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