2002 SUZUKI GRAND VITARA Assembly

YH4
GRAND
VITARA
1. Manual selector assembly
(Select lever assembly)
2. Manual lever assembly
3. Select cable bracket
4. Select indicator
5. Slide cover
6. Select lever knob7. Spring
8. Knob button
9. Shift lock solenoid rod
10. Shift lock solenoid
11. Cover
12. Illumination lamp
13. Interlock cam
1. Interlock cam pin
(only for new selector assembly) Tightening Torque
(a): 18 N
.m (1.8 kg-m, 13.5 lb-ft)1. Manual lever
assembly
2. Select indicator
assembly
3. Illumination lamp
assembly
4. Bulb filter
5. Bulb
6. Knob assembly
7. Shift lock solenoid
Type-1 Type-2
Type-1
7B1-62 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 solenoid
and overdrive OFF switch.
4) Disconnect interlock cable from interlock cam of selector as-
sembly.
5) Remove selector assembly mounting bolts.
6) Disconnect select cable from lever of selector assembly.
INSTALLATION
NOTE:
New selector assembly of Type-1 is supplied with held inter-
lock cam at interlock cable connecting position with pin. Re-
move this pin after connecting interlock cable to interlock cam
and tightening cable nut.
Reverse removal procedure to install noting the followings.

Connect interlock cable end to cam referring to steps 2) to 8) of
ªInterlock Cable Installationº section.

Upon completion of installation, confirm that brake (key) interlock
system operates properly.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-63
1. Select lever assembly
2. Bolt
3. Select cable
4. Cable bracket
5. Bolt
6. Blank
7. Washer
8. Clip
9. Nut
10. Manual select lever
11. Lock washer
12. Nut
13. Select cable joint
14. Bush
15. Washer
16. E-ring
17. Transmission range switch assembly
18. Bolt
1. Transmission range
sensor (switch)
2. Select cable
3. Manual shift lever
4. Select cable joint
1. Select cable joint
A. Align with cable joint
B. Tighten with wrench
Tightening Torque
(a): 13 N.m (1.3 kg-m, 9.5 lb-ft)
(b): 7 N.m (0.7 kg-m, 5.5 lb-ft)
INSPECTION
Check select lever for smooth and clear-cut movement and position
indicator for correct indication.
For operation of select lever, refer to left figure.
SELECT CABLE
ADJUSTMENT
1) Before tightening cable end nut, shift select lever to ªNº.
2) Also shift manual shift lever to ªNº.
NOTE:

Make sure that nut and cable joint have clearance under
above conditions.

If select cable has been moved, push it in arrow C direc-
tion as shown in figure at the left till it stops and then con-
firm that select lever is in ªNº position.
3) Turn nut A by hand till it contacts manual select cable joint.
Then tighten nut B with wrench.
4) After select cable was installed, check for the following.

Push vehicle with select lever shifted to ªPº.
Vehicle should not move.

Vehicle can not be driven in ªNº.

Vehicle can be driven in ªDº, ª2º, and ªLº.

Vehicle can be backed in ªRº.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-71
Ignition switch side
1. Ignition switch assembly
2. Clamp screw
3. Interlock cable
Select lever side
Type-1
1. Inner end of interlock cable
2. Interlock cam (or key release cam)
3. Stud bolt4. Cam boss
5. Claw
Select lever side
Type-2
KEY INTERLOCK CABLE
NOTE:
Don't bend interlock cable excessively when removing and
installing it, or system will not operate correctly.
Removal
1) Disconnect negative (±) cable from battery.
2) If equipped with air bag system, disable air bag system.
Refer to ªDisabling Air bag Systemº in Section 10B.
3) Remove steering column hole cover.
4) Tilt steering column if steering column is adjustable.
If no adjustable, loosen steering column bolts.
5) Remove steering column cover.
6) Remove interlock cable clamp screw located at ignition switch
assembly.
7) Disconnect interlock cable inner end.
(Ignition switch side.)
8) With console box removed, take out interlock cable by loosening
lock nuts.
9) Detach cable end from interlock cam (or key release cam) while
pressing claws of interlock cam boss. At this time, be careful not
to cause damage to its claws.

YH4
GRAND
VITARA
1. Ignition switch assembly
2. Clamp screw
3. Outer end
1. Interlock cable
2. Steering column
3. Steering column
holder
Type-1
1. Interlock cam
2. Lever plate
3. Interlock cable
4. Pin with 4 mm (0.15 in.) dia.
7B1-72 AUTOMATIC TRANSMISSION (4 A / T)
Installation
1) Shift select lever to ªNº range and turn ignition key to ªACCº
position.
2) Connect inner end of interlock cable to key interlock lever (Igni-
tion switch side).
3) Install outer end bracket of interlock cable to ignition switch as-
sembly, and tighten screw to specified torque.
Tightening Torque
(a): 2.2 N
.m (0.22 kg-m, 1.5 lb-ft)
4) Pass and connect interlock cable as shown at the left figure.
TYPE-1
5) Fix interlock cam by inserting pin with about 4 mm (0.15 in.) dia.
into holes of cam and lever plate.
6) Install cable end to interlock cam and stud bolt and after making
sure that cable outer is pushed in arrow direction B by leaf
spring, tighten mounting nut to specified torque. Remove pin.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
7) Turn ignition key to ªACCº position and shift select lever to ªNº
range, and check for the followings.
a. When select lever is shifted at ªPº range with knob button
depressed, ignition key can not be turned from ªACCº to
ªLOCKº position.
b. When knob button is released, ignition key can be turned to
ªLOCKº position.
c. When ignition key is at ªLOCKº position, select lever can not
be shifted from ªPº to any other range.
8) Install console box.
9) Install steering column cover.
10) Adjust steering column or tighten steering column bolts.
11) Install steering column hole cover.
12) If equipped with air bag system, enable air bag system.
Refer to ªEnabling Air bag Systemº in Section 10B.

