2001 SUZUKI GRAND VITARA torque

YH4
GRAND
VITARA
MANUAL TRANSMISSION (TYPE 2) 7A1-5
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN´mkg-mlb-ft
Transfer oil filler / level and drain plugs232.317.0
Transmission oil filler / level and drain plugs383.827.5
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back-up light switch454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts505.036.5
Muffler to exhaust No. 2 pipe nuts505.036.5
Universal joint flange bolts505.036.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever
Thread lock cement
THREAD LOCK CEMENT
SUPER 1333B
(99000-32020)

Shift control lever locating bolts
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil drain and filler / level plugs

YH4
GRAND
VITARA
7B1-2 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0753 Shift Solenoid-A (#1)
Electrical 7B1-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0758 Shift Solenoid-B (#2)
Electrical 7B1-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1875 4WD Low Switch Circuit
Malfunction 7B1-52. . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Test 7B1-54. . . . . . . . . . . . . . . . . .
Stall Test 7B1-55. . . . . . . . . . . . . . . . . . . . . . . . . .
Road Test 7B1-56. . . . . . . . . . . . . . . . . . . . . . . . .
Manual Road Test 7B1-57. . . . . . . . . . . . . . . . . .
Time Lag Test 7B1-57. . . . . . . . . . . . . . . . . . . . . .
Engine Brake Test 7B1-58. . . . . . . . . . . . . . . . . .
ªPº Range Test 7B1-58. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7B1-59 . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE 7B1-59. . . . . . . . . . . .
Fluid Level 7B1-59. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Change 7B1-60. . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Hoses 7B1-61. . . . . . . . . . . . . . . . . . .
A / T THROTTLE CABLE 7B1-61. . . . . . . . . . . . . . .
MANUAL SELECTOR ASSEMBLY 7B1-62. . . . .
SELECT CABLE 7B1-63. . . . . . . . . . . . . . . . . . . . . TRANSMISSION RANGE SWITCH 7B1-64. . . . .
A
/
T OUTPUT SPEED SENSOR 7B1-64. . . . . . . .
O / D CUT SWITCH 7B1-64. . . . . . . . . . . . . . . . . . .
SOLENOID VALVES 7B1-64. . . . . . . . . . . . . . . . . .
THROTTLE POSITION SENSOR 7B1-66. . . . . . .
POWER / NORMAL CHANGE SWITCH 7B1-66. .
OIL COOLER PIPES 7B1-67. . . . . . . . . . . . . . . . . .
BRAKE INTERLOCK SYSTEM 7B1-68. . . . . . . . .
Shift Lock Solenoid Control 7B1-68. . . . . . . . . .
Shift Lock Solenoid Control Operations 7B1-68
Shift Lock (Solenoid) Manual Release 7B1-69.
System Inspection 7B1-69. . . . . . . . . . . . . . . . . .
KEY INTERLOCK CABLE 7B1-71. . . . . . . . . . . . .
DISMOUNTING OF TRANSMISSION
(WITH TRANSFER IF EQUIPPED) 7B1-74. . . .
REMOUNTING 7B1-77. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7B1-78 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7B1-78 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7B1-79 . . . . . .
SPECIAL TOOLS7B1-79 . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-3
1. Torque converter
2. Overdrive input shaft
3. Oil pump
4. Overdrive brake
5. Overdrive clutch
6. Forward clutch input shaft
7. Forward clutch
8. Direct clutch
9. One-way clutch
10. Second coast brake
11. Second brake
12. Reverse brake
13. Front planetary gear
14. Rear planetary gear
15. Overdrive planetary gear
GENERAL DESCRIPTION
This automatic transmission is a full automatic type with 3-speed plus overdrive (O / D).
The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled
lock-up mechanism. The gear shift device consists of 3 sets of planetary gear units, 3 disc type clutches, 4 disc
type brakes and 3 one-way clutches. The gear shift is done by selecting one of 6 positions (ªPº, ªRº, ªNº, ªDº, ª2º
and ªLº) by means of the select lever installed on the floor. On the shift knob, there is an overdrive (O / D) cut switch
which allows shift-up to the overdrive mode (except at 4L) and shift-down from the overdrive mode. Also, by using
the P / N change switch located on the console box, it is possible to select the gear change timing of 2 modes, nor-
mal and power.

