CVT - VT3

WORKSHOP MANUAL
TRANSMISSION & CLUTCH OVER-

HAUL
CVT
Model YR 2011
English Edition RDCE-11PNCH080-00
Destination: ALL
July 2011 Printed in Malaysia
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
(Company No.: 100995-U)
Printed in Malaysia 12 July 2011 Eng
WORKSHOP MANUAL -
Group Index /I
00 GENERAL ..................................................................................... 00/1 - 00/6

23C CONTINUOUSLY VARIABLE TRANSMISSION <CVT2 & CVT3> .... 23C/1 - 23C/29
All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

- WORKSHOP MANUAL
/ II Group Index
NOTE

GENERAL 00
Content /1
00 GENERAL
HOW TO USE THIS MANUAL ....................................................... 00/2
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS .... 00/2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
DEFINITION OF TERMS ............................................................ 00/2
STANDARD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
REFERENCE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
INDICATION OF TIGHTENING TORQUE ......................................... 00/2
EXPLANATION OF MANUAL CONTENTS ........................................ 00/3

00 GENERAL
/2 HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL WTC000READS11001
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This manual provides explanations concerning the inspection, checking, adjustment, disassembly and
reassembly of the engine, transmission and major components after they have been removed from
the vehicle.
ON-VEHICLE SERVICE
“On - Vehicle Service” is procedures for performing inspections and adjustments of particularly im-
portant locations with regard to the construction and for maintenance and servicing, but other inspec-
tion (for looseness, play, cracking, damage and etc.) must also be performed.
INSPECTION
Under this title are presented inspection and checking procedures to be performed by using special
tools and measuring instruments and by feeling but for actual maintenance and servicing procedures,
visual inspections should always be performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value as the standard for judging the quality of a part of assembly on inspection or the
value to which the part or assembly is corrected and adjusted. It is given by tolerance
LIMIT
Shown the standard for judging the quality of a part or assembly on inspection and means the max-
imum or minimum value within which the part or assembly must be kept functionally or in strength.
It is a value established outside the range of standard value
REFERENCE VALUE
Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly
and adjustment procedures, and so they can be completed in a shorter time).
CAUTION
Indicates the presentation of information particularly vital to the worker during the performance of
maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of component or vehicle function or performance, etc.
INDICATION OF TIGHTENING TORQUE
The tightening torque shown in this manual is a basic value with a tolerance of ±10% except the fol-
lowings cases when the upper and lower limits of tightening torque are given.
1. The tolerance of the basic value is within ±10%
2. Special bolts or the like are in use.
3. Special tightening methods are used.

GENERAL 00
HOW TO USE THIS MANUAL /3
EXPLANATION OF MANUAL CONTENTS WTC000READS11002
DOIIC000R9001

00 GENERAL
SYMBOL DESCRIPTION
A Indicates the group title
B Indicates the section title
C Indicates the group number
D Indicates the page number
E Component Diagram
A diagram of the component parts is provided near the front of each section in order
to give a reader a better understanding of the installed condition of the component
parts.
F Denotes non reusable part
G Denotes tightening torque.
For bolts and nuts which do not have a tightening torque listed, refer to the “Tighten-
ing torque”
H Symbol for lubrication sealants and adhesives.
Information concerning the locations for lubrication and for application of sealants
and adhesives is provided, by using symbols, in the diagrams of component parts or
on the page following the component parts page, and explained.
Grease (multipurpose grease unless there is a brand

or type specified)
DOIIC000R9058
Sealant or adhesive
DOIIC000R9059
Brake fluid or automatic transmission fluid

DOIIC000R9060
Engine oil, gear oil or air condition compressor oil

DOIIC000R9061
Adhesive tape or butyl rubber tape.

DOIIC000R9062
Indicates procedures to be performed before the work in that section is started, and
J
procedures to be performed after the work in that section is finished.
Maintenance and servicing Procedures
The number provided within the diagram individual the sequence for maintenance
and servicing procedures.
1. A diagram of the components part is provided near the front of each section in
K order to give the reader a better understanding of the installed condition of
component parts.
2. The number provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol N indicates a non reusable part; the tightening
torque is provided where applicable.
Removal steps:
The part designation number correspond to the number in the illustration to indicate
removal steps.

