Suzuki Grand Vitara JB627. Manual — part 203

4F-51 Electronic Stability Program:

Specifications

Tightening Torque Specifications

S6JB0B4607001

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Special Tool

S6JB0B4608001

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Yaw rate / G sensor assembly bolt

8

0.8

6.0

)

09956–02311

SUZUKI scan tool

Brake pressure gauge

—

)

This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / ) / )
/ ) / ) / ) / )

Table of Contents 5- i

5

Section 5

CONTENTS

Transmission / Transaxle

Precautions . . . . . . . . . . . . .5-1

Precautions. . . . . . . . . . . . . . . . 5-1

Precautions for Transmission / Transaxle. . . . 5-1

Automatic Transmission/Transaxle. ... 5A-1

Precautions. . . . . . . . . . . . . . ...5A-1

Precautions in Diagnosing Trouble . . . . . . 5A-1
General Service Procedure Information. . . .. 5A-1
Precautions for Disassembly and

Reassembly . . . . . . . . . . . . . .. 5A-1

General Description . . . . . . . . . . . .5A-2

Automatic Transmission Description. . . . ... 5A-2
Clutch / Brake Functions of Automatic

Transmission. . . . . . . . . . . . . . 5A-5

Table of A/T Component Operation . . . . . 5A-6
Operation of Shift Solenoids and TCC

Solenoid . . . . . . . . . . . . . . . 5A-6

Automatic Gear Shift Table. . . . . . . . . 5A-7
CAN Communication System Description. . ... 5A-8
Electronic Shift Control Input / Output Table. ... 5A-9
Brake Interlock System Description . . . . . 5A-9
A/T Diagnosis General Description . . . . ...5A-10
On-Board Diagnostic System Description. . .5A-10

Schematic and Routing Diagram. . . . . ..5A-12

Electronic Shift Control Input / Output

Diagram . . . . . . . . . . . . . . ..5A-12

Electronic Shift Control System Wiring

Diagram . . . . . . . . . . . . . . ..5A-13

Component Location . . . . . . . . . . .5A-15

Electronic Shift Control System Components

Location . . . . . . . . . . . . . . ..5A-15

Diagnostic Information and Procedures. . ..5A-16

A/T System Check . . . . . . . . . . . 5A-16
Malfunction Indicator Lamp (MIL) Check (E-

OBD model) . . . . . . . . . . . . . 5A-18

Transmission Warning Light Operation Check

(Non-E-OBD model). . . . . . . . . . 5A-18

“POWER” Lamp Operation Check . . . . . 5A-18
DTC Table. . . . . . . . . . . . . . .5A-19
DTC Check . . . . . . . . . . . . . ...5A-22
DTC Clearance . . . . . . . . . . . . . 5A-22
Fail Safe Table. . . . . . . . . . . . .. 5A-23
Scan Tool Data . . . . . . . . . . . . . 5A-25
Visual Inspection. . . . . . . . . . . ...5A-28

A/T Basic Check. . . . . . . . . . . . 5A-28
Road Test. . . . . . . . . . . . . . ..5A-29
Manual Road Test. . . . . . . . . . . .5A-30
Stall Test . . . . . . . . . . . . . . ...5A-31
Time Lag Test . . . . . . . . . . . . ...5A-32
Line Pressure Test . . . . . . . . . . . 5A-33
Engine Brake Test. . . . . . . . . . . .5A-34
“P” Range Test. . . . . . . . . . . . ..5A-34
A/T Symptom Diagnosis. . . . . . . . . 5A-35
No Gear Shift to 5th gear . . . . . . . . ..5A-39
No Lock-Up Occurs. . . . . . . . . . ...5A-40
Transmission Warning Light Circuit Check –

Light Does Not Come “ON” at Ignition Switch
ON (Non-E-OBD model) . . . . . . . . .5A-41

Transmission Warning Light Circuit Check –

Light Remains “ON” at Ignition Switch ON
(Non-E-OBD model). . . . . . . . . . 5A-41

