Continuously Variable Transaxle (Cvt): Removal & Installation Suzuki SX4 I рестайлинг

Removal

1. Remove console box. See «CONSOLE BOX COMPONENTS»(ref-514561-S29435778172012112100000)
2. Disconnect adjuster case (select cable end) from select lever assembly. See «Select Cable Removal and Installation»(ref-514590-S36290591272012112100000)
3. Disconnect key interlock cable end and detach cable casing cap from select lever assembly. See «Key Interlock Cable Removal and Installation»(ref-514590-S03443345612012112100000)
4. Remove select lever assembly from floor panel.

Installation

Reverse removal procedure noting the following.

1. Tighten select lever nuts to specified torque. See «Select Lever Assembly Components»(ref-514590-S00631802602012112100000)
2. After installing select lever assembly, adjust select cable. See «Select Cable Adjustment»(ref-514590-S08324711672012112100000)

1. Remove console box See «CONSOLE BOX COMPONENTS»(ref-514561-S29435778172012112100000)
2. Disconnect connector from select lever.
3. Remove shift lock solenoid (1) using flat-head screwdriver or the like.

Reference Shift Lock Solenoid Inspection

Reverse removal procedure for installation.

Scheme 52

1. Remove console box. See «CONSOLE BOX COMPONENTS»(ref-514561-S29435778172012112100000)
2. Disconnect select lever connector (1).
3. Check for continuity between terminals at each switch position. If check result is not as specified, replace select lever assembly.

Scheme 53

1. Remove steering wheel. See «STEERING WHEEL REMOVAL AND INSTALLATION»(ref-514559-S42019703962012112100000)
2. Disconnect connectors (1) from paddle-up switch (2) and paddle-down switch (3).
3. Check for continuity between terminals of shift paddle switch connector (4). If found defective, replace shift paddle switch. Shift Paddle switch specification Release: No continuity Pull: Continuity

Scheme 54

Select Cable Removal and Installation

Reference: SELECT CABLE COMPONENTS

1. Disconnect negative cable from battery.
2. Remove air cleaner assembly. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-514568-S42483472292012112100000)
3. Remove console box. See «CONSOLE BOX COMPONENTS»(ref-514561-S29435778172012112100000)
4. Disconnect select cable from selector lever and then detach from bracket. See «Select Cable Removal and Installation»(ref-514590-S36290591272012112100000)
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.

1. Apply grease to pin and cable joint. See «Select Cable Components»(ref-514590-S03456524102012112100000) .
2. Tighten bolts to specified torque. See «Select Cable Components»(ref-514590-S03456524102012112100000)
3. Adjust selector cable. See «SELECT CABLE ADJUSTMENT»(ref-514590-S08324711672012112100000)

Reference: TRANSMISSION RANGE SENSOR INSPECTION AND ADJUSTMENT

1. Adjust select cable. See «Select Cable Adjustment»(ref-514590-S08324711672012112100000)
2. Use new washer (1).
3. Adjust transmission range sensor See «Transmission Range Sensor Inspection and Adjustment»(ref-514590-S14832650612012112100000)
4. 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 55

Scheme 56

Scheme 57

1. Apply parking brake and block wheels.
2. Turn ignition switch to "ON" position, shift select lever to "N" range.
3. Disconnect negative cable from battery.
4. Remove air cleaner assembly. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-514568-S42483472292012112100000)
5. Insert pin remover (4 mm) (1) to aligning hole on manual select lever (2) and check that the position of aligning hole on transmission range sensor (3) as shown in figure. If not, loosen transmission range sensor bolts (4) and align them.
6. Tighten transmission range sensor bolts to specified torque. Tightening torque Transmission range sensor bolt (a): 5.9 N.m (0.60 kg-m, 4.51 lbf-ft)
7. Check that engine starts with shifted select lever in "N" and "P" ranges but it does not start in "D" or "R" range. Also, check that back-up light lights in "R" range. If faulty condition cannot be corrected by adjustment, disconnect transmission range sensor connector and check that continuity exists as shown by moving manual select lever.
8. Connect negative cable to battery.
9. Check transmission range sensor for the following. Perform «"P" RANGE TEST»(ref-514590-S06142701332012112100000) . Check engine starts at "P" and "N" ranges. And check engine does not start at other than "P" and "N" ranges. Check shift position indicator (in combination meter) is consistent with select lever range. Check back-up light is turned ON only when shifting select lever to "R" range.
10. Install air cleaner assembly. See «CONSOLE BOX COMPONENTS»(ref-514561-S29435778172012112100000)

Key Interlock Cable Removal and Installation

Note. Do not bend interlock cable excessively when removing and installing it, or system will not operate correctly.

