Before beginning any service procedure, refer to section T1 of this manual for air bag system service warnings. AUTOMATIC TRANSAXLE (FA4A-EL) RANSAXLE MECHANICAL SYSTEM TEST PREPARATION ANGE TEST [P POSITION TEST. K-10] "AUTOMATIC TRANSAXLE FLUID A K-40 Al THROTTLE CABLE THROTTLE CABLE ELECTRICAL PREPARATION : ELECTRICAL SIGNAL SCSCSS=SY INSPECTION . TRANSAXLE FLUID ENSOR INPUT/TURBI 7 F= VEHICLE SPEEDOMETER ENSOR ...-.eseeeeee ‘SOLENOID VALVES... ‘OUD OFF INDICATOR LIGHT _. MODULE... TRANSAXLE CONTHOL VALVE BODY (0 REMOVAL / INSTALLATION) 2... K-43! LSHIFT-LOCK EMERGENCY OVERRIDE. BASIC INSPECTION ... ‘SYMPTOM TROUBLESHOtK MECHANICAL SYSTEM TEST MECHANICAL SYSTEM TEST PREPARATION ‘SST 49.0378 4008 For 498019 902 For ‘ll prossure test oil prossure est Oi pressure it pressure gauge set galigo Parot 49.0378 4008) 49 B019 903 For 4918019 901 For ‘ol prosoure test ol pressure fst Hose il pressure (Pan of ‘gauge 490378 4008) 49 H019 002 For oil prossure test ‘Adapter OS = MECHANICAL SYSTEM TEST PREPARATION 1. Engage the parking brake and use wheel chocks at the front and rear of the wheels. 2. Check the engine coolant] 3. Check the engine oi 4. 5. Refer to section E.) H Teferto section] NT Check the idle speed and Ignitan ting in P position [(Hefer to section FiMECHANICAL SYSTEM TEST K LINE PRESSURE TEST Procedure 'OLE SPEED Eee LINE PRESSURE TIOLE: LINE PRESSURE AT STALL ee Warning + Draining the ATF when itis hot is dangerous. Hot ATF can shoot out when the square-head plug is removed, causing burns and serious injury. Wait until the transaxle and ATF are cool before draining the ATF. 1. Connect the SSTs (49 HO19 002, 49 BO19 901, and 49 BO19 903) to the line pressure irspection port. 2. Shift the selector lever to D range and read the line pressure at idle. 3. Connect the SST (49 B019 902) to the line pressure inspection port. Caution + If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is de- pressed, the transaxle could be damaged. Therefore, do steps 4 and 5 within 5 seconds of each other. 4. Firmly depress the brake pedal with the left foot, and then gradually depress the accelerator pedal with the right. SLL Shift the selector to N position and let the engine idle for 1 minute or more to cool the ATF. Read the line pressure at idle and at the engine stall speed for the remaining ranges in the same man- ner. (1) 2 range (2) 1 range (3) R position 8. Shift the selector lever to D range and disconnect the solenoid valve connector. (Refer to page K-34.)| 9. Read the line pressure at idle and at the engine stall speed in the same manner. 10. Connect the solenoid connector (Refer 10 pi K-3K MECHANICAL SYSTEM TEST Specified line pressure: Line pressure kPa (kgticm?, psi) Range/Posi Idle ‘Stall zene | eee w BP D. D (solenoid connector disconnected), 2, 1 430-850(43~-57,62-81} | 920—1,040(93-10.7, 140-152) R 730-870 (7.48.9, 10-120) | 1,500—1,700 ( 152—17.4, 217-247} Tightening tora Evaluation of Line Pressure Test 11. Install a new square head plug in the line pressure inspection port. .0—9.8 Nm { 50—100 kgf-cm , 44—86 in-Ibf } Line pressure Possible cause Below specification in R position and all ranges ‘Worn oil pump Fluid leaking from oil pump, control valve body, or transaxle case Pressure regulator valve sticking ‘Throttie cable misadjusted Throttle valve sticking Trrattle modulator valve sticking | Below specication in D, 2, and # ranges ud eaking rom yerauke ou forward cach Below specification in 2 range Frid laking from hyGraulic oul of 4 brake band ‘Below specification in 1 range and A position Fluid leaking from hydraulle circuit of low and reverse brake Below specification in D range (solenoid connector jected) Fluid leaking from hydraulic circuit of 3-4 clutch Bow specication nF posiion| Fiuid leaking from hydraulic circuit of reverse clutch Above specification in R position and all anges Theotte valve sticking “Thoitle modulator valve sticking Pressure regulator valve sticking “Throttle cable misacjusted K-4MECHANICAL SYSTEM TEST K im. ‘. STALL SPEED STALL TEST Procedure IDLE SPEED. 1. Shift the selector lever to D range. Caution * If the accelerator pedal is depressed for longer than 5 seconds while the brake pedal is de- pressed, the transaxle could be damaged. Therefore, do steps 2 and 3 within 5 seconds of each other. 2. Firmly depress the brake pedal with the left foot, and then gradually depress the acceleretor pedal with the right, \When the engine speed no longer increases, quickly read the engine speed and reloase the accelerator. Shift the selector to N position and let the engine idle for 1 minute or more to cool the ATF. Perform stall tests for the remaining ranges and position in the same manner. (1) 2 range (2) 1 range (8) R position wae Engine stall speed 25: 1,950—2,250 rpm BP: 2,200—2,500 rpm K-5K MECHANICAL SYSTEM TEST Evaluation of Stall Test Condition Possible Cause In position and all anges ‘Wom oll pump Insufficient line pressure | or transaxle case ‘Stuck pressure regulator valve il leakage from ol pump, control valve, and! InD range Forward dutch sipping ‘One-way clutch 1 sipping ‘One-way clutch 2 slipping ‘Above specification Tn? range ‘2-4 brake band slipping In R position Below specification in R position and all ranges Low and reverse brake slipping ing reverse brake or reverse clutch 4) Engine braking felt in 1 range. ») Engine braking not felt in 1 range Tow and reverse brake Engine out of tune ‘One-way clutch slipping within torque converter ‘determine whether problem is low and Reverse clutch TIME LAG TEST Procedure ‘WHEEL cHOCK ReGen ® IDLE SPEED é K-6MECHANICAL SYSTEM TEST K . Shift the selector from N position to D range. . Use a stopwatch to measure the time it takes from shifting until shock is felt. Shift the selector lever to N position and run the engine at idle speed for at least 1 minute. Do the time lag test for the following shifts in the same manner. Make three measurements for each test and average the result. 5. While depressing the brake pedal, perform the test for the following shifts in the same manner. (1) N position-=D range (2) N position+2 range (8) N position—-R position BeRe Time lag: N position--D range ... approx. 0.5—0.6 seconds N position-»2 range ... approx. 0.5—0.7 seconds N position—R position ... approx. 0.6—0.7 seconds Evaluation of Time Lag Test Condition Possible Cause C ren «| Forward clutch sipping ‘Above specification ‘One-way clutch 1 sipping Nposition-+D range shift ‘One-way clutch 2 slipping races NED accumulator not operating properly Excessive line pressure Ax wpectical 2-4 brake band slipping Bmw opetean | ERR pear pay aatree a ee ean aaae N position 2 range shift TNR accumulator not operating propery Lesbos Excessive line pressure K-7K ROAD TEST ROAD TEST ROAD TEST PREPARATION 1. Check and correct as necessary, the engine coolant, engine oil, and ATF levels before testing. 2. Warm up the engine thoroughly to raise the ATF temperature to operating level (60—70 °C { 140-158 °F). 3. Check the idle speed and ignition timing in P position [{Flafer to section FTIF2.) SHIFT DIAGRAM D RANGE (EXCEPT O/D OFF MODE) 25) [E55] Tec OPERATION AVAILABLE 9 78} | a ol THROTTLE OPENING =| we owen’ oT i * ° 20412) 40(25) 60/37) 80(50) 100/63) 12075) 4087) 160(99) VEHICLE SPEED _ krvh( mph) D RANGE (EXCEPT O/D OFF MODE) (BP) [EEE] 100 opearion AVAILABLE THROTTLE OPENING 5 i ° zo(12} 4025) 60{S7) B{50} 100(63} 120{75} 40487} 16099) VEHICLE SPEED _ wh mph) K-8ROAD TEST K D RANGE TEST D range (Except O/D OFF mode) 1. Shift the selector lever to D range. 2: Accelerate the vehicle to half throttle and wide open throttle. 3. Verify that 1-2, 2-3, and 3-4 upshifts and downshifts are obtained. The shift points must be as shown in the table below. 4. Drive the vehicle in fourth, third, and second gears and verify that kickdown ocours for 4-+3, 4-2, 3-+2, 3-1, 2->1, and that the shift points are as shown in the table below. 5. Decelerate the vehicle and verify that engine braking effect is felt in fourth and third gears. Note * There is torque converter clutch non-operation in the following conditions. 1. The engine coolant temperature is below 62 °C { 144 °F ). 