AT-308
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSES FOR SYMPTOMS
5. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT- 4 0 4 , "
COMPONENTS" .
2. Check A/T fluid condition. Refer to AT- 2 5 6 , "
FLUID CONDITION
CHECK" .
OK or NG
OK >> GO TO 6.
NG >> GO TO 8.
6. DETECT MALFUNCTIONING ITEM
1. Remove control valve assembly. Refer to AT- 4 0 4 , "
Control Valve Assembly and Accumulators" .
2. Check the following items:
–Shift valve B
–Shift solenoid valve B
–Pilot valve
–Pilot filter
OK or NG
OK >> GO TO 7.
NG >> Repair or replace damaged parts.
7. CHECK SYMPTOM
Check again. Refer to AT- 2 7 0 , "
Cruise Test — Part 1" and AT- 2 7 3 , "Cruise Test — Part 2" .
OK or NG
OK >>INSPECTION END
NG >> 1. Perform TCM input/output signal inspection. Refer to AT- 2 8 6 , "
TCM Terminals and Reference
Va l u e" .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
8. DETECT MALFUNCTIONING ITEM
1. Remove control valve assembly. Refer to AT- 4 0 4 , "
Control Valve Assembly and Accumulators" .
2. Check the following items:
–Shift valve B
–Shift solenoid valve B
–Pilot valve
–Pilot filter
3. Disassemble A/T. Refer to AT- 4 2 4 , "
Disassembly" .
4. Check the following items:
–Servo piston assembly
–High clutch assembly. Refer to AT- 4 6 9 , "High Clutch" .
–Oil pump assembly. Refer to AT- 4 4 3 , "Oil Pump" .
OK or NG
OK >> GO TO 7.
NG >> Repair or replace damaged parts.
SAT171B
AT-310
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSES FOR SYMPTOMS
5. DETECT MALFUNCTIONING ITEM
1. Remove control valve assembly. Refer to AT- 4 0 4 , "
Control Valve Assembly and Accumulators" .
2. Check the following items:
–Shift valve A
–Overrun clutch control valve
–Shift solenoid valve A
–Pilot valve
–Pilot filter
OK or NG
OK >> GO TO 6.
NG >> Repair or replace damaged parts.
6. CHECK SYMPTOM
Check again. Refer to AT- 2 7 0 , "
Cruise Test — Part 1" and AT- 2 7 3 , "Cruise Test — Part 2" .
OK or NG
OK >>INSPECTION END
NG >> 1. Perform TCM input/output signal inspection. Refer to AT- 2 8 6 , "
TCM Terminals and Reference
Va l u e" .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
7. DETECT MALFUNCTIONING ITEM
1. Remove control valve assembly. Refer to AT- 4 0 4 , "
Control Valve Assembly and Accumulators" .
2. Check the following items:
–Shift valve A
–Overrun clutch control valve
–Shift solenoid valve A
–Pilot valve
–Pilot filter
3. Disassemble A/T. Refer to AT- 4 2 4 , "
Disassembly" .
4. Check the following items:
–Servo piston assembly
–Torque converter. Refer to AT- 4 2 4 , "Disassembly" .
–Oil pump assembly. Refer to AT- 4 4 3 , "Oil Pump" .
–Brake band
OK or NG
OK >> GO TO 6
NG >> Repair or replace damaged parts.
AT-312
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSES FOR SYMPTOMS
A/T Does Not Hold Lock-Up ConditionECS00EBQ
SYMPTOM:
A/T does not hold lock-up condition for more than 30 seconds.
1. CHECK DIAGNOSTIC RESULTS
Perform self-diagnosis. Refer to AT- 2 4 2 , "
SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)" or AT-
246, "Diagnostic Procedure Without CONSULT-II" .
Does self-diagnosis show damage to engine speed signal circuit after cruise test?
YES >> Check engine speed signal circuit. Refer to AT- 3 8 2 , "ENGINE SPEED SIGNAL" .
NO >> GO TO 2.
2. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT- 4 0 4 , "
COMPONENTS" .
2. Check A/T fluid condition. Refer to AT- 2 5 6 , "
FLUID CONDITION
CHECK" .
OK or NG
OK >> GO TO 3.
NG >> GO TO 5.
3. DETECT MALFUNCTIONING ITEM
1. Remove control valve assembly. Refer to AT- 4 0 4 , "
Control Valve Assembly and Accumulators" .
2. Check the following items:
–Torque converter clutch control valve
–Torque converter clutch solenoid valve
–Pilot valve
–Pilot filter
OK or NG
OK >> GO TO 4.
