2002 SUZUKI GRAND VITARA Top

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-9
1-1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the
point required for proper analysis and diagnosis.
CUSTOMER QUESTIONNAIRE (EXAMPLE)
Customer's name:Model:VIN:
Date of issue:Date Reg.Date of problem:Mileage:
Problem Symptoms

ªABSº warning light abnormal: fails to turn on/fails to go off /
flashes

Abnormal noise while vehicle is running: from motor, from valve,
other__________________

Wheel is locked at braking:

Pump motor does not stop (running):

Braking does not work:

Other:
Frequency of occurrence
Continuous/Intermittent ( times a day, a month) /
other______________
Conditions for Occurrence
of Problem

Vehicle at stop & ignition switch ON:

When starting: at initial start only / at every start / Other______________

Vehicle speed: while accelerating / while decelerating / at stop /
while turning / while running at constant speed /
other________________

Road surface condition: Paved road / rough road / snow-covered
road / other_________________

Chain equipment:
Environmental Condition
Weather: fair / cloudy / rain / snow / other___________________

Temperature: F (C)
Diagnostic Trouble Code

First check: Normal code/malfunction code ( )

Second check after
test drive: Normal code / malfunction code ( )

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-15
1. Battery
2. Main fuses
3. Ignition switch
4. Circuit fuses
5. ABS hydraulic unit / control module
5-1. Terminal arrangement for ABS hydraulic unit /
control module assembly
5-2. ABS fail-safe relay (Solenoid valve relay)
5-3. ABS pump motor relay
5-4. Pump motor
5-5. Solenoid valves
6. ªABSº warning lamp
7. Right-rear wheel speed sensor
8. Left-rear wheel speed sensor
9. Right-front wheel speed sensor
10. Left-front wheel speed sensor
11. Data link connector
12. Diagnosis connector
13. Stop lamp
14. Stop lamp switch
15. PCM (ECM+TCM) or ECM
16. G sensor (For 4WD model only)
17. 4WD switch (For 4WD model only)
18. 4WD indicator lamp (For 4WD model only)
19. 4WD controller (If equipped)
20. EBD warning lamp (Brake warning lamp)
21. Combination meter
22. Parking brake switch
23. Brake fluid lever switch
24. Warning lamp driver moduleWire colorB : Black
B / Bl : Black / Blue
B / O : Black / Orange
B / W : Black / White
Bl : Blue
Bl /B : Blue / Black
Bl / O : Blue / Orange
Br : Brown
G : Green
G / B : Green / Black
G / W : Green / White
Lg : Lightgreen
Lg / B : Lightgreen / Black
O / B : Orange / Black
O / G : Orange / Green
O / W : Orange / White
P : Pink
P / B : Pink / Black
V / G : Violet / Green
W / BI : White / Blue
W / G : White / Green
W / Y : White / Yellow
Y : Yellow
Y / B : Yellow / Black
SYSTEM CIRCUIT
TERMINALCIRCUIT
A1Right-rear wheel speed sensor (+)
A2Right-front wheel speed sensor (±)
A3Right-front wheel speed sensor (+)
A4G sensor ground (For 4WD model only)
A5ÐÐÐ
A6ÐÐÐ
A7Idle up signal
A8Diagnosis switch terminal
A9Stop lamp switch
A10Ground (For ABS control module)
A11ABS fail-safe relay
A12Right-rear wheel speed sensor (±)
A13Left-front wheel speed sensor (±)
A14G sensor signal (For 4WD model only)
A15ÐÐÐ
A16ÐÐÐ
A17ªABSº warning lamp
A18Left-rear wheel speed sensor (+)
A19Left-rear wheel speed sensor (±)
A20Left-front wheel speed sensor (+)
A21ÐÐÐ
A22Data link connector
A23ÐÐÐ
A244WD switch (For 4WD model only)
A25Ignition switch
A26ªEBDº warning lamp
A27ABS pump motor relay
A28Ground (For ABS pump motor)

