diagnosis Table” in this
section.
Are check and repair complete?Go to Step 11. Check and repair mal-
function part(s).
Go to Step 11.
9 Troubleshooting for DTC
1) Check and repair according to applicable
DTC diag. flow Table.
Are check and repair complete?
10 Check for Intermittent Problems
1) Check for intermittent problems referring to
the next page.
Is there any faulty condition?Repair or replace mal-
function part(s).
Go to Step 11.Go to Step 11.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-11
STEP 1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a inspection form will facilitate collecting information to the point required for
proper analysis and diagnosis.
STEP 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK, RECORD AND
CLEARANCE
First, referring to DTC check section, check DTC (including pending DTC). If DTC exists, print or write down
DTC and freeze frame data and then clear them by referring to DTC clearance section. DTC indicates malfunc-
tion in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred in
the past and normal condition has been restored. In order to know that, check symptom in question according to
Step 5 and then recheck DTC according to Step 6.
Diagnosing a trouble based on the DTC in this step only or failure to clear the DTC in this step may result in an
faulty diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unneces-
sary.
STEP 3 and STEP 4. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the A/T and
engine referring to Visual Inspection section.
STEP 5. TROUBLE SYMPTOM CONFIRMATION
Check trouble symptoms based on information obtained in Step 1 “CUSTOMER COMPLAINT ANALYSIS” and
Step 2 “DTC/FREEZE FRAME DATA CHECK”.
Also, recheck DTC according to “DTC CONFIRMATION PROCEDURE” described in each “DTC FLOW
TABLE”.
STEP 6 and STEP 7. RECHECKING AND RECORD OF DTC/FREEZE FRAME DATA
Refer to “DTC CHECK” in this section for checking procedure.
STEP 8. A/T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE
Perform A/T basic check according to the “A/T Basic Check Flow Table” first. When the end of the flow table has
been reached, check the parts of the system suspected as a possible cause referring to “TROUBLE DIAGNO-
SIS TABLE” and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer
complaint analysis, trouble symptom confirmation and/or A/T basic check) and repair or replace faulty parts, if
any.
STEP 9. DIAGNOSTIC TROUBLE CODE FLOW TABLE
Based on the DTC indicated in Step 6 and 7 and referring to “DIAGNOSTIC TROUBLE CODE FLOW TABLE” in
this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, PCM
or other part and repair or replace faulty parts.11 Final Confirmation Test
1) Clear DTC if any.
2) Perform final confirmation test referring to
the next page.
Is there any problem symptom, DTC or abnor-
mal condition?Go to Step 6. End. Step Action Yes No

7B1-12 AUTOMATIC TRANSMISSION (4 A/T)
STEP 10. CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“INTERMITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in Step 2.
STEP 11. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the A/T is free from any abnormal conditions.
If what has been repaired is related to the malfunction DTC, clear the DTC once, set conditions under which
DTC was detected and A/T and/or vehicle was repaired and confirm that no DTC is indicated.
CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)
NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of
each market.