2004 SUZUKI GRAND VITARA change

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
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
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
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
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
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.