Continuously Variable Transaxle (Cvt): Overhaul Suzuki Kizashi I

Precautions for Disassembly and Reassembly

As the CVT consists of high precision component, the following cautions should be strictly observed when handling its parts in disassembly and reassembly.

1. Never disassemble the CVT except where indicated in this section. Otherwise, disassembly will spoil its original performance.
2. Make sure to wash dirt off from the CVT so that no such dirt will enter the CVT during dismounting and remounting.
3. When servicing, select a clean place free from dust and dirt.
4. Place a rubber mat on the work bench to protect parts from damage.
5. Use lint-free paper not cloth rags.
6. Replace each gasket, oil seal and O-ring with a new one.
7. Keep component parts in group for each subassembly and avoid mixing them up.
8. Clean all parts with cleaning solvent thoroughly and air-dry them.
9. Keep face and eyes away from solvent spray while air blowing parts.
10. Check mating surface for irregularities and remove them, if necessary. Clean it again.
11. Apply CVT fluid to all O-rings.
12. Replace oil seals that are removed and apply grease to their lips.

CVT Assembly Dismounting and Remounting

Reference: CVT ASSEMBLY COMPONENTS

Scheme 97

Scheme 98

1. Remove bolts (1) fastening engine and CVT assembly.
2. Dismount CVT assembly with engine, see «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .
3. Remove front drive shafts, see «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION: FRONT»(ref-585617-S17552051012013111200000) .
4. For 4WD model, remove transfer. Refer to «TRANSFER DISMOUNTING AND REMOUNTING»(ref-585625-S01899617802013111200000)
5. For 2WD model, remove drive intermediate shaft, see «DRIVE INTERMEDIATE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-585617-S38714809442013111200000) .
6. Remove drive plate cover, see «CVT ASSEMBLY COMPONENTS»(ref-585587-S39481336622013111200000) .
7. Remove torque converter No. 1 and No. 2 bolt as follows. a) Insert flat-end screwdriver or the like (2) to hole (3) of CVT assembly as shown in figure. Lock drive plate (1), engage a flat-end screwdriver or the like with gear of drive plate as shown in figure. Remove torque converter No. 1 or No. 2 bolt through drive plate cover opening. Turn crankshaft by 60° by turning crankshaft pulley bolt using wrench. Repeat Step a ) through c ) 5 times.
8. Remove starting motor, see «STARTING MOTOR REMOVAL AND INSTALLATION»(ref-585581-S04660534432013111200000) .
9. Remove the following parts, see «ENGINE MOUNTINGS COMPONENTS»(ref-585578-S18230687082013111200000) . Front mounting bracket Rear mounting Engine rear mounting bracket No. 1 Engine rear mounting bracket No. 2
10. Remove bolts and nut fastening engine and CVT assembly, and then detach CVT assembly from engine. CAUTION: When detaching CVT assembly from engine, move it in parallel with crankshaft and be careful not to apply excessive force to drive plate and torque converter.

Scheme 99

Scheme 100

Scheme 101

1. Make sure that torque converter is installed correctly to CVT assembly, see «INPUT SHAFT OIL SEAL REPLACEMENT»(ref-585587-S12793937022013111200000) .
2. Attach CVT assembly to engine.
3. Tighten bolts and nut to specified torque, see «CVT ASSEMBLY COMPONENTS»(ref-585587-S39481336622013111200000) .
4. Install the following parts, see «ENGINE MOUNTINGS COMPONENTS»(ref-585578-S18230687082013111200000) . Front mounting bracket Rear mounting Engine rear mounting bracket No. 1 Engine rear mounting bracket No. 2
5. Tighten torque converter No. 1 and No. 2 bolts as follows. NOTE: Torque converter No. 1 bolt is used for accurate positioning. Tighten torque converter No. 1 bolt first so that bolt holes for torque converter and drive plate are positioned properly, and that torque converter No. 2 bolt is tightened securely. One torque converter No. 1 bolt and five torque converter No. 2 bolts are required to secure torque converter and drive plate. Align bolt hole of drive plate with bolt hole of torque converter by turning crankshaft. Insert flat-end screwdriver or the like (2) to hole (3) of CVT assembly as shown in figure. Lock drive plate (1), engage a flat-end screwdriver or the like with gear of drive plate as shown in figure. Tighten torque converter No. 1 bolt to 5 N.m (0.51 kgf-m, 4.0 lbf-ft) through starting motor opening. Turn crankshaft by 60° and tighten torque converter No. 2 bolts by hand through starting motor opening. Tighten torque converter No. 1 bolt to specified torque. Tightening torque Torque converter No. 1 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft) Turn crankshaft by 60° and tighten torque converter No. 2 bolts to specified torque. Tightening torque Torque converter No. 2 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
6. Install starting motor, see «STARTING MOTOR REMOVAL AND INSTALLATION»(ref-585581-S04660534432013111200000) .
7. Install drive plate cover, see «CVT ASSEMBLY COMPONENTS»(ref-585587-S39481336622013111200000) .
8. For 2WD model, install drive intermediate shaft, see «DRIVE INTERMEDIATE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-585617-S38714809442013111200000) . CAUTION: Oil leaks will occur if the oil seal lip is damaged. Do not pull out or push in the drive intermediate shaft aslant. Slide the shaft in axial direction.
9. For 4WD model, install transfer, see «TRANSFER DISMOUNTING AND REMOUNTING»(ref-585625-S01899617802013111200000) .
10. Install front drive shaft, see «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION: FRONT»(ref-585617-S17552051012013111200000) .
11. Remount engine with CVT assembly to vehicle. Refer to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S38629691852013111200000) .
12. Tighten engine fastening bolts (1) and CVT assembly to specified torque, see «CVT ASSEMBLY COMPONENTS»(ref-585587-S39481336622013111200000) .
13. Refill CVT fluid, see «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000) .
14. Check CVT fluid level, see «CVT FLUID CHECK»(ref-585587-S11373563342013111200000) .
15. After installation, check for CVT fluid leakage at each connection.
16. After replacing CVT assembly, perform learning control initialization, see «TCM INITIALIZATION AND LEARNING CONTROL»(ref-585587-S04742508202013111200000) .