Valve Body: Service and Repair

CONTROL VALVE

Removal and Installation


COMPONENT PARTS LOCATION












REMOVAL

1.Disconnect battery cable from negative terminal.
2.Remove engine undercover.
3.Disconnect the CVT unit connector. Removal And Installation Procedure For CVT Unit Connector.
4.Remove drain plug from oil pan, and then drain the CVT fluid.
5.Remove drain plug gasket from drain plug.





6.Remove the oil pan mounting bolts, and then remove the oil pan and oil pan gasket.










7.Remove oil pan gasket (1) from oil pan (2).
8.Remove the magnets (3) from the oil pan.





9.Check inside of oil pan for foreign material.
- If large amount of worn material is found, wear of clutch and brake plate is suspected.
- If iron powder is found, wear of bearings, gears, clutch, and gear plate is suspected.
- If aluminum powder is found, bush wear and incorporation of turning or burr of aluminum casting part are suspected.
In any case, check parts where the wear is seen.





10.Remove the lock nut (1) and (2), and then remove the manual plate (3).





11.Remove the collar (4) from the manual shaft (A).

CAUTION:
Never drop the collar.





12.Remove the snap ring (1) from the CVT unit connector (A).
13.Press the CVT unit connector (A) into the transaxle case.

CAUTION:
Never damage the CVT unit connector.





14.Remove the oil strainer assembly mounting bolts, and then remove the oil strainer assembly (1).










15.Remove the control valve mounting bolts (A), (B) and (C), and then remove the control valve from the transaxle case.






CAUTION:
Never drop the control valve.










16.Remove the lip seals (1) from the transaxle case.






INSTALLATION






1.Install the lip seals (1) to the transaxle case.










2.Confirm the direction of control valve linkage(A), operability of harness (B) , and fluid application to O-ring (C).

CAUTION:
- Never touch or wipe the installation surface of control valve.
- Never drop a return spring included in ratio control valve (D).
- Never install linkage in the opposite direction.
- Confirm that linkage groove (E) is fit to step motor groove (F).
- Cable routing of harness (B) must be done above the sensor (G).





3.Adjust linkage (A) to engage linkage groove (C) into pulley sensor pin (B), temporarily tighten control valve ASSY using two control valve ASSY tightening bolts.






CAUTION:
- Never pinch the harness into between the control valve and the transaxle case.
- When installing control valve ASSY, pay attention not to bump it.





4.Fix the control valve using the control valve mounting bolts (A), (B) and (C).














5.Install the oil strainer assembly (1) using the oil strainer assembly mounting bolts.










6.Install the collar (1) to the manual shaft (A).










7.Install the manual plate (1) while aligning with the groove (A) of the manual valve. Install the lock-nut (2), and then tighten to the specified torque.





8.Install the lock-nut (3), and then tighten to the specified torque.





9.Install the CVT unit connector (A) to the transaxle case.






CAUTION:
Engage CVT unit connector groove (B) and the convex portion (C) of transaxle case.





10.Install the snap ring (1) to the CVT unit connector (A).





11.Install the magnets (3) while aligning it with the convex side of oil pan.

CAUTION:
Completely eliminate the iron powder from the magnet mounting area of oil pan and the magnet.
12.Install the oil pan gasket (1) to the oil pan (2).

CAUTION:
Completely wipe out any moisture, oil, and old gasket from the oil pan gasket mounting surface and bolt mounting hole of oil pan and transaxle case.
13.Install the oil pan to the transaxle case with the following procedure.





a.Install the oil pan assembly to the transaxle case, and then temporarily tighten the oil pan mounting bolt ().










b.Tighten the oil pan mounting bolts in the order shown in the figure to the specified torque.





c.Tighten the oil pan mounting bolts again clockwise from (1)
shown in the figure to the specified torque.
14.Install drain plug gasket to drain plug.

CAUTION:
Never reuse drain plug gasket.
15.Install drain plug to oil pan.
16.Connect the CVT unit connector. Removal And Installation Procedure For CVT Unit Connector.
17.Install engine undercover.
18.Connect battery cable to negative terminal.
19.Fill CVT fluid from CVT fluid charging pipe to the specified level.
20.Check CVT fluid level and condition. Checking CVT Fluid.
21.Erase the CVT fluid degradation data. Trouble Diagnosis.
22.When replacing the control valve, erase EEP ROM in TCM. Service After Replacing TCM, Control Valve And Transaxle Assembly.