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Continuously Variable Transaxle (Cvt): Removal & Installation Suzuki Kizashi I

Automatic Trans 22 illustrations ~1578 words

Transmission Control Module (TCM) Removal and Installation

CAUTIONTCM consists of highly precise parts, therefore when handling it, be careful not to expose to excessive shock. When performing the replacing TCM with used one, all learned controls which are stored in TCM memory should be erased after the replacement. Neglecting this initialization may cause excessive shift shock.

Scheme 75

Scheme 75: Removal
Scheme 75: Removal
  1. Disconnect negative (-) cable at battery.
  2. Remove driver side instrument panel undercover, see «INSTRUMENT PANEL REMOVAL AND INSTALLATION»(ref-585593-S40931411942013111200000) .
  3. Disconnect connectors (2) from TCM (1).
  4. Remove TCM by removing nuts (3).

Installation

Reverse removal procedure noting the following points.

  1. After replacing TCM, perform «TCM INITIALIZATION AND LEARNING CONTROL»(ref-585587-S04742508202013111200000) .

Shift Paddle Switch Removal and Installation

CAUTIONTo avoid impairment of the original performance, do not remove horn plate from steering wheel assembly. If it is removed, one replace the entire steering wheel assembly with new one.

Scheme 76

Scheme 76: Removal
Scheme 76: Removal
  1. Remove steering wheel, see «STEERING WHEEL REMOVAL AND INSTALLATION»(ref-585616-S27367718822013111200000) .
  2. Remove screws (1) and release claws (2).
  3. Disconnect connectors and then remove shift paddle switches (3).

Reference: SHIFT PADDLE SWITCH INSPECTION

Reverse removal procedure.

Removal

  1. Disconnect negative (-) cable at battery.
  2. Remove console box, see «CENTER CONSOLE BOX REMOVAL AND INSTALLATION»(ref-585603-S01735880062013111200000) .
  3. Disconnect adjuster case (select cable end) from select lever assembly, see «SELECT CABLE REMOVAL AND INSTALLATION»(ref-585587-S27478846212013111200000) .
  4. Disconnect select lever connector.
  5. Remove select lever nuts and detach select lever assembly from floor panel.

Reverse removal procedure noting the following points.

  1. Tighten select lever nuts to specified torque, see «SELECT LEVER ASSEMBLY COMPONENTS»(ref-585587-S39719190862013111200000) .
  2. After installing select lever assembly, adjust select cable, see «SELECT CABLE ADJUSTMENT»(ref-585587-S39051494732013111200000) .

Select Cable Removal and Installation

Reference: SELECT CABLE COMPONENTS

WARNINGTouching a hot exhaust system component will cause a burn. Do not perform any service work on the select cable until the exhaust system is cool.
  1. Disconnect negative (-) cable at battery.
  2. Remove air cleaner assembly, see «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S10930133882013111200000) .
  3. Remove console box, see «CENTER CONSOLE BOX REMOVAL AND INSTALLATION»(ref-585603-S01735880062013111200000) .
  4. Disconnect select cable from select lever and then detach it from bracket, see «SELECT LEVER ASSEMBLY REMOVAL AND INSTALLATION»(ref-585587-S28597486272013111200000) .
  5. Remove clip of select cable and disconnect select cable from manual select lever.
  6. Remove select cable retainer from dash panel.

Reference: SELECT CABLE ADJUSTMENT

Reverse removal procedure noting the following points.

  1. Apply grease to pin and cable joint, see «SELECT CABLE COMPONENTS»(ref-585587-S18513163062013111200000) .
  2. Use new clip.
  3. Tighten bolts to specified torque, see «SELECT CABLE COMPONENTS»(ref-585587-S18513163062013111200000) .
  4. Adjust select cable, see «SELECT CABLE COMPONENTS»(ref-585587-S18513163062013111200000) .

CVT Oil Pan and Oil Strainer Removal and Installation

CAUTIONThe oil pan bolts are pre-coated with adhesive. If these bolts are reused, CVT fluid may leak. Be sure to replace the oil pan bolts with new ones whenever they are removed.

Scheme 77

Scheme 77: Removal
Scheme 77: Removal

Scheme 78

Scheme 78
Scheme 78
  1. Hoist vehicle.
  2. Remove left side engine undercover.
  3. Drain CVT fluid, see «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000) .
  4. Remove CVT oil pan (1) and oil pan gasket (2).
  5. Remove oil strainer (1), if necessary.

Reference: CVT OIL PAN AND OIL STRAINER INSPECTION

Reverse removal procedure noting the following points.

  1. Apply CVT fluid to new O-ring of oil strainer.
  2. Install oil strainer bolts noting the length and tighten them to specified torque.

