2002 SUZUKI GRAND VITARA transmission range

YH4
GRAND
VITARA
7B1-56 AUTOMATIC TRANSMISSION (4 A / T)
8) Stall speed should be within the following specification.
Stall speed: 2,100 ± 2,400 r / min. for G16 engine
2,300 ± 2,600 r / min. for J20 engine
2,300 ± 2,600 r / min. for H25 engine
Check result
Possible cause
Lower than standard
level
Faulty engine output

Defective torque converter
Higher than standard
level in ªDº range
Slippery O/D clutch

Slippery forward clutch

Malfunctioning O/D one-way clutch

Malfunctioning one-way clutch No. 2

Low line pressure
Higher than standard
level in ªRº range
Slippery direct clutch

Slippery reverse brake

Low fluid pressure

Slippery O/D clutch

Defective O/D one-way clutch
ROAD TEST
This test is to check if upshift and downshift take place at specified
speed while actually driving vehicle on a level road.
WARNING:

Carry out test in very little traffic area to prevent an acci-
dent.

Test requires 2 persons, a driver and a tester.
1) Warm up engine.
2) With engine running at idle, shift select lever ªDº.
3) Accelerate vehicle speed by depressing accelerator pedal grad-
ually.
4) While driving in ªDº range, check if gear shift occurs properly as
shown in Gear Shift Diagram in this section.
Test result
Possible cause
When 1
2 upshift fails to
occur1±2 shift valve stuck
When 2
3 upshift fails to
occur2±3 shift valve stuck
When 3
O/D upshift
fails to occur3±4 shift valve stuck
When gear shift point is in-
correct
Maladjusted throttle cable

Defective shift solenoid valve
-A or -B

1±2, 2±3 or 3±4 shift valve not
operating properly

YH4
GRAND
VITARA
1
1. Shift solenoids connector
AUTOMATIC TRANSMISSION (4 A / T) 7B1-57
MANUAL ROAD TEST
This test check the gear being used in ªLº, ª2º or ªDº range when
driven with unoperated gear shift control system. Test drive vehicle
on a level road.
NOTE:
Before this test, check diagnostic trouble code (DTC).
1) Disconnect coupler of shift solenoid valves on transmission.
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when disconnecting shift solenoid
valves coupler.
2) With select lever in ªPº, start engine and warm it up.
3) With select lever in ªLº range, start vehicle and accelerate to 20
km/h (12.5 mile/h). Check in this state that 1st gear is being
used.
4) At 20 km/h (12.5 mile/h), shift select lever to 2 range and acceler-
ate to 40 km/h (25 mile/h). Check in this state that 3rd gear is
being used.
5) At 40 km/h (25 mile/h), shift select lever to D range and check
that O/D gear is used when speed is higher than 40 km/h (25
mile/h).
6) After above checks, stop vehicle then engine, and connect shift
solenoids coupler with ignition switch OFF.
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when connecting shift solenoid valves
coupler.
7) Clear DTC with scan tool.
TIME LAG TEST
This test is to check conditions of clutch, reverse brake and fluid
pressure. ªTime lagº means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels re-
spectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from ªNº to ªDº range
and measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from ªNº to ªRº
range.
Specification for ªNº
ªDºLess than 1.2 sec.
time lagªNº
ªRºLess than 1.5 sec.
NOTE:

When repeating this test, be sure to wait at least minute
after select lever is shifted back to ªNº range.

Engine should be warmed up fully for this test.
Test resultPossible causes
When ªNº
ªDº time lag
exceeds specification
Low line pressure

Worn forward clutch
When ªNº
ªRº time lag
exceeds specification
Low line pressure

Worn direct clutch

Worn reverse brake

YH4
GRAND
VITARA
7B1-58 AUTOMATIC TRANSMISSION (4 A / T)
ENGINE BRAKE TEST
WARNING:
Before test, make sure that there is no vehicle behind so as
to prevent rear-end collision.
1) While driving vehicle in 3rd gear of ªDº range, shift select lever
down to ª2º 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 ªLº range.
3) If engine brake fails to operate in above tests, possible causes
for such failure are as follows. Check each part which is sus-
pected to be the cause.
Condition
Possible cause
Fails to operate when shifted
down to ª2º rangeSecond coast brake defec-
tive
Fails to operate when shifted
down to ªLº rangeReverse brake defective
ªPº RANGE TEST
1) Stop vehicle on a slope, shift select lever to ªPº range and at the
same time apply parking brake.
2) After stopping engine, depress brake pedal and release parking
brake.
3) Then, release brake pedal gradually and check that vehicle re-
mains stationary.
4) Depress brake pedal and shift select lever to ªNº range.
5) Then, release brake pedal gradually and check that vehicle
moves.
WARNING:
Before test, check to make sure no one is around vehicle
or down on a slope and keep watchful for safety during
test.

