2001 SUZUKI GRAND VITARA Owners Manual

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

AUTOMATIC TRANSMISSION (4 A/T) 7B1-59
•Tighten TCC (lock-up) solenoid valve bolt to specified
torque.
Tightening torque
TCC solenoid valve bolt :
5.5 N·m (0.55 kg-m, 4.0 lb-ft)
•Tighten pressure relief valve bolt to specified torque.
Tightening torque
Pressure relief valve bolt :
5.5 N·m (0.55 kg-m, 4.0 lb-ft)
•Tighten lower valve body plate (1), TCC (lock-up) control
valve plate (2) flange bolt to specified torque.
Tightening torque
Lower valve body and TCC control valve Plate bolts :
5.5 N·m (0.55 kg-m, 4.0 lb-ft)
Unit Assembly
1) Apply A/T fluid to new O-ring and spring and install them to
accumulator piston and install accumulator piston to trans-
mission case.
1. Solenoid valve No. 2 (TCC solenoid valve)
2. O-ring
4. Upper spring

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

7B1-62 AUTOMATIC TRANSMISSION (4 A/T)

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.