Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 75

 

  Index      Suzuki     Suzuki Grand Vitara JB416 / JB420 ESP model - service and repair manual 2007 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  73  74  75  76   ..

 

 

Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 75

 

 

5-ii Table of Contents

DTC P0973 / P0976: Shift Solenoid “A” 

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

DTC P0974 / P0977: Shift Solenoid “A” 

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

DTC P1702: Internal Control Module Memory 

Check Sum Error .............................................. 5A-*

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

Malfunction........................................................ 5A-*

DTC P1774: CAN Communication Bus Off.......5A-22
DTC P1777: TCM Lost Communication with 

ECM (Reception Error) ...................................5A-25

DTC P1778: TCM Lost Communication with 

BCM (Reception Error) ..................................... 5A-*

DTC P1874: 4L Switch Circuit Malfunction 

(Short) .............................................................5A-26

DTC P1875: 4L Switch Circuit Malfunction 

(Open) .............................................................5A-27

DTC P1878: Torque Converter Clutch 

Shudder ............................................................ 5A-*

DTC P2763: Torque Converter Clutch (TCC) 

Circuit High ....................................................... 5A-*

DTC P2764: Torque Converter Clutch (TCC) 

Circuit Low ........................................................ 5A-*

Inspection of TCM and Its Circuits ....................5A-28

TCM Power and Ground Circuit Check............... 5A-*

Repair Instructions ............................................5A-33

A/T Fluid Level Check ......................................... 5A-*
A/T Fluid Change ................................................ 5A-*
Manual Selector Assembly Components ............ 5A-*
Manual Selector Assembly Removal and 

Installation......................................................... 5A-*

Select Lever Knob Installation............................. 5A-*
Manual Selector Assembly Inspection ................ 5A-*
“3” Position Switch Inspection ............................. 5A-*
Select Cable Component .................................... 5A-*
Select Cable Adjustment..................................... 5A-*
Transmission Range Sensor Removal and 

Installation......................................................... 5A-*

Transmission Range Sensor Inspection and 

Adjustment ........................................................ 5A-*

Key Interlock Cable Removal and Installation..... 5A-*
Brake and key Interlock System Inspection ........ 5A-*
Mode Select Switch Inspection ........................... 5A-*
Input Shaft Speed Sensor Removal and 

Installation......................................................... 5A-*

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

Installation......................................................... 5A-*

Output Shaft Speed Sensor Inspection............... 5A-*
Oil Cooler Hose and Pipe Components .............. 5A-*
Oil Cooler Hose and Pipes Removal and 

Installation......................................................... 5A-*

Solenoid Valves (Shift Solenoid-A, Shift 

Solenoid-B, TCC Pressure Control Solenoid 
and Pressure Control Solenoid Removal 
and Installation .................................................. 5A-*

Solenoid Valves (Shift Solenoid-A, Shift 

Solenoid-B, TCC Pressure Control Solenoid 
and Pressure Control Solenoid Inspection........ 5A-*

Transmission Fluid Temperature Sensor 

Removal and Installation................................... 5A-*

Transmission Fluid Temperature Sensor 

Inspection.......................................................... 5A-*

Transmission Control Module (TCM) 

Removal and Installation................................... 5A-*

A/T Relay Inspection ........................................... 5A-*

Automatic Transmission Unit Components .......5A-33

Automatic Transmission Assembly 

Dismounting and Remounting........................... 5A-*

Automatic Transmission Unit Disassembly ......... 5A-*
Oil Pump Components ........................................ 5A-*
Oil Pump Disassembly and Assembly ................ 5A-*
Oil Pump Inspection ............................................ 5A-*
Overdrive (Planetary Gear Side) Components .... 5A-*
Overdrive (Planetary Gear Side) Disassembly 

and Assembly.................................................... 5A-*

Overdrive (Planetary Gear Side) Inspection ....... 5A-*
Overdrive (Case Side) Components ................... 5A-*
Overdrive (Case Side) Disassembly and 

