PDF Factory Service Repair Manual Kia Rondo 2016 - 10 MB
Get the official factory service and repair manual for the 2016 Kia Rondo.
This comprehensive PDF contains the same information used by professional Kia technicians.
It covers every aspect of the vehicle, including engine, transmission, brakes, suspension, and electrical systems.
Step-by-step instructions, wiring diagrams, and detailed illustrations make any repair job manageable.
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General Information
Important Safety Notice
Proper service methods and repair procedures are essential for safe, reliable operation of all motor vehicles as well as personal safety
of the operator. The service procedures and descriptions in this shop manual provide general directions for a service and repair.
Procedure, techniques, tools, and parts for service including the skill of the technician vary. It is impossible to provide advice or caution
as to each case in this manual.
Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is not recommended by the vehicle
manufacturer, must first assure thoroughly that neither their personal safety nor the safe operation of the vehicle will be first jeopardized
by the replacement part, service procedure, or tool they select.
Reminds you to be especially careful in those areas where carelessness will cause death or serious injury.
Reminds you to be especially careful in those areas where carelessness may cause death or serious injury.
Reminds you to be especially careful in those areas where carelessness may cause personal injury.
Gives you information that will prevent you from making errors that could damage the vehicle.
Gives you added information that will help you complete a particular procedure.
The following list contains some general WARNINGS that you should follow while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires you to be under the vehicle.
• Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.
• Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in park unless instructed otherwise for a
specific operation.
• Place supporters against the front and rear surfaces of the tires to help prevent the vehicle from moving.
• Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide poisoning.
• Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts.
• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and
muffler.
• Do not smoke while working on a vehicle.
• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle.
• When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan blades! Your vehicle may be
equipped with a cooling fan that may turn on, even though the ignition switch is in the OFF position. For this reason care should be
taken to ensure that the radiator fan electric motor is completely disconnected when working under the hood and the engine is not
running.
General Information
Identification Numbers
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Measuring Body Dimensions
1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensions and actual - measurement dimensions are used in this manual.
Dimensions Projected
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the reference
dimensions used for used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the different value in
height of the two surface.
Measuring Actual Dimensions
1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference dimensions when
a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement.
Check the probes and gauge itself to make sure there is no free play.
Measurement Point
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• To avoid damage, remove the engine cover on room temperature.
• To avoid damage of the engine cover, do not disengage both front and rear mounting point at the same time.
2. Install in the reverse order of removal.
Engine Mechanical System
Components
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2. Locate the micro phone (B) close to the center of belt span (A) and bounce the belt by finger 2~3 times. Read a value on the
display.
[With A/C]
[Without A/C]
If adjustment is necessary:
1. Loosen the mounting bolts (A).
2. Tighten the adjusting bolt (B) counterclockwise in loose tension; fasten the bolt clockwise in high tension.
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6. Remove the timing chain (A).
7. Remove the timing chain guide (A).
Inspection
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the CVVT sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace if necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace if necessary.
3. Check that the tensioner piston moves smoothly.
Installation
1. The TDC marks of the intake and exhaust CVVT sprockets are slightly turned from the TDC position as shown when the timing
chain is removed.
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(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.
(4) Install the bearing caps and tighten the bolts with specified torque.
Tightening torque
M6 bolts:
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
M8 bolts:
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
If the oil clearance is greater than specification, replace the camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
Bearing oil clearance
Standard:
0.032 ~ 0.062 mm (0.00126 ~ 0.00244 in.)
4. Inspect the camshaft end play.
(1) Install the camshaft bearing caps.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
If the end play is greater than specification, replace the camshaft.
If necessary, replace the bearing caps and cylinder head as a set
Camshaft end play
Standard:
0.10 ~ 0.19 mm (0.0039 ~ 0.0075 in.)
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(1) Using a steel square, measure the out-of-square of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.
If the free length is not as specified, replace the valve spring.
Valve spring
[Standard]
Free height: 45.93 mm (1.8083 in.)
Out-of-square : Less than 1.5°
Hydraulic Lash Adjuster (HLA)
With the HLA filled with engine oil, hold A and press B by hand.
If B moves, replace the HLA.
Problem Possible cause Action
1. Temporary noise when starting a cold This noise will disappear after the oil in the
Normal
engine engine reaches the normal pressure.
