Replacing And Tightening Torque Converter Bolts During Transmission Replacement (TS 01 04022R2)

Publication date: 2015-02-13
Reference number: TS 01 04022R2
Supersedes refnos: TS 01 04022R

REPLACING AND TIGHTENING TORQUE CONVERTER BOLTS DURING TRANSMISSION REPLACEMENT

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 01 04022R2, Date of Issue: February 13, 2015

SUZUKI:	All Models Equipped With a Torque Converter 1986-2013
SECTION:	Transmission

Superceded Bulletin(s): TS 01 04022R2, Date of Issue: December 20, 2010

CONDITION

After a torque converter replacement, engine rpm is abnormally high under all driving conditions, which may set a P0741 DTC. Unusual transmission noise and fluid contamination may also develop.

CAUSE

Longer bolts or incorrectly tightened bolts come into contact with the torque converter housing and deforms the housing. Clutch material strips off and plugs the valve body.

CORRECTION

Only use specified bolts and torque specifications when reassembling the drive plate and torque converter.

NOTE:

Discard bolt(s) whenever removed. Only replace with the specified part in the Suzuki Electronic Parts Catalog - Do not substitute.
Part numbers for replacement torque converter bolts are listed in the tables below with torque specifications.
Part numbers listed in this bulletin are current as of February 2015.

Technical Service Department

Dealership Circulation - Initial and file:

NOTE: For vehicles that use Type 1 and Type 2 torque converter bolts:

Never install Type 2 bolts first. Always install and finger tighten Type 1 first. There is no specific position on the flex plate or torque converter, it only needs to be finger tightened first to allow for proper alignment.
Then install and finger tighten Type 2 bolts.
Tighten all bolts to specification. Always follow the service manual procedure and specification for proper tightening torque.

PARTS INFORMATION

AERIO

AERIO PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Aerio	2002-2003	19	1.9	14	09103-08421	6
Aerio	2004-2007	25	2.5	18.1	09103-08421	6

EQUATOR

EQUATOR PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Equator	2009-2013	51	5.2	38	21111-82Z00	4	2.5L
Equator	2009-2013	74	7.5	55	21111-82Z00	4	4.0L

ESTEEM

ESTEEM PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Esteem	1995-1997	19	1.9	14	09103-10286	6
Esteem	1998-2002	19	1.9	14	09103-08421	6

FORENZA

FORENZA PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Forenza	2004-2008	45	4.5	33	20999-86Z00	3

GRAND VITARA

GRAND VITARA PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Grand Vitara	1999-2008	65	6.5	47	09103-10340	1	Type 1
	1999-2008	65	6.5	47	09103-10286	3	Type 2
	2009-2013	30	3	22.5	09103-08508	1	Type 1	4AT 2.4L
	2009-2013	30	3	22.5	09103-08507	5	Type 2	4AT 2.4L
	2009-2010	65	6.5	47	09103-10340	1	Type 1	5AT 3.2L
	2009-2010	65	6.5	47	09103-10286	5	Type 2	5AT 3.2L

KIZASHI

KIZASHI PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Kizashi	2010-2013	23	2.3	17	09103-08516	5	Type 2
Kizashi	2010-2013	23	2.3	17	09103-08517	1	Type 1

SIDEKICK

SIDEKICK PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Sidekick	1989-91	55	5.5	40	09103-10286	3	Product of Japan
	1989-91	55	5.5	40	01550-1016A	3	Product of Canada
	1992-1995	55	5.5	40	09103-10286	3	C Model (8 Valve)
	1992-1995	60-70	6.0-7.0	43.5-50.5	09103-10286	3	V Model (16 Valve)
	1996-1998	55	5.5	40	09103-10286	3	C Model (8 Valve)
	1996-1998	65	6.5	47	09103-10286	3	V Model (16 Valve)

SIDEKICK SPORT

SIDEKICK SPORT PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Sidekick Sport	1996	65	6.5	47	09103-10286	6
	1996	65	6.5	47	09103-10286	6	JS3TD21V_T4102341~
	1997-1998	65	6.5	47	09103-10286	6

SWIFT

SWIFT PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Swift	1989-1997	18-19	1.8-1.9	13-14	09103-10286	6
	1998-1999	18-19	1.8-1.9	13-14	09103-08421	6
	2000-2001	19	1.9	14	09103-08421	6

SX-4

SX-4 PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
SX-4	2007-2009	23	2.3	17	09103-08516	5	Type 2
	2007-2009	23	2.3	17	09103-08517	1	Type 1
	2010-2013	23	2.3	17	09103-08516	5	Type 2	CVT
	2010-2013	23	2.3	17	09103-08517	1	Type 1	CVT

VERONA

VERONA PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Verona	2004-2006	45	4.5	33	20999-86Z00	3

VITARA

VITARA PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
Vitara	1999-2003	65	6.5	47	09103-10340	1	Type 1	SQ416
	1999-2003	65	6.5	47	09103-10286	2	Type 2	SQ416
	1999-2003	65	6.5	47	09103-10340	1	Type 1	SQ420
	1999-2003	65	6.5	47	09103-10286	5	Type 2	SQ420
	2004-2005	65	6.5	47	09103-10340	1	Type 1
	2004-2005	65	6.5	47	09103-10286	3	Type 2

X-90

X-90 PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
X-90	1996-1998	65	6.5	47	09103-10286	3

XL-7 (JA627)

XL-7 (JA627) PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
XL-7	2001-2006	65	6.5	47	09103-10340	1	Type 1
XL-7	2001-2006	65	6.5	47	09103-10286	3	Type 2

XL7 (JC636)

XL7 (JC636) PARTS INFORMATION

Model	Model Year(s)	Tightening Torque			Converter Bolt Part Numbers	Qty	Notes
Model	Model Year(s)	N-m	kgf-m	lb-ft	Converter Bolt Part Numbers	Qty	Notes
XL7	2007-2008	60		44	22622-78J00	6
XL7	2009	62		46	22622-78J20	4