2004 SUZUKI GRAND VITARA check transmission fluid

YH4
GRAND
VITARA
1. Drain plug (Apply sealant)
2. Reverse idle gear shaft bolt (DO NOT LOOSEN IT)
3. Filler / level plug (Apply sealant)
1. Drain plug
2. Filler / level plug
Type 1
Type 2
1. Level gauge
2. FULL HOT mark
3. LOW HOT mark
4. FULL COLD mark
5. LOW COLD mark
0B-20 MAINTENANCE AND LUBRICATION
ITEM 6-10
Manual Transmission Oil Inspection and Change
Inspection
1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transmission.
4) Check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found up
to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified oil.
5) Tighten level plug to specified torque.
Refer to Section 7A or 7A1 for installation and tightening torque.
Change
Change transmission oil with new specified oil referring to Section
7A or 7A1.
ITEM 6-11
Automatic Transmission Fluid Inspection and Change
Inspection
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Check fluid level.
For fluid level checking procedure, refer to On-vehicle service in
Section 7B1 and be sure to perform it under specified conditions.
If fluid level is low, replenish specified fluid.

YH4
GRAND
VITARA
1. Drain plug
Transfer
Front differential
Rear differential
1
21
2
MAINTENANCE AND LUBRICATION 0B-21
Change
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to On-vehicle service in
Section 7B1.
Fluid cooler hose change
Replace inlet and outlet hoses of cooler hose and their clamps.
For replacement procedure, refer to On-vehicle service in Section
7B1.
ITEM 6-12 and 6-13
Transfer and Differential Oil Inspection and Change
Inspection
1) Check transfer case and differential for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transfer or differentials (front and rear) and
check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found up
to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified oil
referring to Section 7D, 7B or 7F.
4) Tighten level plug to specified torque.
Refer to Section 7D, 7E or 7F for tightening torque.
Change
Change transfer oil or differentials oil with new specified oil referring
to Section 7D, 7E and 7F respectively.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-25
Steering

Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.

Check that the vehicle does not wander or pull to
one side.
Engine

Check that engine responds readily at all speeds.

Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to ªHIº position for this check.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSG, SH or SJ (Refer to engine oil viscosity chart in item 1-4)
Engine coolant (Ethylene glycol
base coolant)ªAntifreeze / Anticorrosion coolantº
Brake fluidDOT 3
Manual transmission oilRefer to Section 7A or 7A1Transfer oilRefer to Section 7A or 7A1.
Differential oil (front & rear)Refer to Section 7E or 7F.
Automatic transmission fluid and
Power steering fluidRefer to Section 3B1 or 7B1.
Door hingesEngine oil or water resistance chassis greaseHood latch assemblyEngine oil or water resistance chassis grease
Key lock cylinderSpray lubricant

YH4
GRAND
VITARA
3B1-12 POWER STEERING (P / S) SYSTEM
TIE-ROD END BOOT CHECK
Check boot for crack and damage and if any, replace it with a new
one.
AIR BLEEDING PROCEDURE
1) Hoist the front end of vehicle and apply safety stands.
2) Fill P / S fluid reservoir with fluid up to specified level.
NOTE:
Before starting engine, place transmission gear shift lever
in ªNeutralº (shift selector lever to ªPº range for A / T mod-
el), and set parking brake.
3) After running engine at idling speed for 3 to 5 seconds, stop it
and add fluid to satisfy specification.
4) With engine stopped, turn steering wheel to the right and left as
far as it stops, repeat it a few times and fill fluid to specified level.
5) With engine running at idling speed, repeat stop-to-stop turn of
steering wheel till all foams in P / S fluid reservoir are gone.
NOTE:
Make sure to bleed air completely. If air remains in fluid, P / S
pump may make humming noise or steering wheel may feel
heavy.
6) Finally check to make sure that fluid is filled to specified level.

YH4
GRAND
VITARA
7B1-26 AUTOMATIC TRANSMISSION (4 A / T)
Operation
VISUAL INSPECTION
Visually check following parts and systems.
INSPECTION ITEM
REFERRING SECTION

A / T fluid ± ± ± ± ± level, leakage, color

A / T fluid hoses ± ± ± ± ± disconnection, looseness, deterioration

Throttle (accelerator) cable ± ± ± ± ± play, installation

A / T throttle cable ± ± ± ± ± play, installation

A / T select cable ± ± ± ± ± installation, operation

Engine oil ± ± ± ± ± level, leakage

Engine coolant ± ± ± ± ± level, leakage

Battery ± ± ± ± ± fluid level, corrosion of terminal

Connectors of electric wire harness ± ± ± ± ± disconnection, friction

Fuses ± ± ± ± ± burning

Parts ± ± ± ± ± installation, damage

Bolt ± ± ± ± ± looseness

Other parts that can be checked visually
Also check following items at engine start, if possible.

ªO / D OFFº lamp

ªPOWERº lamp


Malfunction indicator lamp

Charge warning lamp

Engine oil pressure warning lamp

Engine coolant temp. meter

Other parts that can be checked visually
Section 0B
Section 7B1
Section 6E1 / 6E2
Section 7B1
Section 7B1
Section 0B
Section 0B
Section 6 / 6-1 / 7B1
Section 8
Section 7B1
Section 7B1
Section 6 / 6-1
Section 6H
Section 8 (Section 6A1 / 6A2 /
6A4 for pressure check)

YH4
GRAND
VITARA
7B1-30 AUTOMATIC TRANSMISSION (4 A / T)
Running condition Gear shift Abnormal
noise
ConditionPossible CauseCorrection
Poor 1st speed run-
ning or excessive
slippage in ªDº or ª2º
Fluid pressure leakage from forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Overdrive clutch slippingReplace.
Unable to run or ex-
cessive slippage in
ªLº range
Fluid pressure leakage of forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Reverse brake disc slippingReplace.

Broken brake piston O-ringReplace.
Unable to run or ex-
cessive slippage in
ªRº range
Fluid pressure leakage to direct clutch due
to wear or breakage of center support seal
ringReplace.

Worn direct clutchReplace.
Poor 1±2 shift, ex-
cessive slippage
Fluid pressure leakage to overdrive clutch
due to wear or breakage of O/D case seal
ringReplace.

Faulty second brakeReplace.

Broken O-ring of second brake pistonReplace.

Faulty second coast brake (in ª2º range)Replace.
Poor 2±3 shift, ex-
cessive slippage
Fluid pressure leakage to overdrive clutch
due to wear or breakage of O/D case seal
ringReplace.

Worn direct clutch bushingReplace.

Direct clutch slippingReplace.

Foreign material caught in direct clutch pis-
ton check ballReplace.
Poor start or surging
in ªDº range
Fluid pressure leakage of forward clutch
due to wear or breakage of O/D case seal
ringReplace.

Malfunction of forward clutchReplace.
Poor 3±4 shift, ex-
ili

Faulty overdrive brakeReplace.
cessive slippage
Faulty overdrive clutchReplace.
Poor start or judder-
ing in ªRº range
Fluid pressure leakage of direct clutch due
to wear or breakage of oil center support
seal ringReplace.

Worn direct clutchReplace.
Excessive shock on
1± 2 shift
Faulty one-way clutchReplace.
Non operate lock-up
system
Faulty torque converterReplace.
Abnormal noise in
ªPº or ªNº range
Worn oil pumpReplace.
SCAN TOOL DATA-Refer to SECTION 6 / 6-1.
INSPECTION OF PCM AND ITS CIRCUIT-Refer to SECTION 6 / 6-1.
WIRE HARNESS AND CONNECTORS-Refer to SECTION 6 / 6-1.

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.