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GRAND VITARA
Suzuki GRAND VITARA Manual
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5B-3
Manual T
ransmission/T
ra
nsaxle:
Rep
air Instructions
Manual T
ransmission Assembly Component
s
S5JB0A5206001
6
9
19
20
21
10
18
5
A
3
8
4
27
OIL
1217G
1217G
2
1
24
1322
23
22
25
26
17
16
15
12
11
28
29
13
14
A
30
31
32
33
7
1217G
OIL
1217G
(a)
(a)
(a)
(a)
(a)
(a)
(a)
(b)
34
(c)
34
(c)
34
(c)
35
(c)
1217G
37
36
38
1217G
(a)
I5JB0A520018-
03
www.CarGarage.ir
www.CarGarage.ir
www.CarGarage.ir
143
145
Table of Contents
Default Chapter
1
Table of Contents
1
Precautions
4
Precautions for Transmission / Transaxle
4
Automatic Transmission/Transaxle
5
Precautions
5
Precautions in Diagnosing Trouble
5
General Service Procedure Information
5
Precautions for Disassembly and Reassembly
5
General Description
7
Automatic Transmission Description
7
Clutch / Brake Functions of Automatic Transmission
9
Table of A/T System Component Operation
10
CAN Communication System Description
11
Electronic Shift Control Input / Output Table
12
Brake Interlock System Description
15
A/T Diagnosis General Description
15
On-Board Diagnostic System Description
15
Schematic and Routing Diagram
17
Automatic Gear Shift Table
17
Bearing and Race Installation Diagram
20
Component Location
21
Electronic Shift Control System Components Location
21
Diagnostic Information and Procedures
22
A/T System Check
22
Malfunction Indicator Lamp (MIL) Check
24
Transmission Warning Light Operation Check (Vehicle Is Equipped with Engine Diagnosis Connector)
24
POWER" Lamp Operation Check
24
DTC Table
25
DTC Check
26
DTC Clearance
27
Fail Safe Table
28
Scan Tool Data
30
Visual Inspection
33
A/T Basic Check
33
Road Test
34
Manual Road Test
35
Stall Test
36
Time Lag Test
37
Line Pressure Test
37
Engine Brake Test
39
P" Range Test
39
A/T Symptom Diagnosis
40
No Gear Shift to 4Th Gear
47
No Lock-Up Occurs
48
Transmission Warning Light Circuit Check - Light Does Not Come "ON" at Ignition Switch on (Vehicle Is Equipped with Engine Diagnosis Connector)
49
Transmission Warning Light Circuit Check - Light Remains "ON" at Ignition Switch on (Vehicle Is Equipped with Engine Diagnosis Connector)
49
POWER" Light Circuit Check - Light Does Not Come "ON" at Ignition Switch on
50
DTC P0705 Transmission Range Sensor Circuit Malfunction
50
DTC P0707 Transmission Range Sensor Circuit Low
52
DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low
54
DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High
55
DTC P0717 Input / Turbine Speed Sensor Circuit no Signal
56
DTC P0722 Output Speed Sensor Circuit no Signal
57
DTC P0741 / P0742 TCC Circuit Performance or Stuck off / TCC Circuit Stuck
58
Performance or Stuck off / TCC Circuit Stuck on
58
DTC P0751 / P0752 Shift Solenoid-A Performance or Stuck off / Shift Solenoid-A Stuck
59
Performance or Stuck off / Shift Solenoid-A Stuck on
59
DTC P0756 / P0757 Shift Solenoid-B Performance or Stuck off / Shift Solenoid-B Stuck
60
Performance or Stuck off / Shift Solenoid-B Stuck on
60
DTC P0962 Pressure Control Solenoid "A" Control Circuit Low
61
DTC P0963 Pressure Control Solenoid "A" Control Circuit High
62
DTC P0973 / P0976 Shift Solenoid "A" Control Circuit Low / Shift Solenoid "B" Control Circuit Low
63
DTC P0974 / P0977 Shift Solenoid "A" Control Circuit High / Shift Solenoid "B" Control Circuit High
65
DTC P1702 Internal Control Module Memory Check Sum Error
66
DTC P1703 CAN Invalid Data - TCM
66
DTC P1723 Range Select Switch Malfunction
67
Www.cargarage.ir DTC P1774: CAN Communication Bus off
67
DTC P1777: TCM Lost Communication with ECM (Reception Error)
70
DTC P1778: TCM Lost Communication with BCM (Reception Error)
71
DTC P1874 4L Switch Circuit Malfunction (Short)
72
DTC P1875 4L Switch Circuit Malfunction (Open)
73
DTC P1878 Torque Converter Clutch Shudder
75
DTC P2763 Torque Converter Clutch (TCC) Circuit High
75
DTC P2764 Torque Converter Clutch (TCC) Circuit Low
77
Inspection of TCM and Its Circuits
78
TCM Power and Ground Circuit Check
82
Repair Instructions
84
A/T Fluid Level Check
84
A/T Fluid Change
85
Manual Selector Assembly Components
85
Manual Selector Assembly Removal and Installation
86
Select Lever Knob Installation
86
Manual Selector Assembly Inspection
86
3" Position Switch Inspection
86
Select Cable Component
87
Select Cable Adjustment
87
Transmission Range Sensor Removal and Installation
88
Transmission Range Sensor Inspection and Adjustment
88
Key Interlock Cable Removal and Installation
89
Brake and Key Interlock System Inspection
91
Mode Select Switch Inspection
92
Input Shaft Speed Sensor Removal and Installation
92
Input Shaft Speed Sensor Inspection
92
Output Shaft Speed Sensor Removal and Installation
93
Output Shaft Speed Sensor Inspection
93
Oil Cooler Hose and Pipe Components
