2002 SUZUKI GRAND VITARA Oil pan

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-61
09900-06107
Snap ring pliers
(Opening type)09991-06010
Magnet clutch pulley installer09991-06020
Armature plate spanner09991-06030
Armature plate remover
09991-06040
Lip type seal protector09991-06050
Lip type seal installer
REQUIRED SERVICE MATERIAL
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Compressor oil for DENSO
compressor (Refrigerant oil)COMPRESSOR OIL (ND-OIL 8, 250 cc)
99000-27080
O-ring

Each component
Compressor oil for
SEIKO SEIKI compressor
(Refrigerant oil)COMPRESSOR OIL RS20 (150 cc)
99000-99088-00D
O-ring

Each component
RefrigerantREFRIGERANT DRUM (200 g)
95794-50G00
Refrigerant charge
SPECIAL TOOLS

YH4
GRAND
VITARA
1
1. Steering column hole cover 1. Steering column cover screw
2. Steering column upper cover
3. Steering column lower cover: Standard screw
: Tapping screw
*
* *
AIR BAG STEERING WHEEL AND COLUMN 3C1-9
3) Connect all connectors that have been removed in removal.
4) Install steering column upper and lower cover, and then tighten
steering column cover screws.
CAUTION:
When installing lower cover and upper cover, be careful
so that contact coil and combination switch lead wire is
not caught between covers.
5) Install steering column hole cover.
6) Install steering wheel to steering column. Refer to ªSTEERING
WHEELº in this section.
STEERING COLUMN
CAUTION:
Once the steering column is removed from the vehicle, the
column is extremely susceptible to damage.
Dropping the column assembly on its end could collapse
the steering shaft or loosen the plastic shear pins which
maintain column length leaning on the column assembly
could cause it to bend or deform.
Any of the above damage could impair the column's col-
lapsible design.
When loosening steering column mounting bolts, make
sure that steering column assembly and steering shaft low-
er assembly have been separated. Loosening them with
steering column assembly and steering shaft lower assem-
bly assembled could cause damage to bearing in steering
shaft lower assembly.
NOTE:
When servicing steering column or any column-mounted
component, remove steering wheel. But when removing steer-
ing column simply to gain access to instrument panel compo-
nents, leave steering wheel installed on steering column.

YH4
GRAND
VITARA
1. Fluid pressure check hole
2. Oil pan
1. Oil pan
2. Exhaust pipe
7B1-54 AUTOMATIC TRANSMISSION (4 A / T)
LINE PRESSURE TEST
Purpose of this test is to check operating conditions of each part by
measuring fluid pressure in fluid pressure line. Line pressure test
requires following conditions.

Automatic fluid is at normal operating temperature (70 to 80C /
158 ± 176F).

Fluid is filled to proper level (between FULL HOT and LOW HOT
on dipstick).
1) Apply parking brake securely and place checks against wheels.
2) Attach oil pressure gauge to fluid pressure check hole in trans-
mission case.
Special Tool
(A): 09925-37810
CAUTION:
After attaching oil pressure gauge, check that not fluid
leakage exists.
3) Depress foot brake fully, run engine at idle and stall and then
check fluid pressure in ªDº or ªRº range.
CAUTION:
Do not continue running engine at stall speed longer than
5 seconds.
G16 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.9 ± 4.4 kg / cm2
55 ± 63 psi
5.1 ± 5.7 kg / cm2
73 ± 81 psi
At stall speed11.7 ± 13.2 kg / cm2
166 ± 188 psi
14.2 ± 16.7 kg / cm2
202 ± 237 psi
J20 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.8 ± 4.3 kg / cm2
54 ± 61 psi
5.3 ± 5.9 kg / cm2
75 ± 84 psi
At stall speed9.7 ± 11.2 kg / cm2
138 ± 159 psi
12.9 ± 15.5 kg / cm2
183 ± 220 psi
H25 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.9 ± 4.4 kg / cm2
55 ± 63 psi
6.6 ± 7.2 kg / cm2
94 ± 102 psi
At stall speed11.3 ± 12.7 kg / cm2
161 ± 181 psi
14.7 ± 22.7 kg / cm2
209 ± 323 psi

YH4
GRAND
VITARA
1. Dipstick (G16 / J20)
2. Dipstick (H25)
1. Drain plug
2. Propeller shaft
1. Dipstick (G16 / J20)
2. Dipstick (H25)
7B1-60 AUTOMATIC TRANSMISSION (4 A / T)
LEVEL CHECK AT ROOM TEMPERATURE
The fluid level check at room temperature performed after repair or
fluid change before test driving is just preparation for level check of
normal operating temperature. The checking procedure itself is the
same as that described previously. If the fluid level is between FULL
COLD and LOW COLD, proceed to test drive. And when the fluid
temperature has reached the normal operating temperature, check
fluid level again and adjust it as necessary.
FLUID CHANGE
1) Lift up vehicle.
2) With engine is cool, remove drain plug from oil pan and drain A / T
fluid.
3) Install drain plug.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Lower vehicle and fill proper amount of an equivalent of DEX-
RON
-III.
5) Check fluid level according to procedure described under LEV-
EL CHECK NORMAL OPERATING TEMPERATURE.
Fluid specification
An equivalent of DEXRON
-III
Fluid capacity
When draining
from drain plug
hole
2.5 liters (5.28/4.40 US/lmp.pt.)
When
overhauling
6.9 liters (14.58/12.14 US/lmp.pt.)
for G16
7.1 liters (15.00/12.50 US/lmp.pt.)
for J20 / H25

