CO-46
[VQ]
WATER PUMP
WATE R P U M PPFP:21020
Removal and InstallationBBS004X6
CAUTION:
When removing water pump assembly, be careful not to get engine coolant on drive belts.
Water pump cannot be disassembled and should be replaced as a unit.
After installing water pump, connect hose and clamp securely, then check for leaks using radiator
cap tester (commercial service tool) and radiator cap tester adapter [SST: EG17650301].
REMOVAL
1. Remove engine cover. Refer to EM-133, "INTAKE MANIFOLD COLLECTOR" .
2. Remove air duct (inlet). Refer to EM-131, "
AIR CLEANER AND AIR DUCT" .
3. Remove undercover and splash guard (RH).
4. Drain engine coolant from radiator. Refer to CO-34, "
Changing Engine Coolant" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
5. Remove drive belts. Refer to EM-128, "
DRIVE BELTS" .
6. Remove reservoir tank of radiator. Refer to CO-37, "
RADIATOR" .
7. Remove reservoir tank of power steering oil pump with piping connected, and move it to aside.
8. Support oil pan (lower) bottom with transmission jack.
9. Remove engine mounting insulator (RH) and engine mounting bracket (RH). Refer to EM-223, "
ENGINE
ASSEMBLY" .
1. Water pump 2. Timing chain tensioner (primary) 3. Chain tensioner cover
4. Water drain plug (front) 5. Water pump cover 6. O-ring
7. O-ring
PBIC2515E
WATER PUMP
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10. Remove water drain plug (front) on water pump side of cylinder
block to drain engine coolant from engine inside.
11. Remove chain tensioner cover and water pump cover from front timing chain case.
U s e s e a l c u t t e r [ S S T: K V 1 0 1111 0 0 ] o r e q u i v a l e n t t o o l t o c u t l i q u i d g a s k e t f o r r e m o v e .
12. Remove idler pulley and bracket. Refer to EM-173, "
TIMING CHAIN" .
13. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt.
b. Loosen upper mounting bolt slowly, and then turn timing chain
tensioner (primary) on the mounting bolt so that plunger is fully
expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body
of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain ten-
sioner (primary).
CAUTION:
Be careful not to drop mounting bolts inside timing chain
case.
14. Remove water pump as follows:
a. Remove three water pump mounting bolts. Secure a gap
between water pump gear and timing chain, by turning crank-
shaft pulley counterclockwise until timing chain looseness on
water pump sprocket becomes maximum.
b. Screw M8 bolts [pitch: 1.25 mm (0.049 in) length: Approx. 50
mm (1.97 in)] into water pumps upper and lower mounting bolt
holes until they reach timing chain case. Then, alternately
tighten each bolt for a half turn, and pull out water pump.
CAUTION:
Pull straight out while preventing vane from contacting
socket in installation area.
Remove water pump without causing sprocket to contact
timing chain.
c. Remove M8 bolts and O-rings from water pump.
CAUTION:
Do not disassemble water pump.
INSPECTION AFTER REMOVAL
Check for badly rusted or corroded water pump body assembly.
PBIC2516E
PBIC3562E
PBIC1193E
JLC357B
CO-48
[VQ]
WATER PUMP
Check for rough operation due to excessive end play.
Replace water pump, if necessary.
INSTALLATION
1. Install new O-rings to water pump.
Apply engine oil and engine coolant to O-rings as shown in
the figure.
Locate O-ring with white paint mark to engine front side.
2. Install water pump.
CAUTION:
Do not allow timing chain case to nip O-rings when install-
ing water pump.
Make sure that timing chain and water pump sprocket are
engaged.
Insert water pump by tightening mounting bolts alternately
and evenly.
3. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger.
NOTE:
Plunger stopper tab and lever are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin through hole of lever into ten-
sioner body hole.
The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition.
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
SLC943A
PBIC1397E
SLC031B
PBIC3568E
WATER PUMP
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e. Install timing chain tensioner (primary).
Remove any dirt and foreign materials completely from the
back and the mounting surfaces of timing chain tensioner (pri-
mary).
f. Pull out stopper pin after installing, and then release plunger.
g. Make sure again that timing chain and water pump sprocket are
engaged.
4. Install chain tensioner cover and water pump cover as follows:
a. Before installing, remove all traces of old liquid gasket from mat-
ing surface of water pump cover and chain tensioner cover
using scraper. Also remove traces of old liquid gasket from the
mating surface of front timing chain case.
b. Apply a continuous bead of liquid gasket with tube presser [SST:
WS39930000] to mating surface of chain tensioner cover and
water pump cover.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
Attaching should be done within 5 minutes after coating.
c. Tighten mounting bolts.
5. Install water drain plug (front) on water pump side of cylinder block.
Apply liquid gasket to the thread of water drain plug (front).
Use Genuine Liquid Gasket or equivalent.
6. Install in the reverse order of removal in this step.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may gen-
erate a pounding noise during and just after engine start. However, this does not indicate an unusualness.
Noise will stop after hydraulic pressure rises.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant using radiator cap tester adapter [SST: EG17650301] and radiator cap
tester (commercial service tool). Refer to CO-34, "
LEAK CHECK" .
Start and warm up engine. Visually check if there is no leaks of engine coolant.
PBIC3569E
SLC446B
PBIC2650E
WATER INLET AND THERMOSTAT ASSEMBLY
CO-51
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INSPECTION AFTER REMOVAL
1. Check valve seating condition at ordinary room temperature. It should seat tightly.
2. Check valve operation.
If the malfunctioning condition, when valve seating at ordinary
room temperature, or measured values are out of the standard,
replace water inlet and thermostat assembly.
INSTALLATION
Note the following, and install in the reverse order of removal.
Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant using radiator cap tester adapter [SST: EG17650301] and radiator cap
tester (commercial service tool). Refer to CO-34, "
LEAK CHECK" .
Start and warm up engine. Visually check if there is no leaks of engine coolant.
Thermostat Standard
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Maximum valve lift 8.6 mm / 95°C (0.339 in / 203°F)
Valve closing temperature 77°C (171°F)
SLC949A
WATER OUTLET AND WATER PIPING
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7. Remove engine coolant temperature sensor as necessary.
CAUTION:
Be careful not to damage engine coolant temperature sensor.
8. Remove water outlet, heater pipe, water bypass pipe and water connector.
INSTALLATION
Note the following, and install in the reverse order of removal.
Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
When inserting water bypass pipe and heater pipe into water connector, apply neutral detergent to O-ring.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant using radiator cap tester adapter [SST: EG17650301] and radiator cap
tester (commercial service tool). Refer to CO-34, "
LEAK CHECK" .
Start and warm up engine. Visually check if there is no leaks of engine coolant.
CVT-1
CVT
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION CVT
A
B
CVT
CVT
INDEX FOR DTC ........................................................ 6
Alphabetical Index .................................................... 6
DTC No. Index ......................................................... 7
PRECAUTIONS .......................................................... 8
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 8
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect .......................................... 8
OPERATION PROCEDURE ................................. 8
Precautions for TCM and CVT Assembly Replace-
ment ......................................................................... 9
EEPROM ERASING PATTERNS .......................... 9
METHOD FOR ERASING THE EEPROM IN THE
TCM ...................................................................... 9
METHOD FOR WRITING DATA FROM THE
ROM ASSEMBLY IN THE TRANSAXLE .............. 9
CHECK METHOD ................................................. 9
Removal and Installation Procedure for CVT Unit
Connector ............................................................... 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
Precautions ............................................................. 11
PREPARATION ......................................................... 12
Special Service Tools ............................................. 12
Commercial Service Tools ...................................... 12
CVT FLUID ............................................................... 13
Checking CVT Fluid ............................................... 13
Changing CVT Fluid ............................................... 14
CVT SYSTEM ........................................................... 15
Cross-Sectional View - RE0F09A .......................... 15
Control System ....................................................... 16
Hydraulic Control System ....................................... 17
TCM Function ......................................................... 18
CONTROL SYSTEM OUTLINE .......................... 18
CONTROL SYSTEM DIAGRAM ......................... 18
CAN Communication .............................................. 19
SYSTEM DESCRIPTION .................................... 19
Input/Output Signal of TCM .................................... 19Line Pressure and Secondary Pressure Control .... 20
NORMAL CONTROL .......................................... 20
FEEDBACK CONTROL ...................................... 20
Shift Control ............................................................ 20
“D” POSITION ..................................................... 21
“M” POSITION ..................................................... 21
DOWNHILL ENGINE BRAKE CONTROL (AUTO
ENGINE BRAKE CONTROL) .............................. 21
ACCELERATION CONTROL .............................. 21
Lock-up and Select Control .................................... 21
TORQUE CONVERTER CLUTCH AND SELECT
CONTROL VALVE CONTROL ............................ 22
Control Valve .......................................................... 23
FUNCTION OF CONTROL VALVE ..................... 23
TROUBLE DIAGNOSIS ............................................ 24
DTC Inspection Priority Chart ................................. 24
Fail-safe .................................................................. 24
FAIL-SAFE FUNCTION ....................................... 24
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ...................................................... 25
INTRODUCTION ................................................. 25
WORK FLOW ...................................................... 26
DIAGNOSTIC WORKSHEET .............................. 27
CVT Electrical Parts Location ................................. 30
Circuit Diagram ....................................................... 31
Inspections Before Trouble Diagnosis .................... 32
CVT FLUID CHECK ............................................ 32
STALL TEST ........................................................ 32
LINE PRESSURE TEST ..................................... 33
Road Test ............................................................... 35
DESCRIPTION .................................................... 35
CONSULT-II OPERATION PROCEDURE ........... 35
Check Before Engine Is Started ............................. 37
Check at Idle ........................................................... 37
Cruise Test .............................................................. 38
Vehicle Speed at Which Gear Shifting Occurs ....... 40
TCM Input/Output Signal Reference Values ........... 40
TCM TERMINAL CONNECTOR LAYOUT .......... 40
CVT-4 On Board Diagnosis Logic ....................................143
Possible Cause .....................................................143
DTC Confirmation Procedure ...............................143
WITH CONSULT-II ............................................143
Diagnostic Procedure ...........................................144
DTC P1726 ELECTRIC THROTTLE CONTROL
SYSTEM ..................................................................145
Description ............................................................145
On Board Diagnosis Logic ....................................145
Possible Cause .....................................................145
DTC Confirmation Procedure ...............................145
WITH CONSULT-II ............................................145
Diagnostic Procedure ...........................................146
DTC P1740 LOCK-UP SELECT SOLENOID VALVE
CIRCUIT ..................................................................147
Description ............................................................147
CONSULT-II Reference Value ..............................147
On Board Diagnosis Logic ....................................147
Possible Cause .....................................................147
DTC Confirmation Procedure ...............................147
WITH CONSULT-II ............................................147
Wiring Diagram — CVT — L/USSV ......................148
Diagnostic Procedure ...........................................149
Component Inspection ..........................................151
LOCK-UP SELECT SOLENOID VALVE ............151
DTC P1745 LINE PRESSURE CONTROL .............152
Description ............................................................152
On Board Diagnosis Logic ....................................152
Possible Cause .....................................................152
DTC Confirmation Procedure ...............................152
WITH CONSULT-II ............................................152
Diagnostic Procedure ...........................................152
DTC P1777 STEP MOTOR - CIRCUIT ...................153
Description ............................................................153
CONSULT-II Reference Value ..............................153
On Board Diagnosis Logic ....................................153
Possible Cause .....................................................153
DTC Confirmation Procedure ...............................153
WITH CONSULT-II ............................................153
Wiring Diagram — CVT — STM ...........................154
Diagnostic Procedure ...........................................155
Component Inspection ..........................................156
STEP MOTOR ...................................................156
DTC P1778 STEP MOTOR - FUNCTION ...............157
Description ............................................................157
CONSULT-II Reference Value ..............................157
On Board Diagnosis Logic ....................................157
Possible Cause .....................................................157
DTC Confirmation Procedure ...............................157
WITH CONSULT-II ............................................157
Diagnostic Procedure ...........................................158
CVT INDICATOR CIRCUIT .....................................159
Description ............................................................159
CONSULT-II Reference Value ..............................159
Diagnostic Procedure ...........................................159
CVT INDICATOR SYMPTOM CHART ...............159
TROUBLE DIAGNOSIS FOR SYMPTOMS ............160Wiring Diagram — CVT — NONDTC ...................160
CVT Indicator Lamp Does Not Come On ..............164
SYMPTOM: ........................................................164
DIAGNOSTIC PROCEDURE .............................164
Engine Cannot Be Started in “P” or “N” Position ...165
SYMPTOM: ........................................................165
DIAGNOSTIC PROCEDURE .............................165
In “P” Position, Vehicle Moves Forward or Backward
When Pushed .......................................................166
SYMPTOM: ........................................................166
DIAGNOSTIC PROCEDURE .............................166
In “N” Position, Vehicle Moves ..............................166
SYMPTOM: ........................................................166
DIAGNOSTIC PROCEDURE .............................166
Large Shock “N” → “R” Position ...........................167
SYMPTOM: ........................................................167
DIAGNOSTIC PROCEDURE .............................167
Vehicle Does Not Creep Backward in “R” Position .168
SYMPTOM: ........................................................168
DIAGNOSTIC PROCEDURE .............................168
Vehicle Does Not Creep Forward in “D” Position ..169
SYMPTOM: ........................................................169
DIAGNOSTIC PROCEDURE .............................169
CVT Does Not Shift ...............................................170
SYMPTOM: ........................................................170
DIAGNOSTIC PROCEDURE .............................170
Cannot Be Changed to Manual Mode ...................171
SYMPTOM: ........................................................171
DIAGNOSTIC PROCEDURE .............................171
CVT Does Not Shift in Manual Mode ....................171
SYMPTOM: ........................................................171
DIAGNOSTIC PROCEDURE .............................171
Vehicle Does Not Decelerate by Engine Brake .....172
SYMPTOM: ........................................................172
DIAGNOSTIC PROCEDURE .............................172
TRANSMISSION CONTROL MODULE ..................174
Removal and Installation .......................................174
COMPONENTS .................................................174
REMOVAL ..........................................................174
INSTALLATION ..................................................175
SHIFT CONTROL SYSTEM ....................................176
Removal and Installation .......................................176
CONTROL DEVICE COMPONENTS ................176
CONTROL CABLE COMPONENTS ..................177
REMOVAL ..........................................................177
INSTALLATION ..................................................178
Adjustment of CVT Position ..................................178
Checking of CVT Position .....................................179
CVT SHIFT LOCK SYSTEM ...................................180
Description ............................................................180
Shift Lock System Electrical Parts Location ..........180
Wiring Diagram — CVT — SHIFT ........................181
Shift Lock Control Unit Reference Values .............183
SHIFT LOCK HARNESS CONNECTOR TERMI-
NALS LAYOUT ..................................................183
SHIFT LOCK CONTROL UNIT INSPECTION