Assembly........................................................... 5A-*

Overdrive (Case Side) Inspection ....................... 5A-*
Forward Clutch Components .............................. 5A-*
Forward Clutch Disassembly and Assembly....... 5A-*
Forward Clutch Inspection .................................. 5A-*
Direct Clutch Components .................................. 5A-*
Direct Clutch Disassembly and Assembly........... 5A-*
Direct Clutch Inspection ...................................... 5A-*
Center Support Components .............................. 5A-*
Center Support Disassembly and Assembly....... 5A-*
Center Support Inspection .................................. 5A-*
Planetary Gears and Output Shaft 

Components...................................................... 5A-*

Planetary Gears and Output Shaft 

Disassembly and Assembly .............................. 5A-*

Planetary Gears and Output Shaft Inspection..... 5A-*
Valve Body Assembly Components .................... 5A-*

Automatic Transmission Unit Assembly............5A-34

Specifications .....................................................5A-43

Bearing and Race Installation Specification......5A-43
Tightening Torque Specifications......................5A-44

Special Tools and Equipment ...........................5A-44

Special Tool ......................................................5A-44

Manual Transmission/Transaxle .............5B-*

General Description ............................................. 5B-*

Manual Transmission Construction..................... 5B-*

Diagnostic Information and Procedures ............ 5B-*

Manual Transmission Symptom Diagnosis ......... 5B-*

Repair Instructions .............................................. 5B-*

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

Assembly Components ..................................... 5B-*

Gear Shift Lever Front Case Assembly 

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

Gear Shift Shaft and Fork Components .............. 5B-*

Table of Contents 5-iii

Input Shaft Assembly, Output Shaft Assembly 

and Countershaft Assembly Components .........5B-*

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

and Installation...................................................5B-*

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

Installation..........................................................5B-*

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

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

Gear Shift Control Lever Rear Case 

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

Gear Shift Control Lever Rear Case 

Assembly Inspection ..........................................5B-*

Gear Shift Lever Front Case Assembly 

Removal and Installation....................................5B-*

Gear Shift Lever Front Case Assembly 

Disassembly and Reassembly...........................5B-*

Gear Shift Lever Front Case Assembly 

Inspection...........................................................5B-*

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

and Remounting.................................................5B-*

Manual Transmission Unit Disassembly ..............5B-*
Manual Transmission Unit Reassembly...............5B-*
Locating Spring Inspection...................................5B-*
Input Shaft Disassembly ......................................5B-*
Input Shaft Inspection ..........................................5B-*
Input Shaft Reassembly.......................................5B-*
Countershaft Disassembly and Assembly............5B-*
Countershaft and Reverse Idle Gear 

Inspection...........................................................5B-*

Output Shaft Disassembly and Assembly ............5B-*
Output Shaft Inspection .......................................5B-*
Manual Transmission Front Case 

Disassembly and Assembly ...............................5B-*

Manual Transmission Adapter Case 

Disassembly and Assembly ...............................5B-*

Specifications....................................................... 5B-*

Tightening Torque Specifications.........................5B-*

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

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

Clutch ........................................................5C-*

General Description ............................................. 5C-*

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

Component Location ........................................... 5C-*

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

Diagnostic Information and Procedures............ 5C-*

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

Repair Instructions .............................................. 5C-*

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

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

Clutch Pedal Position (CPP) Switch 

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

Clutch Fluid Pipe and Hose Removal and 

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

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

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

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

Removal and Installation................................... 5C-*

Clutch Cover, Clutch Disc and Flywheel 

Components...................................................... 5C-*

Clutch Cover, Clutch Disc and Flywheel 

Removal and Installation................................... 5C-*

Clutch Cover, Clutch Disc and Flywheel 

Inspection.......................................................... 5C-*

Specifications....................................................... 5C-*

Tightening Torque Specifications........................ 5C-*

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

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

5A-1 Automatic Transmission/Transaxle: 

Transmission / Transaxle

Automatic Transmission/Transaxle

Precautions

Precautions in Diagnosing Trouble

S5JB0E5100001

• Do not disconnect couplers from TCM, battery cable 

from battery, TCM ground wire harness from engine or 
main fuse before checking the diagnostic information 
(DTC, freeze frame data, etc.) stored in TCM memory. 
Such disconnection will clear memorized information 
in TCM memory.

