2004 SUZUKI GRAND VITARA troubleshoot

YH4
GRAND
VITARA
G16 / J20 Engines
H25 Engine
1. PCM
2. J / B
3. O / D cut switch
4. P / N change switch
5. J / C
1. PCM
2. Fuse
3. O / D cut switch
4. P / N change switch
5. J / C
6. J / C
AUTOMATIC TRANSMISSION (4 A / T) 7B1-35
DIAGNOSTIC FLOW TABLE B-1 ªO / D OFFº LIGHT CIRCUIT CHECK
(ªO / D OFFº LIGHT DOESN'T LIGHT AT IGNITION SWITCH ON BUT
ENGINE STARTS UP)
WIRING DIAGRAM
TROUBLESHOOTING
STEPACTIONYESNO
1ªO / D OFFº light circuit check:
(1) With ignition switch OFF, disconnect
couplers from PCM.
(2) Using service wire, connect E61-20
(G16 / J20 engines) or E61-7 (H25 engine)
terminal of disconnected PCM coupler and
ground.
Does ªO / D OFFº light turn ON at ignition
switch ON?Poor E61-20 (G16 / J20
engines) or E61-7 (H25
engine) terminal
connection.
If OK, substitute a known-
good PCM and recheck.Bulb burned out or faulty
ªW / Bº, ªB / Wº wire.

YH4
GRAND
VITARA
7B1-36 AUTOMATIC TRANSMISSION (4 A / T)
Switch ON
positionSwitch OFF
positionSwitch ON
position
Switch OFF
position
DIAGNOSTIC FLOW TABLE B-2 ªO / D OFFº LIGHT CIRCUIT CHECK
(ªO / D OFFº LIGHT COMES ON STEADILY)
WIRING DIAGRAM ± Refer to Table B-1 in this section.
TROUBLESHOOTING
STEPACTIONYESNO
1Check O / D cut Switch Position.
Is O / D cut switch turned OFF (Is switch button at OFF
position)?Go to Step 2.Turn O / D cut switch
OFF.
2Check Lamp Circuit for Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Turn ignition switch ON.
Does ªO / D OFFº lamp come ON steadily?ªW / Bº circuit shorted
to ground.Go to Step 3.
3Check O / D cut Switch Circuit.
1) Check resistance between terminal E61-33
(G16 / J20 engines) or E61-14 (H25 engine) of
disconnected PCM connector and body ground with
O / D cut switch OFF.
Is continuity indicated?Go to Step 4.Check PCM ground
circuit for open.
If ground circuit is
OK, substitute a
known-good PCM
and recheck.
4Check O / D cut Switch for Operation.
1) Remove console box.
2) Disconnect O / D cut switch connector.
3) Check continuity between switch terminals under
each condition below.
Switch OFF position: No continuity
Switch ON position: Continuity
Is check result satisfactory?ªY / Rº circuit shorted
to ground.Replace O / D cut
switch.
Fig. for Step 1. Fig. for Step 4.

YH4
GRAND
VITARA
G16 / J20 Engines
H25 Engine
1. PCM
2. J / B
3. O / D cut switch
4. P / N change switch
5. J / C
1. PCM
2. Fuse
3. O / D cut switch
4. P / N change switch
5. J / C
6. J / C
AUTOMATIC TRANSMISSION (4 A / T) 7B1-37
DIAGNOSTIC FLOW TABLE B-3 ªPOWERº LIGHT CIRCUIT CHECK
(ªPOWERº LIGHT DOESN'T LIGHT AT IGNITION SWITCH ON BUT
ENGINE STARTS UP)
WIRING DIAGRAM
TROUBLESHOOTING
STEPACTIONYESNO
1ªPOWERº light circuit check:
(1) With ignition switch OFF, disconnect
couplers from PCM.
(2) Using service wire, connect E61-21 (G16 /
J20 engines) or E61-10 (H25 engine)
terminal of disconnected PCM coupler and
ground.
Does ªPOWERº light turn ON at ignition switch
ON?Poor E61-21 (G16 / J20
engines) or E61-10 (H25
engine) terminal
connection.
If OK, substitute a known-
good PCM and recheck.Bulb burned out or faulty
ªGr / Blº, ªB / Wº wire.