2. The closed throttle position switch is ON. 3. The brake switch is ON. 6. Drive the vehicle and verify that torque converter clutch operation is obtained. D range (O/D OFF mode) Gi 4. Turn the O/D OFF switch from OFF to ON. 2. Accelerate the vehicle to half throttle and wide open throttle, and verify that 1-2 and 2-3 upshift and downshift are obtained. The shift points must be as shown in the table below. 3. Drive the vehicle in third and second gears and verify that kickdown ocours for 3-+2, 3-+1, 2-»1, and that the shift points are as shown in the table below. 4, Decelerate the vehicle and verify that engine braking effect is felt in third gear. Throtie gum [_Veiele speed toni (meh) [Turbine speed (om) a oF z oP 7 TGR-GGR [52-68 3206] | 65—50 (5326) | 5.600--6,200 | 5300-5, 880 Wideopen [aanaah |as—100 5868 |o0—108 (61-65 | 5600-6,00 | 5400—5.900 aGR=AGR | 148-158 (52—69) [162-172 T0r—108)] 5.7606. 100 | §,600—6,100 : TGR-=2GR | 3343 (20-27 } [3312 (21-26) | ,600-—4,600 | 33004, 150 2GRSGR [6464 {4062} | 66—B5 (4152 } | 3,800,950 | 3.650—5,650 Pate Uae) ‘SGRAGR | 127—152 (79-34) | 112-142, 70-88} | 4,900—5,800 | 4,000—5,050 mode TECON WAY | 271507084) [92120 (57—74}] 4900—5,000 | 20002, 050 Closed thratte | 46A=3GR |27—33 (17-20) |33—30(21—24) | 750-850 | 850-950 bosition 3GR-1GR | 11—17(7—11} | 12—-18(8—11} | 450-650 450—600 > AGR=9GR | 145-185 (67—05) | T5I—161 (94-09) | Sas0—4,100 | .00—4,000 Sacewray’? [2GR=2GR [ee —o4 (5267) | 99 (5661 | .260—<,600 | 3260—3.600 BGR=IGR | 4248 (27—20} | 4480 (27—31 } | 2.500—-2,800 | 2.450—2,700 ‘wigs pon [LIGR=2GR | 6258 3226 | 6059 (00-28) [5,600~6.200| 5300—5,50, tate 2GR=AGR_[os—102 (58-68 }[98—106 (61-65 }5,600--6,000 | 5,400—5,600 Vrarevoue | 1OR=26R [e042 20-27) [aa—41 (20-25) [8600-4900 | 2004050 om oF 2GA>AGR | 6484 (4062) | 66—85 (4162) | 3800—4,950 | 3.650—4,.650 mode Glosed throtte | 4GR>3GR | 149165 (6026) [162168 To0—104)| 4,050—4,150 | 4,050—4,150 Position 3GR>1GR | 11—17(7—11) | 12—-18(8—11} | 450-650 450—600 [ricksown (wae [ 86R-=2GR [e420 (52-67) [100 (5761) | 3as0—,600 [8 260—9.500 openthrotiey — [ 2GR=1GR | 42—48 (2729 } | 4480 (2731 } | 2,500—-2,800 | 2,450—2,700K ROAD TEST, AUTOMATIC TRANSAXLE FLUID (ATF) 2 RANGE TEST 2range 1. Shift the selector lever to 2 range. 2. Accelerate the vehicle to half throttle and wide open throttle, and verify that second gear is held. 3. Decelerate the vehicle and verify that engine braking effect is felt. Shift Point a Throttle a Vehicle speed (km/h {mph}) | Turbine speed (rpm) | -" condition oe BP 2 P . 4GR=3GR | 149-155 (92-96) [162168 ( 100-104) | 4,050—4,150 | 4,050—4,150 ‘3GR--2GR_| 93-99 { 58—61 } [97—103 ( 60-63 | 3,600—3,800 | 3,450—3.650 | 1 RANGE TEST 1 range 1. Shift the selector lever to 1 range. 2. Accelerate the vehicle with half throttle and wide open throttle, and verify that first gear is held. 3. Decelerate the vehicle and verify that engine braking effect is felt. Throttle - Vehicle speed krvh (meh Turbine speed (rom) shite ee condition 2 BP 25 8P 1 = 2GR—1GR | 42—48 (26-29) | 4450 (27—31 ) | 2,600—2,800 | 2,450—2,700 | P POSITION TEST Shift into P position on a gentle slope, release the brake, and verify that the vehicle does not roll. AUTOMATIC TRANSAXLE FLUID (ATF) ATF Inspection Condition ‘One way of determining whether the transaxle should be disassembled is by noting: 1. If the ATF is muddy or varnished. 2. Ifthe ATF smells strange. ATF condition Color Condition Clear red Narmal Dark Powertrain components damaged Tight pink Water in the ATF Reddish brown Deterioration ofthe ATE 3. If ATF condition is not OK, repair as follows ‘* Dark color condition Overhaul transaxle and repair or replace parts as necessary, ‘+ Light pink and/or reddish-brown condition. Replace ATF. K-10AUTOMATIC TRANSAXLE FLUID (ATF) K HOT RANGE COOL RANGE Level 1. Park the vehicle on level ground. 2. Apply the parking brake and position wheel chocks se- curely to prevent the vehicle from rolling. 3. If necessary, inspect the ATF before warming up the en- gine. In this case, use the cool range (15—25 °C { 59-77 °F }). 4, Warm up the engine until the ATF reaches 50—70 °C { 140—158 °F }. 5. While depressing the brake pedal, shift the selectorlever to each range (P—1), pausing momentarily in each range. 6. Shift back to P position. 7. While the engine is idling, ensure that the dipstick is in the HOT 65 °C { 149 °F } range. Add ATF to the specifica tion if necessary. ATE type: M-III or Dexron®I Replacement Remove the dipstick. Remove the drain plug and washer. Drain the ATF into a suitable container. Install a new washer and the drain plug. aepo Tightening torque: 40—53 N-m { 4.0—5.5 kgf-m , 29—39 ft.lbf } 5. Remove the dipstick and add the specified amount and type of ATF through the oil filler tube. ATF type: M-IIl or Dexron®l Capacity: 4.91 {5.2 US qt, 3 Imp qt} 6. Install the dipstick. 7. Ensure that the dipstick is in the HOT 65 °C { 149 °F } range. 8, Add ATF to the specified level if necessary. K-11K THROTTLE CABLE THROTTLE CABLE PREPARATION ssT 49.0378 4008 For 49.8019 902 For adjustment of adjustment of Oil pressure throttle cable | Oil pressure throttle cable ‘gauge sot gauge (Part ot 49.0378 4008) 49.8019 903 For 498019901 For adjustment of adjustment ot Hose throttiecable | Oil pressure throttle cable (Partot gauge 49 0378 4008) 49 H019 002 For 49.6017 580 For Adjustment of support of engine Adapter throttle cable | Suppor, engine 49.017 501 For 49 GO17 502 For support of engine suppor of engine Bar Support (Par ot (Pan of 49. GO17 5A0) 49. GO17 5A0) 49.6017 503 For support of engine Hook _ _ (Part of 49.G017 540) THROTTLE CABLE Inspection K-12 1. Check the cable and housing for damage. 2. Verify that the accelerator operates smoothly. 3, Replace the throttle cable assembly if necessary.THROTTLE CABLE K Replacement 4. Remove the throttle cable from the throttle lever (throttle body). Note ‘+ Loosen bolt (first. 2. Loosen and remove bolts (D) and @). 8. Remove the throttle cable from the bracket. . Remove the splash shield. . Drain the ATF into a container. . Suspend the engine by using the SST. Remove the transverse member (BP). . Remove the engine mounting member. . Remove the oil pan and gasket, Remove the control valve body! (Refer to page K-43.) | Beenons 11. Remove the throttle cable from the throttle cam. 12. Remove the mounting bolts and throttle cable from the transaxle. 13. Install a new throttle cable to the throttle cam. 14. Connect the throttle cable to the throttle lever (throttle body). 15. Install new bolts in the areas indicated in the figure and tighten them to the specified torque. Tightening torque: 7,910.7 Nem { 80—110 kgf-cm , 70—95 in-Ibf } K-13K THROTTLE CABLE 16. Install the control valve body. Bolt length (measured from below the head) ®: 30 mm {1.18 in} ©: 50 mm {1.97 in} Tightening torque: 7,910.7 Nem { 80—110 kgf-cm , 70—95 in-Ibf } Note ‘+ Lightly apply sealant to both sides of the gasket. 17. Install a new gasket and install the oil pan. Tightening torque: 8.4—10.7 Nem { 85—110 kgt-cm , 74—95 intbf } 18. Install the engine mounting member. Refer to page K-43. 19. Install the transverse member (BP). 20. Remove the SST. 21. Install the splash shield. 22. Add ATF, and with the engine idling, check the ATF level and check for fa ler page K-10) 23. Adjust the throttle cable as follows. Adjustment 1. Remove the square-head plug Land install the SSTs. 2. Shift into P position and start the engine. Warm up the engine to normal operating temperature, and adjust the idle speed if necessary, Caution + Loosen bolt (1) first. 3. Loosen bolts @ and @. 4. Verify that the throttle lever is closed throttle position. 5. Tighten bolt ©. Tightening torque: 6.99.8 N-m { 70—100 kgf-om , 6186 in-Ibf } K-14THROTTLE CABLE K 6. Pull the throttle cable in the direction of arrow ® as shown in the figure until the line pressure exceeds the specified pressure. Caution © Ifthe line pressure will not decrease to the adjust- ment pressure, tighten bolt (2) with the line pres- sure at the closest point (point X) to the adjustment pressure. 7. Push the throttle cable in the direction of arrow @) until the line pressure decreases to the adjustment pressure. Adjustment pressure 490 kPa { 5.0 kgf/cm? , 71 psi } (Engine is idling) _Z 5 LINE PRESSURE . 8 BEGINS TO 8 Tighten bolt @. 8 1 incaease YG] aowustine pomr Tightening torque: g 6.99.8 N-m { 70—100 kaf-cm , 61—26 in-lbf } ® POSITION THROTTLE GABLE 9. Stop the engine and verify that the throttle cable moves smoothly. 