2. Continuous noise when the engine is Oil leakage of the high pressure chamber
started after parking more than 48 hours on the HLA, allowing air to get in
3. Continuous noise when the engine is first Noise will disappear within 15 minutes
Insufficient oil in cylinder head oil gallery when engine runs at 2000-3000 rpm.
started after rebuilding cylinder head
4. Continuous noise when the engine is If it doesn’t disappear, refer to step 7 below.
started after excessively cranking the
• Oil leakage of the high-pressure
engine by the starter motor or band
chamber in the HLA, allowing air to get
in
5. Continuous noise when the engine is
• Insufficient oil in the HLA Do not run engine at a speed higher than
running after changing the HLA
3000 rpm, as this may damage the HLA.
• Check oil level.
Engine oil level too high or too low
• Drain or add oil as necessary.
6. Continuous noise during idle after high Excessive amount of air in the oil at high
Check oil supply system.
engine speed engine speed
Check oil quality.
Deteriorated oil
If deteriorated, replace with specified type.
Low oil pressure
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Installation
1. Install a new rear oil seal.
(1) Apply engine oil on the edge of new oil seal.
(2) Using SST (09231-H1100, 09214-2E000) and a hammer, tap in the oil seal (A) until the SST face is aligned with the cylinder
block assembly rear face.
2. Install the other parts reverse order of removal.
Engine Mechanical System
Components
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(7) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with
the same color mark. Recheck the oil clearance.
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(8) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance.
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and
start over.
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or
scraper. Clean them only with solvent or detergent.
Crankshaft Bore Identification Mark
Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.
Cylinder Block Specifications
Calss Mark Inside Diameter
59.000 ~ 59.006 mm
a A
(2.32283 ~ 2.32307 in.)
59.006 ~ 59.012 mm
b B
(2.32307 ~ 2.32330 in.)
59.012 ~ 59.018 mm
c C
(2.32330 ~ 2.32354 in.)
Crankshaft Journal Identification Mark
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10. Remove the cooling fan assembly mounting bolts (A).
Tightening torque:
4.9 ~ 7.9 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.8 lb-ft)
[RH]
[LH]
11. Remove the cooling fan (A).
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1. Timing chain cover 8. O-ring (suction side)
2. Outer roter 9. O-ring (discharge side)
3. Inner roter 10. Oil screen gasket
4. Oil pump cover 11. Oil screen
5. Relief plunger 12. Oil pan
6. Relief spring 13. Oil filter
7. Relief plug 14. Oil pressure switch (OPS)
Engine Mechanical System
Engine Oil Schemetics
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1. Intake manifold assembly 3. Electronic throttle body
2. Intake manifold gasket 4. Intake manifold stay
Engine Mechanical System
Removal and Installation
1. Remove the engine cover.
2. Disconnect the battery negative terminal.
3. Remove the air cleaner assembly.
(Refer to Intake And Exhasut System - "Air Cleaner")
4. Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
5. Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold.
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• Cold Cranking Ampere (CCA): Cold Cranking Amps is a rating used in the battery industry to define a battery's ability to start an
engine in cold temperatures.
- The rating is the number of amps a new, fully charged battery can deliver at -18 °C(-0.4 °F) for 30 seconds, while maintaining a
voltage of at least 7.2 volts for a 12 volt battery.
- The higher the CCA rating, the greater the starting power of the battery.
• RESERVE CAPACITY (RC) : Reserve Capacity is a battery industry rating, defining a battery's ability to power a vehicle with
an inoperative alternator or fan belt.
- The rating is the number of minutes a battery at 26.7 °C(80 °F) can be discharged at 25 amps and maintain a voltage of 10.5
volts for a 12 volt battery.
- The higher the reserve rating, the longer your vehicle can operate should your alternator or fan belt fail.
