2003 SUZUKI GRAND VITARA brake fluid

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
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
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
1. Dipstick (G16 / J20)
2. Dipstick (H25)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-59
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
FLUID LEVEL
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal operating
temperature (70 ± 80C / 158 ± 176F). As a guide to check fluid
temperature, warm up engine till engine coolant temperature
meter indicated around 1 unit above ªCº point.
5) Keep engine idling and shift selector slowly to L and back to P
position.
6) With engine idling, pull out dipstick, wipe it off with a clean cloth
and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it. Fluid
level should be between FULL HOT and LOW HOT. If it is below
LOW HOT, add an equivalent of DEXRON-III up to FULL HOT.
Fluid specification
An equivalent of DEXRON-III
NOTE:

DO NOT RACE ENGINE while checking fluid level, even af-
ter the engine start.

DO NOT OVERFILL. Overfilling can causes foaming and
loss of fluid through breather. Then slippage and trans-
mission failure can result.

Bringing the level from LOW HOT to FULL HOT requires
0.3 liters (0.64/0.53 US/lmp.pt).

If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour af-
ter it is stopped.

YH4
GRAND
VITARA
1. Clutch pedal
2. Clevis lock nut
3. Push rod
1. Clutch master cylinder
2. Clutch pipe
3. Clutch hose
4. Clutch operating cylinder
1. Pipe
2. Hose
3. Spanner
4. Flare nut wrench2, (a)
7C1-4 CLUTCH
ON-VEHICLE SERVICE
CLUTCH PEDAL HEIGHT
Adjust clutch pedal height by loosening clevis lock nut and turning
push rod as shown.
Clutch pedal height is normal if clutch pedal is about
20 mm (0.79 in.) higher than brake pedal.
After adjusting, tighten lock nut to specified torque.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
CLUTCH PEDAL FREE TRAVEL
Depress clutch pedal, stop the moment clutch resistance is felt and
measure distance (clutch pedal free travel). Free travel should be
within following specification.
Pedal free travel ªaº: 15 ± 25 mm (0.6 ± 1.1 in.)
CLUTCH FLUID PIPE AND HOSE
REMOVAL
NOTE:
Do not allow fluid to get on painted surface.
1) Remove dust and dirt from each joint of hose and pipe to be dis-
connected and clean around reservoir cap.
2) Take out fluid with syringe or such.
3) Disconnect fluid pipe from hose.
NOTE:
To disconnect pipe from hose, separate them by using flare
nut wrench and spanner so as not to kink them.

YH4
GRAND
VITARA
1. Master cylinder
1. Attaching bolt
2. Attaching nut
3. Clevis pin
ªAº
7C1-6 CLUTCH
INSTALLATION
1) To bleed air from master cylinder itself, tilt it as shown in figure
and add fluid into it.
NOTE:
After bleeding air from master cylinder, plug pipe hole in it
to prevent fluid from spilling out of it till pipe is connected.
2) Install master cylinder assembly and new gasket to body, attach-
ing bolt, nuts and push rod clevis pin.
NOTE:
Do not reuse gasket.
3) Torque attaching bolt and nut to specification.
4) Connect fluid pipe and torque flare nut to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
5) Apply grease to clevis pin and install it.
ªAº: Grease 99000-25010
6) Fill reservoir with specified brake fluid and check fluid leakage.
7) After installation, bleed air from system and check clutch pedal
free travel. Refer to BRAKE section for air bleeding procedure.
FLUID INSPECTION
Fluid level should be always between MIN and MAX lines on reser-
voir. If fluid decreases quickly, check for leakage, repair leaky point,
if any, and add fluid up to MAX level.
NOTE:

Brake fluid damages painted surface badly. Should it get on
painted surface, remove it immediately and clean surface
thoroughly.

Do not use shock absorber fluid or any other fluid which con-
tains mineral oil. Do not use container which has been used
for mineral oil or which is wet from water. Mineral oil will
cause swelling and distortion of rubber parts in hydraulic
clutch system and water will mix with brake fluid, lowering
fluid boiling point. Keep all fluid containers capped to pre-
vent contamination.

Make sure not to use fluid whose container cap was first
opened more than a year ago.

YH4
GRAND
VITARA
3
4
1. Reservoir cap
2. Cylinder
3. Piston assembly
4. Push rod
5. Piston stopper
6. Circlip
7. Boot
8. Lock nut
9. Clevis
1. Circlip
2. Push rod
3. Piston
4. Cylinder
1. Circlip
2. Push rod
3. Piston stopper
CLUTCH 7C1-7
DISASSEMBLY AND ASSEMBLY CLUTCH
MASTER CYLINDER
DISASSEMBLY
1) Remove boot and then circlip with piston pushed in.
2) Remove push rod and blow compressed air gradually into hole
for pipe connection to remove piston assembly, using care to
prevent it from jumping out.
INSPECTION
Inspect all disassembled parts for wear or damage and replace
parts if necessary.
NOTE:

Wash disassembled parts with brake fluid.

Do not reuse piston assembly and circlip.
Inspect cylinder bore for scoring or corrosion. It is best to replace
corroded cylinder. Corrosion can be identified as pits or excessive
roughness.
NOTE:
Polishing bore of cylinder with anything abrasive is prohib-
ited, as damage to cylinder bore may occur.
Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from
cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot
be kept away from cylinder bore surfaces.
ASSEMBLY
NOTE:
Before installation, wash each part in specified brake fluid.
1) Apply brake fluid to inside of piston assembly and cylinder body.
2) Install piston assembly into cylinder.
3) With piston pushed down, install circlip as shown.
And install boot.