Scheme 58

Scheme 59

1. Disable air bag system. Except advanced air bag model: See «DISABLING AIR BAG SYSTEM»(ref-514550-S41301456402012112100000) Advanced air bag model: See «DISABLING AIR BAG SYSTEM»(ref-514551-S34474211252012112100000)
2. Remove steering column hole cover.
3. Remove steering column cover. See «STEERING WHEEL AND COLUMN COMPONENTS»(ref-514559-S38875079742012112100000)
4. Turn ignition switch to "ACC" position.
5. Remove knee protector plate (if equipped).
6. Pull out key interlock cable (1) from key cylinder cover (2) while pressing check hook with flat-head screwdriver (3) or the like.
7. Turn ignition switch to "LOCK" position.
8. Remove console box. See «CONSOLE BOX COMPONENTS»(ref-514561-S29435778172012112100000)
9. Detach cable end (1) from interlock cam (2) while pressing claws (3) of interlock cam boss. At this time, be careful not to cause damage to its claws. Detach cable casing cap (4) from selector bracket (5) while pressing check hook.
10. Remove interlock cable.

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Lay interlock cable to its original cabling route.
2. Turn ignition switch to "ACC" position.
3. Insert cable casing cap (1) into key cylinder cover (2) securely.
4. Pull out lock button (1) of selector side cable end (2).
5. Shift selector lever to "N" position.
6. Install cable casing cap (3) to selector bracket (4).
7. Turn ignition switch to "ACC" position and connect cable end (1) to interlock cam (2).
8. Drive lock button (5) in cable end until it locks cable expansion and contraction.
9. Check key interlock system. See «Brake and Key Interlock System Inspection»(ref-514590-S28325648392012112100000)
10. Install knee protector to steering column (if removed).
11. Install steering column cover. See «STEERING WHEEL AND COLUMN COMPONENTS»(ref-514559-S38875079742012112100000)
12. Install steering column hole cover.
13. Enable air bag system. Except advanced air bag model: See «ENABLING AIR BAG SYSTEM»(ref-514550-S18517973622012112100000) Advanced air bag model: See «ENABLING AIR BAG SYSTEM»(ref-514551-S26296054452012112100000)

Scheme 64

1. Disconnect negative cable from battery.
2. Remove air cleaner inlet hose. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-514568-S42483472292012112100000)
3. Disconnect connector (1) from primary pulley speed sensor.
4. Remove primary pulley speed sensor (2) from transaxle.

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

Reverse removal procedure noting the following.

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: 5.9 N.m (0.60 kg-m, 4.5 lbf-ft)
3. Connect connector and fix wire harness with clamp securely.

Scheme 65

1. Disconnect negative cable from battery.
2. Remove air cleaner assembly. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-514568-S42483472292012112100000)
3. Detach wire harness (1) from transaxle.
4. Remove secondary pulley speed sensor (2) from transaxle.
5. Disconnect connector from secondary pulley speed sensor.

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

Reverse removal procedure noting the following.

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: 5.9 N.m (0.60 kg-m, 4.5 lbf-ft)
3. Connect connector and fix wire harness with clamp securely.

CVT Oil Pan and Oil Strainer Removal and Installation

Scheme 66

Scheme 67

1. Disconnect negative cable from battery.
2. Lift up vehicle.
3. Drain CVT fluid, see «CVT Fluid Check»(ref-514590-S18157453952012112100000).
4. Remove CVT oil pan (1) and oil pan gasket (2).
5. Remove oil strainer (1), if necessary. (Scheme 69): Identifying Oil Strainer

Reference: CVT OIL PAN INSPECTION

Reverse removal procedure noting the following.

Scheme 68

Scheme 69

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) see scheme 78: Identifying Oil Strainer Bolts
3. Clean mating surface of transaxle case and CVT oil pan wiping CVT fluid and dust. Remove CVT fluid, old gasket and dust from mating surface.
4. Use new gasket (1) for CVT oil pan (2).
5. Align the dowel pin (3) of transaxle case and the dowel pin hole (4) of CVT oil pan, and then install CVT oil pan.
6. Tighten CVT oil pan bolts in numerical order ("1" - "18") evenly and gradually to specified torque. CAUTION: Use new CVT oil pan bolts. Tightening torque CVT oil pan bolt* (a): 7.9 N.m (0.81 kg-m, 6.0 lbf-ft)
7. Replenish CVT fluid, see «CVT Fluid Change»(ref-514590-S30269455542012112100000).
8. Check CVT fluid level, see «CVT Fluid Check»(ref-514590-S18157453952012112100000).
9. Check for CVT fluid leakage after warming up CVT.

