Service Manual2005 MAINTENANCE AND REPAIR

Evanda

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Transaxle Fluid Level Checking Procedure

Tools Required

DW260-070 Plug Remover/Installer

Inspection Procedure

Start the engine and allow the engine to idle for approximately 5 minutes, or, if possible, drive the vehicle for a few kilometers(miles) to warm the transaxle fluid. Check the fluid level when the transaxle is over 30°C(86°F).

Press the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the park position. (Left-Hand Drive Shown, Right-Hand Drive Similar.)

Raise and suitably support the vehicle.
Place a fluid container below the fluid level plug.

Caution : Do not remove the fluid level plug if the transaxle fluid is hot. This may cause injury if the fluid drains from the plug hole.

Remove the fluid level plug using the plug remover/installer DW260-070. Because the transaxle operates correctly over a range of levels, fluid may or may not drain out of the plug hole when the plug is removed.

Check the oil fluid level. If fluid does not drain through the plug hole after adding a total of 4 liters, then the transaxle was either underfilled or the transaxle is leaking fluid. Inspect the transaxle for fluid leaks. Fix any leaks before setting the transaxle fluid level.

Install the fluid level plug using the plug remover/installer DW260-070.

Tighten

Tighten the Plug to 45 N•m (33 lb-ft).

When the fluid level checking procedure is completed, wipe any fluid from the transaxle case with a rag or shop towel. Also, check that the fluid fill cap and the vent tube are properly installed.

Changing the Fluid

Tools Required

DW260-070 Plug Remover/Installer

Removal and Installation Procedure

Raise and suitably support the vehicle.
Place a fluid container below the fluid drain plug.
Remove the transaxle fluid drain plug using the plug remover/installer DW260-070.

Tighten

Tighten the Plug to 45 N•m (33 lb-ft).

Adding transaxle fluid. Refer to "Transaxle Fluid Level Checking Procedure" in this section.
Connect the negative battery cable.

Fluid Level Set After Service

Add transaxle fluid through the fill cap hole prior to adjusting the fluid level. The amount of fluid to add should be based on the type of service done.

Adjustment Notice

Use ESSO LT 71141 or TOTAL ATF H50235 transaxle fluid only.
Oil pan removed : 4L (4.2 qt)
Torque converter removed : 2L (2.1 qt)
Complete overhaul : 6.9±0.2L (7.3±0.2 qt)
Drain plug removed : 4L (4.2 qt)

Check the transaxle fluid level. Refer to "Transaxle Fluid Level Checking Procedure" in this section.
Add additional fluid through the fill cap hole in 0.5 liter (0.5 quart) increments until the fluid comes out through the plug hole.
Allow the fluid to finish draining out through the plug hole, then install the fluid level plug.
When the fluid level setting procedure is completed, wipe any fluid from the transaxle case with a rag or shop towel. Also, check that the fluid fill cap and the vent tube are properly installed.

Repairing Fluid Leaks

Locating Leaks

General Method

Verify that the leak is transaxle fluid.
Thoroughly clean the suspected leak area.
Operate the vehicle for about 25 kilometers (15 miles) or until the transaxle reaches normal operating temperature, 88°C (190°F).
Park the vehicle over clean paper or cardboard.
Turn the engine off and look for fluid spots on the paper.
Make the necessary repairs to correct the leak.

Powder Method

Thoroughly clean the suspected leak area.
Apply an aerosol-type powder (foot powder) to the suspected leak area.
Operate the vehicle for about 25 kilometers (15 miles) or until the transaxle reaches normal operating temperature, 88°C (190°F).
Turn the engine off.
Inspect the suspected leak area and trace the leak path through the powder to find the source of the leak.
Make the necessary repairs.

Repairing the Fluid Leak

The following are potential causes for fluid leaks. Check and repair, as necessary.

Fasteners are not tightened to specifications.
Fastener threads and tapped holes are dirty or corroded.
Gaskets, seals or sleeves are misaligned, damaged, or warped, or scratched.
The manual shaft is nicked or damaged.
There is a loose or worn bearing causing excess seal or sleeve wear.
Case or component porosity.
The fluid level is too high.
There is a plugged vent or a damaged vent tube.
There is water or coolant in the fluid.
Fluid drain back holes are plugged.

Case Porosity Repair

Caution : Epoxy adhesive may cause skin irritations and eye damage. Read and follow all information on the container label as provided by the manufacturer.

