2003 SUZUKI GRAND VITARA Valve

YH4
GRAND
VITARA
G16/J20 Engines H25 Engine
G16/J20 Engines
H25 Engine
1. PCM
2. Shift solenoid-A
3. Shift solenoid-B
4. TCC solenoid
AUTOMATIC TRANSMISSION (4 A / T) 7B1-47
DTC P0743 (DTC NO.65 / 66) TCC (LOCK-UP) SOLENOID ELECTRICAL
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
Voltage at terminal C51-1-8 for G16 / J20 (C51-1-2 for
H25) of PCM is high while TCC solenoid OFF is com-
manded or low while TCC solenoid ON is comman-
ded.
TCC (lock-up) solenoid valve

TCC (lock-up) solenoid valve circuit

PCM
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC.
3) Start engine, warm it up to normal operating temperature and shift transfer lever to ª2Hº or ª4Hº range.
4) Shift selector lever in D range and keep it there for 10 seconds.
5) Increase vehicle speed to about 80 km / h (50 mph) in 4th gear and in D range.
6) Keep driving at above speed for 20 seconds.
7) Release accelerator pedal, decrease vehicle speed and stop vehicle.
8) Check DTC and / or pending DTC.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-49
DTC P0751 SHIFT SOLENOID VALVE-A (#1) PERFORMANCE OR STUCK OFF
DTC P0756 SHIFT SOLENOID VALVE-B (#2) PERFORMANCE OR STUCK OFF
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While running in D range, gear change control from
PCM to A / T does not agree with actual A / T gear posi-
tion even though solenoid valve is electrically in good
condition.
(A / T gear position is calculated based on engine
speed signal and vehicle speed sensor signal.)
(2 driving cycles detection logic)DTC P0751:

Shift solenoid valve-A stuck or leakage.

2-3 shift valve stuck.

Valve body fluid passage clogged.

Mechanical malfunction in transmission.
(Direct clutch malfunction)
DTC P0756:

Shift solenoid valve-B stuck or leakage.

1-2 shift valve stuck.

3-4 shift valve stuck.

Valve body fluid passage clogged.

Mechanical malfunction in transmission.
(2nd brake malfunction)
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool and check fuel level meter
indication is 1 / 4 or more.
3) Start engine, warm it up to normal operating temperature and shift transfer lever to ª2Hº or ª4Hº range.
4) Increase vehicle speed with D range, and check that gear position changes from 1st to 2nd, 3rd and 4th in that
order as vehicle speed increases, referring to ªGear Shift Diagramº in this section.
5) Stop vehicle and check pending DTC and DTC by using scan tool.
TROUBLESHOOTING
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Shift solenoid valve-A or -B operation check:
1) Check shift solenoid valve-A or -B for operation
referring to ªSolenoid Valves Operation Checkº
section.
Is it in good condition?Go to Step 3.Faulty shift solenoid
valve-A or -B.
3Valve body check:
1) Check valve body and its passage referring to
ªUnit Repairº section.
Are they in good condition?Overhaul and repair
automatic transmis-
sion.Faulty valve body.

YH4
GRAND
VITARA
G16/J20 Engines H25 Engine
H25 Engine G16/J20 Engines
1. PCM
2. Shift solenoid-A
3. Shift solenoid-B
4. TCC solenoid
7B1-50 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0753 (DTC NO.61 / 62) SHIFT SOLENOID-A (#1) ELECTRICAL
DTC P0758 (DTC NO.63 / 64) SHIFT SOLENOID-B (#2) ELECTRICAL
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
DTC P0753:
Voltage detected at C51-1-2 for G16/J20 (C51-1-6 for
H25) terminal is specified voltage or lower when shift
solenoid valve-A is ON or specified voltage or higher
when it is OFF.
Shift solenoid valve-A

Shift solenoid valve-A circuit

PCM
DTC P0758:
Voltage detected at C51-1-1 terminal is specified volt-
age or lower when shift solenoid valve-B is ON or spe-
cified voltage or higher when it is OFF.
Shift solenoid valve-B

Shift solenoid valve-B circuit

PCM

YH4
GRAND
VITARA
G16 / J20 Engines
H25 Engine
1. PCM
2. 4WD low switch
3. J / C
7B1-52 AUTOMATIC TRANSMISSION (4 A / T)
DTC P1875 4WD LOW SWITCH CIRCUIT MALFUNCTION (if equipped)
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While driving at higher than specified vehicle speed
and with more than specified throttle valve opening,
the following conditions are satisfied for specified time.

Vehicle speed sensed by vehicle speed sensor is
more than 10 km / h higher than that sensed by A / T
output speed sensor.
(2 driving cycles detection logic)
4WD LOW switch or its circuit

PCM
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool.
3) Start engine.
4) Increase vehicle speed to about 30 km/h (19 mph) or more in D range and is in 2H position.
5) Keep driving at above vehicle speed for 30 seconds.
6) Stop vehicle and shift transfer lever to 4L position with A/T selector lever is in P range
7) Increase vehicle speed to about 25 km/h (15 mph) or more in D range and is in 4L position.
8) Keep driving at above vehicle speed for 30 seconds.
9) Stop vehicle and check pending DTC and DTC by using scan tool.

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. Radiator
2. Inlet hose (Outlet from oil cooler)
3. Outlet hose (Inlet to coil cooler)
4. Converter housing
5. Outlet hose
6. Inlet hose
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
G16 / J20
H25
1. A / T throttle cable
2. Stopper
3. Inner cable
4. A / T assemblyR100 mm
(3.94 in.)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-61
OIL COOLER HOSES
When replacing them, be sure to note the followings.

to replace clamps at the same time.

to insert hose as far as its limit mark.

to clamp hose securely.
A / T THROTTLE CABLE
ADJUSTMENT
1) Pull inner cable by force of 2 N (0.2 kg, 0.45 lb) or less to be no
slack of inner cable with A / T throttle cable curved as shown in
the figure.
2) Fix stopper to inner cable with clearance ªcº.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
3)For G16 / J20 engines
a) Check clearance ªcº. If it is out of specifications, adjust it by
turning cable adjusting nut.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
b) Tighten lock nut securely.
For H25 engine
a) Warm up engine and transmission to normal operating tem-
perature.
b) Make sure that accelerator cable is adjusted as specified.
c) With throttle valve closed, check clearance ªcº which should
be within the following specification.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
If it is out of specification, adjust it by turning cable adjusting nut.