Transmission Control Module (TCM) Removal and Installation

Scheme 70

1. Disconnect negative cable from battery.
2. Disable air bag system. Except advanced air bag model: See «DISABLING AIR BAG SYSTEM»(ref-514550-S41301456402012112100000) Advanced air bag model: See «DISABLING AIR BAG SYSTEM»(ref-514551-S34474211252012112100000)
3. Remove glove box.
4. Disconnect connectors from TCM (1).
5. Remove TCM.

Reverse removal procedure noting the following.

1. Connect TCM connectors securely.
2. Enable air bag system. Except advanced air bag model: See «ENABLING AIR BAG SYSTEM»(ref-514550-S18517973622012112100000) Advanced air bag model: See «ENABLING AIR BAG SYSTEM»(ref-514551-S26296054452012112100000)
3. After replacing TCM, perform the «TCM LEARNING CONTROL INITIALIZATION»(ref-514590-S28483768442012112100000) .

Scheme 71

1. Disconnect negative cable from battery.
2. Remove CVT relay (1), from fuse box.
3. Check that there is no continuity between terminal "c" and "d". If there is continuity, replace CVT relay.
4. Connect battery positive (+) terminal to terminal "b" of relay. Connect battery negative (-) terminal to terminal "a" of relay. Check for continuity between terminal "c" and "d". If there is no continuity when relay is connected to the battery, replace CVT relay.

Scheme 72

Scheme 73

1. Lift up vehicle and drain CVT fluid.
2. Remove drive shaft joints from differential gear of transaxle. Refer to «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-514599-S06713669722012112100000) for procedure to disconnect drive shaft joints. 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 (A): 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, drive in 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»(ref-514599-S06713669722012112100000)
7. Replenish CVT fluid. See «CVT Fluid Change»(ref-514590-S30269455542012112100000) .
8. Check CVT fluid level. See «CVT Fluid Check»(ref-514590-S18157453952012112100000) .

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.

Scheme 74

Scheme 75

1. Remove front bumper, if necessary. See «FRONT BUMPER AND REAR BUMPER COMPONENTS»(ref-514563-S19474663122012112100000)
2. Replace clamps at same time
3. Clamp clamps securely

CVT Fluid Cooler Removal and Installation

Note. Required amount of CVT fluid to refill is 0.2 liters (0.42/0.35 US/Imp. pt.) after replacing the CVT fluid cooler.

Scheme 76

1. Disconnect negative cable from battery.
2. Disconnect CVT fluid cooler No. 1 hose (1) and No. 2 hose (2).
3. Remove CVT fluid cooler bolts (5), and then remove CVT fluid cooler (3).
4. Remove fluid cooler bracket (4), if necessary.

Reverse removal procedure noting the following.

Scheme 77

Scheme 78

1. Tighten CVT fluid cooler bracket bolts in numerical order ("1" - "2") shown in figure. Tightening torque CVT fluid cooler bracket bolt* (a): 25 N.m (2.5 kg-m, 18.5 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 clamps securely.
4. Refill CVT fluid, see «CVT Fluid Change»(ref-514590-S30269455542012112100000) .
5. After installation, check CVT fluid leakage each connection.

Scheme 79

Scheme 80

Input Shaft Oil Seal Replacement

Scheme 81

Scheme 82

Scheme 83

Scheme 84

1. Dismount transaxle. See «CVT Assembly Dismounting and Remounting»(ref-514590-S24258684402012112100000)
2. Remove torque converter (1) from transaxle.
3. Remove input shaft oil seal (1) by using flat-head rod or the like (2). CAUTION: CVT fluid will 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, drive in 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. 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 transaxle. See «CVT Assembly Dismounting and Remounting»(ref-514590-S24258684402012112100000)
8. Replenish proper amount of CVT. See «CVT Fluid Change»(ref-514590-S30269455542012112100000) .
9. Check CVT fluid level. See «CVT Fluid Check»(ref-514590-S18157453952012112100000)