2003 SUZUKI GRAND VITARA Shift gear arm

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-23
User name: Model: VIN:
Date of issue: Date of Reg: Date of problem: Mileage:
PROBLEM SYMPTOMS
Engine does not start
Vehicle does not move
(forward, rearward)
No lock-up (TCC clutch operation)
Shift point too high or too low
Excessive gear change shockEngine stops
Transmission does not shift
(1st, 2nd, 3rd, 4th, Rev) gear
Automatic shift does not occur
Transmission slipping in
(1st, 2nd, 3rd, 4th, Rev) gear
Other:
VEHICLE/ ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS
Environmental Condition
Weather
Temperature
Frequency
RoadFair/Cloudy/Rain/Snow/Always/Other ( )
Hot/Warm/Cool/Cold/(
C
F)/Always
Always/Sometimes/( times/ day, month)/Only Once
Urban/Suburb/Highway/Mountainous (uphill/downhill)/Paved road/Gravel/
Other( )
Vehicle Condition
Engine
Brake
O/D cut switch
P/N change switch
(P,R,N,D,2,L) range/(
) range
Cold/Warming up phase/Warmed up
At stop/During driving (constant speed/accelerating/decelerating/
right hand corner/left hand corner)/Other ( )/Speed ( km/h mile/h)
Speed( r/min)/Throttle opening(idle/about %/full)
Apply/Not apply
ON/OFF
Power/Normal
Malfunction indicator lamp condition
Always ON Sometimes ON Always OFF Good condition
Diagnostic trouble
codeFirst check : No codeMalfunction code( )
Second check : No code Malfunction code( )
Transmission range
Transmission temp.
Vehicle
CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)
NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of each
market.

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) 7B1-33
O / D cut
switchOFF ON
VoltageBattery
voltage0 V
DIAGNOSTIC FLOW TABLE A-2 (NO GEAR SHIFT TO O / D)
SYSTEM DESCRIPTION
PCM does not shift to O / D gear under any of the following conditions.

O / D cut switch: ON

4WD LOW switch: ON

Cruise control module: O / D OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

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

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor,
its circuit or engine
cooling system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-2 (G16 / J20 engines) or C51-1-6 (H25
engine) terminal of PCM coupler and ground,
C51-1-1 terminal of PCM coupler and ground.

O / D cut switch OFF (ªO / D OFFº lamp OFF).

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Drive vehicle with 4th gear condition
referring to ªGear shift diagramº in this
section.
Is each voltage about 0 V?Faulty shift solenoid
valve, its circuit or
transmission.ªGº wire or ªG / Rº wire
shorted to power circuit.
If OK, go to Step 4.
4O / D cut switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-33 (G16 / J20 engines) or
E61-14 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 5.Faulty O / D cut switch or
its circuit.
If OK, substitute a known-
good PCM and recheck.

YH4
GRAND
VITARA
7B1-46 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0741 TCC (LOCK-UP) SOLENOID VALVE PERFORMANCE OR STUCK OFF
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While running in 2nd or 4th gear, D range, TCC control
of PCM does not agree with actual operation of trans-
mission TCC even though solenoid valve is electrically
in good condition.
(2 driving cycles detection logic)
TCC (lock-up) solenoid valve stuck

TCC control valve stuck

Valve body fluid passage clogged

TCC faulty
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 and keep driving
about 20 mph, 30 km/h in 2nd of ªDº range for 10 seconds. (Throttle valve should be not at idle position and
the opening should be kept constant in this step.)
5) Keep driving about 50 mph, 80 km/h in 4th of ªDº range for 10 seconds.
6) Release accelerator pedal, decrease vehicle speed and stop vehicle.
7) 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.
2TCC solenoid valve operation check:
1) Check TCC solenoid valve operation referring to
ªSolenoid Valves Operation Checkº in this section.
Is it in good condition?Go to Step 3.Faulty TCC solenoid
valve.
3Valve body check:
1) Check valve body referring to ªUnit Repairº in this
section.
Is it in good condition?Faulty torque
converter.Faulty valve body.

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
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