2003 SUZUKI GRAND VITARA oil pressure

YH4
GRAND
VITARA
ªAº: Drill hole with approximately
3 mm (0.12 in.) diameter.
REAR SUSPENSION 3E-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to SECTION 3.
SHOCK ABSORBER CHECK

Inspect for deformation or damage.

Inspect bushings for wear or damage.

Inspect for evidence of oil leakage.
Replace any defective part.
WARNING:
When handling rear shock absorber in which high-pressure
gas is sealed, make sure to observe the following precau-
tions.
1) Don't disassemble it.
2) Don't put it into the fire.
3) Don't store it where it gets hot.
4) Before disposing it, be sure to drill a hole in it where
shown by an arrow in the figure and let gas and oil out.
Lay it down sideways for this work.
5) The gas itself is harmless but it may issue out of the hole
together with chips generated by the drill. Therefore, be
sure to wear goggle.
LOWER ROD, UPPER ROD, LATERAL ROD
CHECK
Inspect for cracks, deformation or damage.
Replace any defective part.
Inspect each bush for wear and breakage. If found defective, re-
place.
AXLE HOUSING AND COIL SPRING CHECK
Inspect for cracks, deformation or damage.
Inspect for evidence of oil leakage at axle housing.
If any, replace defective part.

YH4
GRAND
VITARA
1. Boot
2. Boot band
1. Circlip1. Cage Wheel side
ªAº Fill grease 85g (3.0 oz)
4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
ASSEMBLY
CAUTION:

To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with cloth
is allowed.

For M / T vehicle with H25 engine
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint. i.e. yellow
grease to wheel side joint and black one to differential
side.

Bend each boot band against forward rotation.

Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its du-
rability.
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part.
2) Fit wheel side boot on shaft.
Fill up inside of boot with joint grease of about 90 gram.
Before fixing boot band, insert screwdriver into boot on joint side
and allow air to enter boot so that air pressure in boot becomes
the same as atmospheric pressure.
3) Fixing boot band.
4) Install boot onto drive shaft till its small diameter side fits to shaft
groove and fix there with boot band.
5) Install cage to shaft.
CAUTION:
Install cage directing smaller outside diameter side to
shaft end.
6) Install circlip by using snap ring plier.

YH4
GRAND
VITARA
ªAº: Fill grease 90 ± 95 g (3.2 ± 3.4 oz)
1. Circlip
[LH] [RH] Differential side
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-7
7) Apply grease to entire surface of cage.
Use joint grease in tube included in spare part or joint grease
(99000-25120).
8) Insert cage into outer race and fit circlip into groove of outer
race.
CAUTION:
Position opening of circlip ªaº so that it will not be lined
up with a ball.
9) Apply grease to inside of outer race, and fit boot to outer race.
Fill up inside of boot with joint grease.
ªAº: Joint Grease 99000-25120
(about 90 ± 95g / 3.2 ± 3.4 oz)
10) Fitting boot to outer race, adjust so that measurements ªbº and
ªcº become as indicated in figure.
Length ªbº: 203.2 ± 213.2 mm
(8.00 ± 8.40 in.)
196.8 ± 206.8 mm
(7.75 ± 8.14 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
ªcº: 125.5 ± 135.5 mm
(4.94 ± 5.33 in.)
127.5 ± 137.5 mm
(5.02 ± 5.41 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
Before fixing boot band, insert screwdriver into boot on joint
side and allow air to enter boot so that air pressure in boot be-
comes the same as atmospheric pressure.
11) Clamp boot band. Check boots for distortion or dent.

YH4
GRAND
VITARA
BRAKES 5-3
SUBSTANDARD OR
CONTAMINATED BRAKE FLUID
Improper brake fluid, mineral oil or water in the fluid
may cause the brake fluid to boil or the rubber compo-
nents in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the
drum brake wheels.
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol
out of the system. Replace all rubber parts in the sys-
tem, including hoses. Also, when working on the
brake mechanisms, check for fluid on the linings. If ex-
cessive fluid is found, replace the linings.
If master cylinder piston seals are satisfactory, check
for leakage or excessive heat conditions. If condition
is not found, drain fluid, flush with brake fluid, refill and
bleed system.
The system must be flushed if there is any doubt as
to the grade of fluid in the system or if fluid has been
used which contained parts that have been subjected
to contaminated fluid.
DIAGNOSIS
ROAD TESTING BRAKES
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both
light and heavy pedal forces at various speeds to de-
termine if the vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the
other without brake application. If it does, check the
tire pressure, front end alignment and front suspen-
sion attachments for looseness. See diagnosis chart
for other causes.
BRAKE FLUID LEAKS
Check the master cylinder fluid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low level indicates a leak in the
system. In such a case, check the entire brake system
for leakage. If even a slight evidence of leakage is
noted, the cause should be corrected or defective
parts should be replaced.
If fluid level is lower than the minimum level of reser-
voir, refilling is necessary. Fill reservoir with specified
brake fluid.
Brake fluid: Refer to reservoir tank cap.
CAUTION:
Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
tank cap, do not use or mix different type of
fluid when refilling; otherwise serious damage
will occur.
Do not use old or used brake fluid, or any fluid
from a unsealed container.