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-21
1. Ignition switch
2. G sensor
3. ABS hydraulic unit control
module assembly
4. ABS hydraulic unit/
control module
connector of harness
O/G
DTC 15 (DTC C1015) ± G SENSOR CIRCUIT (FOR 4WD MODEL ONLY)
DESCRIPTION
While a vehicle is at stop or running, if the potential difference between the sensor signal terminal ªA14º and the
sensor ground terminal ªA4º is not within the specified voltage value, or if the signal voltage while at a stop does
not vary from that while running, this DTC is set.
Therefore, this DTC may be set when a vehicle is lifted up and its wheel(s) is turned. In such case, clear the DTC
and check again.

YH4
GRAND
VITARA
Viscosity chart
SAE
1. Reverse idle gear shaft bolt
(DO NOT LOOSEN IT)
MANUAL TRANSMISSION (TYPE 1) 7A-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 1.5 liters (3.2 / 2.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to its thread.
CAUTION:

Transmission oil must not be poured through gear shift
control lever part.

Do not loosen or remove reverse idle gear shaft bolt.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
Viscosity chart
SAE
Temperature
1. Drain plug
2. Oil level / filler plug
MANUAL TRANSMISSION (TYPE 2) 7A1-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 2.6 liters (5.5 / 4.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to thread of plug (c).
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 38 N´m (3.8 kg-m, 27.5 lb-ft)
(b): 23 N´m (2.3 kg-m, 17.0 lb-ft)

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
1. Malfunction indicator lamp (MIL)
2. Scan tool
3. DLC
7B1-18 AUTOMATIC TRANSMISSION (4 A / T)
[For Vehicle without Monitor Connector]
ON-BOARD DIAGNOSTIC SYSTEM
For automatic transmission control system, PCM (ECM) has follow-
ing functions. Refer to Section 6 / 6-1 for details.

When the ignition switch is turned ON with the engine at a stop,
malfunction indicator lamp (MIL) turns ON to check the bulb of the
MIL.

When PCM detects a malfunction in A / T control system (and / or
a malfunction which gives an adverse effect to vehicle emission)
while the engine is running, it makes the malfunction indicator
lamp in the meter cluster of the instrument panel turn ON and
stores the malfunction area in its memory. (If it detects that contin-
uously 3 driving cycles are normal after detecting a malfunction,
however, it makes MIL turn OFF although DTC stored in its
memory will remain.)

It is possible to communicate through DLC by using not only SU-
ZUKI scan tool (Tech-1) but also generic scan tool. (Diagnostic in-
formation can be accessed by using a scan tool.)
2 Driving Cycle Detection Logic
Refer to section 6 / 6-1 for details.
Pending DTC
Refer to section 6 / 6-1 for details.
Freeze Frame Data
Refer to section 6 / 6-1 for details.

YH4
GRAND
VITARA
1. Malfunction indicator lamp (MIL)
2. Scan tool
3. DLC
4. Monitor connector
5. Diagnosis switch terminal
6. Ground terminal MIL
OFF
Time (sec.)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-19
[For Vehicle with Monitor Connector]
ON-BOARD DIAGNOSTIC SYSTEM
For automatic transmission control system, PCM (ECM) has follow-
ing functions. Refer to Section 6 / 6-1 for details.

When the ignition switch is turned ON with the engine at a stop,
malfunction indicator lamp (MIL) turns ON to check the bulb of the
MIL.

When PCM detects a trouble in electronic shift control system, it
stores its trouble code in back-up memory in itself. (The memory
is kept as it is even if the trouble was only temporary and disap-
peared immediately. And it is not erased unless the power to PCM
is shut off for 30 seconds or longer.)

It is possible to communicate through DLC by using not only SU-
ZUKI scan tool (Tech-1) but also generic scan tool. (Diagnostic in-
formation can be accessed by using a scan tool.)

It is also possible to communicate by not using scan tool. PCM
indicates trouble area in memory by means of flashing of malfunc-
tion indicator lamp at the time of inspection (i.e. when diagnosis
switch terminal is grounded and ignition switch is turned ON).