YH4
GRAND
VITARA
7B1-4 AUTOMATIC TRANSMISSION (4 A / T)
ItemSpecifications
Torque
conver-
terType
Stall torque ratio3-element, 1-step, 2-phase type (with TCC (lock-up)
mechanism)
2.4 (G16 engine) 2.0 (J20 engine) 1.9 (H25 engine)
Oil
pumpType
Drive systemTrochoid type oil pump
Engine driven
TypeForward 4-step, reverse 1-step planetary gear type
Shift position
ªPº range Gear in neutral, output shaft fixed,engine start
ªRº range Reverse
ªNº range Gear in neutral, engine start
ªDº range Forward 1st
2nd
3rd
4th (O / D)
(O / D ON) automatic gear change
ªDº range Forward 1st
2nd
3rd
(O / D OFF) automatic gear change
ª2º range (Normal mode) Forward 1st
2nd  3rd automatic gear
change
(Power mode) Forward 2nd  3rd automatic gear
change and fixed at 2nd gear
ªLº range Forward 1st  2nd  3rd reduction, and fixed at 1st gear
GearEngine typeG16 engineJ20 / H25 engines
change
device1st (low gear)2.8262.826device2nd (second gear)1.4931.493
Gear3rd (top gear)1.0001.000Gear
ratio4th (overdrive
4th gear)0.7300.689
Reverse (reverse
Reverse gear)2.7032.703
Control elements
Wet type multi-disc clutch 3 sets. . . . . . . . . .
Wet type multi-disc brake 4 sets. . . . . . . . . .
One-way clutch 3 sets. . . . . . . . . . . . . . . . . . .
TransferHi: 1.000 Lo: 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125 (G16 engine) 4.875 (J20 / H25 engines)
Lubrica-
tionLubrication systemForce feed system by oil pump
CoolingCooling systemRadiator assisted cooling (water-cooled)
Fluid usedAn equivalent of DEXRON
III

YH4
GRAND
VITARA
Engine
Vehicle speed
sensor
Throttle position
sensor
ECT sensor
Cruise control
module
(if equipped)Torque converter Planetary gear
Final gear
reduction unit
Oil pump
Shift and TCC
solenoid valvesClutch and brake
Control valve
ªO / D OFFº lamp
ªPOWERº lamp
MILTransmission range
switch
O / D cut switch
P / N change switch
Transfer 4L switch
(if equipped)
CMP sensor Powertrain (engine) control module
Power transmission
Fluid pressure circuit
Electric signalInput speed sensor Brake pedal switch
Output speed sensor
AUTOMATIC TRANSMISSION (4 A / T) 7B1-7
ELECTRONIC SHIFT CONTROL SYSTEM
The gear ratio change in ªDº or ª2º range and torque converter clutch operation are controlled by Powertrain (En-
gine) Control Module.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-29
Gear shift Transmission fluid Running condition
ConditionPossible CauseCorrection
Poor 3±4 shift, ex-
3±4 shift valve stickingReplace.
cessive slippage
Shift solenoid valve-B stickingReplace.
Excessive shock on
Regulator valve stickingReplace.
1±2 shift
Faulty accumulator, second brake pistonReplace.
Excessive shock on
Regulator valve stickingReplace.
2±3 shift
Faulty accumulator, direct clutch pistonReplace.
Excessive shock on
3±4 shift
Regulator valve stickingReplace.
Non operate lock-
TCC (Lock-up) control valve stickingReplace.
up system
Solenoid valve No.2 (TCC solenoid valve)
stickingReplace.
TROUBLE DIAGNOSIS TABLE 3
ConditionPossible CauseCorrection
Low fluid pressure
Leakage from oil pressure circuitOverhaul.
Unable to run in all
range
Wear in oil pumpReplace.

