2005 SUZUKI GRAND VITARA H25

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
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
1. Radiator
2. Inlet hose (Outlet from oil cooler)
3. Outlet hose (Inlet to coil cooler)
4. Converter housing
5. Outlet hose
6. Inlet hose
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
G16 / J20
H25
1. A / T throttle cable
2. Stopper
3. Inner cable
4. A / T assemblyR100 mm
(3.94 in.)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-61
OIL COOLER HOSES
When replacing them, be sure to note the followings.

to replace clamps at the same time.

to insert hose as far as its limit mark.

to clamp hose securely.
A / T THROTTLE CABLE
ADJUSTMENT
1) Pull inner cable by force of 2 N (0.2 kg, 0.45 lb) or less to be no
slack of inner cable with A / T throttle cable curved as shown in
the figure.
2) Fix stopper to inner cable with clearance ªcº.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
3)For G16 / J20 engines
a) Check clearance ªcº. If it is out of specifications, adjust it by
turning cable adjusting nut.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
b) Tighten lock nut securely.
For H25 engine
a) Warm up engine and transmission to normal operating tem-
perature.
b) Make sure that accelerator cable is adjusted as specified.
c) With throttle valve closed, check clearance ªcº which should
be within the following specification.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
If it is out of specification, adjust it by turning cable adjusting nut.

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
7B1-74 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
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

YH4
GRAND
VITARA
7C1-10 CLUTCH
(B)1
12
(A)
1. Input shaft bearing
2. Flywheel
3. Clutch disc
4. Clutch cover
5. Bolt
6. Release bearing
7. Clutch release fork
8. Boot
9. Clip
10. Clutch release fork support
1. Bolt
2. Clutch cover
1. Input shaft bearing
UNIT REPAIR
CLUTCH COVER, CLUTCH DISC AND FLYWHEEL
DISMOUNTING / REMOUNTING
Refer to SECTION 7A ªDismounting / Remounting of Trans Unitº.
REMOVAL
1) Hold flywheel stationary with special tool (A) and remove clutch
cover bolts, clutch cover and clutch disc.
Special Tool
(A): 09924-17810
2) Pull out input shaft bearing by using special tool (B) and wrench.
Special Tool
(B): 09917-58010 (G16 engine)
(B): 09923-73210 (J20 and H25 engines)
3) Remove release bearing and release fork.

YH4
GRAND
VITARA
7C1-12 CLUTCH
(C)
1
ªAº, (a)1
2
1. Flywheel
2. Bolt
1. Clutch cover
INSTALLATION
NOTE:
Before assembling, make sure that flywheel surface and pres-
sure plate surface have been cleaned and dried thoroughly.
1) Install flywheel to crankshaft and tighten bolts to which sealant
is applied to specification.
Special Tool
(A): 09924-17810
ªAº: Sealant 99000-31110
Tightening Torque
(a): 78 N
.m (7.8 kg-m, 56.5 lb-ft) (G16 engine)
(a): 70 N
.m (7.0 kg-m, 50.5 lb-ft) (J20 and H25 engines)
2) Using special tool (B), install input shaft bearing to flywheel.
Special Tool
(B): 09925-98210
3) Aligning clutch disc to flywheel center by using special tool (C),
install clutch cover and bolts. Then tighten bolts to specification.
NOTE:

While tightening clutch cover bolts, compress clutch disc
with special tool (C) by hand so that disc centered.

Tighten cover bolts little by little evenly in diagonal order.
Special Tools
(A): 09924-17810
(C): 09923-36330 (G16 engine)
(C): 09923-36320 (J20 and H25 engines)
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 16.5 lb-ft)