Tightening torque

CVT oil pan bolt* (a): 7.9 N.m (0.81 kg-m, 6.0 lbf-ft)

Scheme 79

Scheme 79
Scheme 79

Scheme 80

Scheme 80
Scheme 80
  1. Clean matching surface of CVT case and CVT oil pan. Remove CVT fluid, old gasket and dust from matching surface.
  2. Use new gasket (1) for CVT oil pan (2).
  3. Align the dowel pin (3) of CVT case and the dowel pin hole (4) of CVT oil pan, and then install CVT oil pan.
  4. Tighten CVT oil pan bolts in numerical order ("1" - "18") evenly and gradually to specified torque. CAUTION: Be sure to use new oil pan bolts pre-coated with adhesive. Otherwise, bolts may loosen. Tightening torque CVT oil pan bolt* (a): 7.9 N.m (0.81 kg-m, 6.0 lbf-ft) Replenish CVT fluid, see «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000) . Check CVT fluid level, see «CVT FLUID CHECK»(ref-585587-S11373563342013111200000) . Check for CVT fluid leakage after warming up CVT.

Reference: TRANSMISSION RANGE SENSOR INSPECTION

CAUTIONIf the transmission range sensor is removed and reinstalled, a gap will be created between the sensor and the manual select lever shaft. This gap prevents the transmission range sensor from correctly identifying the selected transaxle range. Do not reuse any removed transmission range sensor.

Reverse removal procedure noting the following points.

  1. Adjust select cable, see «SELECT CABLE ADJUSTMENT»(ref-585587-S39051494732013111200000) .
  2. Use new transmission range sensor (4).
  3. Use new washer (1).
  4. Adjust transmission range sensor, see «TRANSMISSION RANGE SENSOR ADJUSTMENT»(ref-585587-S30277369112013111200000) .
  5. Tighten transmission range sensor bolts (2) and new manual select lever nut (3) to specified torque.

Tightening torque

Transmission range sensor bolt (a): 5.9 N.m (0.60 kg-m, 4.5 lbf-ft)

Manual select lever nut (b): 17 N.m (1.7 kg-m, 12.5 lbf-ft)

Scheme 81

Scheme 81
Scheme 81
  1. Disconnect negative (-) cable at battery.
  2. Remove air cleaner inlet hose, see «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S10930133882013111200000) .
  3. Disconnect connector (1) from primary pulley speed sensor.
  4. Remove primary pulley speed sensor (3) from transaxle by removing primary pulley speed sensor bolt (2).

Reference: PRIMARY PULLEY SPEED SENSOR AND SECONDARY PULLEY SPEED SENSOR INSPECTION

Reverse removal procedure noting the following points.

Scheme 82

Scheme 82: Installation
Scheme 82: Installation
  1. Apply CVT fluid to new O-ring of sensor.
  2. Tighten primary pulley speed sensor bolt to specified torque. Tightening torque Primary pulley speed sensor bolt (a): 5.9 N.m (0.60 kg-m, 4.5 lbf-ft)
  3. Connect connector and fix wire harness with clamp securely.

Secondary Pulley Speed Sensor Removal and Installation

CAUTIONBe careful not to drop washer when removing and installing secondary pulley speed sensor.
  1. Disconnect negative (-) cable at battery.
  2. Remove air cleaner assembly, see «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S10930133882013111200000) .
  3. Disconnect connector from secondary pulley speed sensor.
  4. Remove secondary pulley speed sensor (2) from transaxle by removing secondary pulley speed sensor bolt (1).

Reference: PRIMARY PULLEY SPEED SENSOR AND SECONDARY PULLEY SPEED SENSOR INSPECTION

Reverse removal procedure noting the following points.

Scheme 83

Scheme 83: Installation
Scheme 83: Installation
  1. Apply CVT fluid to new O-ring of sensor.
  2. Tighten secondary pulley speed sensor bolt to specified torque. Tightening torque Secondary pulley speed sensor bolt (a): 5.9 N.m (0.60 kg-m, 4.5 lbf-ft)
  3. Connect connector and fix wire harness with clamp securely.

Input Shaft Oil Seal Replacement

CAUTIONContamination and rough handling of the transaxle may cause premature wear, functional problems and damage to parts. Thoroughly clean the exterior of the transaxle before disassembling it. Keep workbench, tools and hands clean during the service operation. Use special care when handling aluminum parts so as not to damage them. Keep removed parts free of dust and other foreign matter.

