2004 SUZUKI GRAND VITARA torque

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. Dipstick (G16 / J20)
2. Dipstick (H25)
1. Drain plug
2. Propeller shaft
1. Dipstick (G16 / J20)
2. Dipstick (H25)
7B1-60 AUTOMATIC TRANSMISSION (4 A / T)
LEVEL CHECK AT ROOM TEMPERATURE
The fluid level check at room temperature performed after repair or
fluid change before test driving is just preparation for level check of
normal operating temperature. The checking procedure itself is the
same as that described previously. If the fluid level is between FULL
COLD and LOW COLD, proceed to test drive. And when the fluid
temperature has reached the normal operating temperature, check
fluid level again and adjust it as necessary.
FLUID CHANGE
1) Lift up vehicle.
2) With engine is cool, remove drain plug from oil pan and drain A / T
fluid.
3) Install drain plug.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Lower vehicle and fill proper amount of an equivalent of DEX-
RON
-III.
5) Check fluid level according to procedure described under LEV-
EL CHECK NORMAL OPERATING TEMPERATURE.
Fluid specification
An equivalent of DEXRON
-III
Fluid capacity
When draining
from drain plug
hole
2.5 liters (5.28/4.40 US/lmp.pt.)
When
overhauling
6.9 liters (14.58/12.14 US/lmp.pt.)
for G16
7.1 liters (15.00/12.50 US/lmp.pt.)
for J20 / H25

YH4
GRAND
VITARA
1. Manual selector assembly
(Select lever assembly)
2. Manual lever assembly
3. Select cable bracket
4. Select indicator
5. Slide cover
6. Select lever knob7. Spring
8. Knob button
9. Shift lock solenoid rod
10. Shift lock solenoid
11. Cover
12. Illumination lamp
13. Interlock cam
1. Interlock cam pin
(only for new selector assembly) Tightening Torque
(a): 18 N
.m (1.8 kg-m, 13.5 lb-ft)1. Manual lever
assembly
2. Select indicator
assembly
3. Illumination lamp
assembly
4. Bulb filter
5. Bulb
6. Knob assembly
7. Shift lock solenoid
Type-1 Type-2
Type-1
7B1-62 AUTOMATIC TRANSMISSION (4 A / T)
MANUAL SELECTOR ASSEMBLY
REMOVAL
1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connector for illumination lamp, shift lock solenoid
and overdrive OFF switch.
4) Disconnect interlock cable from interlock cam of selector as-
sembly.
5) Remove selector assembly mounting bolts.
6) Disconnect select cable from lever of selector assembly.
INSTALLATION
NOTE:
New selector assembly of Type-1 is supplied with held inter-
lock cam at interlock cable connecting position with pin. Re-
move this pin after connecting interlock cable to interlock cam
and tightening cable nut.
Reverse removal procedure to install noting the followings.

Connect interlock cable end to cam referring to steps 2) to 8) of
ªInterlock Cable Installationº section.

Upon completion of installation, confirm that brake (key) interlock
system operates properly.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-63
1. Select lever assembly
2. Bolt
3. Select cable
4. Cable bracket
5. Bolt
6. Blank
7. Washer
8. Clip
9. Nut
10. Manual select lever
11. Lock washer
12. Nut
13. Select cable joint
14. Bush
15. Washer
16. E-ring
17. Transmission range switch assembly
18. Bolt
1. Transmission range
sensor (switch)
2. Select cable
3. Manual shift lever
4. Select cable joint
1. Select cable joint
A. Align with cable joint
B. Tighten with wrench
Tightening Torque
(a): 13 N.m (1.3 kg-m, 9.5 lb-ft)
(b): 7 N.m (0.7 kg-m, 5.5 lb-ft)
INSPECTION
Check select lever for smooth and clear-cut movement and position
indicator for correct indication.
For operation of select lever, refer to left figure.
SELECT CABLE
ADJUSTMENT
1) Before tightening cable end nut, shift select lever to ªNº.
2) Also shift manual shift lever to ªNº.
NOTE:

Make sure that nut and cable joint have clearance under
above conditions.