YH4
GRAND
VITARA
7B1-38 AUTOMATIC TRANSMISSION (4 A / T)
ª5º
ª4º
DIAGNOSTIC FLOW TABLE B-4 ªPOWERº LIGHT CIRCUIT CHECK
(ªPOWERº LIGHT COMES ON STEADILY)
WIRING DIAGRAM ± Refer to Table B-3 in this section.
TROUBLESHOOTING
STEPACTIONYESNO
1Check Power / Normal Change Switch Position.
Is switch button at Normal position?Go to Step 2.Set Power / Normal
change switch at
Normal position.
2Check Lamp Circuit for Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Turn ignition switch ON.
Does ªPOWERº lamp come ON steadily?ªGr / Blº circuit
shorted to ground.Go to Step 3.
3Check Power / Normal Change Switch Circuit.
1) Check resistance between terminal E61-31
(G16/J20 engines) or E61-9 (H25 engine) of
disconnected PCM connector and body ground with
P / N change switch OFF.
Is continuity indicated?Go to Step 4.Check PCM ground
circuit for open.
If ground circuit is
OK, substitute a
known-good PCM
and recheck.
4Check Power / Normal Change Switch for Operation.
1) Remove Power / Normal change switch.
2) Check continuity between switch terminals ª4º and
ª5º under each condition below.
Normal position: No continuity
Power position: Continuity.
Is check result satisfactory?ªOr / Blº circuit
shorted to ground.Replace Power /
Normal change
switch.
Fig. for Step 1. Fig. for Step 4.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-41
C51-1
-18C51-1
-17C51-1
-16C51-1
-15C51-1
-28C51-1
-27 G16/
J20
H25
C51-1-4 C51-1-3 C51-1-13 C51-1-12 C51-1-20 C51-1-19
Terminal
Select
lever
position
TROUBLESHOOTING (DTC P0705)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Check Transmission Range Switch (Sensor) Circuit for
Operation.
When using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON and check transmission
range signal (P, R, N, D, 2 or L) on display
when shifting select lever to each range.
Is applicable range indicated?
When not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check voltage at terminals C51-1-15, C51-1-16,
C51-1-17, C51-1-18, C51-1-27 and C51-1-28 for
G16/J20 (C51-1-4, C51-1-3, C51-1-13, C51-1-12,
C51-1-20 and C51-1-19 for H25) respectively with
select lever shifted to each range.
Taking terminal C51-1-28 for G16/J20 (C51-1-20 for
H25) as an example, is battery voltage indicated
only when select lever is shifted to ª2º range and
0 V for other ranges as shown in figure?
Check voltage at other terminals likewise, referring
to figure.
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to ªIntermit-
tent and Poor
Connectionº in
section 0A.Go to Step 3.
3Check Select Cable for Adjustment referring to ªSelect
Cable Adjustmentº in this section.
Is it adjusted correctly?Go to Step 4.Adjust.
4Check Transmission Range Switch for Installation
Position.
1) Shift select lever to ªNº range.
2) Check that ªNº reference line on switch and center
line on shaft are aligned.
Are they aligned?Go to Step 5.Adjust.
5Check Transmission Range Switch (Sensor) referring
to ªTransmission Range Switchº in this section.
Are check results satisfactory?ªYº, ªOr / Gº, ªRº,
ªOr / Blº, ªY / Gº,
ªG / Orº or ªG / Blº
circuit open or short.
If wires and
connections are OK,
substitute a known-
good PCM and
recheck.Replace TR switch.
Fig. for Step 2.

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.