2003 SUZUKI GRAND VITARA shift cable

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
7B1-24 AUTOMATIC TRANSMISSION (4 A / T)
MALFUNCTION INDICATOR LAMP (MIL) CHECK
Refer to the same item in Section 6 / 6-1 for checking procedure.
ªO / D OFFº LAMP CHECK
1) Check that O / D cut switch button is at OFF position (pushed).
2) Turn ignition switch ON.
3) Check that ªO / D OFFº lamp lights for about 2 ± 4 sec. and then goes OFF.
If anything faulty is found, advance ªDiagnostic flow table B-1 or B-2º O / D OFF ªLAMP CIRCUIT CHECKº.
ªPOWERº LAMP CHECK
1) Check that Power / Normal change switch button is at Normal position.
2) Turn ignition switch ON.
3) Check that ªPowerº Lamp light for 2 ± 4 sec. and then goes OFF.
If anything faulty is found, advance ªDiagnostic flow table B-3 or B-4 ªPOWERº LAMP CIRCUIT CHECK 2.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
Refer to the same item in Section 6 / 6-1 for checking procedure.
DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE
Refer to the same item in Section 6 / 6-1 for clearance procedure.
DIAGNOSTIC TROUBLE CODE (DTC) TABLE (A / T RELATED CODE)
DTC NO.MIL
Using
scan toolNot using
scan toolDETECTED ITEMDETECTING CONDITION
Vehicle
without
monitor
connectorVehicle
with
monitor
connector
±12±No trouble.±±
P070572Transmission range
sensor circuit
Multiple signals inputted simulta-
neously or no signal inputted while
2 driving
cycles
Not
applicablesensor circuit
malfunction
neously or no signal in utted while
running at 60 km / h or more.
cyclesa licable
P071576Input / Turbine speed
sensor circuit
malfunctionInput shaft revolution speed is lower
than specified value while
vehicle is running with ªDº range and
specified engine speed or higher.2 driving
cyclesNot
applicable
P072075Output speed sensor
circuit malfunctionOutput speed sensor signal not
inputted while VSS signal being
inputted.2 driving
cyclesNot
applicable
*1
P0741
Not
applicableTCC (lock-up) solenoid
performance or stack
offActual TCC operation does not
agree with ON / OFF control from
PCM to TCC.2 driving
cyclesNot
applicable
P074365
66TCC (lock-up)
solenoid electricalMonitor signal OFF is detected
When TCC control solenoid is ON or
monitor signal ON is detected when
it is OFF.1 driving
cycleNot
applicable
*1
P0751
Not
applicableShift solenoid A (#1)
performance or stuck
offGear change control from PCM to
A / T does not agree with actual gear
position of A / T.2 driving
cyclesNot
applicable
P075361
62Shift solenoid A (#1)
electricalMonitor signal OFF is detected
when shift solenoid A (#1) is ON or
monitor signal ON is detected when
it is OFF.1 driving
cycleNot
applicable

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-25
DIAGNOSTIC TROUBLE CODE (DTC) TABLE (A / T RELATED CODE) (cont'd)
DTC NO.MIL
Using
scan toolNot using
scan toolDETECTED ITEMDETECTING CONDITION
Vehicle
without
monitor
connectorVehicle
with
monitor
connector
*1
P0756
Not
applicableShift solenoid B (#2)
performance or stuck
offGear change control from PCM to
A / T does not agree with actual gear
position of A / T.2 driving
cyclesNot
applicable
P075863
64Shift solenoid B (#2)
electricalMonitor signal OFF is detected
when shift solenoid B (#2) is ON or
monitor signal ON is detected when
it is OFF.1 driving
cycleNot
applicable
*1
P1875
Not
applicable4WD low switch circuit
malfunctionDifference between vehicle speed
detected by VSS and vehicle speed
detected by output speed sensor
and compensated by 4WD low
switch is larger than specification.2 driving
cyclesNot
applicable
NOTE:
*1: Applicable to vehicle without monitor connector only.
FAIL-SAFE TABLE
When any of the following DTC is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues
to exist but that mode is canceled when ECM detects normal condition after that.
DTC NO.
Using
scan toolNot using
scan toolTROUBLE AREAFAIL SAFE OPERATION
P0177
P011814
15ECT SENSOR
Each control except 4-A / T is permitted on the basis of
30.1C engine coolant temp.

4-A / T control is performed assuming 31C (engine warmed
up) or higher after 15 min. from engine start.
P0122
P012321
22TP SENSOR
Each control except 4-A / T is performed on the basis of 124
throttle valve opening.

4-A / T control is performed on the basis of 0 throttle valve
opening.
P070572TR SWITCHA / T control is performed in priority order of L, 2, N, D, R
and P.
P072075OUTPUT SPEED
SENSOR CIRCUIT
MALFUNCTIONA / T control is performed by using signal from VSS.
P075361
62SHIFT SOLENOID
A (#1)
A / T control using 3rd gear is performed when D range, 1st
or 2nd gear is used.

TCC solenoid OFF.
P075863
64SHIFT SOLENOID
B (#2)
A / T control using 4th gear is performed when D range 2nd
or 3rd gear is used.

When both shift solenoid A (#1) and B (#2) failed
simultaneously, A / T control using 4th gear is always
performed in D range.

