2005 SUZUKI GRAND VITARA warning

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-19
-1. ªABSº warning lamp
-2. ABS hydraulic unit / control
module assembly
-3. Diagnosis connector
3-1. Diag. switch terminal
3-2. Diag. ground terminal
-4. ABS hydraulic unit/
control module connector
of harness
1. ABS hydraulic
unit / control
module connector
TABLE ± D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAG. SWITCH
TERMINAL CONNECTED TO GROUND
CIRCUIT DESCRIPTION
When the diag. switch terminal is connected to the ground with the ignition switch turned ON, the ABS control mod-
ule outputs a diagnostic trouble code by flashing ªABSº warning lamp.
INSPECTION
STEPACTIONYESNO
1Is it shorted diag. switch terminal and ground terminal by
service wire properly?Go to step 2.Connect service
wire securely.
21) Disconnect service wire.
2) Disconnect ABS hydraulic unit / control module
connector. (See Fig. 1)
3) Measure resistance between diag. switch terminal
and connector terminal ªA8º.
Is it infinite (
)?ªPº circuit open.Go to step 3.
31) Measure resistance between ground terminal of
monitor connector and body ground.
Is continuity indicated?Go to step 4.ªBº circuit open or
poor connection.
41) Check for proper connection to ABS hydraulic
unit / control module at terminal ªA8º and ªA10º.
2) If OK, then check ªABSº warning lamp circuit
referring to ªTABLE A, B and Cº.
Is it in good condition?Substitute a
known-good ABS
hydraulic unit /
control module
assembly and
recheck.Repair ªABSº
warning lamp
circuit.
Fig. 1

YH4
GRAND
VITARA
5E1-20 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
TABLE ± E EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK-LAMP
COMES ªONº STEADY
CIRCUIT DESCRIPTION
EBD warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and ABS
control module / hydraulic unit assembly through lamp driver module in combination meter. Refer to ªTABLE-Aº for
circuit diagram.
STEP
ACTIONYESNO
11) Make sure that:

Parking brake is completely released.Go to step 2.Release parking
brake completely

Brake fluid level is upper than the minimum level.
Are the check results OK?and / or replenish
brake fluid.
2Does ªABSº warning lamp come on?Perform ªTABLE Bº
previously
outlined.Go to step 3.
31) Disconnect ABS hydraulic unit / control module
connector.
2) Check for proper connection to ABS hydraulic unit /
control module connector at terminals ªA26º.
3) If OK, apply chocks to wheels and select gear in neutral
position (P range for A / T).
4) Keep brake pedal depressed and start engine.
Release parking brake.
5) Connect terminal ªA26º of disconnected connector to
ground using service wire.
Does EBD warning lamp (brake warning lamp) turn off?Substitute a
known-good ABS
hydraulic unit /
control module
assembly and
recheck.ªBrº circuit open.
If wire and
connection are
OK, replace
combination
meter.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-31
1. Diagnosis
connector
(6 pins connector)
2. Diag. switch
terminal
3. Ground
4. Service wire
Brake
pedal
Ignition
sw.
Motor
Solenoid
Rear3.0 sec.
3.0
ON-VEHICLE SERVICE
PRECAUTION
When connector are connected to ABS hydraulic unit / control mod-
ule assembly, do not disconnect connectors of sensors and turn
ignition switch ON. Then DTC will be set in ABS control module.
ABS HYDRAULIC UNIT OPERATION CHECK
1) Check that basic brake system other than ABS is in good condi-
tion.
2) Check that battery voltage is 11V or higher.
3) With ªABSº warning lamp, check that no abnormality is de-
tected in ABS. Refer to ªDIAGNOSTIC TROUBLE CODE
(DTC) CHECKº in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake dragging
occurs. If it does, correct.
7) With diag. switch terminal of diagnosis connector connected to
ground by using service wire, turn ignition switch ON and check
if ªABSº warning lamp indicates DTC 12.
8) Turn ignition switch OFF.
9) Perform following checks with help of another person.
Brake pedal should be depressed and then ignition switch
turned ON by one person and wheel should be turned by
another person's hand. At this time, check that:

Operation sound of solenoid is heard and wheel turns only
about 0.5 sec. (Brake force is depressurized).

Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF
ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace hydrau-
lic unit / control module assembly.
11) Turn ignition switch OFF and remove service wire from diagno-
sis connector.

YH4
GRAND
VITARA
7A-6 MANUAL TRANSMISSION (TYPE 1)
3, (a)
1. Coupler
2. Clamp3. 4WD switch
4. Boot No. 2
1. Back up light switch
2. 4WD switch
1. Back up light switch coupler
2. Front propeller shaft
SWITCHES
TRANSFER 4WD SWITCH
1) Remove console box and lift transmission control lever boots
No. 2 and No. 3. (Refer to page 7A-4.)
2) Remove transfer control lever boot No. 2, unclamp wiring on
transfer case to free it and pull off coupler.
3) Replace switch and connect as it was.
Tightening Torque
(a): 20 N
.m (2.0 kg-m, 14.5 lb-ft)
4) Turn ON ignition switch, shift transfer shift control lever to 4WD
position and check that indicator lights. Turn OFF switch after
checking.
NOTE:

When removing and reinstalling switch, use care not to let
dust enter transfer box inside.

Make sure to reset clamp for wiring which is located
where invisible directly.

It is recommended to work on transfer shift control lever
boot No. 1 from underside of vehicle on lift.

