2004 SUZUKI GRAND VITARA wheel

YH4
GRAND
VITARA
5E1-38 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
1. Clamps
2. Sensor bolt
SENSOR INSPECTION

Check sensor (pole piece) for damage or bent.

Check sensor for resistance.
Resistance between
terminals : 1.2 ± 1.6 k
at 20C, 68F
Resistance between
terminal and sensor body: 1 M
or more
If any faulty is found, replace.
SENSOR ROTOR INSPECTION

Check rotor serration (teeth) for being missing, damaged or de-
formed.

Turn wheel and check if rotor rotation is free from eccentricity and
looseness.

Check that no foreign material is attached.
If any faulty is found, repair or replace.
INSTALLATION
1) Check that no foreign material is attached to sensor and rotor.
2) Install it by reversing removal procedure.
Tightening Torque
(a): 21 N
.m (2.1 kg-m, 15.0 lb-ft)
CAUTION:
Do not pull wire harness or twist more than necessary
when installing rear wheel speed sensor.
3) Check that there is no clearance between sensor and knuckle.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-39
1. Rear axle
2. Retainer ring
3. Sensor rotor
4. Vinyl envelope
ªAº Grind with grinderªAº
1. Sensor rotor 4
31
2
2 1
3
REAR SENSOR ROTOR
REMOVAL
1) Remove rear axle shaft. Refer to REAR AXLE SHAFT RE-
MOVAL in Section 3E.
2) In order to remove sensor rotor from retainer ring, grind with a
grinder one part of the sensor rotor as illustrated till it becomes
thin.
CAUTION:

Cover vinyl sheet or the like over wheel bearing so that
fine grains from grinding will not enter there.

Be careful not to go so far as to grind the retainer ring.
3) Break with a chisel the thin ground sensor rotor, and it can be re-
moved.
INSTALLATION
1) Press-fit sensor rotor as shown.
NOTE:
Use care not to cause any damage to outside of retainer
ring.
2) Install rear axle shaft. Refer to REAR AXLE SHAFT INSTALLA-
TION in Section 3E.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-41
(d)
TRANSFER 4WD SWITCH
For removal, inspection and installation of this switch, refer to
SWITCHES in Section 7A.
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake pipe flare nut: (a)161.611.5
ABS hydraulic unit nut: (b)212.115.5
ABS hydraulic unit bracket bolt: (c)101.07.5
Wheel speed sensor bolt(Front): (d)232.317.0Wheel s eed sensor bolt(Rear): (e)212.115.5
Parking lever assy mounting bolt: (f)232.317.0

YH4
GRAND
VITARA
1. Fluid pressure check hole
2. Oil pan
1. Oil pan
2. Exhaust pipe
7B1-54 AUTOMATIC TRANSMISSION (4 A / T)
LINE PRESSURE TEST
Purpose of this test is to check operating conditions of each part by
measuring fluid pressure in fluid pressure line. Line pressure test
requires following conditions.

Automatic fluid is at normal operating temperature (70 to 80C /
158 ± 176F).

Fluid is filled to proper level (between FULL HOT and LOW HOT
on dipstick).
1) Apply parking brake securely and place checks against wheels.
2) Attach oil pressure gauge to fluid pressure check hole in trans-
mission case.
Special Tool
(A): 09925-37810
CAUTION:
After attaching oil pressure gauge, check that not fluid
leakage exists.
3) Depress foot brake fully, run engine at idle and stall and then
check fluid pressure in ªDº or ªRº range.
CAUTION:
Do not continue running engine at stall speed longer than
5 seconds.
G16 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.9 ± 4.4 kg / cm2
55 ± 63 psi
5.1 ± 5.7 kg / cm2
73 ± 81 psi
At stall speed11.7 ± 13.2 kg / cm2
166 ± 188 psi
14.2 ± 16.7 kg / cm2
202 ± 237 psi
J20 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.8 ± 4.3 kg / cm2
54 ± 61 psi
5.3 ± 5.9 kg / cm2
75 ± 84 psi
At stall speed9.7 ± 11.2 kg / cm2
138 ± 159 psi
12.9 ± 15.5 kg / cm2
183 ± 220 psi
H25 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.9 ± 4.4 kg / cm2
55 ± 63 psi
6.6 ± 7.2 kg / cm2
94 ± 102 psi
At stall speed11.3 ± 12.7 kg / cm2
161 ± 181 psi
14.7 ± 22.7 kg / cm2
209 ± 323 psi

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
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. Dipstick (G16 / J20)
2. Dipstick (H25)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-59
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
FLUID LEVEL
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal operating
temperature (70 ± 80C / 158 ± 176F). As a guide to check fluid
temperature, warm up engine till engine coolant temperature
meter indicated around 1 unit above ªCº point.
5) Keep engine idling and shift selector slowly to L and back to P
position.
6) With engine idling, pull out dipstick, wipe it off with a clean cloth
and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it. Fluid
level should be between FULL HOT and LOW HOT. If it is below
LOW HOT, add an equivalent of DEXRON-III up to FULL HOT.
Fluid specification
An equivalent of DEXRON-III
NOTE:

DO NOT RACE ENGINE while checking fluid level, even af-
ter the engine start.

DO NOT OVERFILL. Overfilling can causes foaming and
loss of fluid through breather. Then slippage and trans-
mission failure can result.

Bringing the level from LOW HOT to FULL HOT requires
0.3 liters (0.64/0.53 US/lmp.pt).

If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour af-
ter it is stopped.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-79
09925-37810
Oil pressure gauge09927-56010
Gear stopper
(only for G16 / J20)09931-76030
16 / 14 pin DLC
(OBD-II adapter) cable
09931-76011
SUZUKI scan tool (Tech 1A) kit1. Storage case
2. Operator's manual
3. Tech 1A
4. DLC cable
5. Test lead / probe
6. Power source cable
7. DLC cable adapter
8. Self±test adapterMass storage cartridge
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
A / T fluidAn equivalent of DEXRON-III
Automatic transmission

Parts lubrication when installing
Lithium greaseSUZUKI SUPER GREASE A
(99000±25010)
Cable ends
SealantSUZUKI BOND NO.1215
(99000-31110)
Flywheel bolts
SPECIAL TOOLS