2005 SUZUKI GRAND VITARA Service Workshop Manual

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-71
Ignition switch side
1. Ignition switch assembly
2. Clamp screw
3. Interlock cable
Select lever side
Type-1
1. Inner end of interlock cable
2. Interlock cam (or key release cam)
3. Stud bolt4. Cam boss
5. Claw
Select lever side
Type-2
KEY INTERLOCK CABLE
NOTE:
Don't bend interlock cable excessively when removing and
installing it, or system will not operate correctly.
Removal
1) Disconnect negative (±) cable from battery.
2) If equipped with air bag system, disable air bag system.
Refer to ªDisabling Air bag Systemº in Section 10B.
3) Remove steering column hole cover.
4) Tilt steering column if steering column is adjustable.
If no adjustable, loosen steering column bolts.
5) Remove steering column cover.
6) Remove interlock cable clamp screw located at ignition switch
assembly.
7) Disconnect interlock cable inner end.
(Ignition switch side.)
8) With console box removed, take out interlock cable by loosening
lock nuts.
9) Detach cable end from interlock cam (or key release cam) while
pressing claws of interlock cam boss. At this time, be careful not
to cause damage to its claws.

YH4
GRAND
VITARA
1. Ignition switch assembly
2. Clamp screw
3. Outer end
1. Interlock cable
2. Steering column
3. Steering column
holder
Type-1
1. Interlock cam
2. Lever plate
3. Interlock cable
4. Pin with 4 mm (0.15 in.) dia.
7B1-72 AUTOMATIC TRANSMISSION (4 A / T)
Installation
1) Shift select lever to ªNº range and turn ignition key to ªACCº
position.
2) Connect inner end of interlock cable to key interlock lever (Igni-
tion switch side).
3) Install outer end bracket of interlock cable to ignition switch as-
sembly, and tighten screw to specified torque.
Tightening Torque
(a): 2.2 N
.m (0.22 kg-m, 1.5 lb-ft)
4) Pass and connect interlock cable as shown at the left figure.
TYPE-1
5) Fix interlock cam by inserting pin with about 4 mm (0.15 in.) dia.
into holes of cam and lever plate.
6) Install cable end to interlock cam and stud bolt and after making
sure that cable outer is pushed in arrow direction B by leaf
spring, tighten mounting nut to specified torque. Remove pin.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
7) Turn ignition key to ªACCº position and shift select lever to ªNº
range, and check for the followings.
a. When select lever is shifted at ªPº range with knob button
depressed, ignition key can not be turned from ªACCº to
ªLOCKº position.
b. When knob button is released, ignition key can be turned to
ªLOCKº position.
c. When ignition key is at ªLOCKº position, select lever can not
be shifted from ªPº to any other range.
8) Install console box.
9) Install steering column cover.
10) Adjust steering column or tighten steering column bolts.
11) Install steering column hole cover.
12) If equipped with air bag system, enable air bag system.
Refer to ªEnabling Air bag Systemº in Section 10B.

YH4
GRAND
VITARA
1. Inner end of interlock cable
2. Key release cam
1. Key release cam
2. Cable outer(a)
Type-2
Type-2
AUTOMATIC TRANSMISSION (4 A / T) 7B1-73
TYPE-2
5) With key release cam set as shown at the left figure, connect
inner end of interlock cable to key release cam. (Select lever
side.)
6) Move key release cam so that it is set at such angle as shown
at the left figure and with special tool inserted in hole A , fix key
release cam.
Special Tool
(A): 09925-78210 (6 mm)
7) With key release cam fixed with special tool, install cable outer
to bracket and after making sure that cable outer is pushed in
arrow direction B by leaf spring, tighten mounting nut to speci-
fied torque. Remove special tool.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
8) Turn ignition key to ªACCº position and shift select lever to ªNº
range, and check for the followings.
a. When select lever is shifted at ªPº range with knob button
depressed, ignition key can not be turned from ªACCº to
ªLOCKº position.
b. When knob button is released, ignition key can be turned to
ªLOCKº position.
c. When ignition key is at ªLOCKº position, select lever can not
be shifted from ªPº to any other range.
9) Install console box.
10) Install steering column cover.
11) Adjust steering column or tighten steering column bolts.
12) Install steering column hole cover.
13) If equipped with air bag system, enable air bag system.
Refer to ªEnabling Air bag Systemº in Section 10B.