“POWER” Light Circuit Check – Light Does

Not Come “ON” at Ignition Switch ON. . . .5A-41

DTC P0705: Transmission Range Sensor

Circuit Malfunction. . . . . . . . . . ...5A-42

DTC P0707: Transmission Range Sensor

Circuit Low . . . . . . . . . . . . . ..5A-44

DTC P0711: Transmission Fluid Temperature

Sensor Range / Performance. . . . . . ..5A-45

DTC P0712: Transmission Fluid Temperature

Sensor “A” Circuit Low . . . . . . . . . 5A-46

DTC P0713: Transmission Fluid Temperature

Sensor “A” Circuit High . . . . . . . . ...5A-47

DTC P0717: Input / Turbine Speed Sensor

Circuit No Signal . . . . . . . . . . . .5A-48

DTC P0722: Output Speed Sensor Circuit No

Signal . . . . . . . . . . . . . . . ..5A-50

DTC P0741 / P0742: TCC Circuit

Performance or Stuck OFF / TCC Circuit
Stuck ON. . . . . . . . . . . . . . .5A-51

DTC P0751 / P0752: Shift Solenoid-A

Performance or Stuck OFF / Shift Solenoid-
A Stuck ON . . . . . . . . . . . . . .5A-52

DTC P0756 / P0757: Shift Solenoid-B

Performance or Stuck OFF / Shift Solenoid-
B Stuck ON . . . . . . . . . . . . . .5A-53

DTC P0771 / P0772: Shift Solenoid-E

Performance or Stuck OFF / Shift Solenoid-
E Stuck ON . . . . . . . . . . . . . .5A-55

5-ii Table of Contents

DTC P0781: 1-2 Shift . . . . . . . . . . 5A-56
DTC P0797: Pressure Control Solenoid “C”

Stuck ON. . . . . . . . . . . . . . .5A-57

DTC P0962 / P0966 / P0970: Pressure

Control Solenoid “A” Control Circuit Low /
Pressure Control Solenoid “B” Control
Circuit Low / Pressure Control Solenoid “C”
Control Circuit Low. . . . . . . . . . ..5A-58

DTC P0963 / P0967 / P0971: Pressure

Control Solenoid “A” Control Circuit High /
Pressure Control Solenoid “B” Control
Circuit High / Pressure Control Solenoid “C”
Control Circuit High . . . . . . . . . . .5A-60

DTC P0973 / P0976 / P0985: Shift Solenoid

“A” Control Circuit Low / Shift Solenoid “B”
Control Circuit Low / Shift Solenoid “E”
Control Circuit Low. . . . . . . . . . ..5A-61

DTC P0974 / P0977 / P0986: Shift Solenoid

“A” Control Circuit High / Shift Solenoid “B”
Control Circuit High / Shift Solenoid “E”
Control Circuit High . . . . . . . . . . .5A-62

DTC P1702: Internal Control Module Memory

Check Sum Error . . . . . . . . . . . 5A-64

DTC P1703: CAN Invalid Data - TCM. . . ...5A-64
DTC P1723: Range Select Switch

Malfunction. . . . . . . . . . . . . ..5A-65

DTC P1874: 4L Switch Circuit Malfunction

(Short) . . . . . . . . . . . . . . . .5A-66

DTC P1875: 4L Switch Circuit Malfunction

(Open) . . . . . . . . . . . . . . . .5A-67

DTC P2742: Transmission Fluid Temperature

Sensor “B” Circuit Low . . . . . . . . . 5A-69

DTC P2743: Transmission Fluid Temperature

Sensor “B” Circuit High . . . . . . . . ...5A-70

DTC P2763: Torque Converter Clutch (TCC)

Circuit High . . . . . . . . . . . . . .5A-71

DTC P2764: Torque Converter Clutch (TCC)

Circuit Low . . . . . . . . . . . . . ..5A-72

DTC U0073: Control Module Communication

Bus Off . . . . . . . . . . . . . . . 5A-74

DTC U0100: Lost Communication with ECM . 5A-77
DTC U0140: Lost Communication with Body

Control Module. . . . . . . . . . . . 5A-78

Inspection of TCM and Its Circuits . . . . . 5A-79
TCM Power and Ground Circuit Check. . . .5A-84

Repair Instructions . . . . . . . . . . . 5A-85

Learning Control Initialization. . . . . . . 5A-85
A/T Fluid Level Check . . . . . . . . . ...5A-85
A/T Fluid Change . . . . . . . . . . . ..5A-86
Oil Cooler Hoses Replacement. . . . . . .5A-87
Manual Selector Assembly Components . . ..5A-88
Manual Selector Assembly Removal and