• For vehicle without engine diagnosis connector, 

diagnostic information stored in TCM memory can be 
cleared as well as checked by using SUZUKI scan 
tool or OBD generic scan tool. Before using scan tool, 
read its Operator’s (Instruction) Manual carefully to 
have good understanding as to what functions are 
available and how to use it.
It is indistinguishable which module turns on MIL 
because not only ECM but also TCM turns on MIL. 
Therefore, check both ECM and TCM for DTC when 
MIL lights on.
When checking TCM for DTC, keep in mind that DTC 
is displayed on the scan tool as follows depending on 
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– OBD generic scan tool displays DTC detected by 

each of ECM and TCM simultaneously.

• For vehicle with engine diagnosis connector, using 

SUZUKI scan tool the diagnostic information stored in 
TCM memory can be checked and cleared as well. 
Before its use, be sure to read Operator’s Manual 
supplied with it carefully to have good understanding 
of its functions and usage.

• Not using scan tool (if equipped with AT monitor 

connector), the DTC stored in TCM memory also can 
be checked and cleared. DTC stored in the TCM 
memory is outputted by displaying DTC on digital 
display odometer with diagnosis terminal of monitor 
connector grounded. If no DTC is stored in TCM 
memory, DTC 0000 is outputted. If one or more DTCs 
are stored in TCM memory, they are outputted starting 
from smallest code number in increasing order. After 
all DTCs are outputted, all DTCs are outputted 
repeatedly.

• Be sure to read “Precautions for Electrical Circuit 

Service in Section 00 in related manual” before 
inspection and observe what is written there.

• TCM and/or ECM replacement:

When substituting a known-good TCM and/or ECM, 
check for the following conditions.
Neglecting this check may result in damage to a good 
TCM and/or ECM.
– All relays and actuators have resistance of 

specified value.

– MAF sensor, Manifold absolute pressure (MAP) 

sensor, TP sensor and fuel tank pressure sensor 
are in good condition. Also, the power circuit of 
these sensors is not shorted to the ground.

• Communication of ECUs, ECM, TCM, BCM, 

combination meter, 4WD control module (if equipped), 
ABS/ESP

® control module, keyless start control 

module (if equipped), steering angle sensor (if 
equipped) and DLC is established by CAN (controller 
Area Network). For more detail of CAN 
communication, refer to “CAN Communication 
System Description”. The
refore, handle CAN 
communication line with care referring to “Precaution 
for CAN Communication System in Section 00 in 
related manual”.

Automatic Transmission/Transaxle:  5A-2

General Description

Automatic Transmission Description

S5JB0E5101001

This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D).
The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-up 
mechanism. The gear shift device consists of 3 sets of planetary gear units,3 disc type clutches, 4 disc type brakes 
and 3 one-way clutches. The gear shift is done by selecting one of 7 positions (“P”, “R”, “N”, “D”, “3”, “2” and “L”) by 
means of the select lever installed on the floor. Also, by using the P/N mode switch located on the console box, it is 
possible to select the gear change timing of 2 modes, normal and power.

1

13

14

16

15

19

17

18

20

2

3

4

5

6

7

8

9

10

11

12

I5JB0A510004-01

1. Torque converter clutch (TCC)

8. Second coast brake

15. O/D one-way clutch

2. Torque converter

9. Second brake

16. Forward clutch input shaft

3. O/D clutch

10. Reverse brake

17. One-way clutch No.1

4. O/D brake

11. Front planetary gear

18. One-way clutch No.2

5. O/D planetary gear

12. Rear planetary gear

19. Intermediate shaft

6. Forward clutch

13. O/D input shaft

20. Output shaft

7. Direct clutch

14. Oil pump

 

 

 

 

 

 

 

Content   ..  73  74  75  76   ..