Starting System
Starter
Item Specification
Rated voltage 12 V, 1.2 kW
The number of pinion teeth 13
Performance Ampere Max. 70 A
[No-load, 11 V] Speed Min. 2,400 rpm
Tightening Torques
Item N.m kgf.m lb-ft
Ignition coil installation bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Spark plug installation 14.7 ~ 24.5 1.5 ~ 2.5 10.9 ~ 18.1
Condenser bracket installation bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Alternator installation bolt [12 mm (0.47 in.)] 21.6 ~ 32.4 2.2 ~ 3.3 15.9 ~ 23.9
Alternator installation bolt [14 mm (0.55 in.)] 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
Battery (+) terminal tightening nut 7.8 ~ 9.8 0.8 ~ 1.0 5.2 ~ 8.7
Battery (-) terminal tightening nut 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Battery mounting bracket bolt 9.8 ~ 14.7 1.0 ~1.5 7.2 ~10.9
Battery tray installation bolt 9.8 ~ 14.7 1.0 ~1.5 7.2 ~10.9
Battery sensor cable installation bolt 21.6 ~ 32.4 2.2 ~ 3.3 15.9 ~ 23.9
Starter installation bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Engine Electrical System
Special Service Tools
Tool (Number and name) Illustration Use
Alternator pulley remover wrench Removal and installation of alternator pulley
(09373-27000)
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1. OAD (Overrunning Alternator Decoupler) pulley 6. Rear bearing
2. Front housing 7. Rear housing
3. Front bearing 8. Rectifier assembly
4. Stator 9. Regulator assembly
5. Rotor 10. Rear cover
Engine Electrical System
Circuit Diagram
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Engine Electrical System
Removal
1. Disconnect the battery negative terminal.
2. Remove the air duct and air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
3. Disconnect the starter cable (A) from the B terminal on the solenoid then disconnect the connector from the S terminal (B).
4. Remove the 2 bolts holding the starter, then remove the starter (A).
Installation
1. Install in the reverse order of removal.
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1. Connect the cruise control switch connector to the control switch.
2. Measure voltage between terminals on the harness side connector when each function switch is ON (switch is depressed).
Function switch Terminal Voltage (V)
CANCEL 2-4 0.63 ~ 0.97
SET– 2-4 1.03 ~ 1.37
RES+ 2-4 1.58 ~ 2.02
CRUISE 2-4 2.08 ~ 2.52
3. If not within specification, replace switch.
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the driver airbag module.
(Refer to Restraint - "Driver Airbag (DAB) Module and Clock Spring")
3. Remove the steering wheel.
(Refer to Steering System - "Steering Column and Shaft")
4. Remove the steering wheel cover (A) after loosening the screws.
5. Disconnect the heated steering connector (A).
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Emission Control System
Removal
1. Lift the vehicle.
2. Disconnect the vapor hose quick-connector (A) and ventilation hose (B).
3. Remove the protector installation bolts (C) and then remove the canister assembly (D).
4. Remove the canister bracket (A) after loosening the mounting bolts
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The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Intermittent Problem Inspection Procedure
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing. An
example would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician
should thoroughly make out a "Customer Problem Analysis Sheet" and recreate (simulate) the environment and condition which
occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins, and then verify
that the connectors are always securely fastened.
3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
● Simulating Vibration
1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.
Strong vibration may break sensors, actuators or relays
2) Connectors and Harness
: Lightly shake the connector and wiring harness vertically and then horizontally.
● Simulating Heat
1) Heat components suspected of causing the malfunction with a hair dryer or other heat source.
• DO NOT heat components to the point where they may be damaged.
• DO NOT heat the ECM directly.
● Simulating Water Sprinkling
1) Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
DO NOT sprinkle water directly into the engine compartment or electronic components.
● Simulating Electrical Load
1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window defogger, etc.).