10. Restart the engine and accelerate it slighty, then run it at idle. 11. Verify that the line pressure is within specilication. Specified pressure: 422—558 kPa { 4.35.7 kgt/cm? , 62—81 psi} (Engine is idling) 12. If not correct, repeat from step 3. 13. Stop the engine. 14. Remove the SSTs and install a new square-head plug ie Tightening torqu '5.0—9.8 N-m { 50—100 kgf-cm , 44—86 in-Ibf } K-15K ELECTRICAL SIGNAL INSPECTION ELECTRICAL SIGNAL INSPECTION PREPARATION, Sst a a ae = ees clo — ieee fae cee ae = a a - Fons oe eg ee note (== fe eee ceed = cen | eee eee woven = 0 S ——s ete Z Z ; es Fens = eee |e et oo . oe 7 — ed a ae Peni Adapter Power ‘eres00 . rowan = = eee eee rey re = a os eee one osenee | ett ee _ ee oo K-16ELECTRICAL SIGNAL INSPECTION K For 49 To8s 009 For 49 T088 004 inspection of | ingpection of NGS OBDII electrical signal | Case | ‘lecrical signal Adapter Z Cartot (Part of =O 497088000) (== 449 TOSS 0A0) 49 7088 008 For 49 7088 008 eer For inspection of fe inspection of Battery Hookup Setica vignal | Instruction \, ‘lericl signal pear Marval eas \ 449 T088 0A0) = ELECTRICAL SIGNAL INSPECTION Assembly of SST EC-AT tester (49 G019 901), adapter (49 H019 902), and adapter (49 B019 9A1) EEK ELECTRICAL SIGNAL INSPECTION EC-AT tester (49 G019 901B) and adapter (49 BO19 91) Sy Doo CEE K-18ELECTRICAL SIGNAL INSPECTION K NGS oi on Inspection Procedure Caution Donot connect the NGS to the data link connector 2when the EC-AT tester is connected to the pow- er in control module. Doing so can cause incorrect test results. When using the EC- 1. T tester (49 GO19 901C) Assemble the SST! (Refer to page K-18.) 2. Turn the EC-AT tester select switch to the & mark on the panel 3. Turn the ignition switch and the EC-AT tester main switch to ON. 4. Check the indication of the respective light or digital dis- play in each condition, referring to the indication table on the following page. K-19K ELECTRICAL SIGNAL INSPECTION When using the EC-AT tester (49 G019 901B) "asvemnble the SST (Retr 10 page K-18 Set the EC-AT selector switch to position 3. Set the EC-AT tester vehicle switch to the 323 position. Set the EC-AT tester select switch to position A, Turn the ignition switch and the EC-AT tester main switch to ON. Check the indication of the respective light or digital dis- playin each condition, referring to the indication table on the following page. o gReps When using the EC-AT tester (49 G019 901) and adapter unit (49 H019 902) Assemble the SS Set the EC-AT selector switch to position 3. Set the adapter unit vehicle switch to the 323 posit Set the adapter unit select switch to position A. Turn the ignition switch and the EC-AT tester main switch to ON Check the indication of the respective light or digital dis- play in each condition, referring to the indication table on the following page. n. 2 ghens When using the NGS 1. Assemble the SST (NGS) [(Refer to page K-19.) 2, Select the PID DATA MONITOR AND RECORD func- tion [(Refer to section F1.IF2.)] K-20ELECTRICAL SIGNAL INSPECTION K Indication Table Of Light And Digital Display EC-AT tester (49 GO19 901) Tem Indication | ___ Condition’ Possible cause [iapat(ghy on Poe postion ee OFF R position, all ranges Transaxle D ON D range _ eas OFF Other aries, all pOROTS | 1.9 vango atch or wi (INHIBITOR = ON 2range Transaxle range swtch or wiring sm ao (OFF ‘Ginor ranges, all posters ri ON T range = uo OFF Other ranges, all positions Eng coolant lamparature switch (WATER THERMO SW) 2 oa ‘ATE temperature above 130°C Transasothid temperature |° (06°F) Transaxle hid temperature sensor (ATE THERMOSENSOR). [5 ATE tempéilure bolow 13D | sensor or wing (266°F) ‘ON ‘OID OFF switch released — — OD OFF switch (HOLD SW) LON C8 OFF swich leased [op oFF ten orig ‘Closed throttle position switch ‘ON Closed throttie position ‘Closed throttle position switch or (oes) [OFF ior positon wring z ON Brako podal depressed ; Brake switch (BRAKE LIGHT Sw) | ke eset eoreed —___| rake switch or wing Tnpat (Digital Display) ‘Tarotle position sensor voltage | POM terminal |Guno HUE SENSORY) rou Constant Throttle poston sensor or wiring VEHICLE SPEED komih | Vehicle speed | Vehicle moving ee on sane DAUM SPEED ‘pm [num speed [Ale me Inpro speedsenor or ‘Output (Light) = a Shift solenoid A [ON 2GR, SGR, or 4GR | Powertrain control module, shift 2) OFF 1GA solenoid A, or wing . ‘Shit solenoid B [ON GR oF 2GR Powertrain contol module, shift sotenow | 2-3) OFF IGA oraGA solenoid 8, or wiring VALVE ‘Shift solenoid C [ON AGR, 2GR, or 4GR Powertrain control module, shift o OFF 3GR solenoid G, or wiring ToC ON TOG speraiion Powertrain control module, TCC fe (Cock.ur) [OFF TCC non-operaion solenoid valve, o wing SHIFT SIGNAL Not used ‘O/D OFF indicator light = ~ (HOLD INDICATOR) ee 7 Fist gear 2 ‘Second gear eee 3 Third gear 4 Fourth gear K-21K ELECTRICAL SIGNAL INSPECTION EC-AT tester (49 G019 901B) Tem [indication Condition Possible cause Taput (ight) - = ‘ON Por N position 3 ce ‘OFF | Frposiion, all ranges: Toenen | Orr [ow es aT range switch anges, all postions iwttartor’ > on coe “Transaxle range switch or wiing sw) ° OFF ~ [Other ranges, all postions af ON ‘range ‘OFF_____| Other ranges, allposifions Engine coolant temperature switch WATER THERMO sw) |Notused ea ‘RIF temperature above 130°C ‘Transanle fluid temperature sen- (286°F} ‘Transaxle fuid temperature con- sor (ATF THERMOSENSOR)— [SEE ‘ATR temperature below 180°C | sor or wing (286°F} = OW, (1D OFF Switch released 01D OFF switch HoLD sw) FEN SD OFF snich topransed (01D OFF switch or wiring ‘Closed throtle position switch [ON Giosed throttle position ‘Closed throtle position switeh or (OLE SW) OFF Other position wiring ON Brake pedal dopressed Brake switch (BRAKE LIGHT SW) | ON SS Brake switch or wing Input (Digital Display) Throtle position sensor voltage | POMTommInal | constant aaa (THROTTLE SENSOR V) Constant eee a : Vehicle speed sensor, vaicle VEHICLE SPEED kwh Vohicle moving ee ae DRUM SPEED rpm | Drum speed | Allthe time ee Output (Light) a ‘Shit solenoid A TON. GR, SGA, or 4GR Powertrain contol module, shit (1-2) OFF GR solenoid A, or wiring ‘Shit solencid B [ON 1GR or GR Powertrain control module, shit sotenoi — [2-3) OFF GR or 4GR solenoid 8, or wiring VALVE ‘Shit solenoid G [ ON TGR, 2GR, of GR Powertrain contol module, shit (4) OFF: ‘scr solenoid C, or wiring Tee ON [TCC operation Powertrain control module, TCC (Lock-ur) [OFF "TCC non-operation solenoid valve, or witing SHIFT SIGNAL Not used 1D OFF indicator Tight (HOLD INDICATOR). een Output (Digital Display) 7 First gear [2_______[ Second gear GEAR 3 Third gear = 4 Fourh gear K-22ELECTRICAL SIGNAL INSPECTION K EC-AT tester (49 G019 901C) Tier Tadieation Condition Possible cause input (Light) a ON P oF postion OFF Fposiion, all ranges D ON Drange TRANSMIS: FF ‘Other ranges, all positions SION RANGE o Siherrages ps ‘Transaxle range swtch or wiing switcH 26) ON range OFF ‘thor ranges, all positions 1 0 ‘ON range OFF ‘Other ranges, all postions on (O10 OFF switch depressed s FF switch o wii HOLDIOID OFF SWITCH a Oe err Seat er O10 OFF 5 8 ON ‘Brake pedal depressed rake Sitch or wit beiasaaiibald OFF ‘Brake pedal released Broke swt 2 [CLOSED THROTTLE POSITION. [ON Closed throttle position Closed throttle postion switch or SWITCH OFF ‘Other postion wing [—~ ESUMEVAGGEL switch ON or on vehicle speed 8 krvh (5 mph } Tower than presot spaed (Driving vehi cso control operation) |. rot mode, etch, oF 4GR INHIBIT SIGNAL | RESUME/ACCEL swich OFF and | Cus control male, ewe, vahicle speed kopt at preset OFF {Spaod (diving vehicle, cruise con- {1ol operation and not cruise con- trol operation) input (Digital Display) [THROTTLE POSITION SENS: St ternal THROTTLE POSITION SENSOR | POM terminal | Constant = () | voltage ae Voizie spoed seneor, vehicle VEHICLE SPEED (dan) | Voile speed | Vehicle moving ena TURBINE SPEED (pm) |Drumspeed | Alithe time Tnpatuin peod smear of Transaxle Tuid temperature POM teminal | ATF temperature 10°C (50°F F | Traneaxle fad trmperature sensor(TFT SENSOR) —_(V) | voltage AATF temperature 40°C {108 °F}: | sensor or wiring ‘Output (Light) Shitsoiencia A [ON 2GR,GGR, or 4GR Powertrain contol module, shift (GHIFTA) [OFF 1GR = solenoid A, or wing ‘Shit saienaia 8 [ON TGR or2GR Powertrain contol module, shit i 7 SenoidB, or wt sournoo SHIFTS) [OFF 3GR oF GR so ng VALE Shift solencid © [ON TGR, 2GR, of GR Powertrain coniol module, shit (SHITC) [OFF 3aR soleneid C, or wig Torque convert: [ON TCC operation -owertrain control modu ercutch (TEC Bewersain contol maui, TCC ConTROL) [OFF TOC nonoperation solenoid valve, or wiring HOLDIOMD OFF INDICATOR [ON O10 OFF mode | Pownrain control module, O10 UGHT OF Except O10 OFF in6de OFF indicator ight. or wiring ‘Output (Digital Display) i Fist gear 2 | Second gear GEAR PC - = -OSITION = ae a Fourth gear K-23K ELECTRICAL SYSTEM COMPONENTS WITHOUTTACHOMETER WITH TACHOMETER ELECTRICAL SYSTEM COMPONENTS O/D OFF SWITCH Inspection Inspection of operation Turn the ignition switch ON. 2 Verify that the O/D OFF indicator light is not illuminated. Depress the O/D OFF switch and verity that the O/D OFF indicator light illuminates. 