Scheme 84

Scheme 84
Scheme 84

Scheme 85

Scheme 85
Scheme 85

Scheme 86

Scheme 86
Scheme 86

Scheme 87

Scheme 87
Scheme 87
  1. Dismount CVT assembly, see «CVT ASSEMBLY DISMOUNTING AND REMOUNTING»(ref-585587-S29986396022013111200000) .
  2. Remove torque converter (1) from CVT assembly.
  3. Remove input shaft oil seal (1) by using flat-end screwdriver or the like (2). CAUTION: CVT fluid may leak if the press-fitted part of the oil seal on the transaxle housing is damaged with the flat-head rod. Use the flat-head rod very carefully so that it will not scratch the press-fitted part of the oil seal.
  4. Apply grease to new input shaft oil seal lip. : Grease 99000-25030 (SUZUKI Super Grease C)
  5. Using special tool, install input shaft oil seal (1) at specified position as shown in figure. Special Tool 09914-87910 09922-59420 Input shaft oil seal installing depth "a": 0.5 - 1.5 mm (0.020 - 0.059 in.)
  6. Install torque converter (3) noting the following points. CAUTION: Failure to take proper precautions before and during installation of the torque converter can cause damage to other parts. Check the pump hub portion carefully before installing the torque converter. A torque converter having nicks, burrs or other damage at the pump hub portion will damage the oil seal, causing oil leaks. If the hub portion is damaged in any way, replace the torque converter. Do not drop the torque converter when installing it. If you drop the torque converter, it will damage the oil pump gear and cause a critical defect in the operation of the CVT. Install torque converter aligning projection (1) of torque converter and grooves (2) of oil pump. Install torque converter, using care not to damage input shaft oil seal. After installing torque converter (3), check that distance "a" is within specification. Torque converter installing position "a": More than 17.0 mm (0.669 in.) Check torque converter for smooth rotation.
  7. Remount CVT assembly, see «CVT ASSEMBLY DISMOUNTING AND REMOUNTING»(ref-585587-S29986396022013111200000) .
  8. Refill CVT fluid, see «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000)
  9. Check CVT fluid level, see «CVT FLUID CHECK»(ref-585587-S11373563342013111200000) .
  10. After installation, check for CVT fluid leakage at each connection.

Scheme 88

Scheme 88: Differential Side Oil Seal Replacement
Scheme 88: Differential Side Oil Seal Replacement

Scheme 89

Scheme 89
Scheme 89

Scheme 90

Scheme 90
Scheme 90
  1. Hoist vehicle and drain CVT fluid, see «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000) .
  2. Remove drive shaft joints from differential gear of transaxle. Refer to «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION:FRONT»(ref-585617-S17552051012013111200000) for procedure to disconnect drive shaft joints. NOTE: For differential side oil seal removal, it is not necessary to remove drive shafts from steering knuckle.
  3. Remove differential side oil seal (1) using special tool. Special Tool 09913-50121 CAUTION: CVT fluid may leak if the press-fitted part of the oil seal on the transaxle housing is damaged with the special tool. Use the special tool very carefully so that it will not scratch the press-fitted part of the oil seal.
  4. Apply grease to new differential side oil seal lip. : Grease 99000-25030 (SUZUKI Super Grease C)
  5. Using special tool, install new differential side oil seals (1) at specified position as shown in figure. Special Tool 09925-17910 09924-74510 Differential side oil seal installing depth Right side "a": 9.2 - 10.2 mm (0.363 - 0.401 in.) (2WD model) Left side "b": 1.3 - 2.3 mm (0.052 - 0.090 in.)
  6. Install drive shaft, see «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION: FRONT»(ref-585617-S17552051012013111200000) .
  7. Replenish CVT fluid, see «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000) .
  8. Check CVT fluid level, see «CVT FLUID CHECK»(ref-585587-S11373563342013111200000) .
  9. Check for fluid leakage.

Scheme 91

Scheme 91: CVT Fluid Cooler Components
Scheme 91: CVT Fluid Cooler Components

CVT Fluid Cooler Hoses Replacement

Rubber hoses for CVT fluid cooler should be checked at specified interval. If replacing them, be sure to note the following points.

Scheme 92

Scheme 92: CVT Fluid Cooler Hoses Replacement
Scheme 92: CVT Fluid Cooler Hoses Replacement

Scheme 93

Scheme 93
Scheme 93
  1. Remove front bumper, if necessary. See «FRONT BUMPER REMOVAL AND INSTALLATION»(ref-585603-S29130228662013111200000) .
  2. Replace clamps with new ones at the same time.
  3. Clamp new clamps securely.

Scheme 94

Scheme 94: Removal
Scheme 94: Removal
  1. Disconnect negative (-) cable at battery.
  2. Disconnect CVT fluid cooler No. 1 hose (2) and No. 3 hose (1).
  3. Remove CVT fluid cooler bolts, and then remove CVT fluid cooler (3).
  4. Remove fluid cooler bracket (4), if necessary.

Reverse removal procedure noting the following points.

Scheme 95

Scheme 95: Installation
Scheme 95: Installation

Scheme 96

Scheme 96
Scheme 96
  1. Tighten CVT fluid cooler bracket bolts, if removed. Tightening torque CVT fluid cooler bracket bolt No. 1 (a): 20 N.m (2.0 kg-m, 15.0 lbf-ft) CVT fluid cooler bracket bolt No. 2 (b): 85 N.m (8.7 kg-m, 63.0 lbf-ft)
  2. Tighten CVT fluid cooler bolts (1) to specified torque. Tightening torque CVT fluid cooler bolt (a): 13 N.m (1.3 kg-m, 9.5 lbf-ft)
  3. Clamp new clamps securely.
  4. Refill CVT fluid, see «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000) .
  5. Check CVT fluid level, see «CVT FLUID CHECK»(ref-585587-S11373563342013111200000) .
  6. After installation, check CVT fluid leakage each connection.

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