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
Engine
Vehicle speed
sensor
Throttle position
sensor
ECT sensor
Cruise control
module
(if equipped)Torque converter Planetary gear
Final gear
reduction unit
Oil pump
Shift and TCC
solenoid valvesClutch and brake
Control valve
ªO / D OFFº lamp
ªPOWERº lamp
MILTransmission range
switch
O / D cut switch
P / N change switch
Transfer 4L switch
(if equipped)
CMP sensor Powertrain (engine) control module
Power transmission
Fluid pressure circuit
Electric signalInput speed sensor Brake pedal switch
Output speed sensor
AUTOMATIC TRANSMISSION (4 A / T) 7B1-7
ELECTRONIC SHIFT CONTROL SYSTEM
The gear ratio change in ªDº or ª2º range and torque converter clutch operation are controlled by Powertrain (En-
gine) Control Module.

YH4
GRAND
VITARA
7B1-26 AUTOMATIC TRANSMISSION (4 A / T)
Operation
VISUAL INSPECTION
Visually check following parts and systems.
INSPECTION ITEM
REFERRING SECTION

A / T fluid ± ± ± ± ± level, leakage, color

A / T fluid hoses ± ± ± ± ± disconnection, looseness, deterioration

Throttle (accelerator) cable ± ± ± ± ± play, installation

A / T throttle cable ± ± ± ± ± play, installation

A / T select cable ± ± ± ± ± installation, operation

Engine oil ± ± ± ± ± level, leakage

Engine coolant ± ± ± ± ± level, leakage

Battery ± ± ± ± ± fluid level, corrosion of terminal

Connectors of electric wire harness ± ± ± ± ± disconnection, friction

Fuses ± ± ± ± ± burning

Parts ± ± ± ± ± installation, damage

Bolt ± ± ± ± ± looseness

Other parts that can be checked visually
Also check following items at engine start, if possible.

ªO / D OFFº lamp

ªPOWERº lamp


Malfunction indicator lamp

Charge warning lamp

Engine oil pressure warning lamp

Engine coolant temp. meter

Other parts that can be checked visually
Section 0B
Section 7B1
Section 6E1 / 6E2
Section 7B1
Section 7B1
Section 0B
Section 0B
Section 6 / 6-1 / 7B1
Section 8
Section 7B1
Section 7B1
Section 6 / 6-1
Section 6H
Section 8 (Section 6A1 / 6A2 /
6A4 for pressure check)

YH4
GRAND
VITARA
7B1-28 AUTOMATIC TRANSMISSION (4 A / T)
Transmission fluid Running condition Running condition Gear shift
TROUBLE DIAGNOSIS TABLE 1
ConditionPossible CauseCorrection
TCC does not operate
Brake pedal (stop lamp) switch or its
circuit faulty (H25 engine only)

4WD low switch or its circuit faulty

Engine coolant temp. sensor or its
circuit faulty

Cruise control signal circuit faulty
(if equipped)DIAGNOSTIC FLOW TABLE A-1
Gear does not change
to 4th
O / D cut switch or its circuit faulty

4WD low switch or its circuit faulty

Engine coolant temp. sensor or its
circuit faulty

Cruise control signal circuit faulty
(if equipped)DIAGNOSTIC FLOW TABLE A-2
TROUBLE DIAGNOSIS TABLE 2
ConditionPossible CauseCorrection
Low fluid pressure
Clogged oil pump strainer

Malfunction of pressure regulator valveWash strainer.
Overhaul valve body.
High fluid pressure
Pressure regulator valveOverhaul valve body.
Unable to run in all
range
Regulator valve stickReplace.

Clogged oil strainerWash strainer.

Seized or broken planetary gearRepair or replace.

Faulty manual valveReplace.
Poor 1st speed run-
ning or excessive
slippage in ªDº or
ª2º
Faulty 1±2 shift valveReplace.
Poor 1±2 shift, ex-
ili

Regulator valve stickingReplace.
cessive slippage
1±2 shift valve stickingReplace.

Shift solenoid valve-B stickingReplace.

Intermediate coast modulator valve stick-
ingReplace.
Poor 2±3 shift, ex-
ili

2±3 shift valve stickingReplace.
cessive slippage
Shift solenoid valve-A stickingReplace.
Poor start or surg-
ing in ªDº range
Regulator valve stickingReplace.