Identify this switch by its leg part which is different for that
of back up light switch.
BACK UP LIGHT SWITCH
WARNING:
Refrain from work while exhaust center pipe is hot.
REMOVAL AND INSTALLATION
NOTE:
When replacing switch, use care not to let dust enter transmis-
sion through switch hole.
1) Lift up vehicle.
2) Remove coupler(s) for switch wiring.

YH4
GRAND
VITARA
7B1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-1
GENERAL DESCRIPTION7B1- 3 . . . . . . . . . . . . . .
CLUTCH / BRAKE FUNCTIONS 7B1- 5. . . . . . . . .
TABLE OF COMPONENT OPERATION 7B1- 6. . .
ELECTRONIC SHIFT CONTROL
SYSTEM 7B1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSIS7B1-17 . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION IN DIAGNOSING
TROUBLE 7B1-20. . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE 7B1-21. . . . . . . . . .
Customer Problem Inspection Form 7B1-23. . .
Malfunction Indicator lamp (MIL)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
ªO / D OFFº Lamp Check 7B1-24. . . . . . . . . . . . .
ªPOWERº Lamp Check 7B1-24. . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Clearance 7B1-24. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) Table7B1-24 . . .
Fail-Safe Table 7B1-25. . . . . . . . . . . . . . . . . . . . .
Visual Inspection 7B1-26. . . . . . . . . . . . . . . . . . .
A / T Basic Check 7B1-27. . . . . . . . . . . . . . . . . . .
Trouble Diagnosis Table 1 7B1-28. . . . . . . . . . .
Trouble Diagnosis Table 2 7B1-28. . . . . . . . . . . Trouble Diagnosis Table 3 7B1-29. . . . . . . . . . .
Scan Tool Data 7B1-30. . . . . . . . . . . . . . . . . . . . .
Inspection of PCM and Its Circuit 7B1-30. . . . .
Wire Harness and Connectors 7B1-30. . . . . . . .
Diagnostic Flow Table A-1 7B1-31. . . . . . . . . . .
Diagnostic Flow Table A-2 7B1-33. . . . . . . . . . .
Table B-1 ªO / D OFFº Light Circuit
Check 7B1-35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-2 ªO / D OFFº Light Circuit
Check 7B1-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-3 ªPOWERº Light Circuit
Check 7B1-37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-4 ªPOWERº Light Circuit
Check 7B1-38. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0705 Transmission Range
Sensor (Switch) Circuit Malfunction 7B1-39. .
DTC P0715 Input / Turbine Speed
Sensor Circuit Malfunction 7B1-42. . . . . . . . . .
DTC P0720 Output Speed Sensor
Circuit Malfunction 7B1-44. . . . . . . . . . . . . . . . .
DTC P0741 TCC Solenoid Valve
Performance or Stuck Off 7B1-46. . . . . . . . . . .
DTC P0743 TCC Solenoid Electrical 7B1-47. .
DTC P0751 Shift Solenoid Valve-A (#1)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
DTC P0756 Shift Solenoid Valve-B (#2)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
SECTION 7B1
AUTOMATIC TRANSMISSION
(4 A
/
T)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS

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
AUTOMATIC TRANSMISSION (4 A / T) 7B1-31
Brake pedal Released Depressed
Voltage 0 VBattery
voltage
DIAGNOSTIC FLOW TABLE A-1 (NO TCC LOCK-UP OCCURS)
SYSTEM DESCRIPTION
PCM turns TCC solenoid OFF under any of the following conditions.

Brake pedal switch: ON

4WD LOW switch: ON

Cruise control module: TCC OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor, its
circuit or engine cooling
system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-8 (G16 / J20 engines) or C51-1-2 (H25
engine) terminal of PCM coupler and ground.

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Brake pedal released.

Drive vehicle with TCC ON condition
referring to ªTCC lock-up diagramº in
this section.
Is it battery voltage?Faulty TCC solenoid
valve, its circuit or
transmission.Go to Step 4.
4Is vehicle equipped with H25 engine?Go to Step 5.Go to Step 6.
5Brake switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-31 terminal of PCM coupler
terminal and ground.
Is the result as specified?Go to Step 6.Faulty brake pedal switch
or its circuit.
If OK, substitute a known-
good PCM and recheck.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-33
O / D cut
switchOFF ON
VoltageBattery
voltage0 V
DIAGNOSTIC FLOW TABLE A-2 (NO GEAR SHIFT TO O / D)
SYSTEM DESCRIPTION
PCM does not shift to O / D gear under any of the following conditions.

O / D cut switch: ON

4WD LOW switch: ON

Cruise control module: O / D OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor,
its circuit or engine
cooling system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-2 (G16 / J20 engines) or C51-1-6 (H25
engine) terminal of PCM coupler and ground,
C51-1-1 terminal of PCM coupler and ground.

O / D cut switch OFF (ªO / D OFFº lamp OFF).

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Drive vehicle with 4th gear condition
referring to ªGear shift diagramº in this
section.
Is each voltage about 0 V?Faulty shift solenoid
valve, its circuit or
transmission.ªGº wire or ªG / Rº wire
shorted to power circuit.
If OK, go to Step 4.
4O / D cut switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-33 (G16 / J20 engines) or
E61-14 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 5.Faulty O / D cut switch or
its circuit.
If OK, substitute a known-
good PCM and recheck.