Fluid Pan: Service and Repair

Main Control Cover - 3.5L GTDI













Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. Remove the Air Cleaner (ACL) and outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

3. Remove the brake booster vacuum tube from the LH turbocharger air inlet hose.





4. Remove the vacuum tube from the LH turbocharger air inlet hose.





5. Compress the constant tension clamp and remove the bypass hose from the LH turbocharger air inlet hose.





6. Disconnect the 2 quick connect couplings and remove the crankcase vent tube.





7. Loosen the 2 clamps and remove the LH turbo inlet tube.





8. Remove the 4 retainers and the underbody shield.





9. Loosen the clamp and disconnect the LH turbocharger-to-Charge Air Cooler (CAC) hose from the turbocharger and position it aside.





10. Remove the transmission fluid drain plug and allow the transmission fluid to drain.





11. Install the transmission fluid drain plug.
- Tighten to 9 Nm (80 lb-in).





12. Disconnect the transaxle electrical connector and remove the wiring harness fastener from the main control cover stud.





13. Remove the 2 nuts, pull the transmission fluid cooler thermal bypass valve off of the main control cover studbolts and position it aside.





14. NOTE: Note the location of the studbolts for assembly.

Remove the 14 bolts and the main control cover.





Installation

1. Inspect the transaxle side cover seal for damage and install new if necessary.





2. NOTICE: Inspect the 20-pin solenoid body connector seal to make sure that the seal is on the inside of the main control cover or a transmission fluid leak will occur.

NOTE: Install the studbolts in the locations noted during disassembly.
Install the main control cover and loosely install the 14 bolts.

1. Bolt location

2. Studbolt location





3. Tighten the main control cover bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).





4. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly on the main control cover studbolts and install the 2 nuts.
- Tighten to 9 Nm (80 lb-in).





5. Connect the transaxle electrical connector and install the wiring harness fastener on the main control cover stud.





6. Position the LH turbocharger-to-CAC hose on the turbocharger and tighten the clamp.
- Tighten to 5 Nm (44 lb-in).





7. Install the underbody shield and the 4 retainers.





8. Position the LH turbocharger inlet tube in place and tighten the 2 clamps.
- Tighten to 5 Nm (44 lb-in).





9. Install the crankcase vent tube.





10. Install the bypass hose on the LH turbocharger air inlet hose.





11. Install the vacuum tube on the LH air inlet hose.





12. Install the brake booster vacuum tube on the LH air inlet hose.





13. Fill the transaxle with clean transmission fluid, refer to Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill.