2004 SUZUKI GRAND VITARA Air condition

YH4
GRAND
VITARA
7B1-22 AUTOMATIC TRANSMISSION (4 A / T)
1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a inspection form will facilitate collecting information to the point required for proper
analysis and diagnosis.
2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK, RECORD AND CLEARANCE
First, referring to DTC check section, check DTC (including pending DTC). If DTC exists, print or write down
DTC and freeze frame data and then clear them by referring to DTC clearance section. DTC indicates malfunc-
tion in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred
in the past and normal condition has been restored. In order to know that, check symptom in question according
to Step 5 and then recheck DTC according to Step 6.
Diagnosing a trouble based on the DTC in this step only or failure to clear the DTC in this step may result in
an faulty diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unnec-
essary.
3 and 4. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the A / T and
engine referring to Visual Inspection section.
5. TROUBLE SYMPTOM CONFIRMATION
Check trouble symptoms based on information obtained in Step 1 ªCUSTOMER COMPLAINT ANALYSISº and
Step 2 ªDTC/FREEZE FRAME DATA CHECKº.
Also, recheck DTC according to ªDTC Confirmation Procedureº described in each ªDTC FLOW TABLEº.
6 and 7. RECHECKING AND RECORD OF DTC/FREEZE FRAME DATA
Refer to ªDTC Checkº section for checking procedure.
8. A/T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE
Perform A / T basic check according to the ªA / T Basic Check Flow Tableº first. When the end of the flow table
has been reached, check the parts of the system suspected as a possible cause referring to TROUBLE DIAG-
NOSIS TABLE and based on symptoms appearing on the vehicle (symptoms obtained through steps of custom-
er complaint analysis, trouble symptom confirmation and/or A / T basic check) and repair or replace faulty parts,
if any.
9. DIAGNOSTIC TROUBLE CODE FLOW TABLE
Based on the DTC indicated in Step 6 and 7 and referring to ªDIAGNOSTIC TROUBLE CODE FLOW TABLEº
in this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator,
PCM or other part and repair or replace faulty parts.
10. CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
ªINTERMITTENT AND POOR CONNECTIONº in Section 0A and related circuit of DTC recorded in Step 2.
11. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the A / T is free from any abnormal conditions.
If what has been repaired is related to the malfunction DTC, clear the DTC once, set conditions under which
DTC was detected and A / T and/or vehicle was repaired and confirm that no DTC is indicated.

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
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.

YH4
GRAND
VITARA
Oscilloscope waveforms
2V/Div.
Waveforms at specified idle
speed in ªPº range5ms / Div.
AUTOMATIC TRANSMISSION (4 A / T) 7B1-43
TROUBLESHOOTING (DTC P0715)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Input speed sensor circuit check:
1) Remove PCM cover.
2) With ignition switch OFF, disconnect PCM
connectors.
3) Check for proper connection to input speed sensor
at C51-1-10 and C51-1-11 terminals for G16/J20
(at C51-1-8 and C51-1-16 terminals for H25)
4) If OK, check resistance of sensor circuit.
Resistance between C51-1-10
and C51-1-11 for G16 / J20
(C51-1-8 and C51-1-16 for H25):530 ± 650
at
20C, 68F
Resistance between C51-1-10 /
C51-1-11 for G16 / J20 (C51-1-8 /
C51-1-16 for H25) and ground: 1 M
or more
Are check results satisfactory?Go to Step 4.Go to Step 3.
3Input speed sensor check:
1) With ignition switch OFF, disconnect input speed
sensor connector.
2) Check for proper connection to input speed sensor
at each terminals.
3) If OK, then check resistance of input speed sensor.
Are measured values as specified in Step 2?ªBl / Gº or ªBl / Yº wire
open or shorted to
ground.Replace input speed
sensor.
4Check visually input speed sensor and overdrive clutch
drum for the followings.

No damage

No foreign material attached

Correct installation
Are they in good condition?Intermittent trouble
or faulty PCM.
Check for intermittent
referring to
ªIntermittent and
Poor Connectionº in
Section 0A.Clean, repair or
replace.
Reference
Connect oscilloscope between C51-1-11 (+) and C51-1-10 (±) for
G16 / J20 (C51-1-16 (+) and C51-1-8 (±) for H25) of PCM connector
connected to PCM and check input speed sensor signal.

