2005 SUZUKI GRAND VITARA Service Workshop Manual

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
7B1-64 AUTOMATIC TRANSMISSION (4 A / T)
1. A / T vehicle (output) speed sensor
ªNº reference
line
Center line on
manual valve shaft
G16 / J20
1. Service wire
2. PCM connectors disconnected
Switch
position
TRANSMISSION RANGE SWITCH (SENSOR)
INSPECTION & ADJUSTMENT
1) Shift select lever to ªNº range.
2) Check that center line on manual valve shaft and ªNº reference
line on switch are aligned. If not, loosen switch bolt and align
them.
3) Check that engine starts in ªNº and ªPº ranges but it doesn't start
in ªDº, ª2º, ªLº or ªRº range. Also, check that back-up lamp lights
in ªRº range.
4) If faulty condition cannot be corrected by adjustment, discon-
nect transmission range switch coupler and check that continu-
ity exists as shown by moving select lever.
Terminal No.54982310765498231076
P
R
N
D
2
L
A / T OUTPUT SPEED SENSOR
INSPECTION
Check A / T output speed sensor for resistance between terminals
of sensor or PCM coupler.
A / T output speed sensor
resistance value : 387 ± 473
at 20
C, 68
F
O / D CUT SWITCH
INSPECTION
Check O / D cut switch for operation referring to step 4 of Diag. Flow
Table B-2 in this section.
If malfunction is found, replace.
SOLENOID VALVES
(Shift solenoid valves & TCC solenoid valve)
INSPECTION
With couplers of PCM disconnected and using service wire as
shown at the left, check each solenoid valve for clicking sound.
G16 / J20 Engines
Shift solenoid valve - A (#1)C51-1-2
Shift solenoid valve - B (#2)C51-1-1
TCC (Lock-up) solenoid valveC51-1-8

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.

YH4
GRAND
VITARA
7B1-68 AUTOMATIC TRANSMISSION (4 A / T)
1. Select lever
2. Shift lock solenoid
3. Brake light switch
4. Brake pedal
5. Cable
6. Ignition switch
1. Select lever
2. Interlock cam3. Shift lock solenoid rod
4. Shift lock solenoid
Type-1
BRAKE INTERLOCK SYSTEM
SHIFT LOCK SOLENOID CONTROL
This system consists of shift lock solenoid control system and inter-
lock cable control system.
The shift lock solenoid control system is so designed that the selec-
tor lever can not be shifted from ªPº range position unless the igni-
tion switch is turned ON and the brake pedal is depressed. And the
interlock cable control system is so designed that the selector lever
cannot be shifted from ªPº range position unless the ignition switch
is turned to ªACCº or ªONº position. Also, the ignition key cannot be
pulled out of the key slot unless the selector lever is in ªPº range.
SHIFT LOCK SOLENOID CONTROL OPERATIONS
When the select lever is in ªPº range, the ignition key position is
ªONº and depressing the brake pedal cause the electric current to
flow to the solenoid. As the shift lock solenoid rod (or the lock plate)
is drawn toward the solenoid in this state, it frees the interlock cam
(or the detent pin), which then allows the select lever to be shifted
from ªPº range to any other position.
Even when the select lever is in ªPº range, if the ignition key position
is ªLOCKº or ªACCº or the brake pedal is not depressed, the electric
current does not flow to the solenoid.
In this state, the shift lock solenoid rod (or the lock plate) is pushed
away from the solenoid by spring force and it obstructs the interlock
cam (or the detent pin) movement. Thus the select lever button
does not work even when pressed and the select lever shift is pre-
vented.

YH4
GRAND
VITARA
Type-2
1. Select lever
2. Detent pin
3. Detent plate4. Lock plate
5. Shift lock solenoid
1. Cover
2. Screw3. Select lever
4. Button
AUTOMATIC TRANSMISSION (4 A / T) 7B1-69
SHIFT LOCK (SOLENOID) MANUAL RELEASE
Shift lock can be manually released by following procedure.
1) Remove access hole cover by unfastening screw.
2) Turn ignition key to ªACCº position and move shift lock solenoid
rod (or manual release plate) toward rear side of vehicle by using
screw driver or the like.
3) In this state, select lever can be moved to any range or position.
SYSTEM INSPECTION
1) Check to make sure that select lever cannot be moved to any
other range from ªPº range position when ignition switch key is
at ªACCº position, at ªLOCKº position (or it is removed from key-
hole of ignition switch) or brake pedal is not depressed.
2) Shift select lever to ªPº range position, release knob button and
check for the following.

Ignition key can be turned between ªLOCKº and ªACCº posi-
tions back and forth and also it can be removed from ignition
switch.

YH4
GRAND
VITARA
7B1-70 AUTOMATIC TRANSMISSION (4 A / T)
1. Cover
2. Screw
3. Shift lock solenoid rod
(or manual release plate)4. Select lever
5. Button
Not turn between ªACCº
and ªLOCKº positions.
Type-1
Type-2

With shift lock solenoid rod (or manual release plate) moved
in arrow direction and ignition key turned to ªACCº position, se-
lect lever can be shifted from ªPº range position to any other
range.

With shift lock solenoid rod (or manual release plate) moved
in arrow direction and ignition key turned to ªLOCKº position,
select lever can not be shifted from ªPº range position to any
other range.

When ignition switch is turned ªONº and brake pedal is de-
pressed, select lever can be shifted from ªPº range position to
any other range.
3) With select lever shifted to any position other than ªPº range,
check that ignition key cannot be turned ªLOCKº position and it
cannot be removed from ignition switch unless it is at ªLOCKº
position.