GENERAL 00
HOW TO USE THIS MANUAL /5
SYMBOL DESCRIPTION
Disassembly steps:
The part designation number correspond to the number in the illustration to indicate
disassembly steps.
Installation steps:
Specified in case installation is impossible in reverse order of removal steps
Reassembly steps:
Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted
if reassembly is possible in reverse order of disassembly steps.
Classifications of major maintenance/service points
When there are major points relative to maintenance and serving procedures (such as
L essential maintenance and service points, maintenance and service standard values,
information regarding the use of special tools, etc.) these are arranges together as
major maintenance and service points and explained in detail.
Indicates that there are essentials point for removal

or disassembly.
DOIIC000R9052
Indicates that there are essential point for installation

or reassembly
DOIIC000R9051
Indicates that there are essential points for both

DOIIC000R9053
M Operating procedures, caution etc. on removal, installation disassembly and reassembly

and reassembly are described.
N Table for graphic explaination

00 GENERAL
NOTE

CONTINUOUSLY VARIABLE TRANSMISSION <CVT2 & CVT3> 23C
Content /1
23C CONTINUOUSLY VARIABLE TRANSMISSION <CVT2 & CVT3>

GENERAL INTRODUCTION ........................................................... 23C/2
CVT CROSS-SECTION VIEW ....................................................... 23C/3
SPECIFICATIONS ....................................................................... 23C/4

GENERAL SPECIFICATIONS ........................................................ 23C/4
CVT 2 GEAR RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C/4
CVT 3 GEAR RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C/4
LUBRICANTS ......................................................................... 23C/4
TORQUE SPECIFICATIONS ......................................................... 23C/5
SPECIAL TOOLS ........................................................................ 23C/5

TOOLS ................................................................................. 23C/5
TRANSMISSION ........................................................................ 23C/8

DISASSEMBLY AND REASSEMBLY ................................................ 23C/8
DISASSEMBLY SERVICE POINTS ................................................... 23C/10
REASSEMBLY SERVICE POINTS .................................................... 23C/18

/2 GENERAL INTRODUCTION
GENERAL INTRODUCTION WTC23CGINFO001
The transmission's continuously variable ratio is achieved by means of a variator.

The variator consists of two cone pulleys located opposite to each other and a steel drive belt that
loops around the two pulleys like a V-belt.
The variator ratio is transmitted through an intermediate shaft to the differential incorporated into
the transmission housing.
This Student Information provides an overview of the transmission. The design and function of the
various assemblies of the transmission, the power of the transmission and the transmission control
are described individually. In addition, an overview is also provided for the transmission fluid cooling
system and the external gearshift mechanism. All spare parts and service tools are described, as well
as the error codes and actions to be carried out.
The stepless shifting pattern of the transmission provides a very comfortable drive, as well as having
full vehicle performance, available at any time.
The advantages of using an automatic transmission of this type are:
1. Low engine revolutions at constant speeds.
2. Improved emission control/fuel consumption.
3. Low noise, vibration and harshness levels.
4. Smooth acceleration.
5. Flexible driving on mountain roads.
Because of its fully electronic control the VT2/VT3 pushes the limits of its predecessor even further.

GENERAL INTRODUCTION /3
CVT CROSS-SECTION VIEW WTC23CGINFO002
DOINT23CR10024

/4 SPECIFICATIONS
Items 6. Steel belt

1. Torsional damper / flywheel 7. Primary pulley
2. Fluid pump 8. Secondary pulley
3. Reverse clutch 9. Intermediate shaft
4. Planetary gearing 10. Differential
5. Forward clutch
SPECIFICATIONS WTC23CSPECS001
GENERAL SPECIFICATIONS
Items Specification
Transmission Model PUNCH CVT
Transmission type CVT 2 and CVT 3
Torque converter type 3–element with torque converter clutch
Applicable engine S4PE and S4PH
CVT 2 GEAR RATIO
1.3 IAFM 1.6 IAFM
Gear
Min Max Min Max
CVT 2 0.43 2.43 0.43 2.43
SAT-1 2.41 2.41
SAT-2 1.62 1.20
SAT-3 0.97 0.85
SAT-4 0.75 0.71
SAT-5 0.59 0.57
SAT-6 0.46 0.46
Reverse 2.68
Final Drive 5.76
CVT 3 GEAR RATIO
1.6 CFE
Gear
Min Max
CVT 3 0.46 2.55
SAT-1 2.42
SAT-2 1.28
SAT-3 0.90
SAT-4 0.70
SAT-5 0.55
SAT-6 0.46
Reverse 2.55
Final Drive 5.76
LUBRICANTS
Items Specified lubricants Quantity
CVT fluid ESSO EZL799 Approximately 4.15 lit (4.37 U.S.qts, 3.6
Imp.qts) ± 0.05 lit (0.053 U.S.qts, 0.043 Imp.qts)