YH4
GRAND
VITARA
7B1-76 AUTOMATIC TRANSMISSION (4 A / T)
12) Remove engine to transmission nuts.
13) Disconnect connectors from VSS, output speed sensor, input
speed sensor, TR switch, shift & TCC solenoid valves and oth-
er electrical parts, and release their wire harness from clamps.
14) Apply transmission jack and take off rear mounting member by
removing its bolts.
15) With transmission (and transfer if equipped) assembly held up
on jack, move them to the rear and lower them including torque
converter.
WARNING:
Transmission (and transfer if equipped) assembly may
tilt rearward on jack. It is recommended to use an auxil-
iary arm of jack for the purpose of safety.
AFTER DISMOUNTING
WARNING:
Be sure to keep transmission (and transfer if equipped) as-
sembly horizontal throughout the work. Should they be
tilted, torque converter may fall off and cause personal inju-
ry and A / T fluid may flow out.
1) Remove breather hoses.
2) Remove transfer by removing its bolts, if equipped.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-77
ªAº, (d)
1. Drive plate
2. Torque converter
3. Case right stiffener (if equipped)
4. Automatic transmissionTightening torque
(a): 50 N´m
5.0 kg-m
36.5 lb-ft
(b): 65 N´m
6.5 kg-m
47.0 lb-ft
(c): 85 N´m
8.5 kg-m
61.5 lb-ft
(d): 78 N´m
7.8 kg-m
56.5 lb-ft
1. Automatic transmission
2. Transfer (4WD)
3. Engine rear mounting
4. Engine rear mounting member Tightening torque
(a): 50 N´m (5.0 kg-m, 36.5 lb-ft) ªAº: Sealant 99000-31110
REMOUNTING
WARNING:
When moving transmission assembly with torque convert-
er equipped in it, be sure to keep it horizontal. Tilting it with
its front facing down may allow converter to fall off. Where-
by an injury may result.
For remounting, reverse dismounting procedure. Use specified
torque as given below and left.
Tightening torque
N.mkg-mlb-ft
Exhaust No.1 pipe to manifold
bolts or nuts505.036.5
Muffler to exhaust No.2 pipe
nuts606.043.5
Universal joint flange bolts and
nuts505.036.5

Oil filler tube bolts

Select cable bracket bolts232.317.0

Clamp wiring harness and hoses securely.

Refer to ªSelect Cableº section for adjusting procedure of select
cable.

Refer to ªA / T Throttle Cableº section for tuning of A / T throttle
cable.

Follow fluid level check procedure for refilling automatic transmis-
sion fluid and its level adjusting.

Connect battery, and confirm that engine and transmission func-
tion acceptably.

When remounting drive plate, use specified bolts.

YH4
GRAND
VITARA
7B1-78 AUTOMATIC TRANSMISSION (4 A / T)
ON-VEHICLE
SERVICE MOUNTING
EXTERNAL
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
Fastening portion
Tightening torque
Fastening portion
N´mkg-mlb-ft
Automatic transmission fluid drain plug232.317.0
Transfer oil filler / level and drain plugs232.317.0
Transmission case plug171.712.5
Manual select lever nut131.39.5
Manual select cable nut70.75.5
Manual selector assembly bolts181.813.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts
Engine rear mounting member bolts
Transmission case right stiffener bolts
505.036.5
Universal joint flange bolts and nuts505.036.5
Torque converter mounting bolts656.547.0
Adapter case or extension case bolts
(G16 engine)353.525.5
Adapter case or extension case bolts
(J20 / H25 engines)424.230.0
Transmission range switch lock bolt5.50.554.0
Oil pipe union bolts353.522.5
Drive plate bolts787.856.5
Interlock cable clamp screw2.20.221.5
Interlock cable outer mounting nut131.39.5

YH4
GRAND
VITARA
7C1
CLUTCH 7C1-1
GENERAL DESCRIPTION7C1 - 2 . . . . . . . . . . . . .
DIAGNOSIS7C1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7C1 - 4 . . . . . . . . . . . . . . .
Clutch Pedal Height 7C1 - 4. . . . . . . . . . . . . . . . . .
Clutch Pedal Free Travel 7C1 - 4. . . . . . . . . . . . .
Clutch Fluid Pipe and Hose 7C1 - 4. . . . . . . . . . .
Clutch Master Cylinder 7C1 - 5. . . . . . . . . . . . . . .
Fluid Inspection 7C1 - 6. . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly
Clutch Master Cylinder 7C1 - 7. . . . . . . . . . . . . . Clutch Operating Cylinder 7C1 - 8. . . . . . . . . . . .
UNIT REPAIR7C1-10 . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Cover, Clutch Disc and
Flywheel 7C1 - 10. . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7C1-14 . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7C1-14 . . . . .
SPECIAL TOOLS7C1-14 . . . . . . . . . . . . . . . . . . . . .
SECTION 7C1
CLUTCH
CONTENTS