OVERHAUL
AT-251
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10. O-ring 11. Turbine revolution sensor (power
train revolution sensor)12. Bracket
13. Anchor end pin 14. Lock nut 15. Transaxle case
16. Brake band 17. Bearing retainer 18. Seal ring
19. Radial needle bearing 20. Snap ring 21. Reduction pinion gear
22. Reduction pinion gear bearing inner
race23. Reduction pinion gear bearing outer
race24. Strut
25. O-ring 26. O-ring 27. Servo release accumulator piston
28. O-ring 29. Return spring 30. Control valve assembly
31. Oil pan gasket 32. Drain plug gasket 33. Drain plug
34. Magnet 35. Oil pan 36. Oil pan fitting bolt
37. Low & reverse brake tube 38. Oil sleeve 39. O-ring
40. Snap ring 41. O-ring 42. N-D accumulator piston
43. Return spring 44. Lip seal 45. Parking rod
46. Retaining pin 47. Manual shaft oil seal 48. Detent spring
49. Manual shaft 50. Retaining pin 51. Manual plate
52. Parking rod plate 53. O/D servo piston 54. O/D servo piston retainer
55. O/D servo piston retainer fitting bolt 56. O-ring 57. D-ring
58. Servo piston retainer 59. O-ring 60. E-ring
61. Spring retainer 62. O/D servo return spring 63. D-ring
64. Band servo piston 65. Band servo thrust washer 66. Band servo piston stem
67. 2nd servo return spring 68. Parking pawl 69. Parking shaft
70. Return spring 71. Paring pawl spacer 72. PNP switch
73. Idler gear bearing 74. Idler gear 75. Idler gear lock nut
76. Reduction pinion gear adjusting
shim77. Output shaft adjusting shim 78. Side cover
Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-10, "
Components" .
However, refer to the following symbol for others.
: Apply locking sealant (Loctite #518).
BRAKE FLUID
BR-9
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BRAKE FLUIDPFP:KN100
Checking Brake Fluid LevelBFS000BI
Make sure that a brake fluid level in reservoir tank is within the
standard (between MAX and MIN lines).
Visually check around reservoir tank for fluid leakage.
If fluid level is excessively low, check brake system for leakage.
Release parking brake pedal and see if brake warning lamp
goes off. If not, check brake system for fluid leakage.
Drain and RefillBFS000BJ
CAUTION:
Refill with new brake fluid “DOT 3 or DOT 4”.
Do not reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of the body, immediately wipe off them and wash it away with water
immediately.
Before working, turn ignition switch OFF and disconnect electrical connector of ABS actuator and
electric unit (control unit) or battery cables.
1. Connect a vinyl tube to bleed valve.
2. Depress brake pedal, loosen bleed valve, and gradually remove
brake fluid.
3. Clean inside of reservoir tank, and refill with new brake fluid.
4. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
brake pedal until it stops. Tighten bleed valve. Release brake
pedal. Repeat this process a few time, them pause to and new
brake fluid to master cylinder. Continue until new brake fluid
flows out.
5. Bleed air. Refer to BR-10, "
Bleeding Brake System" .
SFIA2632E
BRA0007D
PFIA0403J
TROUBLE DIAGNOSIS
BRC-23
[ABS]
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INSPECTION OF ABS WARNING LAMP AND BRAKE WARNING LAMP
×: ON —: OFF
Note 1: The brake warning lamp turns on during parking brake operation (when switch is on) and brake fluid level sensor operation
(insufficient brake fluid).
Note 2: Turns off after engine start
1. Make sure that when the ignition switch is turned ON, the ABS warning lamp turns ON for approximately 1
second, and that the brake warning lamp turns on. If they do not turn on, perform CAN communication
system diagnosis. Refer to BRC-29, "
CAN Communication System" .
2. Check if the ABS warning lamp turns off approximately 1 second after the ignition switch is turned ON,
and if the brake warning lamp turns off after the engine is started. If they do not turn off, perform self-diag-
nosis.
3. If ABS warning lamp has not turned off 10 seconds after the engine has been started, perform self-diagno-
sis of the ABS actuator and electric unit (control unit).
4. Always erase the self-diagnostic results after completing self-diagnosis. Refer to BRC-17, "
ERASE MEM-
ORY" .
NOTE:
Brake warning lamp turns on during parking brake operation (when switch is ON) and brake fluid level
sensor operation (insufficient brake fluid).
Condition ABS warning lampBrake warning lamp
(Note 1)Remarks
Ignition switch OFF — — —
For a while after ignition switch is turned ON×× (Note 2) —
In a while after ignition switch is turned ON
(When system is normal)—× (Note 2)Turns OFF 2 seconds after ignition
switch is turned ON.
ABS error×— When there is an ABS actuator and elec-
tric unit (control unit) error (power or
ground malfunction). EBD error××
BRC-66
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Basic InspectionBFS000E7
BRAKE FLUID LEVEL, LEAKAGE AND BRAKE PAD
1. Check fluid level in the brake fluid reservoir tank. Refill the brake fluid if fluid level is low.
2. Check the area around the brake piping and actuator for leakage. If leakage or oozing is detected, check
as follows:
If ABS actuator and electric unit (control unit) connections are loose, tighten connections to the speci-
fied torque. Check again for leakage, and make sure that there is no fluid leakage.
If the flare nuts at the connections and the threads of the actuator are damaged, replace the damaged
parts. Then check again for leakage, and make sure that there is no fluid leak.
If leakage or oozing is detected on parts other than actuator connections, wipe with a clean cloth and
check again. If there is still leakage or oozing, replace the damaged part.
If leakage or oozing is detected on actuator body, wipe with a clean cloth and check again. If there is
still leakage or oozing, replace ABS actuator and electric unit (control unit).
CAUTION:
ABS actuator and electric unit (control unit) cannot be disassembled.
3. Check brake pad for wear. Refer to BR-26, "
PAD WEAR INSPECTION" , “FRONT DISC BRAKE”, BR-33,
"PAD WEAR INSPECTION" , “REAR DISC BRAKE”.
POWER SUPPLY CIRCUIT TERMINAL LOOSENESS AND BATTERY
Check battery for looseness on the battery positive/negative terminal and ground connection. Also make sure
that battery voltage does not drop.
INSPECTION OF ABS WARNING LAMP, BRAKE WARNING LAMP, VDC OFF INDICATOR LAMP,
AND SLIP INDICATOR LAMP
×: ON –: OFF
Note 1: Turns off after engine start
Note 2: The brake warning lamp turns on during parking brake operation (when switch is on) and brake fluid level sensor operation
(insufficient brake fluid).
1. Make sure that when the ignition switch is turned ON, the ABS warning lamp, VDC OFF indicator lamp
(when VDC OFF switch is off), and SLIP indicator lamp turn on for approximately 1 second, and that the
brake warning lamp turns on. If they do not turn on, perform CAN communication system diagnosis. Refer
to BRC-81, "
CAN Communication System" . Be sure to check VDC OFF switch before checking VDC OFF
indicator lamp. Refer to BRC-81, "
VDC OFF SWITCH" . Check combination meter if there is no malfunc-
tion in CAN communication system and VDC OFF switch. Refer to DI-4, "
COMBINATION METERS" .
2. Check if the ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp turn off approximately
1 second after the ignition switch is turned ON, and if the brake warning lamp turns off after the engine is
started. If they do not turn off, perform self-diagnosis.
ConditionABS warning
lampBrake warning
lamp (Note 2)VDC OFF indica-
tor lampSLIP indicator
lampRemarks
Ignition switch OFF ———— —
For a while after ignition
switch is turned ON×× (Note 1)××—
In a while after ignition
switch is turned ON
(System normal)—× (Note 1) — —Turns OFF 2 seconds
after ignition switch is
turned ON.
When the VDC OFF
switch is turned ON.
(VDC function OFF)——×——
VDC/TCS/ABS error×—××When there is an
ABS actuator and
electric unit (control
unit) error (power
ground or system
malfunction).
When VDC/TCS is not func-
tioning normally.——××—
EBD error××××—
TROUBLE DIAGNOSIS
BRC-67
[VDC/TCS/ABS]
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3. With the engine running, make sure that the VDC OFF indicator lamp turns on and off when the
VDC OFF switch turns ON and OFF. If it does not operate in accordance with the switch, check the
VDC OFF switch system. Refer to BRC-81, "
VDC OFF SWITCH" .
4. Perform self-diagnosis of ABS actuator and electric unit (control unit) if ABS warning lamp, VDC OFF indi-
cator lamp, and SLIP indicator lamp do not turn off 10 seconds after engine is started.
5. Always erase self-diagnostic results after completing self-diagnosis. Refer to BRC-58, "
ERASE MEM-
ORY" .
NOTE:
Brake warning lamp turns on during parking brake operation (when switch is ON) and brake fluid level
sensor operation (insufficient brake fluid).
CVT FLUID
CVT-13
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CVT
CVT FLUIDPFP:KLE50
Checking CVT FluidBCS001FX
Fluid level should be checked with the fluid warmed up to 50 to 80°C (122 to 176°F). The fluid level check pro-
cedure is as follows:
1. Check for fluid leakage.
2. With the engine warmed up, drive the vehicle in an urban area.
When ambient temperature is 20°C (68°F), it takes about 10
minutes for the CVT fluid to warm up to 50 to 80°C (122 to
176°F).
3. Park the vehicle on a level surface.
4. Apply parking brake firmly.
5. With engine at idle, while depressing brake pedal, move shift
selector throughout the entire shift range.
6. Pull out the CVT fluid level gauge from the CVT fluid charging
pipe after pressing the tab on the CVT fluid level gauge to
release the lock.
7. Wipe fluid off the CVT fluid level gauge. Insert the CVT fluid
level gauge rotating 180° from the originally installed position,
then securely push the CVT fluid level gauge until it meets the
top end of the CVT fluid charging pipe.
CAUTION:
When wiping away the CVT fluid level gauge, always use
lint-free paper, not a cloth rag.
8. Place the selector lever in “P” or “N” and make sure the fluid
level is within the specified range.
CAUTION:
When reinstalling CVT fluid level gauge, insert it into the
CVT fluid charging pipe and rotate it to the original installa-
tion position until it is securely locked.
SMA146B
SCIA1933E
SCIA1931E
SCIA1932E
CVT SYSTEM
CVT-15
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CVT
CVT SYSTEMPFP:31036
Cross-Sectional View - RE0F09ABCS001FZ
1. Converter housing 2. Oil pump 3. Forward clutch
4. Reverse brake 5. Planetary carrier 6. Primary pulley
7. Steel belt 8. Sun gear 9. Side cover
10. Internal gear 11. Secondary pulley 12. Final gear
13. Differential case 14. Idler gear 15. Reduction gear
16. Taper roller bearing 17. Output gear 18. Parking gear
19. Input shaft 20. Torque converter
SCIA7859E
CVT-32
TROUBLE DIAGNOSIS
Inspections Before Trouble DiagnosisBCS001GJ
CVT FLUID CHECK
Fluid Leakage and Fluid Level Check
Inspect for fluid leakage and check the fluid level. Refer to CVT-13, "Checking CVT Fluid" .
Fluid Condition Check
Inspect the fluid condition.
STALL TEST
Stall Test Procedure
1. Inspect the amount of engine oil. Replenish the engine oil if necessary.
2. Drive for about 10 minutes to warm up the vehicle so that the
CVT fluid temperature is 50 to 80°C (122 to 176°F). Inspect the
amount of CVT fluid. Replenish if necessary.
3. Securely engage the parking brake so that the tires do not turn.
4. Install a tachometer where it can be seen by driver during test.
It is good practice to mark the point of specified engine
rpm on indicator.
5. Start engine, apply foot brake, and place selector lever in “D”
position.
6. While holding down the foot brake, gradually press down the
accelerator pedal.
7. Quickly read off the stall speed, and then quickly remove your
foot from the accelerator pedal.
CAUTION:
Do not hold down the accelerator pedal for more than 5 sec-
onds during this test.
8. Move the selector lever to the “N” position.
9. Cool down the CVT fluid.
Fluid status Conceivable cause Required operation
Varnished (viscous
varnish state)Clutch, brake
scorchedReplace the CVT fluid and check
the CVT main unit and the vehicle
for malfunctions (wire harnesses,
cooler pipes, etc.)
Milky white or
cloudyWater in the fluidReplace the CVT fluid and check for
places where water is getting in.
Large amount of
metal powder mixed
inUnusual wear of
sliding parts within
CVTReplace the CVT fluid and check for
improper operation of the CVT.
SAT638A
SAT647B
SCIA7463E
Stall speed: 2,700 - 3,250 rpm
SAT514G