Installation. . . . . . . . . . . . . ...5A-88

Select Lever Knob Installation. . . . . . ...5A-88
Manual Selector Assembly Inspection . . . ..5A-88
“4” Position Switch Inspection . . . . . . ...5A-89
Mode Select Switch Inspection . . . . . . .5A-89
Select Cable Component . . . . . . . . ..5A-90
Select Cable Adjustment. . . . . . . . ...5A-91

Transmission Range Sensor Removal and

Installation . . . . . . . . . . . . . ...5A-91

Transmission Range Sensor Inspection and

Adjustment . . . . . . . . . . . . . ..5A-92

Key Interlock Cable Removal and Installation...5A-93
Brake and key Interlock System Inspection . ..5A-95
Input Shaft Speed Sensor Removal and

Installation . . . . . . . . . . . . . ...5A-95

Input Shaft Speed Sensor Inspection. . . . 5A-96
Output Shaft Speed Sensor Removal and

Installation . . . . . . . . . . . . . ...5A-96

Output Shaft Speed Sensor Inspection. . . .5A-97
Solenoid Valves (Shift Solenoid-A, Shift

Solenoid-B, Shift Solenoid-E, TCC Solenoid,
Pressure Control Solenoid-A, Pressure
Control Solenoid-B, and Pressure Control
Solenoid-C) Removal and Installation. . . .5A-97

Solenoid Valves (Shift Solenoid-A, Shift

Solenoid-B, Shift Solenoid-E, TCC Solenoid,
Pressure Control Solenoid-A, Pressure
Control Solenoid-B, and Pressure Control
Solenoid-C) Inspection. . . . . . . . . 5A-98

Transmission Fluid Temperature Sensor

Removal and Installation. . . . . . . ...5A-100

Transmission Fluid Temperature Sensor

Inspection. . . . . . . . . . . . . ..5A-101

Transmission Control Module (TCM)

Removal and Installation. . . . . . . ...5A-101

A/T Relay Inspection . . . . . . . . . ...5A-102
Oil Cooler Pipes Removal and Installation. ..5A-102
Automatic Transmission Unit Components . .5A-103
Automatic Transmission Assembly

Dismounting and Remounting. . . . . ...5A-104

Automatic Transmission Unit Components . .5A-105
Automatic Transmission Unit Disassembly . .5A-106
Oil Pump Assembly Components . . . . ...5A-117
Oil Pump Disassembly and Assembly . . . 5A-118
Oil Pump Inspection . . . . . . . . . . 5A-120
Clutch Drum & Input Shaft Assembly

Components. . . . . . . . . . . . ..5A-121

Clutch Drum & Input Shaft Assembly

Disassembly. . . . . . . . . . . . ..5A-122

Clutch Drum & Input Shaft Assembly

Reassembly . . . . . . . . . . . . ..5A-126

Clutch Drum & Input Shaft Assembly

Inspection. . . . . . . . . . . . . ..5A-134

Valve Body Assembly Components . . . . 5A-136
Automatic Transmission Unit Assembly. . ..5A-137
Automatic Transmission Unit Assembly

Inspection. . . . . . . . . . . . . ..5A-154

Specifications . . . . . . . . . . . . ...5A-158

Bearing and Race Installation Specification. 5A-158
Tightening Torque Specifications. . . . . 5A-159

Special Tools and Equipment . . . . . . .5A-160

Recommended Service Material . . . . . .5A-160
Special Tool . . . . . . . . . . . . . 5A-160

Manual Transmission/Transaxle . . . 5B-1

General Description . . . . . . . . . . . .5B-1

Manual Transmission Construction. . . . . .5B-1

Table of Contents 5-iii

Diagnostic Information and Procedures. . . 5B-2

Manual Transmission Symptom Diagnosis . . . 5B-2

Repair Instructions . . . . . . . . . . . ..5B-3

Manual Transmission Assembly Components . 5B-3
Gear Shift Control Lever Rear Case

Assembly Components . . . . . . . . . . 5B-4

Gear Shift Lever Front Case Assembly

Components. . . . . . . . . . . . . .. 5B-5

Gear Shift Shaft and Fork Components. . . .. 5B-6
Input Shaft Assembly, Output Shaft Assembly

and Countershaft Assembly Components . . 5B-7

Manual Transmission Oil Change . . . . . ... 5B-8
Transmission Shift Control Lever Removal

and Installation. . . . . . . . . . . . .. 5B-9

Transmission Shift Control Lever Inspection. ... 5B-9
Back Up Light Switch Removal and

Installation. . . . . . . . . . . . . ...5B-10

Back Up Light Switch Inspection. . . . . ... 5B-10
Gear Shift Control Lever Rear Case

Assembly Removal and Installation . . . . 5B-10

Gear Shift Control Lever Rear Case

Assembly Disassembly and Reassembly . ... 5B-11

Gear Shift Control Lever Rear Case

Assembly Inspection . . . . . . . . . ... 5B-11

Gear Shift Lever Front Case Assembly

Removal and Installation. . . . . . . . . 5B-11

Gear Shift Lever Front Case Assembly

Disassembly and Reassembly. . . . . . 5B-12

Gear Shift Lever Front Case Assembly

Inspection. . . . . . . . . . . . . . 5B-13

Engine Rear Mounting Replacement . . . . 5B-13
Manual Transmission Assembly Dismounting

and Remounting. . . . . . . . . . . .. 5B-14

Manual Transmission Unit Disassembly . . ... 5B-16
Manual Transmission Unit Reassembly. . . 5B-17
Locating Spring Inspection. . . . . . . . 5B-20
Input Shaft Disassembly . . . . . . . . ...5B-20
Input Shaft Inspection . . . . . . . . . ... 5B-21
Input Shaft Reassembly. . . . . . . . . 5B-22
Countershaft Disassembly and Assembly. . .5B-24
Countershaft and Reverse Idle Gear

Inspection. . . . . . . . . . . . . . 5B-27

Output Shaft Disassembly and Assembly . . .5B-28
Output Shaft Inspection . . . . . . . . . 5B-29

Manual Transmission Front Case

Disassembly and Assembly . . . . . . . 5B-29

Manual Transmission Adapter Case

Disassembly and Assembly . . . . . . . 5B-30

Specifications. . . . . . . . . . . . . .5B-30

Tightening Torque Specifications. . . . . ..5B-30

Special Tools and Equipment . . . . . . ...5B-31

Recommended Service Material . . . . . ...5B-31
Special Tool . . . . . . . . . . . . . ..5B-31

Clutch . . . . . . . . . . . . . ... 5C-1

General Description . . . . . . . . . . . .5C-1

Clutch (Hydraulic Type) Construction . . . . .5C-1

Component Location . . . . . . . . . . ...5C-2

Clutch Fluid Pipe and Hose Location . . . . ..5C-2

Diagnostic Information and Procedures. . . 5C-3

Clutch (Hydraulic Type) Symptom Diagnosis. ..5C-3

Repair Instructions . . . . . . . . . . . ..5C-4

Clutch Pedal Height Inspection . . . . . . ...5C-4
Clutch Pedal Free Travel Check . . . . . . .5C-4
Clutch Fluid Inspection. . . . . . . . . . 5C-4
Air Bleeding of Clutch System. . . . . . . .5C-4
Clutch Pedal Position (CPP) Switch Removal

and Installation . . . . . . . . . . . . ..5C-5

Clutch Pedal Position (CPP) Switch

Inspection and Adjustment. . . . . . . . 5C-5

Clutch Fluid Pipe and Hose Removal and

Installation . . . . . . . . . . . . . . .5C-5

Clutch Fluid Pipe and Hose Inspection . . . ...5C-6
Clutch Master Cylinder Removal and

Installation . . . . . . . . . . . . . . .5C-6

Clutch Master Cylinder Inspection . . . . . ..5C-7
Clutch Operating Cylinder Assembly

Removal and Installation. . . . . . . . ...5C-7

Clutch Cover, Clutch Disc and Flywheel

Components. . . . . . . . . . . . . ..5C-8

Clutch Cover, Clutch Disc and Flywheel

Removal and Installation. . . . . . . . ...5C-9

Clutch Cover, Clutch Disc and Flywheel

Inspection. . . . . . . . . . . . . . 5C-10

Specifications. . . . . . . . . . . . . .5C-11

Tightening Torque Specifications. . . . . ..5C-11

Special Tools and Equipment . . . . . . ...5C-11

Recommended Service Material . . . . . ...5C-11
Special Tool . . . . . . . . . . . . . ..5C-11