Thoroughly clean the area to be repaired with a cleaning solvent. Air dry the area.
Using instructions from the manufacturer, mix a sufficient amount of epoxy to make the repair.
While the transaxle case is still hot, apply the epoxy. You can use a clean, dry soldering acid brush to clean the area and also apply the epoxy cement. Make certain that the area to be repaired is fully covered.
Allow the epoxy cement to dry for 3 hours before starting the engine.
Repeat the fluid leak diagnosis procedures. Refer to "Fluid Leak Diagnosis and Repair" in this section.

Shift Control Lever Assembly

Removal Procedure

Disconnect the negative battery cable.
Remove the floor console. Refer to Section 9G, Interior Trim.
Disconnect the electrical switch connectors.

Remove the shift control cable adjuster pinch nut.
Loosen the nut from the shift control cable mounting bracket on the shift control assembly.
Remove the cable from the bracket.

Remove the bolt holding the shift control assembly to the floor panel.
Remove the shift control assembly.

Installation Procedure

Install the bolts and the shift control assembly.

Tighten

Tighten the bolts to 8 N•m (71 lb-in).

Install the shift control cable onto the bracket and tighten the nut.
Install the shift control cable adjuster pinch nut.

Tighten

Tighten the shift control cable adjuster pinch nut to 8 N•m (71 lb-in).

Connect the electrical switch connectors.
Install the floor console. Refer to Section 9G, Interior Trim.
Connect the negative battery cable.

Shift Control Cable

Removal Procedure

Disconnect the negative battery cable.
Remove the air filter housing assembly and bolts.
Remove the clip from the selector lever connection on the transaxle case and disconnect the shift control cable from the selector lever connection.
Remove the clip from the shift control cable at the transaxle mount connection.

Remove the floor console. Refer to Section 9G, Interior Trim.
Loosen the shift control cable adjuster pinch nut.
Loosen the nut from the cable bracket.
Remove the shift control cable from the shift control assembly.

Remove the shift control cable from the transaxle mount.
Pull the shift control cable through the fire wall of the vehicle, bringing the rubber grommet with it.

Installation Procedure

Install the shift control cable into the fire wall of the vehicle.
Install the shift control cable onto the transaxle mount.

Install the shift control cable onto the shift control assembly.
Tighten the nut on the cable bracket.
Install the shift control cable adjuster pinch nut.

Tighten

Tighten the nut to 8 N•m (71 lb-in).

Install the clip to the shift control cable at the transaxle mount connection.
Install the clip to the select lever connection on the transaxle case.
Adjust the shift control cable. Refer to "Shift Control Cable Adjustment" in this section.
Install the air filter housing assembly and bolts.

Tighten

Tighten the bolts to 10 N•m (89 lb-in).

Connect the negative battery cable.

Shift Control Cable Adjustment

Adjustment Procedure

It is very important to match the shift control lever correctly with the selector lever connection. Place the shift control lever in the P position and check the selector lever connection to see if it is all the way forward. If it is not, proceed with the following adjustment.

Remove the battery and battery tray. Refer to Section 1E, Engine Electrical.
Remove the floor console. Refer to Section 9G, interior Trim.

Place the shift control lever in the P position.
Loosen the pinch bolt nut on the shift control lever.

Place the selector lever connection all the way forward on the transaxle case.
Insert the shift control cable into the shift control lever tightly.
Secure the shift control cable with the shift control cable adjuster pinch bolt and nut.

Tighten

Tighten the nut to 8 N•m (71 lb-in).

Install the floor console.
Install the air filter housing.
Install the battery and the battery tray. Refer to Section 1E, Engine Electrical.

Transaxle Control Module(TCM)

Removal Procedure

Disconnect the negative battery cable.
Disconnect the wiring connectors.
Remove the transaxle control module(TCM) and nuts.

Installation Procedure

Install the TCM and nuts.

Tighten

Tighten the TCM mounting nuts to 23 N•m (17 lb-ft).

Connect the wiring connectors.
Connect the negative battery cable.

Park/Neutral Start Switch

Removal Procedure

Disconnect the negative battery cable.
Disconnect the park/neutral position switch electrical connector.
Disconnect the shift control cable and the retaining clip.

Remove the shift lever nut and the shift lever.

Remove the park/neutral start switch.

Tools Required

DW260-050 P/N Switch Installer

Installation Procedure

Install the park/neutral start switch.

Tighten

Tighten the bolts to 10 N•m (89 lb-in).

Adjust the park/neutral switch using the P/N switch installer DW260-050.

Notice : When install the park/neutral switch, using the special service tools and the shift lever must be positioned "Neutral".

Install the shift lever and the shift lever nut.

Tighten

Tighten the shift lever nut to 10 N•m (89 lb-in).

