Transmission Assembly (2)

WARNING: This page is about a different variant/trim than selected.

Install O-ring to oil pump assembly.

Fig 1: Installing O-Ring To Oil Pump Assembly
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse O-ring.
- Apply ATF to O-ring.
Install bearing race to oil pump assembly.

Fig 2: Identifying Bearing Race
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply petroleum jelly to bearing race.
Install oil pump assembly in transmission case.

Fig 3: Installing Oil Pump Assembly In Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Apply ATF to oil pump bearing.
Apply recommended sealant (Genuine RTV Silicone Sealant or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ]) to oil pump assembly as shown.

Fig 4: Identifying Sealant Applying Area
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Completely remove all moisture, oil, old sealant and any foreign material from the oil pump bolts and oil pump bolt mating surfaces.
Tighten oil pump bolts to specified torque.

Fig 5: Tightening Oil Pump Bolts To Specified Torque
Courtesy of SUZUKI OF AMERICA CORP.

Oil pump bolts: 48 N.m (4.9 kg-m, 35 ft-lb)

CAUTION: Apply ATF to oil pump bushing.
Install O-ring to input clutch assembly.

Fig 6: Identifying O-Ring
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse O-ring.
- Apply ATF to O-ring.
Install converter housing to transmission case and tighten bolts to specified torque.

Fig 7: Locating Converter Housing Bolts
Courtesy of SUZUKI OF AMERICA CORP.

Converter housing bolt: 52 N.m (5.3 kg-m, 38 ft-lb)

Self-sealing bolt (A): 61 N.m (6.2 kg-m, 45 ft-lb)

CAUTION: Do not reuse self-sealing bolt (A).
Make sure that brake band does not close turbine revolution sensor hole.

Fig 8: Identifying Turbine Revolution Sensor Hole
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Install control valve with TCM.

Connect TCM connector and park/neutral position switch connector.

Fig 9: Identifying TCM Connector And Park/Neutral Position Switch Connector
Courtesy of SUZUKI OF AMERICA CORP.
Install A/T assembly harness connector to control valve with TCM.

Fig 10: Identifying A/T Assembly Harness Connector
Courtesy of SUZUKI OF AMERICA CORP.
Connect TCM connectors.

Fig 11: Identifying TCM Connectors
Courtesy of SUZUKI OF AMERICA CORP.
Install O-ring to A/T assembly harness connector.

Fig 12: Identifying O-Ring And A/T Assembly Harness Connector
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse O-ring.
- Apply ATF to O-ring.
Install A/T fluid temperature sensor 2 to bracket.

Fig 13: Identifying A/T Fluid Temperature Sensor 2 And Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Install A/T fluid temperature sensor 2 (with bracket) to control valve with TCM and tighten bolt to specified torque.

Fig 14: Identifying A/T Fluid Temperature Sensor 2 With Bracket
Courtesy of SUZUKI OF AMERICA CORP.

Bracket bolt: 7.9 N.m (0.81 kg-m, 70 in-lb)

CAUTION: Adjust bolt hole of bracket to bolt hole of control valve.
Install control valve with TCM in transmission case.

Fig 15: Identifying Turbine Revolution Sensor Hole
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Make sure that turbine revolution sensor is securely installed into turbine revolution sensor hole.
- Hang down revolution sensor harness toward outside so as not to disturb installation of control valve with TCM.
- Adjust A/T assembly harness connector of control valve with TCM to terminal hole of transmission case.
- Assemble it so that manual valve cutout is engaged with manual plate projection.
  
  Fig 16: Identifying Manual Valve
  Courtesy of SUZUKI OF AMERICA CORP.

Install bolts (A), (B) and (C) to control valve with TCM. Tighten bolt (1), (2) and (3) temporarily to prevent dislocation. After that tighten them in order (1 → 2 → 3), and then tighten other bolts. Tighten control valve with TCM bolts to the specification.

Fig 17: Identifying Control Valve Bolts

Courtesy of SUZUKI OF AMERICA CORP.

==>: Front

BOLT LENGTH SPECIFICATION

Bolt symbol	A	B	C
Number of bolts	5	6	1
Length mm (in)	42 (1.65)	55 (2.17)	40 (1.57)
Tightening torque N.m (kg-m, in-lb)	7.9 (0.81, 70)		With ATF applied
Tightening torque N.m (kg-m, in-lb)	7.9 (0.81, 70)		7.9 (0.81, 70)

Connect A/T fluid temperature sensor 2 connector (A).

Fig 18: Identifying A/T Fluid Temperature Sensor 2 Connector
Courtesy of SUZUKI OF AMERICA CORP.
Securely fasten terminal cord assembly and A/T fluid temperature sensor 2 harness with terminal clips.
Connect revolution sensor connector.

Fig 19: Identifying Revolution Sensor Connector
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Securely fasten revolution sensor harness with terminal clip.

Fig 20: Locating Revolution Sensor Harness With Terminal Clip
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Pull down A/T assembly harness connector.

Fig 21: Locating A/T Assembly Harness Connector
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not damage connector.
Install snap ring to A/T assembly harness connector.

Fig 22: Identifying Snap Ring And A/T Assembly Harness Connector
Courtesy of SUZUKI OF AMERICA CORP.
Install magnets in oil pan.

Fig 23: Identifying Oil Pan Magnets
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Install oil pan to transmission case. Refer to [OIL PAN: REMOVAL AND INSTALLATION ].
Install torque converter.
1. Pour ATF into torque converter.
  
  Fig 24: Refilling ATF Into Torque Converter
  Courtesy of SUZUKI OF AMERICA CORP.
  NOTE:
  - Approximately 2 liters (2-1/8 US qt. 1-3/4 Imp qt) of fluid is required for a new torque converter.
  - When reusing old torque converter, add the same amount of fluid as was drained.
2. Install torque converter while aligning notches of torque converter with notches of oil pump.
  
  Fig 25: Aligning Notches Of Torque Converter With Notches Of Oil Pump
  Courtesy of SUZUKI OF AMERICA CORP.
  
  CAUTION: Install torque converter while rotating it.
3. Measure distance "A" to make sure that torque converter is in proper position.
  
  Fig 26: Measuring Distance A To Torque Converter In Proper Position
  Courtesy of SUZUKI OF AMERICA CORP.
  
  Distance "A": 25.0 mm (0.98 in) or more