YH4
GRAND
VITARA
Oscilloscope waveforms
2 V/Div.
5 ms / Div.
Waveforms at about 25 mph, 40 km / h
AUTOMATIC TRANSMISSION (4 A / T) 7B1-45
TROUBLESHOOTING (DTC P0720)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Output speed sensor circuit check:
1) Remove PCM cover.
2) With ignition switch OFF, disconnect PCM
connectors.
3) Check for proper connection to output speed sensor
at C51-1-22 and C51-1-23 terminals for G16 / J20
(at C51-1-9 and C51-1-10 terminals for H25).
4) If OK, check resistance of sensor circuit.
Resistance between C51-1-22
and C51-1-23 for G16 / J20
(C51-1-9 and C51-1-10 for H25): 387 ± 473
at
20 C, 68 F
Resistance between C51-1-22 /
C51-1-23 for G16/J20 (C51-1-9 /
C51-1-10 for H25) and ground: 1 M
or more
Are check results satisfactory?Go to Step 4.Go to Step 3.
3Output speed sensor check:
1) With ignition switch OFF, disconnect output speed
sensor connector.
2) Check for proper connection to output speed sensor
at each terminals.
3) If OK, then check resistance of output speed sensor.
Are measured values as specified in Step 2?ªOrº or ªWº wire
open or shorted to
ground.Replace output
speed sensor.
4Check visually output speed sensor and sensor rotor
for the followings.

No damage

No foreign material attached

Correct installation
Are they in good condition?Intermittent trouble
or faulty PCM.
Check for intermittent
referring to
ªIntermittent and
Poor Connectionº in
Section 0A.Clean, repair or
replace.
Reference
Connect oscilloscope between C51-1-23 (+) and C51-1-22 (±) for
G16/J20 (C51-1-10 (+) and C51-1-9 (±) for H25) of PCM connector
connected to PCM and check output speed sensor signal.

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
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
CLUTCH 7C1-3
DIAGNOSIS
ConditionPossible CauseCorrection
Slipping
Improper clutch pedal free travel.

Worn or oily clutch disc facing.

Warped disc, pressure plate or flywheel
surface.

Weakened diaphragm spring.

Master cylinder piston or seal cup not returning.Bleed air or replace master
cylinder.
Replace disc.
Replace disc, clutch cover or
flywheel.
Replace clutch cover.
Repair master cylinder.
Dragging clutch
Improper clutch pedal free travel.

Weakened diaphragm spring, or worn spring tip.

Rusted input shaft splines.

Damaged or worn splines of transmission
input shaft.

Excessively wobbly clutch disc.

Clutch facings broken or dirty with oil.

Fluid leakage.Bleed air or replace master
cylinder.
Replace clutch cover.
Lubricate.
Replace input shaft.
Replace disc.
Replace disc.
Repair or replace.
Clutch vibration
Glazed (glass-like) clutch facings.

Clutch facings dirty with oil.

Release bearing slides unsmoothly on input
shaft bearing retainer.

Wobbly clutch disc, or poor facing contact.

Weakened torsion springs in clutch disc.

Clutch disc rivets loose.

Distorted pressure plate or flywheel surface.

Weakened or loosened engine mounting
bolt or nut.Repair or replace disc.
Replace disc.
Lubricate or replace input
shaft bearing retainer.
Replace disc.
Replace disc.
Replace disc.
Replace clutch cover or flywheel.
Retighten or replace mounting.
Noisy clutch
Worn or broken release bearing.

Input shaft front bearing worn down.

Excessive rattle of clutch disc hub.

Cracked clutch disc.

Pressure plate and diaphragm spring rattling.Replace release bearing.
Replace input shaft bearing.
Replace disc.
Replace disc.
Replace clutch cover.
Grabbing clutch
Clutch disc facings soaked with oil.

Clutch disc facings excessively worn.

Rivet heads showing out of facing.

Weakened torsion springs.Replace disc.
Replace disc.
Replace disc.
Replace disc.