3. Ifnot as sper OFF switch, db e005, fied, check the terminal voltage of the O/D Inspection of voltage 1. Remove the rear console and front console. 2. Turn the ignition switch to ON. 3. Measure the voltage at the O/D OFF switch connector terminals. Bs: Battery positive voltage ‘Connector terminal Position x a ‘Normal (Vy Br 0 Depressed (V) a a 4. If not as specified, check for continuity at the O/D OFF switch. Inspection of continuity 1. Disconnect the negative battery cable. 2. Disconnect the O/D OFF switch connector. 3. Check for continuity at the O/D OFF switch. 0 : Continuity ‘Connector terminal Position x z Normal Depressed ee 7 Se Ce #onPee a —§ — 00144-62004) Oh {8010 gem ,70—5 nse e131 (95-154 ,69-97) 6t29(65-93, 48-65) MOLYBDEUM BASED: 2-3 9 {0.080.102 3-51 (38-53, 28-30) Nem (gm, br} K-36TRANSAXLE K Battery and battery cover Air cleaner assembly Battery carrier . Solenoid connector Transaxle range switch connector Selector cable ". Vehicle speedometer sensor connector |. Harness bracket Throttle cable Wheels and tires . Splash shields . Transverse member (BP) Tie-rod end 17. Dy 18. Joint shaft (BP! 19. Manifold bracket 20. Starter 21. No.2 engine mount Installation note .............. page K~40. 23. Oil hose (inner) 24. Cil hose (outer) Service . ceseeeess Section 25. No.4 engine mount . Stabilizer control link Le Removal note... page K-37 Installation note page K-39) Removal note Lower arm| 1, Remove the clinch bolt from the lower arm ball joints. Caution © Wrap a rag around the ball joint dust seal to pro- tect it from damage. 2. Pry the lower arm out of the knuckle. Engine mounting member 1. Support the engine by using the SST before removing the engine mounting member. 2. Remove the engine mounting member. K-37K-38 TRANSAXLE Drive shafts Caution + The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines contact the oil seal. 1. Separate the right side drive shaft from the transaxle by prying with a bar inserted between the outer ring and the transaxle. 2. Suspend the drive shaft by using a rope. 3. Install the SST into the transaxle to hold the side gears. Torque converter nuts Hold the drive plate and remove the torque converter nuts. Transaxle 1. Loosen the SST and lean the engine toward the trans- axle. 2. Support the transaxle on a jack, making sure that it does, not fall from the jack. Caution * Do not allow the transaxle to lean toward the torque converter side. 3. Remove the transaxle mounting bolts. 4. Remove the transaxle.\ BLIND COVER ae TRANSAXLE K Installation note Transaxle 1. Setthe transaxle on a jack and make sure thatit does not fall, 2, Istall the transaxle mounting bolts. Tightening torque: ‘55—80 N.m { 5.6—8.2 kgf-m , 41—59 ftlbf } Torque converter nuts Hold the drive plate and install the torque converter nuts. Tightening torque: ‘35—49 N-m { 3.5—5.0 kgf-m , 26—36 ftbf } No.4 engine mount 1. Install the No.4 engine mount. 2. Hand-tighten the nuts of transaxle side. 3. Tighten the nuts and bolts of the body side, as shown in the figure, Tightening torque: “44—60 Nem { 4.4—6.2 kgf-m , 32—44 ft-bf } 4, Tighten the nuts on the transaxle side. Tightening torque: ‘67—93 N-m { 6.8—9.5 kgf-m , 50—68 ftbt } K-39K TRANSAXLE No.1 engine mount i | Caution | * Misaligning the bolts will cause damage to the . bolt holes. 1. Use the SST (49 GO17 5A0) to make sure the transaxle bolt holes and the No.1 engine mount meet evenly. 2. After the 3 bolts are set in the holes, tighten the bolts to the specified torque. Tightening torque: ‘67—93 N-m { 6.89.5 kgf-m , 50—68 ft-bf } No.2 engine mount 1. Install the engine mount bracket to the transaxle, as shown in the figure. HAND-TIGHTEN Ss» Tightening torque: 38—51 Nm { 3.85.3 kgf-m , 2838 ftlbf } 2. Hand-tighten the nuts and bolts of the engine mount rub- ber. PROJECTING | PARTS Tightening torque: 67—93 Nm { 6.8—9.5 kgf-m , 50—68 ftibf } Joint shaft (BP) 1. Insert the joint shaft to the transaxle. 2, Install the joint shaft to the cylinder block and tighten the bolts in the order shown, Tightening torque: 42—62 Nm { 4.3—6.3 kgf. , 32—46 ftbf } Drive shafts 1. Inspect the oil seal for damage. Caution + The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines contact the oil seal. 2. Remove the SST from the transaxle case.TRANSAXLE K FRONT SIDE ? = 3. Install the clip with the ends facing upwarc. (Refer to section N.) 4. Apply ATF to the oil seal lip. Install the drive shaft 5. Verify that the drive shatftis correctly seated by pulling on the shaft. It must not slide out. Engine mounting member Note «Verify that the engine mount rubbers are installed as shown. ‘Put the No.2 engine mount stud bolts in the installa- tion holes when installing the engine mounting mem- ber. 1. Install the bolts and nuts as shown. Tightening torque @): 64—89 N-m { 6.5—9.1 kgf-m , 48-65 ftlbf } ©: 38—51 Nem { 3.8—5.3 kgf-m , 28—36 ftlbf } 2. Tighten the No.2 engine mount rubber nut and bolt. Tightening torque: 67—93 Nem { 6.8—9.5 kgf-m , 50—68 ft-bf } 3. Remove the SST (49 G017 5A0) K-41K TRANSAXLE OIL SEAL (TRANSAXLE) Preparation ssT 49 G030 795 For 49 G030 796 For Installation of oil installation of oi! Installer, ol seal Body seal seal (Part of 49 G030 795) 49 G030 787 For installation of ol Handle seal _ _ (Part of 49 G030 795) On-vehicle Replacement 1. Remove the drive shaft and joint shaft. [(Refer to page K-34.) 2. Remove the oll seal. 3. Using the SST and a hammer, tap a new oil seal in evenly until the SST contacts the transaxle case. 4, Coat the lip of the oil seal with ATF. 5. Install the drive shaft and joint shaft. K-42TRANSAXLE CONTROL VALVE BODY (ON-VEHICLE REMOVAL / INSTALLATION) Preparation ssT 49GO17 SAD For 496017 501 For support of engine ‘suppor of engine Suppor, Bar engine (Part of 49 GO17 SAO) 49 G017 502 For 49 G017 503 For support of engine ‘supfort of engine Support Hook: (Patt of (Part of 49 GOTT SAO) 49 GOI7 SAO) On-vehicle Removal Warning PNPMSON 9. Disconnect the solenoid connectors. * Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear eye protection when using compressed air to clean components. 1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before removal. Disconnect the negative battery cable. Support the engine by using the SST. Jack up the vehicle and support it with safety stands. Drain the ATF into a container. Remove the transverse member. (BP) Remove the engine mounting member, Remove the oil pan and gasket. K-43K TRANSAXLE 10. Remove the bolts as shown is the figure. 11. Remove the control valve body. On-vehicle Installation 1. Install the control valve body as shown. Tightening torque: 7.9—10.7 Nem { 80—110 kgf-cm , 70—95 inibf } 2. Connect the solenoid connectors. 3. Apply a thin coat of silicone sealant to both sides of a new gasket 4. Install the gasket and the oil pan. Tightening torque: 7.9—10.7 Nem { 80—110 kgt-cm , 70—95 inbf } Bolt length (measured from below the head) @: 30 mm {1.18 in} ©: 50 mm {1.97 in} 5. Install the engine mounting member. 6. Loosely install bolts @ and ©). Tightening torque ‘@: 64—89 N-m { 6.5—9.1 kgf-m , 48-65 ftibf } @: 38-51 Nem { 3.85.2 kgf-m , 28—37 ftbf } 7. Install the transverse member. (BP) Tightening torque: ‘94-131 Nem { 9.5—13.4 kgf-m , 69-97 ftlbt } 8. Remove the SST from the engine. 9. Pour in ATF and, with the engine idling, check the ATF level and check for leaks.|(Refer to page K-10.) 10. Carry out the time lag test and line pressure test. [Refer to page K-2. 