94
Oil Cooler Hose and Pipes Removal and Installation
94
Solenoid-B, Valves
95
Solenoid and Pressure Control Solenoid Removal and Installation
95
Solenoid and Pressure Control Solenoid Inspection
96
Removal and Installation
97
Solenoid Valves
97
Transmission Fluid Temperature Sensor Removal and Installation
97
Transmission Fluid Temperature Sensor Inspection
98
Transmission Control Module (TCM) Removal and Installation
99
A/T Relay Inspection
99
Automatic Transmission Unit Components
100
Automatic Transmission Assembly Dismounting and Remounting
101
Automatic Transmission Unit Disassembly
102
Oil Pump Components
107
Oil Pump Disassembly and Assembly
108
Oil Pump Inspection
108
Overdrive (Planetary Gear Side) Components
110
Overdrive (Planetary Gear Side) Disassembly and Assembly
110
Overdrive (Planetary Gear Side) Inspection
112
Overdrive (Case Side) Components
113
Overdrive (Case Side) Disassembly and Assembly
114
Overdrive (Case Side) Inspection
115
Forward Clutch Components
116
Forward Clutch Disassembly and Assembly
116
Forward Clutch Inspection
118
Direct Clutch Components
119
Direct Clutch Disassembly and Assembly
119
Direct Clutch Inspection
121
Center Support Components
122
Center Support Disassembly and Assembly
123
Center Support Inspection
126
Planetary Gears and Output Shaft Components
127
Planetary Gears and Output Shaft Disassembly and Assembly
128
Planetary Gears and Output Shaft Inspection
129
Valve Body Assembly Components
130
Automatic Transmission Unit Assembly
130
Specifications
139
Tightening Torque Specifications
139
Special Tools and Equipment
140
Recommended Service Material
140
Special Tool
140
Manual Transmission/Transaxle
142
General Description
142
Manual Transmission Construction
142
Diagnostic Information and Procedures
143
Manual Transmission Symptom Diagnosis
143
Repair Instructions
144
Manual Transmission Assembly Components
144
Gear Shift Control Lever Rear Case Assembly Components
146
Gear Shift Lever Front Case Assembly Components
147
Gear Shift Shaft and Fork Components
148
Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components
149
Manual Transmission Oil Change
150
Transmission Shift Control Lever Removal and Installation
151
Transmission Shift Control Lever Inspection
151
Back up Light Switch Removal and Installation
152
Back up Light Switch Inspection
152
Gear Shift Control Lever Rear Case Assembly Removal and Installation
152
Gear Shift Control Lever Rear Case Assembly Disassembly and Reassembly
153
Gear Shift Control Lever Rear Case Assembly Inspection
153
Gear Shift Lever Front Case Assembly Removal and Installation
153
Gear Shift Lever Front Case Assembly Disassembly and Reassembly
154
Gear Shift Lever Front Case Assembly Inspection
155
Engine Rear Mounting Replacement
155
Manual Transmission Assembly Dismounting and Remounting
155
Manual Transmission Unit Disassembly
158
Manual Transmission Unit Reassembly
159
Locating Spring Inspection
162
Input Shaft Disassembly
162
Input Shaft Inspection
163
Input Shaft Reassembly
164
Countershaft Disassembly and Assembly
166
Countershaft and Reverse Idle Gear Inspection
169
Output Shaft Disassembly and Assembly
170
Output Shaft Inspection
170
Manual Transmission Front Case Disassembly and Assembly
171
Manual Transmission Adapter Case Disassembly and Assembly
171
Specifications
172
Tightening Torque Specifications
172
Special Tools and Equipment
173
Recommended Service Material
173
Special Tool
173
Clutch
175
General Description
175
Clutch (Hydraulic Type) Construction
175
Component Location
176
Clutch Fluid Pipe and Hose Location
176
Diagnostic Information and Procedures
176
Clutch (Hydraulic Type) Symptom Diagnosis
176
Clutch Pedal Height Inspection
177
Clutch Pedal Free Travel Check
177
Clutch Fluid Inspection
177
Repair Instructions
178
Clutch Pedal Position (CPP) Switch Removal and Installation
178
Clutch Pedal Position (CPP) Switch Inspection and Adjustment
178
Clutch Fluid Pipe and Hose Removal and Installation
178
Clutch Fluid Pipe and Hose Inspection
179
Clutch Master Cylinder Removal and Installation
179
Clutch Master Cylinder Inspection
180
Clutch Operating Cylinder Assembly Removal and Installation
180
Clutch Cover, Clutch Disc and Flywheel Components
181
Clutch Cover, Clutch Disc and Flywheel Removal and Installation
182
Clutch Cover, Clutch Disc and Flywheel Inspection
183
Specifications
184
Tightening Torque Specifications
184
Special Tools and Equipment
184
Recommended Service Material
184
Special Tool
184
Other manuals for Suzuki GRAND VITARA
Owner's Manual
1736 pages
Service Manual
518 pages
Brochure
5 pages
4
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Suzuki GRAND VITARA Specifications
General
Brand
Suzuki
Model
GRAND VITARA
Category
Automobile
Language
English
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