SPECIAL TOOLS /5
TORQUE SPECIFICATIONS
Items Value
Transmission Nut M8 self locking shift lever 1.45 kgm (14.5 Nm, 10.49 ft.lbs) ± 0.15 kgm (1.5
Nm, 1.08 ft.lbs)
Bolt primary cover M6X16 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.25 kgm (2.5
Nm, 1.81 ft.lbs)
Flanged bolt oil pan M6X16 0.9 kgm (9 Nm, 6.51 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
Bolt speed sensors 0.85 kgm (8.5 Nm, 6.15 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs)
Bolt oil pump 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm,
0.72 ft.lbs)
Primary nut 19.75 kgm (197.5 Nm, 142.85 ft.lbs) ± 1.75 kgm
(17.5 Nm, 12.66 ft.lbs)
Plug M14 2.1 kgm (21 Nm, 15.19 ft.lbs) ± 0.3 kgm (3 Nm,
2.17 ft.lbs)
Plug M10 1.5 kgm (15 Nm, 10.85 ft.lbs) ± 0.22 kgm (2.2
Nm, 1.59 ft.lbs)
Countersunk head screw M6X16 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.09 kgm (0.9
Nm, 0.65 ft.lbs)
Drain plug 1.1 kgm (11 Nm, 7.96 ft.lbs) ± 0.1 kgm (1 Nm,
0.72 ft.lbs)
Bolt valve body 1.1 kgm (11 Nm, 7.96 ft.lbs) ± 0.1 kgm (1 Nm,
0.72 ft.lbs)
Bolt position switch 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.09 kgm (0.9
Nm, 0.65 ft.lbs)
Bolt bracket output speed sensor 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.09 kgm (0.9
Nm, 0.65 ft.lbs)
SPECIAL TOOLS WTC23CSTOOL001
TOOLS
Tool Number Name Use
Mot. 1335 Circlip plier To lift out the pump
DOINT23CR10026
P480125 Stamp Oil seal selector shaft

installer
DOIIT23CR09003

/6 SPECIAL TOOLS

P480137 Stamp Primary bearing installer
DOIIT23CR09004
MD998350 Stamp Primary bearing installer
DOINT23CR11032
MD998348 Puller assembly Primary bearing re-

mover
DOINT23CR11030
MB991202 Primary bearing re-

mover
DOIMT22DR10152
P480130 Stamp Oil seal input shaft in-

staller
DOIIT23CR09006
P480129 Centering bush Oil seal input shaft in-

staller
DOIIT23CR09007
P480127 Removing tool Oil seal selector shaft

remover
DOIIT23CR09008

SPECIAL TOOLS /7

P480142 Centering pin To install hydraulic unit
DOIIT23CR09009
P480143 Stamp Install oil seal differen-

tial
DOIIT23CR09010

/8 TRANSMISSION
TRANSMISSION WTC23CSHAUL001
DISASSEMBLY AND REASSEMBLY
DOINT23CR11031

TRANSMISSION /9
— Non- reusable part

Disassembly steps
1. Input shaft plug 27. Input speed sensor (Primary speed sensor)
2. Oil seal input shaft 28. Output speed sensor bracket bolt (Secondary
3. Output shaft plug speed sensor bracket bolt)
4. Differential oil seal 29. Output speed sensor bracket (Secondary
5. Sealing ring plug M14 speed sensor bracket )
6. Plug M14 30. Output speed sensor (Secondary speed sensor)
7. Breather pipe with plug 31. Oil pan gasket
8. Breather cap 32. Cpl valve body (Hydraulic unit)
9. Clip (metal) 33. Valve body bolt
10. Breather pipe clip (plastic) 34. O-ring
11. Secondary cover o-ring 17.12X2.62 35. Oil filter
12. Secondary cover sealing ring 36. Magnet
13. Secondary cover o-ring 72.63X3.53 37. Oil pan assy
14. Secondary cover 38. Drain plug
15. Countersunk head screw M6X20 39. Position switch bolt
16. Primary ball bearing 40. Cpl position switch (Drive mode sensor)
17. Primary nut 41. O-ring
18. Belle-ville washer 42. Oil cooler connection plug
19. Sealing ring oil pump 43. Sealing ring
20. Oil pump o-ring 44. Plug
21. Oil pump 45. Cap connector protection
22. Oil pump bolt 46. Main connector clip
23. Primary cover o-ring 177,47X2.62 47. Main connector and internal harness cable
24. Primary cover 48. Shift lever
25. Primary cover clip 49. Nut
26. Bolt M6X16 50. Shift lever washer
51. Oil seal
T1 :2.1 kgm (21 Nm, 15.19 ft.lbs) ± 0.3 kgm (3 Nm, 2.17 ft.lbs)
T2 :0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm (0.95 Nm, 0.69 ft.lbs)
T6 :0.85 kgm (8.5 Nm, 6.15 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
T9 :1.5 kgm (15 Nm, 10.85 ft.lbs) ± 0.225 kgm (2.25 Nm, 1.63 ft.lbs)