Connector Inspection Procedure
1. Handling of Connector
A. Never pull on the wiring harness when disconnecting connectors.
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10. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1] 11. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2]
12. Rail Pressure Sensor (RPS) 13. Accelerator Position Sensor (APS)
18. Injector
14. Fuel Tank Pressure Sensor (FTPS) 15. Fuel Level Sender (FLS)
16. A/C Pressure Transducer (APT) 19. Purge Control Solenoid Valve (PCSV)
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31 -
32 Sensor ground Idle DC voltage Max. 50mV
33 -
34 Throttle Position Sensor (TPS) 2 signal input Idle Analog 0.55 ~ 4.37 V
35 -
36 -
37 -
38 -
39 -
40 -
41 Sensor ground Idle DC voltage Max. 50mV
42 -
43 -
44 -
45 -
46 -
47 -
48 -
49 -
50 -
High: Battery voltage
51 Alternator PWM signal output Idle Pulse
Low: Max. 1.5V
52 -
ON Battery voltage
53 Brake switch signal input DC voltage
OFF Max. 2.25V
54 Accelerator Position Sensor (APS) 1 signal input Idle Analog 0.674 ~ 4.379 V
55 -
56 Accelerator Position Sensor (APS) 2 signal input Idle Analog 0.261 ~ 2.204 V
57 -
58 -
59 -
Knocking Variable
60 Sensor ground
Normal Frequency
Knocking Variable
61 Knock Sensor (KS) signal input
Normal Frequency
62 Sensor ground Idle DC voltage Max. 50mV
63 Sensor ground Idle DC voltage Max. 50mV
Relay OFF 71V
64 Injector (Cylinder #1) [Low] control output DC voltage
Relay ON Max. 1.0V
Relay OFF 71V
65 Injector (Cylinder #4) [Low] control output DC voltage
Relay ON Max. 1.0V
Relay OFF 71V
66 Injector (Cylinder #2) [Low] control output DC voltage
Relay ON Max. 1.0V
Relay OFF 71V
67 Injector (Cylinder #3) [Low] control output DC voltage
Relay ON Max. 1.0V
68 -
69 -
70 -
71 -
72 -
73 -
74 -
75 -
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1. Dry bearing 5. Magnet
2. DC motor 6. Hall IC
3. Non-contact hall sensor 7. Yoke
4. Gear 8. Stator
Schematic Diagram
Engine Control / Fuel System
Fail-Safe Mode
Item Fail-Safe
ETC Motor Throttle valve stuck at 7°
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Coil Resistance (Ω) 774 ~ 946 [20°C (68°F)]
Engine Control / Fuel System
Waveform
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Installation
• Install the component with the specified torques.
• Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before
installing.
• DON’T use a cleaner, spray, or grease to sensing element and connector of the sensor because oil component in them may
malfunction the sensor performance.
• Sensor and its wiring may be damaged in case of contacting with the exhaust system (Exhaust Manifold, Catalytic Converter,
and so on).
1. Install in the reverse order of removal.
Heated oxygen sensor installation:
39.2 ~ 49.1 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
Engine Control / Fuel System
Description
Rail Pressure Sensor (RPS) is installed on the delivery pipe and measures the instantaneous fuel pressure in the delivery pipe. The
sensing element (Semiconductor element) built in the sensor converts the pressure to voltage signal. By using this signal, the ECM
can control correct injection amount and timing and adjusts the fuel pressure with the fuel pressure regulator valve if the target
pressure and the actual pressure calculated by the RPS output signal are different.
Engine Control / Fuel System
Specification
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When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after
completion of “Release Residual Pressure in Fuel Line” work.
3. Remove the delivery pipe & injector assembly (Refer to "Delivery Pipe" in this group).
4. Remove the connector (A) and the fixing clip (B), and then separate the injector from the delivery pipe.
Installation
1. Combustion seal
2. Rubber washer
3. Support disc
4. O-ring
• Do not reuse the used injector fixing clip.
• Install the component with the specified torques.
• Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before
installing.
• Apply engine oil to the injector O-ring.
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Removal
(Refer to Fuel Delivery System - "High Pressure Fuel Pump”)
Installation
(Refer to Fuel Delivery System - "High Pressure Fuel Pump”)
Engine Control / Fuel System
Description
Canister Close Valve (CCV) is normally open and is installed on the canister ventilation line. It seals evaporative emission control
system by shutting the canister from the atmosphere during EVAP leak detection process.
Engine Control / Fuel System
Specification
Item Specification
Coil Resistance (Ω) 19.5 ~ 22.5 [20°C(68°F)
Engine Control / Fuel System
Circuit Diagram
(M/T)
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3. Remove the fuel sender (A) in the direction of an arrow.
Installation
1. Install in the reverse order of removal.
Engine Control / Fuel System
Removal
1. Remove the fuel pump (Refer to “Fuel Pump” in this group).
2. Disconnect the electric pump wiring connector (A) and the fuel sender connector (B).
3. Remove the head assembly (A) after releasing the cushion fixing clip (B).
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3. Tighten the clutch cover bolts.
