Mechatronic Assembly Replacement Procedures
The following is a general procedure for Mechatronic Assembly replacement. Refer to the applicable service manual for Pre-removal and Post-installation Operations, and review all Cautions and Warningsbefore proceeding.
1. Record the customer's radio presets.
2. Disconnect the battery (-) terminal.
3. Remove center section of lower engine cover.
4. Loosen radiator drain plug. Drain coolant.
Drain coolant into a clean container. It will be reused for this procedure.
5. Remove lower radiator hose and pipe.
6. Remove fans, fan motors, and fan shroud.
7. Remove battery & tray (Ralliart only).
8. Remove Intercooler Outlet Pipe C.
9. Remove air cleaner element and intake duct.
10. Remove filler plug on the top of the transmission.
11. Remove drain plugs as shown at left and allow transmission fluid to drain for at least 3 minutes.
NOTE:
If there is a plug located at point A, leave it installed.
12. Rotate the transmission harness connector 90° and remove.
13. Remove and discard the transmission side cover and bolts. You will install a new side cover during reassembly.
14. Using a small screwdriver to depress the release tab, carefully remove the internal 4-pin transmission electrical connector.
15. Remove 3 torx screws retaining the valve body connector. They can be discarded. New bolts for the connector are included with the new Mechatronic assembly.
16. Carefully unseat, but DO NOT attempt to remove, the connector.
17. Remove the valve body bolts in the order shown. They can be discarded. New bolts for the valve body are included with the new Mechatronic assembly.
18. Carefully remove the Mechatronic assembly.
TAKE EXTRA CARE WHEN REMOVING THE VALVE BODY. THERE ARE LONG SENSORS THAT CAN BREAK. BROKEN PIECES CAN EASILY FIND THEIR WAY INTO THE TRANSMISSION.
19. Remove the left and right valve body gaskets.
20. Clean and dry the valve body gasket surface.
NOTE:
New valve body gaskets are included with the new Mechatronic assembly. They can only be installed in one direction.
21. Install the new left side (engine side) valve body gasket over the dowel pin.
22. Install the new right side (external filter side) gasket over the dowel pin.
The new Mechatronic assembly is packaged with three seals pre-installed on the tall plastic sensors (see photo left).
REMOVE AND DISCARD THESE SEALS.
New seals (p/n 2800A138) are included with the new Mechatronic assembly, packaged in a plastic bag.
23. On the new valve body, thoroughly lubricate the replacement sensor seals with TS-SST fluid and install them to the valve body.
24. Install the new Mechatronic assembly to the transmission using new bolts included with the new Mechatronic assembly.
Make sure the small connector does not get trapped behind the valve body.
25. Torque mounting bolts in the sequence shown at left to 44 +/- 8 in-lbs.
26. Retorque mounting bolts in the sequence shown to 89 +/- 8 in-lbs.
27. Use new torx screws included with the new Mechatronic assembly to attach the valve body connector and torque to 53 +/- 8 in-lbs.
28. Connect the 4 pin connector.
29. Install a NEW transmission side cover (p/n 2502A042) using new bolts included with the new cover. Torque to 89 +/- 8 in-lbs in the sequence shown at left.
30. Install the transmission harness connector.
31. Install drain plugs. Torque to 26 +/- 4 ft.-lbs.
32. Install a new external transmission oil filter (p/n 2513A040). Torque to 11 +/- 1 ft lb.
33. Fill the transmission with 5.8 quarts of DiaQueen SSTF-1 (p/n C0002610). Tighten filler plug to 26 +/- 4 ft=lbs.
34. Install air cleaner element and intake duct.
35. Install intercooler outlet pipe.
36. Install battery and tray (Ralliart only).
Reconnect battery (-) terminal (all).
37. Reinstall lower radiator hose, fans, fan motors shroud. Refill radiator with saved coolant.
38. Reinstall the engine undercover center section.
39. Restore customer's audio presets and reset the clock.