NG >> Repair or replace damaged parts.
4. CHECK SYMPTOM
Check again. Refer to AT- 2 7 0 , "
Cruise Test — Part 1" .
OK or NG
OK >>INSPECTION END
NG >> 1. Perform TCM input/output signal inspection. Refer to AT- 2 8 6 , "
TCM Terminals and Reference
Va l u e" .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
SAT171B
TROUBLE DIAGNOSES FOR SYMPTOMS
AT-313
[EXC.F/EURO-OBD]
D
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MA
B
AT
5. DETECT MALFUNCTIONING ITEM
1. Remove control valve assembly. Refer to AT- 4 0 4 , "
Control Valve Assembly and Accumulators" .
2. Check the following items:
–Torque converter clutch control valve
–Torque converter clutch solenoid valve
–Pilot valve
–Pilot filter
3. Disassemble A/T. Refer to AT- 4 2 4 , "
Disassembly" .
4. Check torque converter and oil pump assembly.
OK or NG
OK >> GO TO 4.
NG >> Repair or replace damaged parts.
AT-448
[ALL]
REPAIR FOR COMPONENT PARTS
Control Valve AssemblyECS00EC1
COMPONENTS
1. Oil strainer 2. O-ring 3. Snap ring
4. Terminal body 5. O-ring 6. Solenoid valve assembly
7. Control valve lower body 8. Oil cooler relief valve spring 9. Check ball
10. Separating plate 11. Support plate 12. Steel ball
13. Control valve inter body 14. Pilot filter 15. Separating plate
16. Steel ball 17. Control valve upper body
SCIA4973E
REPAIR FOR COMPONENT PARTS
AT-453
[ALL]
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MA
B
AT
Oil Cooler Relief Valve Spring
Check springs for damage or deformation.
Measure free length and outer diameter. Refer to AT- 5 3 0 , "SER-
VICE DATA AND SPECIFICATIONS (SDS)" .
ASSEMBLY
1. Install control valve upper, inter and lower body.
a. Place oil circuit of control valve upper body face up. Install steel
balls in their proper positions.
b. Install reamer bolts f from bottom of control valve upper body.
Using reamer bolts as guides, install separating plate as a set.
CAUTION:
Do not reuse separating plate.
c. Install pilot filter.
SAT138D
SAT771J
SCIA4980E
SAT074F
MA-1
MAINTENANCE
L MAINTENANCE
CONTENTS
C
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SECTION MA
A
B
MA
MAINTENANCE
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
DESCRIPTION ............................................................ 4
Pre-Delivery Inspection Items .................................. 4
GENERAL MAINTENANCE ....................................... 6
General Maintenance ............................................... 6
PERIODIC MAINTENANCE ....................................... 7
Periodic Maintenance ............................................... 7
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (QR20DE AND QR25DE PETROL
ENGINE) ............................................................... 7
CHASSIS AND BODY MAINTENANCE
(QR20DE AND QR25DE PETROL ENGINE) ....... 8
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD22DDTI DIESEL ENGINE) ................ 9
CHASSIS AND BODY MAINTENANCE
(YD22DDTI DIESEL ENGINE) .............................. 9
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 10
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (QR20DE AND QR25DE PETROL
ENGINE) ............................................................. 12
CHASSIS AND BODY MAINTENANCE
(QR20DE AND QR25DE PETROL ENGINE) ..... 13
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD22DDTI DIESEL ENGINE) .............. 14
CHASSIS AND BODY MAINTENANCE
(YD22DDTI DIESEL ENGINE) ............................ 14
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 15
RECOMMENDED FLUIDS AND LUBRICANTS ...... 17
Fluids and Lubricants ............................................. 17
SAE Viscosity Number ........................................... 18
GASOLINE ENGINE ........................................... 18
DIESEL ENGINE ................................................. 18
Engine Coolant Mixture Ratio ................................ 19
ENGINE MAINTENANCE (QR20DE·QR25DE) ........ 20
Checking Drive Belts .............................................. 20
Tension Adjustment ................................................ 20Changing Engine Coolant ....................................... 20
DRAINING ENGINE COOLANT .......................... 20
REFILLING ENGINE COOLANT ......................... 21
FLUSHING COOLING SYSTEM ......................... 22
Checking Cooling System ...................................... 22
CHECKING COOLING SYSTEM HOSES ........... 22
CHECKING RADIATOR ...................................... 22
CHECKING RADIATOR CAP .............................. 22
CHECKING RADIATOR SYSTEM FOR LEAKS ... 23
Checking Fuel Lines ............................................... 24
Changing Air Cleaner Filter .................................... 24
VISCOUS PAPER TYPE ..................................... 24
Changing Engine Oil ............................................... 24
Changing Oil Filter .................................................. 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
INSPECTION AFTER INSTALLATION ................ 26
Checking and Changing Spark Plugs ..................... 26
REMOVAL ........................................................... 26
INSPECTION AFTER REMOVAL (EXCEPT FOR
RUSSIA) .............................................................. 26