Loosely tighten every clutch cover bolts and then tighten the bolt to specifications torque in a diagonal direction. This can
prevent twisting, vibration of the cover, and the lifting of the pressure plate.
Tightening torque :
11.8 ~ 14.7 N.m (1.2 ~ 1.5 kgf.m, 8.7 ~ 10.8 lb-ft)
4. Install the transaxle assembly.
(Refer to Manual Transaxle System - " Manual Transaxle")
Clutch System
Description
• Component location :
• Function
1. Clutch operation is detected through clutch switch signal. This signal enables ECM to cope with instant change of load condition.
2. Clutch switch signal is used to detect engaged gear with vehicle speed and engine speed.
Clutch System
Specifications
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Specified fluid:SAE J1703 (DOT 3 or DOT 4)
3. Loosening the plug screw, press and release the clutch pedal about 10 times.
4. Tighten the plug (A) during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
5. After pressing the clutch pedal 3 times more, loosen the plug (A) and re-tighten it with the pedal pressed. Raise it again, then.
6. Repeat the step 4 two or three times.
(until there is no bubble in the fluid)
Tightening torque:
6.8 ~ 9.8 N.m (0.7 ~ 1.0 kgf.m, 5.0 ~ 7.2 lb-ft)
7. Refill the clutch master cylinder with the specified fluid.
Specified fluid:SAE J1703 (DOT 3 or DOT 4)
Clutch System
Components
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1. Install in the reverse order of removal.
2. Adding manual transaxle fluid after Installing the manual transaxle.
(Refer to Manual Transaxle System - "Manual Transaxle Fluid")
Manual Transaxle System
Description
Component location :Manual transaxle case
Operation principle :Back up lamp switch is pushed by the reverse lug sliding when select arm, and switches the back up lamp.
Function :Turn on the back up lamp when reversing.
Manual Transaxle System
Specification
Item Specification
Current voltage 13V
Working voltage DC 10~15V
Operating force 3.0kg Max
Voltage drop -0.4V
-30°C ~ 100°C
Working temperature
[-30°F ~ 212°F]
Manual Transaxle System
Inspection
1. Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
2. Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
3. Disconnect the back up lamp switch connector (A).
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5. Insert the slide clip in the direction as shown in the illustration and then install the clip (A).
Manual Transaxle System
Description
Control shaft assembly is mounted on the top of the manual transaxle, and select & shift cable are equipped.
Control shaft assembly is operated by shifting the shift lever.
Manual Transaxle System
Removal
1. Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
2. Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
3. Set shift lever to N position.
4. Separate the control cable from the control shaft after remove the pin (A) and washer (B).
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27. Remove the mounting bolt (A, B) after supporting the transaxle by a jack.
Tightening torque
(A) 42.2 ~ 54.0 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
(B) 42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)
28. Remove the transaxle while slowly lower the jack.
Be careful not to damage other system or parts near by when removing the transaxle assembly.
Installation
1. Install in the reverse order of removal.
After replacement or reinstallation procedure of the automatic transaxle assembly, must perform procedures below.
• Adding automatic transaxle fluid.
(Refer to Hydraulic System - "Fluid")
• If the oil seal on the transaxle case side is damaged and fluid is leaking, replace the oil seal with a new unit. When installing the
new oil seal, use the specialized tool (Oil seal installer: 09453-3L241, Bar: 09231-H1100).
• After servicing the automatic transaxle or TCM, clear the diagnostic trouble codes (DTC) using the GDS tool.(DTC cannot be
cleared by disconnecting the battery.)
• After replacing the automatic transaxle, reset the automatic transaxle's values by using the GDS.
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6. Remove the under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")
7. Replace new gasket and the plug after draining the automatic transaxle fluid by removing the drain plug.
(Refer to Hydraulic System - "Fluid")
8. Remove thd air breather hose (A).
9. Remove the valve body cover (B).
Tightening torque:
13.7 ~ 15.7 N.m (1.4 ~ 1.6 kgf.m, 10.1 ~ 11.6 lb-ft)
10. Remove the bolt (3ea) after disconnecting the solenoid valve (B) connector and the oil temperature sensor connector (A).
Tightening torque:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
11. Remove the valve body assembly (A).
Tightening torque: