Suzuki Grand Vitara JB416 / JB420. Manual - part 239

5A-90 Automatic Transmission/Transaxle: 

Oil Cooler Hose and Pipe Components

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Oil Cooler Hose and Pipes Removal and 
Installation

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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 

(2) with oil outlet union locked and remove oil cooler 
pipes (1) 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.

 

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[A]: View from A side

3. Oil hose No.1

6. Oil pipe No.2

9. Oil pipe No.1 bolt

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

1. Radiator

4. Oil hose No.4

7. Oil pipe union bolt

10. Oil pipe No.2 bolt

2. Oil hose No.3

5. Oil pipe No.1

8. Oil pipe tube bolt

: 25 N

⋅m (2.5 kgf-m, 18.0lb-ft)

3. Pipe bolt

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Automatic Transmission/Transaxle:  5A-91

Installation
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

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 referring to “Oil Cooler Hose and Pipe 
Components”.

4) Tighten pipe bolt to specified torque referring to “Oil 

Cooler Hose and Pipe Components”.

5) Check A/T fluid level according to procedure 

described in “A/T Fluid Level Check”. Add if 
necessary.

6) Check for fluid leakage after warming up A/T.

Solenoid Valves (Shift Solenoid-A, Shift 
Solenoid-B, TCC Pressure Control Solenoid and 
Pressure Control Solenoid Removal and 
Installation

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Removal

1) Disconnect negative cable at battery.
2) Pull out fluid level gauge and lift up vehicle.
3) Remove drain plug (3) and drain A/T fluid.
4) Install drain plug (3) with new gasket.
5) Remove oil filler tube (2) and A/T oil pan (1).

6) Remove A/T oil strainer (1).

7) Disconnect shift solenoid–A connector (1), shift 

solenoid–B connector (2), TCC pressure control 
solenoid connector (4) and Pressure control solenoid 
connector (3).

8) Remove solenoid valves.

Installation
Remove removal procedure to install solenoid valves, 
noting the following points.
• For details of solenoid valves and their connectors 

installation, refer to “Automatic Transmission Unit 
Assembly”. Use new O-ring.

• For details of A/T oil pan installation, refer to 

“Automatic Transmission Unit Assembly”.

• Tighten exhaust No.1 pipe bolts & nuts and exhaust 

bracket bolts & nuts.

• Fill A/T fluid and check fluid level according to 

procedure described in “A/T Fluid Change”.

• Check for fluid leakage after warming up A/T.

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5A-92 Automatic Transmission/Transaxle: 

Solenoid Valves (Shift Solenoid-A, Shift 
Solenoid-B, TCC Pressure Control Solenoid and 
Pressure Control Solenoid Inspection

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Solenoid Valves (Shift Solenoid–A and Shift 
Solenoid–B)
Resistance check

CAUTION

!

 

Be very careful as dust etc. does not enter 
when solenoid valves are inspected.

 

Measure resistance between terminal (2) and solenoid 
valve body. If resistance is out of specification, replace 
solenoid valve.

Shift solenoid–A and Shift solenoid–B resistance
Standard: 11 – 15 

Ω (at 20 °C (68 °F))

Operation Check
• With solenoid connected to battery (2) as shown in the 

figure, check that solenoid valve is actuated with click 
sound.

• With shift solenoid valve (1) connected to battery (2), 

confirm that shift solenoid valve is open by blowing air 
(50 – 200 kPa, 0.5 – 2.0 kg/cm

2

, 7 – 28.5 psi) into 

solenoid valve as shown in the figure.

• With shift solenoid valve (1) not connected to battery 

(2), confirm that shift solenoid valve is closed by 
blowing air (50 – 200 kPa, 0.5 – 2.0 kg/cm

2

, 7 – 28.5 

psi) into solenoid valve as shown in the figure.

CAUTION

!

 

Do not insert air gun against strainer 
installed on inlet of solenoid valve too deeply, 
when blowing air into solenoid valve. If not, 
the strainer will be damaged.

 

Pressure Control Solenoid Valve and TCC Pressure 
Control Solenoid Valve
Resistance check

CAUTION

!

 

Be very careful as dust etc. does not enter 
when pressure control solenoid valves are 
inspected.

 

Measure resistance between pressure control solenoid 
valves (Pressure control solenoid and TCC pressure 
control solenoid) (1) terminals. If resistance is out of 
specification, replace valve body assembly.

Pressure control solenoid and TCC pressure control 
solenoid resistance
Standard: 5.0 – 5.6 

Ω (at 20 °C (68 °F))

1. Shift solenoids

1. Shift solenoids

1

2

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Automatic Transmission/Transaxle:  5A-93

Operation check
Check pressure control solenoid valves (Pressure 
control solenoid and TCC pressure control solenoid) (1) 
operation in either of the following methods.
[Using regulated DC power supply]

1) Connect pressure control solenoid valve (1) with 

regulated DC power supply (2) as shown in the 
figure.

2) Turn regulated DC power supply switch ON, 

increase voltage of power supply keeping current 
within 1.0 A.

3) Check that valve (3) moves gradually in arrow “A” 

direction as voltage increases.

4) Check that valve (3) moves in arrow “B” direction as 

voltage decreases.

5) Turn power supply switch OFF.

CAUTION

!

 

Do not feed current 1.0 A or more, or 
pressure control solenoid will be burned out.

 

[Not using regulated DC power supply]

1) Connect pressure control solenoid valve (1) to 

battery (4) setting 21 W bulb (2) in between as 
shown in the figure.

2) Check that valve (3) moves in arrow “A” direction.
3) Disconnect pressure control solenoid valve (1) from 

battery (4) and check that valve (3) moves in arrow 
“B” direction as shown in the figure.

CAUTION

!

 

Set 21 W bulb in between, or pressure control 
solenoid valve will be burned out.

 

Transmission Fluid Temperature Sensor 
Removal and Installation

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Removal

1) Disconnect negative cable at battery.
2) Pull out fluid level gauge and lift up vehicle.
3) Remove drain plug and drain A/T fluid.
4) Install drain plug with new gasket.
5) Remove oil filler tube (2) and A/T oil pan (1).

6) Remove A/T oil strainer (1).

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