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-65
1. Drain plug
2. Propeller shaft
1. Oiler (with transmission fluid)
2. Solenoid valve
3. BatteryA: Hole (Should be dry)
B: Exhausting fluid Terminal Arrangement of PCM Coupler
(Viewed from harness side)
WITH BATTERY VOLTAGE WITHOUT BATTERY VOLTAGE
H25 Engine
Shift solenoid valve ± A (#1)C51-1-6
Shift solenoid valve ± B (#2)C51-1-1
TCC (Lock-up) solenoid valveC51-1-2
REMOVAL
1) Pull out dipstick and lift up vehicle.
2) With engine cooled, remove drain plug from oil pan and drain
A / T fluid.
3) Install drain plug with gasket.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Remove exhaust pipe bracket and disconnect front propeller
shaft from front differential (if equipped).
5) Remove oil pan bolts.
6) Remove oil pan.
7) Remove oil tubes.
8) Remove solenoid valve No.1 (shift solenoid valve A and B) or so-
lenoid valve No.2 (TCC solenoid valve).
OPERATION CHECK
Whenever shift solenoid valves and TCC (lock-up) solenoid valve
are removed from transmission, verify their valve function physical-
ly before they are reinstalled.
1) Apply oiler to solenoid valve and give compression by hands
and then check to be sure that transmission fluid from oiler does
not come out of holes in solenoid valve when battery voltage is
not conducted.
2) Under the same conditions as above, conduct battery voltage
and then make sure that fluid comes out with vigor.
NOTE:

If fluid does not come out with vigor in above step 2 in-
spection, do not re-use that solenoid valve.

Figure at the left shows shift solenoid valve check.
Check TCC solenoid valve also in the same way.

YH4
GRAND
VITARA
7B1-66 AUTOMATIC TRANSMISSION (4 A / T)
14
2
3
INSTALLATION
Reverse removal procedure to install solenoid valves and noting
the following points.

For details of solenoid valve installation, refer to ªUnit Repairº
section. Use new gasket and O-ring.

Install oil tubes in such order as shown in figure.

For details of oil pan installation, refer to ªUnit Repairº section.
Use new oil pan gasket.

Tighten universal joint flange bolts & nuts and exhaust pipe brack-
et bolts to specified torque.

Fill A / T fluid and check fluid level according to procedure de-
scribed in ªCHANGING FLUIDº previously.

Check for fluid leakage after warming up A / T.
THROTTLE POSITION SENSOR
INSPECTION
Refer to SECTION 6E1 / 6E2 for inspection.
POWER / NORMAL CHANGE SWITCH
INSPECTION
Check Power / Normal change switch for operation referring to Step
4 of Diag. Flow Table B-4 in this section.
If malfunction is found, replace.

YH4
GRAND
VITARA
1. Wood block
2. Dash panel
t: 45 mm / 1.8 in.
H: 200 mm / 8 in.
W: 100 ± 150 mm / 4 ± 6 in.
1. Transmission jack
2. Engine rear mounting member
3. Gear shift lever case
4. Bolt
TRANSFER 7D-5
TRANSFER ASSEMBLY
Dismounting and remounting of transfer and transmission together
as a unit is described in Section 7A for Manual Transmission or 7B1
for Automatic Transmission, but it is also possible to dismount and
remount transfer assembly by itself as described below.
DISMOUNTING
IN ENGINE ROOM
1) Disconnect negative (±) cable from battery.
2) Remove distributor assembly (if equipped).
3) Place wood block between engine and dash panel so that it
serves as stopper when engine, transmission and transfer unit
hangs down as rear mounting member is removed.
CAUTION:
Make sure to use wood block to prevent contact which
may occur between dash panel and CMP sensor case
(G16), CMP sensor (J20) or intake manifold (H25), and fan
and shroud.
IN CABIN
1) Remove console box.
2) Remove shift lever of transmission and transfer.
ON LIFT
1) Drain transfer oil.
2) Remove rear propeller shaft.
3) Remove front propeller shaft.
4) Disconnect exhaust center pipe.
5) Disconnect speed sensor coupler.
6) Place transmission jack and remove mounting member.
7) Lower transmission jack gradually and check to ensure that
wood block serves as stopper between engine and dash panel.
8) Remove bolts for gear shift lever case.
9) Pull off breather hose.

YH4
GRAND
VITARA
1. Meter cluster
2. Hazard switch
Terminal
Wire ColorSwitch Position
LH steering vehicle shown
LIGHTING SYSTEM 8B-9
TURN SIGNAL AND HAZARD WARNING
LIGHTS
TURN SIGNAL SWITCH (IN COMBINATION SWITCH)
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect combination switch lead wire coupler.
3) Check for continuity between terminals at each switch position
shown below. If check result is not as specified, replace switch.
TLTBTR
G/RGG/Y
L
N
R
REMOVAL AND INSTALLATION
Refer to Section 3C COMBINATION SWITCH for vehicle without air
bag system and Section 3C1 CONTACT COIL AND COMBINA-
TION SWITCH ASSEMBLY for vehicle with air bag system.
HAZARD SWITCH
REMOVAL
1) Remove meter cluster.
2) Pull hazard switch out of instrument panel.
3) Disconnect coupler from hazard switch.
4) Remove hazard switch.
INSTALLATION
Reverse removal procedure.
INSPECTION
Check for continuity between terminals at each switch position
shown below. If check result is not as specified, replace siwtch.