2001 SUZUKI GRAND VITARA ect

7B1-54 AUTOMATIC TRANSMISSION (4 A/T)
6) Install direct clutch cylinder to center support.
Remove direct clutch piston by blowing air into the second
hole from the left as shown in the figure. Also, remove direct
clutch inner piston by blowing air into hole at the extreme
right. And then remove O-rings from pistons.
Front upper valve body
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 as many throttle valve compensating rings as written
down when disassembled.
•Tighten throttle cam bolt (1) to specified torque.
Tightening torque
Throttle cam bolt (a) : 7.5 N·m (0.75 kg-m, 5.5 lb-ft)
•Tighten pressure relief valve bolts (1) to specified torque.
Tightening torque
Pressure relief valve bolt (b) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
Name of spring Outer diameter Free length
Secondary regulator
valve spring17.43 mm
(0.681 in.)71.27 mm
(2.806 in.)
Cut back valve spring 6.85 mm
(0.259 in.)23.0 mm
(0.906 in.)
Throttle valve
secondary spring8.56 mm
(0.337 in.)18.86 mm
(0.743 in.)
Throttle valve
primary spring10.90 mm
(0.429 in.)39.55 mm
(1.557 in.)

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

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

AUTOMATIC TRANSMISSION (4 A/T) 7B1-61
Special Tool
09925-37811-001 09931-76030 09931-76011
Oil pressure gauge 16/14 pin DLC cable for
Tech 1AMass storage cartridge for
Tech 1ATech 1A kit (SUZUKI scan
tool) (See NOTE “A”.)
09940-53111
Bearing installer Tech 2 kit (SUZUKI scan
tool) (See NOTE “B”.)
NOTE:
“A”: This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Suzuki scan tool, 4. DLC cable, 5. Test lead/probe,
6. Power source cable, 7. DLC cable adapter, 8. Self-test adapter
“B”: This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback
adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loopback connector,
11. Storage case, 12. Power supply

CLUTCH 7C1-1
7C1
SECTION 7C1
CLUTCH
NOTE:
The clutch of this model is the same as that of H25 engine in the construction and operation.
Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for ser-
vice procedure.

DIFFERENTIAL (FRONT) 7E-1
7E
SECTION 7E
DIFFERENTIAL (FRONT)
CONTENTS
General Description ........................................ 7E-2
4WD Control System ..................................... 7E-2
System circuit ............................................ 7E-2
Diagnosis ......................................................... 7E-3
Differential Assembly Diagnosis Table .......... 7E-3
4WD Control System Diagnostic Flow Table 7E-3
Notes on system circuit inspection ............ 7E-3
Flow table .................................................. 7E-4
4WD Control System Circuit Inspection ........ 7E-5
Voltage check ............................................ 7E-54WD Control System Inspection ................... 7E-6
On-Vehicle Service ......................................... 7E-7
Differential Mountings ................................... 7E-7
Rear Mounting for Front Differential Carrier.. 7E-8
Front Differential Assembly ........................... 7E-9
Unit Repair ..................................................... 7E-11
Tightening Torque Specification ................. 7E-11
Special Tool ................................................... 7E-11

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.

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”.

7E-4 DIFFERENTIAL (FRONT)
Flow table
Step Action Yes No
1 Turn ON ignition switch (but engine at stop) and
check malfunction indicator lamp.
Does lamp light up?Go to step 2. A trouble has occurred
at some place. Repair
it referring to
MALFUNCTION INDI-
CATOR LAMP
(“CHECK ENGINE”
LAMP) CHECK in
DIAGNOSIS of Sec-
tion 6.
2 Check 4WD switch circuit.
Turn ignition switch ON and check that voltage
between terminal C51-3-7 and terminal C51-3-17
(ground) is as follows.
 When transfer shift lever is in N or 2H : 10 – 14 V
 When transfer shift lever is in 4L or 4H : 0 – 1 V
Is the check result satisfactory?Go to step 3. Check 4WD switch
(refer to Section 7A),
“BLK/ORN” and “BLK”
circuits of 4WD switch.
If OK, substitute a
known-good ECM
(PCM) and recheck.
3 Check power supply.
1) Turn ignition switch ON.
2) Check voltage between C51-1-9 and C51-3-17
(ground). The check results should be as follows.
 When transfer shift lever is in N or 2H : 0 – 1 V
 When transfer shift lever is in 4L or 4H : 10 – 14 V
Is the check result satisfactory?Go to step 4. Check “RED” circuit. If
it is OK, substitute a
known-good ECM
(PCM) and recheck.
4 Check air pump assembly circuit.
1) Check for proper connection to air pump assem-
bly at all terminals.
2) Turn ignition switch ON.
3) Check voltage between C51-3-18 and C51-3-17
(ground). The check result should be as follows.
 When transfer shift lever is in 2H or N : 0 – 1 V
 When transfer shift lever is in 4L or 4H (more than
4 seconds after shifted to 4L or 4H) : 10 – 14 V
Is the check result satisfactory?Go to step 5. Check air pump
assembly referring to
“ON-VEHICLE SER-
VICE”, and then
“PNK” circuit.
If OK, substitute a
known-good ECM
(PCM) and recheck.
5 Check 4WD indicator lamp circuit.
1) Turn ignition switch ON.
2) Check voltage between E61-19 and C51-3-17
(ground). The check result should be as follows.
 When transfer shift lever is in 2H or N : 10 – 14 V
 When transfer shift lever is in 4L or 4H : 0 – 1 V
Is the check result satisfactory?4WD control system is
in good condition.Check “ORN/BLK” cir-
cuit (including indica-
tor lamp and
combination meter).
If OK, substitute a
known-good ECM
(PCM) and recheck.