11. Cary out the road test. [(Refer to page K-8.)OIL COOLER K OIL COOLER OIL COOLER Removal / Installation 1. Disconnect the negative battery cable. 2, Remove in the order shown in the figure. 3. Install in the reverse order of removal, referring to[Installation Note.| 4. Add ATF to the specified level. 5, Connect the negative battery cable. 8. Inspect for oil leakage from the oil pipes and oil hoses. 7. Inspect the ATF level and condition | (Refer to page K-10. 8. Carry out the line pressure test. (Refer to page 9. Carry out the road test. D s2-47(92-48,20-95) WD 2252426, 18-25} 78107 Nm (20—H10Kgkem, 70-86 nF) Non (ton tt) 1. Connector bolts 5. Hose clamp 2. Washers 6. Radiator 3. Oil pipe 4. Oil hose installation note page K-46) K-45Marks K-46 OIL COOLER Installation note Oil hose 1 2. Align the marks, and slide the oil hose onto the oil pipe until itis fully seated as shown Install the hose clamp onto the hose. If reusing the hose, install the new hose clamp exactly into the mark left by the previous hose clamp. Verity that the hose clamp does not interfere with any other parts.DRIVE PLATE DRIVE PLATE PREPARATION sst 49 E011 140, For 49 E011 103 For holding tive holang drive Brake set, ing plate Shaft plate gear (Part of 49 E01 1A0) 49 E011 104 For 49 E011 105 For holding dive holding drive Collar plate ‘Stopper plate (Part of (Partot 49 E011 1A0) 49 £011 140) DRIVE PLATE Removal / Installation 1. Remove in the order shown in the figure, referring tol Removal Note.| 2. Install in the reverse order of removal, referring tolInstallation Note. Q ere 2 s7—102(98-105, 71-75) LOCKING Cf compouno A. Nan ( kt fb) 1. Bolts 4, Drive plate 2. Washers Removal note. =. bage K-48 3. Backing plate Installation note page K-48 5. Adapter K-47DRIVE PLATE ETT K-48 Removal note Drive plate 1. Set the SST against the drive plate. 2. Remove the bolts and the drive plate. Installation note Drive plate 1. Set the SST against the drive plate. 2. Gradually tighten the drive plate mounting bolts inthe or- der shown. Tightening torque: ‘97—102 N-m { 9.8—10.5 kgf-m , 71—75 ft-lbf }SHIFT MECHANISM K — SHIFT MECHANISM SHIFT-LOCK Inspection ents TOSHiT 1. Tum the ignition switch to ON (engine OFF) re a Verity thatthe selector lever is in P position. ‘out the brake pedal depressed, verity that the selec- tor lever cannot be shifted from P position. Depress the brake pedal and verify that the selector le- ver can be shifted from P position. 5. If not as specified, check the P position switch continuity and/or shift-lock actuator terminal voltage and continu- ity/ (Refer to pages K-51) 2. 3. BRAKE PEDAL, 4 DEPRESSED EMERGENCY OVERRIDE BUTTON Inspection 4. Tum the ignition switch to OFF. 2. Verify that the selector lever is in P position. 3. Without the brake pedal depressed, verify tat the selec- tor lever cannot be shifted from P position. 4, Remove the cover on the indicator panel by using a screwdriver, 5, Insert a screwdriver into the emergency override button and push down. Verify that the selector lever can be shifted from P position. 6. If not as specified, replace the emergency override but- ton. SHIFT TO P POSITION HieliiaUal ass {AND RELEASE THE Inspection SELECTORLEVER POSSIBLE TO TURN 1. Turn the ignition switch to ON (engine OFF). PUSH BUTTON Tere 2. Shift the selector lever to R position. ~~ 3. Verity that the ignition key cannot be turned to LOCK ty position, ol f 4, Shift the selector lever to P position. 5. Verify that the ignition key can be turned to LOCK posi- tion = 6. If not as specified, inspect and repair as necessary. K-49K SHIFT MECHANISM P POSITION SWITCH Inspection 1. Disconnect the negative battery cable. 2. Remove the rear console and front console. 3. Remove the indicator panel screws and lft up the indica- tor panel. 4. Disconnect the P position switch connector. 5. Check for continuity between the terminals. Position/Range | Selector lever release button | Continuity] . Released Yes Depressed Ne ExcoptP | = No 6. If not as specified, replace the P position switch. TOGROUND FROM SHIFTLOCK 7. Connect the connector. ACTUATOR 8. Install and adjust the indicator panel. (Refer to page K-52.) 9. Install the front console and rear console. 10. Connect the negative battery cable. 11. Check for correct operation of the shift-lock system. |(Reter to page K-49.) Replacement 1. Disconnect the negative battery cable. 2. Remove the rear console and front console. 3. Remove the indicator panel screws and lft up the indica- tor panel . Disconnect the connector. Remove the P position switch 6. Install a new P position switch. 7. Connect the connector. 8. Install and adjust the indicator pane. (Refer to page K-52.) 9. Install the front console and rear console. 10. Connect the negative battery cable. 11. Check for correct operation of the shift-lock system. (Refer to page K-49.) K-50SHIFT MECHANISM K = SHIFT-LOCK ACTUATOR CONNECTOR® CONNECTOR A Inspection 1. Remove the rear console and front console. ec BA an 2. Shift the selector lever to P position. ml || 3. Turn the ignition switch to ON (engine OFF), and check =e = for terminal voltage and continuity, referring to the chart a 1 [on page K-Si]as follows. P POSITION qWSUNTT TWSUNT SWITCH rg lock" UNLOCK pecan SIGNAL SIGNAL on Be: Batory positive vottage Check terminal © Probe connected to_| Measure- a Measure Connector | Terminal | Connector | Terminal | ment type ment value B a Body, Voltage (V)_| Brake pedal released—-depressed O>B+ B B ‘Body Voltage (V)_| Except P position—-P position O>Be a A 8 8 Continuity. | Selector lever release button Continuity K B & | Continuity [Constant Continuity 4. If not as specified, repair the wiring hamess and/or re- place the shift-lock actuator. 5. Install the front console and rear console. 6. Verify correct operation of the shift-lock system. [(Refer to page K-49.) Replacement Disconnect the negative battery cable. Remove the rear console and front console. Remove the indicator screws and lift up the indicator panel Disconnect the shift-lock actuator connector. Disconnect the P position switch connector. Remove the shift-lock actuator. Install a new shift-lock actuator. NOOR OVo Tightening torque: 1.31.8 Nm { 1319 kgf-cm , 12—16 inbt } 8. Connect the P position switch connector. 9. Connect the shift-lock actuator connector. 10. Install and adjust the indicator panel. (Refer to page K-52.) 11. Install the front console and rear console. 12. Connect the negative battery cable. 13. Verify correct operation of the shift-lock system. K-51K SHIFT MECHANISM SELECTOR LEVER Inspection 1. Turn the ignition switch to ON (engine OFF). reesar 2. With the brake pedal depressed, verify that there is a BE DEPRESSED “click” at each range when shifted in the pattern shown, 3. Verify that the selector lever can only be shifted as wp BUTTON MUST BE shown. DEPRESSED 4. Verity that there is a “click” at each range position when shifted from P position to 1 range. 5. Verify that the position of the selector lever and the se- lector illumination light are aligned. 6. If not as specified, adjust the indicator panel as follows. 7. Verity that the vehicle operates in each selected range. Adjustment Selector cable 1, Remove the battery, air cleaner assembly, and battery carrier. 2. Shift the selector lever to P position. 3. Loosen nut @) as shown in the figure. 4, Push the selector cable in the direction of the arrow until itdoesn't move any further. 5. Position the selector cable so that there is no loadin the direction of the arrows, and tighten the nut. htening torque: 16—22 Nem { 1.6—2.3 kgf-m , 12—16 ftlbf } 6. Install the battery cartier, air cleaner assembly, and bat- tery. 7. Shift the selector lever from P position to 1 range, and make sure that there is no interference from other com- ponents in that area, Indicator panel 1. Shift the selector lever to P position. 2. Loosen the indicator panel screws. 3. Align the alignment screw in the slider with the hcles in a the indicator panel. Installs suitable heavy-gauge wire to = hold the slider. K-52SHIFT MECHANISM K 4, Tighten the the figure. icator panel screws in the order shown in Tightening torque: 2.0—2.9 N-m { 20—30 kgf-cm , 18—26 in-Ibf } 5. Remove the wire. 6. Verify that the selector lever properly aligns with the indi- cator in all ranges and positions. K-53K SHIFT MECHANISM Removal / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure. 3. Install in the reverse order of removal, referring tolInstallation Note. 4. Connect the negative battery cable. 