If select cable has been moved, push it in arrow C direc-
tion as shown in figure at the left till it stops and then con-
firm that select lever is in ªNº position.
3) Turn nut A by hand till it contacts manual select cable joint.
Then tighten nut B with wrench.
4) After select cable was installed, check for the following.

Push vehicle with select lever shifted to ªPº.
Vehicle should not move.

Vehicle can not be driven in ªNº.

Vehicle can be driven in ªDº, ª2º, and ªLº.

Vehicle can be backed in ªRº.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-65
1. Drain plug
2. Propeller shaft
1. Oiler (with transmission fluid)
2. Solenoid valve
3. BatteryA: Hole (Should be dry)
B: Exhausting fluid Terminal Arrangement of PCM Coupler
(Viewed from harness side)
WITH BATTERY VOLTAGE WITHOUT BATTERY VOLTAGE
H25 Engine
Shift solenoid valve ± A (#1)C51-1-6
Shift solenoid valve ± B (#2)C51-1-1
TCC (Lock-up) solenoid valveC51-1-2
REMOVAL
1) Pull out dipstick and lift up vehicle.
2) With engine cooled, remove drain plug from oil pan and drain
A / T fluid.
3) Install drain plug with gasket.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Remove exhaust pipe bracket and disconnect front propeller
shaft from front differential (if equipped).
5) Remove oil pan bolts.
6) Remove oil pan.
7) Remove oil tubes.
8) Remove solenoid valve No.1 (shift solenoid valve A and B) or so-
lenoid valve No.2 (TCC solenoid valve).
OPERATION CHECK
Whenever shift solenoid valves and TCC (lock-up) solenoid valve
are removed from transmission, verify their valve function physical-
ly before they are reinstalled.
1) Apply oiler to solenoid valve and give compression by hands
and then check to be sure that transmission fluid from oiler does
not come out of holes in solenoid valve when battery voltage is
not conducted.
2) Under the same conditions as above, conduct battery voltage
and then make sure that fluid comes out with vigor.
NOTE:

If fluid does not come out with vigor in above step 2 in-
spection, do not re-use that solenoid valve.

Figure at the left shows shift solenoid valve check.
Check TCC solenoid valve also in the same way.

YH4
GRAND
VITARA
7B1-66 AUTOMATIC TRANSMISSION (4 A / T)
14
2
3
INSTALLATION
Reverse removal procedure to install solenoid valves and noting
the following points.

For details of solenoid valve installation, refer to ªUnit Repairº
section. Use new gasket and O-ring.

Install oil tubes in such order as shown in figure.

For details of oil pan installation, refer to ªUnit Repairº section.
Use new oil pan gasket.

Tighten universal joint flange bolts & nuts and exhaust pipe brack-
et bolts to specified torque.

Fill A / T fluid and check fluid level according to procedure de-
scribed in ªCHANGING FLUIDº previously.

Check for fluid leakage after warming up A / T.
THROTTLE POSITION SENSOR
INSPECTION
Refer to SECTION 6E1 / 6E2 for inspection.
POWER / NORMAL CHANGE SWITCH
INSPECTION
Check Power / Normal change switch for operation referring to Step
4 of Diag. Flow Table B-4 in this section.
If malfunction is found, replace.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-67
1. Oil cooler pipes
2. Union gaskets
3. Pipe bolt
OIL COOLER PIPES
REMOVAL
1) Lift up vehicle.
2) Make sure to wash dirt off from around pipe joints.
3) With engine is cool, loosen oil cooler pipe union bolts with oil out-
let union locked and remove oil cooler pipes from oil outlet
unions and hoses.
NOTE:
To avoid fluid leakage, plug open ends of oil outlet unions
and hoses right after they are disconnected.
INSTALLATION
1) Use new union gaskets and connect oil cooler pipes to oil outlet
unions.
2) Connect hoses to pipes and clamp them securely.
3) Tighten union bolts to specified torque with oil outlet union
locked.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
4) Tighten pipe bolt securely.
5) Check A / T fluid level according to procedure described in ªFluid
Levelº section.
Add if necessary.
6) Check for fluid leakage after warming up A / T.