TCC solenoid OFF.
P074365
66TCC (Lock-up)
SOLENOIDTCC (lock-up) solenoid OFF.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-41
C51-1
-18C51-1
-17C51-1
-16C51-1
-15C51-1
-28C51-1
-27 G16/
J20
H25
C51-1-4 C51-1-3 C51-1-13 C51-1-12 C51-1-20 C51-1-19
Terminal
Select
lever
position
TROUBLESHOOTING (DTC P0705)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Check Transmission Range Switch (Sensor) Circuit for
Operation.
When using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON and check transmission
range signal (P, R, N, D, 2 or L) on display
when shifting select lever to each range.
Is applicable range indicated?
When not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check voltage at terminals C51-1-15, C51-1-16,
C51-1-17, C51-1-18, C51-1-27 and C51-1-28 for
G16/J20 (C51-1-4, C51-1-3, C51-1-13, C51-1-12,
C51-1-20 and C51-1-19 for H25) respectively with
select lever shifted to each range.
Taking terminal C51-1-28 for G16/J20 (C51-1-20 for
H25) as an example, is battery voltage indicated
only when select lever is shifted to ª2º range and
0 V for other ranges as shown in figure?
Check voltage at other terminals likewise, referring
to figure.
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to ªIntermit-
tent and Poor
Connectionº in
section 0A.Go to Step 3.
3Check Select Cable for Adjustment referring to ªSelect
Cable Adjustmentº in this section.
Is it adjusted correctly?Go to Step 4.Adjust.
4Check Transmission Range Switch for Installation
Position.
1) Shift select lever to ªNº range.
2) Check that ªNº reference line on switch and center
line on shaft are aligned.
Are they aligned?Go to Step 5.Adjust.
5Check Transmission Range Switch (Sensor) referring
to ªTransmission Range Switchº in this section.
Are check results satisfactory?ªYº, ªOr / Gº, ªRº,
ªOr / Blº, ªY / Gº,
ªG / Orº or ªG / Blº
circuit open or short.
If wires and
connections are OK,
substitute a known-
good PCM and
recheck.Replace TR switch.
Fig. for Step 2.

YH4
GRAND
VITARA
1
1. 4WD low switch
AUTOMATIC TRANSMISSION (4 A / T) 7B1-53
TROUBLESHOOTING (DTC P1875)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
24WD low switch and its circuit check:
When using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON.
3) Select ªData listº mode on scan tool.
4) Check 4WD low switch signal (ON or OFF) on
display when shifting transfer lever to each
position.
4H or 2H position : OFF
4L position : ON
Is OFF / ON displayed as described above?
When not using SUZUKI scan tool:
1) Remove PCM cover.
2) Turn ignition switch ON.
3) Check voltage at terminal C51-1-26 for G16 / J20
(C51-1-5 for H25) of PCM connector connected
when shifting transfer lever to each position.
4H or 2H position : 10 ± 14 V
4L position : 0 ± 1 V
Is voltage as specified?Check for poor con-
nection at the termi-
nal of PCM if voltme-
ter is used in Step 2.
If connection is OK,
intermittent trouble
or faulty PCM.
Check for intermittent
referring to ªIntermit-
tent and Poor
Connectionº in
Section 0A.Go to Step 3.
34WD low switch check:
1) Check 4WD low switch for operation referring to
ª4WD Low Switch Inspectionº below.
Is check result satisfactory?ªOr / Wº or ªBº circuit
open or short. If wires
and connections are
OK, substitute a
known-good PCM
and recheck.Replace 4WD low
switch.
4WD Low Switch Inspection
1) Disconnect negative cable at battery.
2) Disconnect 4WD low switch coupler.
3) Check continuity between 4WD low switch terminals.
There should be continuity when transfer lever shifted to 4L posi-
tion and should be infinity when transfer lever shifted to 4H or 2H
positions.
If not, replace 4WD low switch.
4) Connect 4WD low switch coupler and battery negative cable.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-55
Check resultPossible cause
Line pressure higher
than standard level in
each range
Malfunctioning regulator valve

Malfunctioning throttle valve

Maladjusted A / T throttle cable
Line pressure lower than
standard level in each
range
Defective O/D clutch

Defective oil pump

Malfunctioning throttle valve

Malfunctioning regulator value

Maladjusted A / T throttle cable
Line pressure lower than
standard level only in ªDº
range
Fluid leakage from forward clutch

Defective O/D clutch

Leakage from ªDº range fluid pressure cir-
cuit
Line pressure lower than
standard level only in ªRº
range
Fluid leakage from direct clutch

Defective O/D clutch

Fluid leakage from reverse brake

Fluid leakage from ªRº range fluid circuit
Tightening torque of transmission case plug:
17 N.m (1.7 kg-m, 12.0 lb-ft)
STALL TEST
This test is to check overall performance of automatic transmission
and engine by measuring stall speed at ªDº and ªRº ranges. Be sure
to perform this test only when transmission fluid is at normal operat-
ing temperature and its level is between FULL and LOW marks.
CAUTION:

Do not run engine at stall more than 5 seconds continu-
ously, for fluid temperature may rise excessively high.

After performing stall test, be sure to leave engine running
at idle for longer than 30 seconds before another stall test.
1) Apply parking brake and block wheels.
2) Install tachometer.
3) Start engine with select lever shifted to ªPº.
4) Depress brake pedal fully.
5) Shift select lever to ªDº and depress accelerator pedal fully while
watching tachometer. Read engine rpm quickly when it has be-
come constant (stall speed).
6) Release accelerator pedal immediately after stall speed is
checked.
7) In the same way, check stall speed in ªRº 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. 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.