Seizure in oil pumpReplace.

Fluid pressure leakage to over drive clutch
due to wear of oil pump bushingReplace.

Faulty in torque converterReplace.

YH4
GRAND
VITARA
7B1-30 AUTOMATIC TRANSMISSION (4 A / T)
Running condition Gear shift Abnormal
noise
ConditionPossible CauseCorrection
Poor 1st speed run-
ning or excessive
slippage in ªDº or ª2º
Fluid pressure leakage from forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Overdrive clutch slippingReplace.
Unable to run or ex-
cessive slippage in
ªLº range
Fluid pressure leakage of forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Reverse brake disc slippingReplace.

Broken brake piston O-ringReplace.
Unable to run or ex-
cessive slippage in
ªRº range
Fluid pressure leakage to direct clutch due
to wear or breakage of center support seal
ringReplace.

Worn direct clutchReplace.
Poor 1±2 shift, ex-
cessive slippage
Fluid pressure leakage to overdrive clutch
due to wear or breakage of O/D case seal
ringReplace.

Faulty second brakeReplace.

Broken O-ring of second brake pistonReplace.

Faulty second coast brake (in ª2º range)Replace.
Poor 2±3 shift, ex-
cessive slippage
Fluid pressure leakage to overdrive clutch
due to wear or breakage of O/D case seal
ringReplace.

Worn direct clutch bushingReplace.

Direct clutch slippingReplace.

Foreign material caught in direct clutch pis-
ton check ballReplace.
Poor start or surging
in ªDº range
Fluid pressure leakage of forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Malfunction of forward clutchReplace.
Poor 3±4 shift, ex-
ili

Faulty overdrive brakeReplace.
cessive slippage
Faulty overdrive clutchReplace.
Poor start or judder-
ing in ªRº range
Fluid pressure leakage of direct clutch due
to wear or breakage of oil center support
seal ringReplace.

Worn direct clutchReplace.
Excessive shock on
1± 2 shift
Faulty one-way clutchReplace.
Non operate lock-up
system
Faulty torque converterReplace.
Abnormal noise in
ªPº or ªNº range
Worn oil pumpReplace.
SCAN TOOL DATA-Refer to SECTION 6 / 6-1.
INSPECTION OF PCM AND ITS CIRCUIT-Refer to SECTION 6 / 6-1.
WIRE HARNESS AND CONNECTORS-Refer to SECTION 6 / 6-1.

YH4
GRAND
VITARA
7B1-46 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0741 TCC (LOCK-UP) SOLENOID VALVE PERFORMANCE OR STUCK OFF
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While running in 2nd or 4th gear, D range, TCC control
of PCM does not agree with actual operation of trans-
mission TCC even though solenoid valve is electrically
in good condition.
(2 driving cycles detection logic)
TCC (lock-up) solenoid valve stuck

TCC control valve stuck

Valve body fluid passage clogged

TCC faulty
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool and check fuel level meter
indication is 1/4 or more.
3) Start engine, warm it up to normal operating temperature and shift transfer lever to ª2Hº or ª4Hº range.
4) Increase vehicle speed with D range, and check that gear position changes from 1st to 2nd and keep driving
about 20 mph, 30 km/h in 2nd of ªDº range for 10 seconds. (Throttle valve should be not at idle position and
the opening should be kept constant in this step.)
5) Keep driving about 50 mph, 80 km/h in 4th of ªDº range for 10 seconds.
6) Release accelerator pedal, decrease vehicle speed and stop vehicle.
7) Check pending DTC and DTC by using scan tool.
TROUBLESHOOTING
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2TCC solenoid valve operation check:
1) Check TCC solenoid valve operation referring to
ªSolenoid Valves Operation Checkº in this section.
Is it in good condition?Go to Step 3.Faulty TCC solenoid
valve.
3Valve body check:
1) Check valve body referring to ªUnit Repairº in this
section.
Is it in good condition?Faulty torque
converter.Faulty valve body.