5. Verity correct operation of the shift-lock system. (Refer To page K-45.) (a—aangtem, ‘Seeotiniy INTERLOCK CABLE Tio Seaham, sr—tapiniety (15M29,y2-16) paar 24-30) conor ” Som Loosen _(2982In) Gas {eo—N0Kgrem, oe ean {so_nokgtem, Hoo Jones inaaty :< 19-107 Nm {010 Karem, jocasintty SELECTOR CABLE REMOVING ORDER; ©-+9-G SELECTOR CABLE MOUNTING ORDER: ()-)-@) K-54SHIFT MECHANISM K 1. Steering column cover 8. Selector lever 2. Rear console 3. Front console 4. Clip page Linstallation note .............. page K-56] 9. Insulator 5. Nut 10. Selector cable 6. Nut 11. Interlock cable Installation note ....... ss... page K-55) Installation note: ... page K-55. 7. Nut Installation note Interlock cable 4. Shift the selector lever from P position to 1 range. 2. Install the interlock cable so that the tip touches the oper- ating lever. Caution * Do not damage the outer sleeve ® when pulling or turning the interlock cable. 3, Install the interlock cable into the bracket groove, then tighten the nut, Tightening torque: ‘9,914.0 Nem { 100—150 kgf-cm , 87—130 in-Ibf } Nut 1. Shift the selector lever and manual shaft to P position. Caution + Bending the selector cable in the manner shown in the figure will damage the cable and cause it to become loose during shifting. Whenhandling and installing the selector cable, hold it straight. 2. After verifying that the selector cable boot is not twisted, install the selector cable to the selector lever, then tight- en nut ®. K-55K SHIFT MECHANISM 3. Push the selector cable in the direction of the arrow until it doesn't move any further. 4. Position the selector cable so that there is no loadin the direction of the arrows, and tighten the nut. Tightening torque: 16—22 N-m { 1.6—2.3 kgf-m , 12—16 ftbf } 5. Shift the selector lever from P position to 1 range, and make sure that there is no interference from other com- ponents in that area. Clip BRACKET Install a new clip flush to the selector cable bracket. cup, K-56SHIFT MECHANISM K Disassembly / Assembly 1. Disassemble in the order shown in the figure, referring ‘o[Pisassemnbly Nate! 2. Assemble in the reverse order of disassembly, referring to/Assembly Note. | 13-18Nen (19-19 kgfem, 12-16 nib) isan Cou 20-29Nm(20-a0 Kglem, 1826 intbt) 2 (2020 kgtem , Sa einiar) {00180 item, 7—f20%n61) 1. Connector 7. Assembly note . page K-58 2. Screws 8. Selector cable bracket 3. Selector lever knob 4. Cover 5. Mlgatr panel 10. P position switch ‘Assembly note _ page K-58) Inspection .- can page K-50) 6. Selector illumination ight 11, Sélector lever K-57(0.11.0 mm (0.008—0.039 in} 0.11.0 (0.004—0.039 in) Heavy.Gauce WiRe K-58 SHIFT MECHANISM Disassembly note Connector 1. Insert a thin piece of metal from the terminal side of the connector, and press down the terminal locking tab. 2. Pull the terminal out of the connector. Assembly note Cam 1. Loosely install the cam to the push rod. 2. Adjust the clearance between the guide plate and the guide pin by tuming the cam. 3. Clearance can be made smaller by turing the cam clockwise. 4, Install the selector lever knob and verify that the clear- ance is as specified, 5. If the clearance is not as specified, repeat from Step 2. 6. Remove the selector lever knob. 7. Apply grease to the cam as shown. Indicator panel 1. Shift the selector lever to P position. 2. Align the alignment screws in the slider with the holes in the indicator panel. Install heavy-gauge wire to held the slider. 3. Temporary install the indicator panel to the selector lever bracket. 4. Tighten the indicator panel screws in the order shown in the figure. Tightening torque: 2.0—2.9 N-m { 20—30 kgf-cm , 18—26 in-Ibf } 5. Remove the wire. 6. Verify that the selector lever properly aligns with the indi- ‘ator panel in all ranges and positions.ON-BOARD DIAGNOSTIC SYSTEM K ON-BOARD DIAGNOSTIC SYSTEM PREPARATION ssT 49 7088 040 For 49 To82 0108, For Gapnosis of Gagrosis of NGS set eCaT Program Card EP Eon 49 T008 002 For 49 To88 001 For Gagnosis of agnosis of Vetil ntertace Eon Control nit SOS | ecar Module atet WS (Part of {Toes oA) XS fe Togs oAo) 49 T008 008 = le 49 7088009 For Caagnosi of agnosis of Nas 080m roar cose conn fatter Cart ot (Part of =O 49 T088 OAO) {fo T098 of0) 497088 08 For 497088 008 For Caagnosis of diagnosis of Battery Hookup ecar Instruction eoar dante Manual (aro! So'To88 070) DIAGNOSTIC TROUBLE CODE Inspection Procedure 1. Connect the SST (NGS) to the data link connector 2 and battery. 2. Tun the ignition switch to ON. 3. Check the diagnostic trouble code(s). 4. Ifa diagnostic trouble code(s) is displayed, check for the cause by using the number on the diagnostic trouble code table. (Repair as necessary.) 5. Following repairs, do the After-Repair procedure to verify that there are no remaining codes. K-59K ON-BOARD DIAGNOSTIC SYSTEM DRIVE AT 50 km/h {31 mph } KICKDOWN STOP VEHICLE K-60 After-Repair Procedure 1. Cancel the: ynostic trouble code memory by using the SST (NGS). [Refer to section FT) 2, Remove the fom the data link connector 2. 3. Drive the vehicle at 50 knv/h { 31 mph }, and depress the accelerator pedal fully to activate kickdown. Stop the vehicle gradually 4. Connect the SST (NGS) to the data link connector 2 and battery. Turn the ignition switch to ON. Hatiy that no clagnostc rouble codes are cispayed Remove the SST from the data link connector 2.ON-BOARD DIAGNOSTIC SYSTEM Troubleshooting «Ifa diagnostic trouble code is shown on the SST, check for the cause by using the chart related to the code shown. Diagnostic Trouble Code K Code No. Display on the NGS Condition ‘TRANS RANGE SENSOR — OKT Poros | TRANS RANGE Transaxle Range Switch TRANS FLUID TEMP SENS — CKT porio | TRANG FLUID ‘Transaxle Fluid Temperature Sensor Po71s | INPUT/TSS CIRCUIT MALFUNCTION Inpul/Turbine Speed Sensor ovat | GEAR 1 INCORRECT RATIO Gear 1 Incorrect Ratio po7s2 | GEAR 2 INCORRECT RATIO Gear 2 Incorrect Ratio po733__| GEARS INCORRECT RATIO Gear 3 Incorrect Ratio 0734 | GEAR 4 INCORRECT RATIO Gear 4 Incorrect Ratio ‘TORQUE CONV CLUTCH SYS — porag | TORQUE COM ‘Torque Converter Clutch System Malfunction P0760 | SHIFT SOLENOID A—MALFUNCTION | Shift Solenoid A pores | SHIFT SOLENOIDB—MALFUNCTION _| Shift Solenoid B P0760 | SHIFT SOLENOID C — MALFUNCTION Shift Solenoid C Kk) 1743 | SOLENOID TOC — OPEN OR SHORT Torque converter clutch solenoid valve [73] K-61K ON-BOARD DIAGNOSTIC SYSTEM TRANS RANGE SENSOR — CKT MALFUNCTION DIAGNOSTIC TROUBLE CODE Po70s | [FANS RANGE SEER DETAILS | No input signal or input of two or more signals from transaxle range switch “Transaxle range switch malfunction POSSIBLE ‘+ Damaged wiring or connectors between transaxle range switch and powertrain controt module CAUSE | © Powertain control module malfunction [STEP] INSPECTION ‘ACTION 1 [Are powertrain control module or tansaxle range Yes |Gotonent step mi switch connections at the connector(s) and connector pins OK? —+ No | Ropaioroplace connoctors) Inepodion sop 6 + Yes: Goto not step U Nov thd st fewer 2 | heck EC-AT tsi depay Yes [Goto sop 6 * Sonetthe ECA eso o powertain contol mod- de «A transaxle ange switch ange and EC-AT tester display correct? em | indi Condition ‘ON [Por position PIN (OFF _ | F position, all anges E - el ‘ON [Drange No | Goto next step 2 ‘OFF | Other ranges, all postions ON [2range 2 OFF | Other ranges, all postions ON [Trange i ‘OFF | Other range: ‘3 | Gheck for continuity between terminals of transaxle | Yes [Goto next step - range switch and powertrain control module ‘= Disconnect negative battery cable ++ Disconnect transaxle range switch and powertrain Control module connectors + Is there continuity between the terminals? No_| Repair or replace connectors and wiring Goto step2 + When Yes, goto step 6 + When No, goto next step 4 | Check for continuity between terminals of the transaxle | Yes | Goto next step range switch as follows + Disconnect negative battery cable ne + Disconnect transaxle range switch connector * Is there continuity between the terminals? Repair or adjust ransaxle range switch Goto step2 ‘= When Yes, goto step 6 ‘+ When No, go to next step 5 | Check for continuity betwoon terminals of wansaxio | Yes |Gotonext step range switch and main relay * Disconnect negative battery cable « Disconnect transaxle range switch and main relay | No | Repair or replace connectors and wiring + Is there continuity between the terminals? 