YH4
GRAND
VITARA
7B1-74 AUTOMATIC TRANSMISSION (4 A / T)
1. Boot No.2
2. Boot cover
1. Boot clamp
2. Boot No.1
3. Gear shift control lever
1. Boot No.2
2. Transfer shift control
lever
3. Transfer shift lever case4. Transfer shift control
case cover
5. Boot No.1
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
G16 / J20 H25
DISMOUNTING OF TRANSMISSION (WITH
TRANSFER IF EQUIPPED)
IN CABIN
1) Remove console box.
NOTE:
To remove clip, push in its center pin first.
2) Remove boot cover and boot No.2. (if equipped)
3) Remove boot clamp and then remove boot No.1 from transfer
gear shift lever case. (if equipped)
4) With transfer shift control case cover pushed down with fingers,
turn it to counterclockwise and take out shift control lever. (if
equipped)
IN ENGINE ROOM
1) Remove battery, dipstick and oil filler tube.
2) Disconnect A
/
T throttle cable from throttle cam and bracket.
3) Remove starter motor. But don't disconnect its wiring harness.
4) Remove transmission to engine bolt and nut.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-75
1. Drain plug
2. Filler and level plug
1. Drain plug
2. Front propeller shaft
1. Match marks
1. Right side transmission stiffener (if equipped)
G16 / J20
ON LIFT
1) Drain transfer oil for 4WD vehicle or A / T fluid for 2WD vehicle.
NOTE:
If 4WD automatic transmission is overhauled later on,
draining A / T fluid at this point will facilitate work.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
2) Before removing propeller shaft, give match marks on joint
flange and propeller shaft as shown in left figure.
3) Remove universal joint flange bolts and take out rear propeller
shaft.
4) Likewise, take out front propeller shaft. (if equipped)
5) Remove nut from the end of select cable and bracket to set
cable free.
6) Remove select cable bracket by removing its 2 bolts.
7) Remove exhaust No.1 and No.2 pipe.
8) Remove transmission stiffener (right side) if equipped.
9) Unclamp and disconnect oil cooler hoses from pipes.
NOTE:
To avoid leakage of transmission fluid, plug open ends of
oil cooler pipes and hoses right after they are discon-
nected.
10) Remove torque converter housing lower plate.
11) Holding drive plate stationary with special tool or the like, re-
move torque converter mounting bolts with wrench.
Special Tool (only for G16 / J20)
(A): 09927-56010

YH4
GRAND
VITARA
7B1-76 AUTOMATIC TRANSMISSION (4 A / T)
12) Remove engine to transmission nuts.
13) Disconnect connectors from VSS, output speed sensor, input
speed sensor, TR switch, shift & TCC solenoid valves and oth-
er electrical parts, and release their wire harness from clamps.
14) Apply transmission jack and take off rear mounting member by
removing its bolts.
15) With transmission (and transfer if equipped) assembly held up
on jack, move them to the rear and lower them including torque
converter.
WARNING:
Transmission (and transfer if equipped) assembly may
tilt rearward on jack. It is recommended to use an auxil-
iary arm of jack for the purpose of safety.
AFTER DISMOUNTING
WARNING:
Be sure to keep transmission (and transfer if equipped) as-
sembly horizontal throughout the work. Should they be
tilted, torque converter may fall off and cause personal inju-
ry and A / T fluid may flow out.
1) Remove breather hoses.
2) Remove transfer by removing its bolts, if equipped.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-77
ªAº, (d)
1. Drive plate
2. Torque converter
3. Case right stiffener (if equipped)
4. Automatic transmissionTightening torque
(a): 50 N´m
5.0 kg-m
36.5 lb-ft
(b): 65 N´m
6.5 kg-m
47.0 lb-ft
(c): 85 N´m
8.5 kg-m
61.5 lb-ft
(d): 78 N´m
7.8 kg-m
56.5 lb-ft
1. Automatic transmission
2. Transfer (4WD)
3. Engine rear mounting
4. Engine rear mounting member Tightening torque
(a): 50 N´m (5.0 kg-m, 36.5 lb-ft) ªAº: Sealant 99000-31110
REMOUNTING
WARNING:
When moving transmission assembly with torque convert-
er equipped in it, be sure to keep it horizontal. Tilting it with
its front facing down may allow converter to fall off. Where-
by an injury may result.
For remounting, reverse dismounting procedure. Use specified
torque as given below and left.
Tightening torque
N.mkg-mlb-ft
Exhaust No.1 pipe to manifold
bolts or nuts505.036.5
Muffler to exhaust No.2 pipe
nuts606.043.5
Universal joint flange bolts and
nuts505.036.5

Oil filler tube bolts

Select cable bracket bolts232.317.0

Clamp wiring harness and hoses securely.

Refer to ªSelect Cableº section for adjusting procedure of select
cable.

Refer to ªA / T Throttle Cableº section for tuning of A / T throttle
cable.

Follow fluid level check procedure for refilling automatic transmis-
sion fluid and its level adjusting.

Connect battery, and confirm that engine and transmission func-
tion acceptably.

When remounting drive plate, use specified bolts.

YH4
GRAND
VITARA
7B1-78 AUTOMATIC TRANSMISSION (4 A / T)
ON-VEHICLE
SERVICE MOUNTING
EXTERNAL
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
Fastening portion
Tightening torque
Fastening portion
N´mkg-mlb-ft
Automatic transmission fluid drain plug232.317.0
Transfer oil filler / level and drain plugs232.317.0
Transmission case plug171.712.5
Manual select lever nut131.39.5
Manual select cable nut70.75.5
Manual selector assembly bolts181.813.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts
Engine rear mounting member bolts
Transmission case right stiffener bolts
505.036.5
Universal joint flange bolts and nuts505.036.5
Torque converter mounting bolts656.547.0
Adapter case or extension case bolts
(G16 engine)353.525.5
Adapter case or extension case bolts
(J20 / H25 engines)424.230.0
Transmission range switch lock bolt5.50.554.0
Oil pipe union bolts353.522.5
Drive plate bolts787.856.5
Interlock cable clamp screw2.20.221.5
Interlock cable outer mounting nut131.39.5