Connect the shift control cable and the retaining clip.
Connect the park/neutral position switch electrical connector.
Connect the negative battery cable.

Oil Cooler Pipes/Hoses

Removal Procedure

Important : Place a drip pan under the hoses to catch the fluid that will run out of the lines.

Disconnect the negative battery cable.
Raise and suitably support the vehicle.
Remove the oil cooler outlet pipe bolt from the right lower side of the radiator.
Remove the oil cooler outlet pipe bracket bolt.

Remove the oil cooler outlet pipe bolt from the transaxle side.
Remove the oil cooler outlet pipe assembly.

Remove the oil cooler inlet pipe bolt from the left lower side of the radiator.

Remove the oil cooler inlet pipe bolt from the transaxle side.
Remove the oil cooler inlet pipe assembly.

Installation Procedure

Install the oil cooler inlet pipe assembly and the bolts.

Tighten

Tighten the oil cooler inlet pipe bolts to 35 N•m (26 lb-ft).

Install the oil cooler outlet pipe assembly and the bolts.

Tighten

Tighten the oil cooler outlet pipe bolts to 35 N•m (26 lb-ft).

Refill the transaxle fluid. Refer to "Transaxle Fluid Checking Procedure" in this section.
Connect the negative battery cable.

Drive Axle Oil Seal

Removal Procedure

Disconnect the negative battery cable.
Remove the drive axles. Refer to Section 3A, Automatic Transaxle Drive Axle.

Notice : Be careful not to damage the bore of the transaxle case.

Remove the transaxle drive seal using a screwdriver. If necessary, crush the seal first with the screwdriver in order to loosen the seal from the case.

Tools Required

DW260-030 Axle Seal Installer

Installation Procedure

Install the transaxle drive seal using the axle seal installer DW260-030.
Install the drive axles. Refer to Section 3A, Automatic Transaxle Drive Axle.
Connect the negative battery cable.

Oil Pan, Oil Pan Gasket

Tools Required

DW260-070 Plug Remover/Installer

Removal Procedure

Disconnect the negative battery cable.
Raise and suitably support the vehicle.
Remove the engine under cover. Refer to Section 9N, Fame and Underbody.
Place a fluid container below the fluid drain plug.
Remove the transaxle fluid drain plug using the plug remover/installer DW260-070 and drain the transaxle fluid.

Remove the oil cooler inlet and outlet pipes. Refer to "Oil Cooler Pipe/Hose" in this section.

Remove the oil pan and oil pan gasket.

Installation Procedure

Install the oil pan, oil pan gasket and bolts.

Tighten

Tighten the oil pan bolts to 6 N•m (53 lb-in).

Install the oil cooler inlet and outlet pipes. Refer to "Oil Cooler Pipe/Hose" in this section.

Install the transaxle fluid drain plug using the plug remove/installer DW260-070.
Install the engine under cover. Refer to Section 9N, Frame and Underbody.
Refill the transaxle fluid. Refer to "Transaxle Fluid Level Checking Procedure" in this section.
Connect the negative battery cable.

Control Valve Body Assembly

Tools Required

DW260-070 Plug Remover/Installer

Removal Procedure

Disconnect the negative battery cable.
Remove the air filter housing.
Disconnect the transaxle wiring harness and the park/neutral position switch electrical connector.

Raise and suitably support the vehicle.
Remove the engine under cover. Refer to Section 9N, Frame and Underbody.
Remove the transaxle fluid drain plug using the plug remover/installer DW260-070 and drain the transaxle fluid.

Remove the oil pan, oil pan gasket. Refer to "Oil Pan, Oil Pan Gasket" in this section.
Remove the valve body mounting bolts.
Remove the automatic transmission input speed sensor mounting bolt.

Remove the automatic transmission output speed sensor mounting bolt.

Remove the control valve body.

Installation Procedure

Install the control valve body and the bolts.

Tighten

Tighten the valve body mounting bolts to 8 N•m (71 lb-in).

Install the input speed sensor mounting bolt.

Tighten

Tighten the input speed sensor mounting bolt to 8 N•m (71 lb-in).

Install the output speed sensor mounting bolt.

Tighten

Tighten the output speed sensor mounting bolt to 6 N•m (53 lb-in).

Install the oil pan and oil pan gasket. Refer to "Oil Pan Gasket" in this section.

Install the transaxle fluid drain plug using the plug remove/installer DW260-070.
Install the engine under cover. Refer to Section 9N, Frame and Underbody.