6 [After diagnostic vouble code has been cleared, re- | Yes | Replace powertrain control module check if diagnostic trouble code is shown 'No_| Probiem is a temporary poor connection of viring or ‘connectors, and should be investigated further K-62ON-BOARD DIAGNOSTIC SYSTEM DIAGNOSTIC TROUBLE CODE PO710 POSSIBLE |* TaNSAXl fud temperature sensor malfunction "TRANS FLUID TEMP SENS — CKT MALFUNCTION (Transaxle Fluid Temperature Sensor) DETAILS | Powertrain control module input voltage is less than 0.09 V or over 5.0 V + Damaged wirng or connectors botween transaxle fluid temperature sensor and powertrain contol module CAUSE |. Powertrain control module malfunction |steP INSPECTION ‘ACTION | Are powerrain contol module or wansexe fuidiem- | Yes | Goto next step perature sensor connections atte connectr(s) and ee (ponmiectos pls OF No | Repair or replace connector(s) Inspection step 8 +Yos: Go to next step ¢ No: End of flowchart 2 | Check EG-AT toster deplay Yes [Goto stop 5 + Connect EC-AT tester to powerteain contol module + Is transaxle fluid temperature sensor votage cor rect? Voltage No | Gotoned sep ‘ATE temp. 20°C (68 °F}: Approx. 4.0 20°C (266 -F): Approx. 1.5 V 3 | Check for continuity between terminals of transaxle fluid) Yes | Go to next step temperature sensor and powertrain contol module + Disconnect negative battery cable >| Repair or replace sonneors and win + Dioconectteteave tu tanporature sensor ana | N@ | Repl or replace connec and wing powertrain confi modie connectors. eee « fe there continuity between torminals? eWomtannetas “4 | Measure resistance between the transaxle fluid temper| Yes |Gotonext step = ture sensor terminals. ‘Disconnect negative battery cable + Disconnect transaxle fud temperature sensor con- rector + Ie esistance between terminals correct? ey Tio. | Roplace wansanie fuld temperature sensor ATF temp. 20°C {68 °F }: 21.0—25.0 ko 40°C { 104°F }: 10.0121 k2 80°C (176°F }:3.0—3.4 ka (= page K-27] 'S | Aller diagnostic vouble code has been cleared. re- | Yes | Replace powertrain contra module check if diagnostic trouble code is shown [= pag@ 80] No [Problems a temporary poor connection of wiring or Connectors, and should be investigated further K-63K ON-BOARD DIAGNOSTIC SYSTEM INPUT/TSS CIRCUIT MALFUNCTION DIAGNOSTIC TROUBLE CODE P0715 | Fee a eee ane con DETAILS | Signal fom igure speed sensor no np to power Gol odle when vehicles mova ‘+ Inputturbine speed sensor malfunction = POSSIBLE |” Damaged hamess or connectors between inpultubine speed sensor and powertrain control module {Powertrain contol module maltuncton sTEP| INSPECTION ACTION 1 | Are powertrain control module or inputiurbine speed | Yes [Goto next step ‘sensor connection al the connector(s) and connector ino OH? [We Repair replace conneciors) Inspection step 5 + Yes: Go to next step + No: End of flowchart 2 | Check EC-AT toster dieplay Yes | Goto stop 5 + Connect EC-AT tester to powertrain control module * Is speed indicated on EC-AT tester after engine is started and vehicle is idling? No [Goto next step (= page K-16 ] ‘3 | Check for continuity between terminals of inpuvturbine | Yes | Goto next step speed sensor and powertrain control module * Disconnect negative battery cable * Disconnect inputturbine speed sensor and power- train control module connectors + Is there continuity between terminals? No. | Repair or replace connectors and wiring Goto step 2 + When Yes, goto step 5 + When No, goto next step “4 | Measure resistance between inputiurbine speed sen- | Yes | Goto next step sor terminals, * Disconnect negative battery cable * Disconnect inputturbine speed sensor connector + Is resistance between terminals correct?” Replace input/turbine speed sensor Resistance: 200—400 02 > page Kae [Frpage R23] 5 | After diagnostic rouble code has been cleared, re- | Yes | Replace powertrain control module. ‘check if diagnostic trouble code is shown [seston FIFZ] [E'BAGE KE] |e | Problem sa temporary poor connection of wining or connectors and should be investigated further K-64ON-BOARD DIAGNOSTIC SYSTEM DIAGNOSTIC TROUBLE CODE P0731 ‘GEAR 1 INCORRECT RATIO {Gear 1 incorrect Ratio) ‘DETAILS [Powertrain convo nadie ouput solenoid pater ofa gor whon goa rat ther than Wt oer = ATF level low ‘> Control valve stuck PogsiLt |> Siero lve atrcten + Soma Sarl made maneon 1 ine pressure low ster INSPECTION ACTION [is dagnoste wouble code P0760, PO7S5, of PO7GO | Ves | Referto owchar for agnostic rouble code PO750, a indicated? Pras, or 760 and, ten to (es page K-70,[71]72]} Goto new stop = 2 | ire amount and condition (cot of ATF OK? Yes | Gotonex step Check for ATF leakage al ransanle connection and gesret Sore een Tio. [Adjust ATF amount or roplaco ATF necessary {Black Detective part n powertrain STATE coloris measure lino pressure at dle when DLight ved Water moved in furd pressures es than specticaton, go 0 step Reh brown: Dotororated ATF + HATE coloris @) of © replace ATF page K-10 3 [is uibine speed OK under folowing conditions? | Yea [Goto step 8 EGAT tester connectod to powertrain contol medule 1 Throtes 2 open, and vehicle spoed i 20 kn {ampn) ind range (Except OD OFF mode), Turbine speed Tio. | Above epociicalon: Gow nen step 25: 2180 rpm Below specticaton: Goto stop 6 &P: 3,000 rpm [= page K-16 hook ino proceur nD range (Except OD OFF | Vos [Gotonest sep trode) Tielno prossure OK? _ Tio | Repair or replace any defecve parts Line pressure when nD range (Except OFF mode) 1fine presoure is tw only when nD or range: ATF Ing: 490-880 KPa (43—5:7 hile? 281 pel) Teakage in forward chtch creut Stale 20-1040 ka (3107 kglem?, 140152 pal) Automatic Transaxle —— Workshop Maral FAQA-EL 3 | Check stall epood in Orange (Excopt O1D OFF mode) | Yes [Gove nex step + ie stall speed OK? eon eeedaree Drange (Except O/D OFF mode) | "No | Repair or replace any defective parts $502,250 rpm 1 igh nal range: Shing of forward cuteh,oneswa 200—2,500 rpm cue ee ee " eet «High nD range: Shing of one-way chtch 2 6 [inspect operation of si slenoid A, 8, C Yes | Goto nen stop 1 Disconnect negative batey cable = Automatic Transaxle + Disconnect solenoid connector Workshop Manual FAAA-EL + Ist operating OK an | NO [Rerlace sit sinc A, Bor — ag Goto step 2 «When Yes, oto stop 8 + When No, goto next step 7 | Gheck operation ofeach valve andinapectetumm | Yes [Go tonext step ae, | opal al ae ad paso Fry ave oping OX ans sen sping OX? | RO |FeB or epa= conte ae nd pie om © Automatic Transaxle Workshop Manual FASA-EL 3 | Aer agnostic voube code has beon cleared = | Yes | Replace poworva contol module check agnostic rouble code iss 3 gestion FIFE J" page K-60] "No | Problem is a temporary slip of investigated futherK ON-BOARD DIAGNOSTIC SYSTEM DIAGNOSTIC TROUBLE CODE P0732 DETAILS “GEAR 2 INCORRECT RATIO. (Gear 2 incorrect Ratio) “= ATE levellow Powertrain control module output solenoid pattem of second gear when gear ratio s other than second gear * Line pressure low POSSIBLE |*+ Forward clutch sippage + One-way clutch t slippage CAUSE |+ 2-4 brake band slippage * Control valve stuck + Solenoid vaive matfunction * Powertrain control module malfunction [STEP INSPECTION “ACTION 1 1 | Is diagnostic trouble code P0750, P0755, or P0760 | Yes | Refer to flowchart for diagnostic trouble code P0750, _ indicated? 0755, or PO760 and then troublashoot No [Gotonext stop 7] 2 | Are amount and condition (color) of ATF OK? Yes | Go tonoxt step Check for ATF leakage a transaxle connection and gasket Golor 4 @ Transparent rod: Normal "No | Adjust ATF amount or roplace ATF if necessary Black. Defective part m powertrain * FATE colors @), measure line pressure at idle when Light red: Water mixed in fd. pressure i less than specification, goto step 4 @ Reddish brown: Deteriorated ATF * HATE coloris @ or @, replace ATF 3. | is turbine speed OK under folowing conditions? Yes [Goto stop + EC-AT tostor connected to powertrain contol module + Throttle is 2/8 open, and vehicle speed is 20 kmh (12 mph} is 2 range Turbine speed No | Above specification: Go to next step 725: 1,200 pm Below spectication: Go to step 6 BP: 1,100 rpm (ee page K-16] “4” | Check line pressure in D, 2 range Yes | Gotonext step + ls line pressure OK? Line pressure when inD, 2 ange 'No_| Repair or replace any defective parts icing: 30-850 KPa {as oy halen? 62-81 pl) + ATF leakage in 2-4 brake band circuit Stale: 820—1040 KPa (9310.7 kglom?, 140-152 ps) * ATF lockage inforwardchtch ret Workshop Manual FACA-EL | Check stall speed in D, 2 range Yes | Go tonext step +s sta speed OK? Stall speed when in D, range No | Repair or roplace any defective parts 5: 1,950—-2,250 rpm + 2-4 brake band sipping BP: 2,200,500 fpm + Forward clutch sipping =" Automatic Transaxle (er pageK=5] Workshop Manual FA4A-EL © | Inspect operation of shit solenoid A, 8, C Yes | Go tonent sop + Disconnect negative batty cable No | Replace sit slancid A,B, or + Ist operating OK? ae Bee + When ¥es, goto stop 8 + When No, goto next stop 7 | Check operation ofeach valve and inspect retum | Yes [Gotonext step — lace control vaive and replace return *'Is each valve operating OK and is retum spring OK? | NO oa: ee ee © Automatic Transaxle Workshop Manual FASA-EL ‘8 | Alter diagnostic rouble code has been cleared, re- | Yes | Replace the powertrain control module check dagnostc trouble code is shown [e* seston FUJFZ] KE60] [No | Problem is a tomporary sip of cutch, and shouldbe Investigated further K-66ON-BOARD DIAGNOSTIC SYSTEM DIAGNOSTIC TROUBLE CODE P0733, GEAR 3 INCORRECT RATIO (Gear 3 Incorrect Ratio) DETAILS | Powervaln coil module ouput solenoid patom of tid gear when ger rat other tan thd ger * ATE level iow * Line pressure low POSSIBLE | + Forward clutch slippage + One-way clutch 1 slippage CAUSE | + 3-4-clutch slippage + Control valve stuck | + Solenoid valve malfunction + Powertrain control module malfunction ISTEP] INSPECTION ACTION | Is agnostic trouble code PO750, PO7SS, or PO760 | Yes | Reler to flowchart for diagnostic trouble code P0750, indicated? P0755, or PO760 and then troubleshoot (= page K-55] CE pags R-7OITI72) No_|Go to next step [2 [Are amount and condition (color) of ATF OK? Yes | Goto next stop ‘Check for ATF leakage at transaxle connection and ‘gasket Golor @ Transparent red: Normal Black: Defective part in powertrain ‘Light red: Water mixed in thud ‘@Raddish brown: Deteriorated ATF ‘Adjust ATF amount or replace ATF if necessary + ITATF color is @), measure line pressure at idle when pressure is less than specication, go to step 4 + IFATE coloris (3) or @, replace ATF is turbine spaed OK under folowing conditions? + Solenoid connector disconnected + EC-AT tester connected to powertrain control module * Throttle is 2/8 open, and vehicle speed is 20 km/h {12 mph} in third gear in D range ‘Turbine speed "25: 800 rpm BP: 750 rpm Yes Goto step 8 ‘Above specification: Go to next stop Below specification: Go to step 6 ‘Check line pressure when solenoid connector is dis- ‘connected * Solenoid connector disconnected * Is ine pressure OK? Line pressure when third gear in D range Teng: 430550 kPa ( 435.7 kofem?, 6281 psi) ‘Stalled: 920—1,040 KPa {9310.7 kgllem?, 140152 psi) (2x page KS) Yes Go tonext step Ropair or replace any detective parts, + ATF leakage in 3-4 cluich ‘== Automatic Transaxle Workshop Manual FASA-EL 5 | Check stall speed when solenoid connector is discon- | Yes |Go tonext step rested +"Solenoid connector csconnectod + Is stall speed OK? : Tio Repairor pace any deoaive pars Siall speed when third gear in D range o'F-a.duten sipping "5: 1,950-~2.250 rpm SS Automate Transaxle 3200-2500 rpm Workshop Manual FAAA-EL, [#= page K-5] © [inspect oporaion af shit solenoid A,B, © Yes [Gotonex sep + Disconnect negative batery cable : - + Disconnect negative blir ca No [Replace shift solenoid A,B, or G {Ket eporating OR? S + When Yes, go o stop {en No, got nom stp 7 | Check operation ofeach valve andinspectretum | Yes | Gotonext stop spring Msach vate operating OK ands tum spring OK? | NO | Repair or replace cota valve and relace ret 1 Automatic Transaxle iE Workshop Manual FASA-EL & | Aer dagnostic woubie code has boon lared,e- | Yes | Roplace powertrain control module check if agnostic rouble code s shown Tio | Probiom a lernporary sip of cach, and shoul be Investigated further K-67K ON-BOARD DIAGNOSTIC SYSTEM DIAGNOSTIC TROUBLE CODE P0734 GEAR 4 INCORRECT RATIO. (Gear 4 Incorrect Ratio) DETAILS Powertrain control module outputs solenoid pattem of fourth gear when gear ratio is ether than fourth gear. + ATF lvellow + Line pressure ow Possia.e | 2-1 brake band sippage + ack dutch stppage CAUSE | Gontel vave stuck 5 Solenoid vave mattnction + Powertrain cont! module matuncion STEP INSPECTION ‘ACTION 1 | Is diagnostic trouble code P0750, P0755, or P0760 Yes | Reter to flowchart for diagnostic trouble code P0750, | indeatod? POTS, or PEO, and then woubloshoot za} No | Gotonex sop 2 [re amounl and condion (colo) of ATE OK? Yes | Goto now step Check for ATF leakage at ansenle connection and eset, _ Color No | Adjust ATF amount orroplace ATF W necessary Transparent red: Normal ‘* IFATF colori (2), measure line pressure at idle when @ Black: Defective part in powertrain pressure is less than specification, repair or replace. {ight ret Water rized in hd ory aefecve pate @ Reddish brown: Deteriorated ATF + If ATF color is 3) or @, replace ATF ‘3 _|Is diagnostic trouble code P0732 (Gear 2 incorrect | Yes | Refer to flowchart for diagnostic trouble code PO732_| tate) waeatoa? (Gear incorrect rat), ad hen youeshoot No | Govern sep | is diagnostic wowbie code PO7&3 (Gear incorect | Yes | Referto flowchart for dagnastc rouble code POTSS tate) neatoa? (Gear incoret rat) ad then au (oe Ka2] No | Goto next step 2 5 [Inspect operation of sit sotonod A,B 6 Yes | Goto now stop 1"Bssonnect negative batty cable + Disconnest send eometor + Disconnect ona No | React alonoa A Bar ee Ye: Goto not step 1 No‘ Gnd of foment 6 | Check operation ofeach valve and inspect etum | Ves | Goto nex sep spring * Is 8ach valve operating OK and i retum spring OK? |e | Repair or replace control valve and replace return po © Automatic Transaxle Wontshop Manual FAGA-EL 7 | Mer diagnostic wouble code has been cleared re | Ves | Replace powertrain contol module Check Gagnos rouble cove is show 25 section FI [ES page K-60] (BBB=K=80) ye) propa is a anporay ipo cen, and shoud be Inveotgated tutor K-68ON-BOARD DIAGNOSTIC SYSTEM K DIAGNOSTIC TROUBLE CODE P0740 ‘TORQUE CONV CLUTCH SYS — MALFUNCTION (Torque Converter Clutch System Malfunction) Sexas | Sara cap by powenan ono medul for torus conver ch poration bua Worque conver cach obtained Teosome [> ATF ove iow 7 wean conte module matinton POSSIBLE | > Torq converter ch tppage + Une pressure ow {Tord converter cutch slonod va matuncton + Comal valve stuck sre INSPECTION AGTION 7 [ie amount and conon clr ot ATF OK? Yes | Go toned sop Check or RTF leakage st Waneebo connection and gant Sor | areal No | Ajit ATF amount of eplacs ATF Wnesnssry Picrapeebedent ire STATE coors ©), dsssomibe vance and repair (black Dee part npr repo any dette pare as nacossay Rauch brown: Deteroraod ATF + IPATF color is (@) or @, replace ATF | Gheckine presere in D rango (Excapt OD OFF | Ves [Gotonent dep ro) Stn proseure OK? fo : No | Repaor place any defective parts Line pressure when in D range (Except 0/D OFF mode) + ATF leakage in transaxle case, oil pump, control Tag fot a (4078 age 62-8 ps) ine Sd 820-100 KPa (83-107 gl? 1152p) © Auomalie Transaxle aS Wornahop Manual FAGA-EL | 3 | inspect operation of solenoid vaive Yes | Goto next step *"Ssconnet negative baton cable + Deconnect selena connector 1 Ritopoaing On? No | Replace torque converter ch olen aie 7 | Chock operation ofeach vave andwapoct eum | Yes |otonen sop Senna 22a valve operating OK ani tun spring OK? | > aaiorvapace Sonal vale and ore tm eng © Automatic Tansee Workshop Manual FAGAEL 3] Ghoakaitrence between engino speed and turbine | Yes [Replace Torus converter Speed durin orqu conver uch operat in 2 qutomatle Transaxle itu gone Workshop Marval FAAA-EL + Contec EC-AT tater to powortain contol module + Ghuckaerencebetweon engi speed and ne Speed aug torque covert cic operation in amigos 7 No | Goto next stop Is there a aference between engine ped and ur Sine spect? =" page K-16. io: dagroscVouble code hasbeen clere,r- | Yes | Replace powertan coral mode check dagrestwoule codes shown No | Brobiam sa impor sip ofclth, end shouldbe invostigated urtor K-69