2001 SUZUKI GRAND VITARA Shift

7B1-42 AUTOMATIC TRANSMISSION (4 A/T)
TROUBLESHOOTING
Engine Brake Test
1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake
operates.
2) In the same way as in step 1, check engine brake for operation when select lever is shifted down to “L”
range.
3) If engine brake fails to operate in above tests, possible causes for such failure are as follows. Check each
part which is suspected to be the cause.
TROUBLESHOOTING
“P” Range Test
1) Stop vehicle on a slope, shift select lever to “P” range and at the same time apply parking brake.
2) After stopping engine, depress brake pedal and release paring brake.
3) Then, release brake pedal gradually and check that vehicle remains stationary.
4) Depress brake pedal and shift select lever to “N” range.
5) Then, release brake pedal gradually and check that vehicle moves.NOTE:
When repeating this test, be sure to wait at least minute after select lever is shifted back to “N”
range.
Engine should be warmed up fully for this test.
Condition Possible cause
When “N” → “D” time lag exceeds specification•Low line pressure
•Worn forward clutch
When “N” → “R” time lag exceeds specification•Low line pressure
•Worn direct clutch
•Worn reverse brake
WARNING:
Before test, make sure that there is no vehicle behind so as to prevent rear-end collision.
Condition Possible cause
Fails to operate when shifted down to “2” range Second coast brake defective
Fails to operate when shifted down to “L” range Reverse brake defective
WARNING:
Before test, check to make sure no one is around vehicle or down on a slope and keep watchful for
safety during test.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-43
On-Vehicle Service
Maintenance Service
Fluid level
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal oper-
ating temperature (70 – 80 °C (158 – 176 °F)). As a guide to
check fluid temperature, warm up engine till engine coolant
temperature meter indicated around 1 unit above “C” point.
5) Keep engine idling and shift selector slowly to “L” and back
to “P” position.
6) With engine idling, pull out dipstick, wipe it off with a clean
cloth and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it.
Fluid level should be between FULL HOT and LOW HOT. if it
is below LOW HOT, add an equivalent of DEXRON
®-III up to
FULL HOT.
Fluid specification :
An equivalent of DEXRON
®-III
[A] : Shift the select lever with its button pushed in.
[B] : Shift the select lever without pushing its button.
NOTE:
DO NOT RACE ENGINE while checking fluid level, even
after the engine start.
DO NOT OVERFILL. Overfilling can causes foaming
and loss of fluid through breather. Then slippage and
transmission failure can result.
Bringing the level from LOW HOT to FULL HOT
requires 0.3 liters (0.64/0.53 US/lmp.pt).
If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour
after it is stopped.

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) 7B1-57
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

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.