Lower the vehicle.
Connect the transaxle wiring harness and the PNP switch electrical connector.
Install the air filter housing.
Refill the transaxle fluid. Refer to "Transaxle Fluid Level Checking Procedure" in this section.
Connect the negative battery cable.

Left Transaxle Mounting Bracket

Tools Required

DW110-060 Engine Support Fixture

Removal Procedure

Remove the air filter housing.
Install the engine support fixture DW110-060.

Remove the left transaxle mounting nut.

Remove the left transaxle mounting bracket bolts and the bracket.

Installation Procedure

Install the bracket and the left transaxle mounting bracket bolts.

Tighten

Tighten the left transaxle mounting bracket bolts to 40 N•m (30 lb-ft).

Install the left transaxle mounting nut to 155 N•m (114 lb-ft).

Remove the engine support fixture DW110-060.
Install the air filter housing.

Transaxle Assembly

Tools Required

DW110-060 Engine Support Fixture

DW260-010 Transaxle Support Fixture

Removal Procedure

Disconnect the negative battery cable.
Position the select lever park position.
Remove the battery. Refer to Section 1E, Engine Electrical.
Remove the air filter housing.
Install the engine support fixture DW110-060.

Disconnect the transaxle wiring harness from the transaxle.
Disconnect the park/neutral position switch electrical connector.

Remove the clips from the shift control cable and disconnect the shift control cable from the transaxle.

Remove the upper transaxle-to-engine bolts.

Remove the left transaxle mounting bracket. Refer to "Left Transaxle Mounting Bracket" in this section.

Raise and suitably support the vehicle.
Remove the centermember. Refer to Section 2C, Front Suspension.
Remove the impact bar. Refer to Section 2C, Front Suspension.
Drain the transaxle fluid.
Remove the oil cooler pipes from the transaxle. Refer to "Oil Cooler Pipes/Hoses" in this section.

Remove the drive axle. Refer to Section 3A, Automatic Drive Axle.
Remove the starter motor. Refer to Section 1E, Engine Electrical.
Remove the torque converter bolts.

Support the transaxle.
Remove the front catalytic converter retaining nuts. Refer to Section 1G, Engine Exhaust.
Remove the front engine mounting bracket bolts and nuts.

Remove the rear transaxle mounting bracket bolts.

Support the transaxle assembly using the transaxle support fixture DW260-010.

Remove the lower engine-to-transaxle bolts.

Remove the transaxle assembly.

Installation Procedure

Install the transaxle into the vehicle.
Support the transaxle assembly using the transaxle support fixture DW260-010.

Install the lower engine-to-transaxle bolts.

Tighten

Tighten the lower engine-to-transaxle bolts (a) to 75 N•m (55 lb-ft).

Tighten the lower engine-to-transaxle bolt (b) to 21 N•m (15 lb-ft).

Tighten the lower engine-to-transaxle bolt (c) to 31 N•m (23 lb-ft).

Install the rear transaxle mounting bracket bolts.

Tighten

Tighten the rear transaxle mounting bracket bolts to 65 N•m (48 lb-ft).

Install the front engine mounting bracket bolts and nuts.

Tighten

Tighten the front engine mounting bracket bolts (a) and nut to 90 N•m (66 lb-ft).

Tighten the front engine mounting bracket bolt (b) and nut to 80 N•m (59 lb-ft).

Tighten the front engine mounting bracket bolt (c) to 65 N•m (48 lb-ft).

Install the front catalytic converter retaining nuts. Refer to Section 1G, Engine Exhaust.

Install the torque converter bolts.
Install the starter motor. Refer to Section 1E, Engine Electrical.
Install the drive axle. Refer to Section 3A, Automatic Drive Axle.

Install the oil cooler pipes from the transaxle. Refer to "Oil Cooler Pipes/Hoses" in this section.
Install the impact bar. Refer to Section 2C, Front Suspension.
Install the centermember. Refer to Section 2C, Front Suspension.
Lower the vehicle.

Install the left transaxle mounting bracket. Refer to "Left Transaxle Mounting Bracket" in this section.

Install the upper transaxle-to-engine bolts.

Tighten

Tighten the upper transaxle-to-engine bolts to 75 N•m (55 lb-ft).

Install the clips to the shift control cable and connect the shift cable.

Install the park/neutral position switch electrical connector.
Connect the transaxle wiring harness to the transaxle.

Remove the engine support fixture DW110-060.
Install the air filter housing.
Install the battery. Refer to Section 1E, Engine Electrical.
Add the transaxle fluid. Refer to "Transaxle Fluid Level Checking Procedure" in this section.
Connect the negative battery cable.