INSPECTION AFTER REMOVAL (FOR RUS-
SIA) ..................................................................... 27
INSTALLATION ................................................... 28
Checking EVAP Vapor Lines .................................. 28
ENGINE MAINTENANCE (YD22DDTI) .................... 29
Checking Drive Belts .............................................. 29
Tension Adjustment ................................................ 29
A/C COMPRESSOR BELT .................................. 30
ALTERNATOR AND WATER PUMP BELT .......... 30
Changing Engine Coolant ....................................... 30
DRAINING ENGINE COOLANT .......................... 30
REFILLING ENGINE COOLANT ......................... 31
FLUSHING COOLING SYSTEM ......................... 32
Checking Cooling System ...................................... 32
CHECKING COOLING SYSTEM HOSES ........... 32
CHECKING RADIATOR ...................................... 32
CHECKING RADIATOR CAP .............................. 33
CHECKING RADIATOR SYSTEM FOR LEAKS ... 33
Checking Fuel Lines ............................................... 34
MA-2 Changing Fuel Filter ............................................... 34
REMOVAL ........................................................... 34
INSTALLATION .................................................... 35
INSPECTION AFTER INSTALLATION ................ 35
Changing Air Cleaner Filter .................................... 35
VISCOUS PAPER TYPE ..................................... 35
Changing Engine Oil ............................................... 35
Changing Oil Filter (TYPE A) .................................. 36
REMOVAL ........................................................... 36
INSTALLATION .................................................... 36
INSPECTION AFTER INSTALLATION ................ 36
Changing Oil Filter (TYPE B) .................................. 37
REMOVAL ........................................................... 37
INSTALLATION .................................................... 38
INSPECTION AFTER INSTALLATION ................ 38
Draining Water ........................................................ 38
CHASSIS AND BODY MAINTENANCE ................... 39
Checking Exhaust System ...................................... 39
Checking Clutch Fluid Level and Leaks ................. 39
Checking Clutch System ........................................ 39
Checking M/T Oil .................................................... 39
Changing M/T Oil .................................................... 40
Checking A/T Fluid ................................................. 40
Changing A/T Fluid ................................................. 41
Checking Transfer Oil ............................................. 41
Changing Transfer Oil ............................................. 42
Checking Propeller Shaft ........................................ 42
Checking Differential Gear Oil ................................ 43
Changing Differential Gear Oil ................................ 43
Balancing Wheels ................................................... 43
Rotation .................................................................. 43Checking Brake Fluid Level and Leaks ................... 44
Checking Brake Lines and Cables .......................... 44
Changing Brake Fluid ............................................. 44
Checking Disc Brake ............................................... 44
ROTOR ................................................................ 44
CALIPER .............................................................. 45
PAD ...................................................................... 45
Checking Steering Gear and Linkage ..................... 45
STEERING GEAR ............................................... 45
STEERING LINKAGE .......................................... 45
Checking Power Steering Fluid and Lines .............. 45
Axle and Suspension Parts ..................................... 46
Drive Shaft .............................................................. 46
Lubricating Locks, Hinges and Hood Latches ......... 46
Checking Seat Belts, Buckles, Retractors, Anchors
and Adjusters .......................................................... 47
Checking Body Corrosion ....................................... 48
HEMMED PANELS .............................................. 48
PANEL JOINT ...................................................... 48
PANEL EDGE ...................................................... 48
PARTS CONTACT ............................................... 48
PROTECTORS .................................................... 48
ANTI-CORROSION MATERIALS ........................ 48
DRAIN HOLES ..................................................... 48
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 49
Standard and Limit .................................................. 49
BELT DEFLECTION AND TENSION ................... 49
RADIATOR ........................................................... 49
ENGINE COOLANT CAPACITY .......................... 49
ENGINE OIL CAPACITY (APPROXIMATE) ........ 49
SPARK PLUG ...................................................... 49