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
7B1-64 AUTOMATIC TRANSMISSION (4 A / T)
1. A / T vehicle (output) speed sensor
ªNº reference
line
Center line on
manual valve shaft
G16 / J20
1. Service wire
2. PCM connectors disconnected
Switch
position
TRANSMISSION RANGE SWITCH (SENSOR)
INSPECTION & ADJUSTMENT
1) Shift select lever to ªNº range.
2) Check that center line on manual valve shaft and ªNº reference
line on switch are aligned. If not, loosen switch bolt and align
them.
3) Check that engine starts in ªNº and ªPº ranges but it doesn't start
in ªDº, ª2º, ªLº or ªRº range. Also, check that back-up lamp lights
in ªRº range.
4) If faulty condition cannot be corrected by adjustment, discon-
nect transmission range switch coupler and check that continu-
ity exists as shown by moving select lever.
Terminal No.54982310765498231076
P
R
N
D
2
L
A / T OUTPUT SPEED SENSOR
INSPECTION
Check A / T output speed sensor for resistance between terminals
of sensor or PCM coupler.
A / T output speed sensor
resistance value : 387 ± 473
at 20
C, 68
F
O / D CUT SWITCH
INSPECTION
Check O / D cut switch for operation referring to step 4 of Diag. Flow
Table B-2 in this section.
If malfunction is found, replace.
SOLENOID VALVES
(Shift solenoid valves & TCC solenoid valve)
INSPECTION
With couplers of PCM disconnected and using service wire as
shown at the left, check each solenoid valve for clicking sound.
G16 / J20 Engines
Shift solenoid valve - A (#1)C51-1-2
Shift solenoid valve - B (#2)C51-1-1
TCC (Lock-up) solenoid valveC51-1-8

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
7B1-68 AUTOMATIC TRANSMISSION (4 A / T)
1. Select lever
2. Shift lock solenoid
3. Brake light switch
4. Brake pedal
5. Cable
6. Ignition switch
1. Select lever
2. Interlock cam3. Shift lock solenoid rod
4. Shift lock solenoid
Type-1
BRAKE INTERLOCK SYSTEM
SHIFT LOCK SOLENOID CONTROL
This system consists of shift lock solenoid control system and inter-
lock cable control system.
The shift lock solenoid control system is so designed that the selec-
tor lever can not be shifted from ªPº range position unless the igni-
tion switch is turned ON and the brake pedal is depressed. And the
interlock cable control system is so designed that the selector lever
cannot be shifted from ªPº range position unless the ignition switch
is turned to ªACCº or ªONº position. Also, the ignition key cannot be
pulled out of the key slot unless the selector lever is in ªPº range.
SHIFT LOCK SOLENOID CONTROL OPERATIONS
When the select lever is in ªPº range, the ignition key position is
ªONº and depressing the brake pedal cause the electric current to
flow to the solenoid. As the shift lock solenoid rod (or the lock plate)
is drawn toward the solenoid in this state, it frees the interlock cam
(or the detent pin), which then allows the select lever to be shifted
from ªPº range to any other position.
Even when the select lever is in ªPº range, if the ignition key position
is ªLOCKº or ªACCº or the brake pedal is not depressed, the electric
current does not flow to the solenoid.
In this state, the shift lock solenoid rod (or the lock plate) is pushed
away from the solenoid by spring force and it obstructs the interlock
cam (or the detent pin) movement. Thus the select lever button
does not work even when pressed and the select lever shift is pre-
vented.

YH4
GRAND
VITARA
Type-2
1. Select lever
2. Detent pin
3. Detent plate4. Lock plate
5. Shift lock solenoid
1. Cover
2. Screw3. Select lever
4. Button
AUTOMATIC TRANSMISSION (4 A / T) 7B1-69
SHIFT LOCK (SOLENOID) MANUAL RELEASE
Shift lock can be manually released by following procedure.
1) Remove access hole cover by unfastening screw.
2) Turn ignition key to ªACCº position and move shift lock solenoid
rod (or manual release plate) toward rear side of vehicle by using
screw driver or the like.
3) In this state, select lever can be moved to any range or position.
SYSTEM INSPECTION
1) Check to make sure that select lever cannot be moved to any
other range from ªPº range position when ignition switch key is
at ªACCº position, at ªLOCKº position (or it is removed from key-
hole of ignition switch) or brake pedal is not depressed.
2) Shift select lever to ªPº range position, release knob button and
check for the following.

Ignition key can be turned between ªLOCKº and ªACCº posi-
tions back and forth and also it can be removed from ignition
switch.