/ 10 TRANSMISSION
DISASSEMBLY SERVICE POINTS

WTC23CSHAUL002
1. Use the screw driver to pinch out the oil dif-

ferential seal (LH and RH).
CAUTION
Be careful not to force the screw driver too
deep, to protect the housing from scratch or
damage.
DOINT23CR11019
2. Use the screw driver pinch out the oil seal

input shaft.
DOINT23CR10002
3. Remove the self locking nut shift lever.
DOINT23CR10003

TRANSMISSION / 11
4. Then remove the shift lever.
DOINT23CR10004
5. Place special tool P480127 on the selector

shaft , press and screw tool clockwise.
DOINT23CR11020
6. Rotate the screw to remove the oil seal.
DOINT23CR10005
7. Remove the primary cover bolts with clamp.
DOINT23CR10006

/ 12 TRANSMISSION
8. Use the screw driver pry primary cover.

NOTE
Use cloth to protect the transmission from
damage.
DOINT23CR10007
9. Remove the big O-ring.
DOINT23CR11021
10. Before remove the oil pump, mark 2 point

on top the oil pump by using permanent ink
pen. The marked point is for easier during
re-installation.
DOINT23CR11022
11. Remove the oil pump bolts.
DOINT23CR10008

TRANSMISSION / 13
12. Using special tool Mot. 1335, lift out the

pump and remove the belle-ville washer.
DOINT23CR10009
13. To remove the primary nut, ensure to do a

mark on it permanently. Use socket size of
46 mm (1.81 in), use high spec of an air im-
pact wrench due to remove the large size of
primary nut .
DOINT23CR10010

/ 14 TRANSMISSION
14. Pinch out the seal of the primary ball bearing

using a small screw driver.
DOINT23CR10011
15. Use the special tool MB991202 and

MD998348 to lift out the primary ball bear-
ing.
DOINT23CR11023
16. Remove the oil pan bolts.
DOINT23CR10014
17. Remove the oil pan and gasket.
DOINT23CR11033

TRANSMISSION / 15
18. Remove the oil filter and O-ring.
DOINT23CR11034
19. Remove the position switch cpl bolt and dis-

connect the position switch cpl connector.
DOINT23CR10015

/ 16 TRANSMISSION
20. Remove the cpl valve body bolts and push

the cpl valve body bracket until end to re-
move another bolts.
DOINT23CR10016
21. Remove the cpl valve body and disconnect

the cpl valve body connectors.
DOINT23CR11035
22. Remove the secondary cover countersunk

head screw (torx).
DOINT23CR10017

TRANSMISSION / 17
23. Remove the secondary cover and O-ring sec-

ondary cover.
DOINT23CR10018
24. Use plier remove the main connector clip.
DOINT23CR10019
25. Remove the Input speed sensor.
DOINT23CR10020
26. Remove the output speed sensor bracket.
DOINT23CR10021

/ 18 TRANSMISSION
27. Use plier remove the output speed sensor.
DOINT23CR10022
28. Press the main connector with finger and

remove the main connector and internal
cable harness.
CAUTION
Do not allowed to use any tool to take out
the main connector and internal cable har-
ness.
DOINT23CR11036
REASSEMBLY SERVICE POINTS

WTC23CSHAUL003
1. Put special tool P480129 on the input shaft

and slide a new oil seal.
DOINT23CR11001

TRANSMISSION / 19
2. Place the special tool P480130 on input shaft,

and knock by rubber hammer.
DOINT23CR11002
3. Slide a new oil seal to the special tool

P480125.
DOINT23CR11003
4. Place special tool P480125 with oil seal on

the selector shaft and knock in the oil seal
until no further possible.
DOINT23CR11004
5. Install the shift lever.

CAUTION
Ensure the shift lever is install to the correct
position, fix only one position as shown in
the illustration.
DOINT23CR10004

/ 20 TRANSMISSION
6. Tighten the self locking nut.

Specified torque:
1.45 kgm (14.5 Nm, 10.49 ft.lbs) ± 0.15 kgm
(1.5 Nm, 1.08 ft.lbs)
DOINT23CR10003
7. Ensure the oil ring connector is seat at it po-

sition as shown in the illustration.
DOINT23CR11037
8. Properly install the main connector and in-

ternal cable harness .
CAUTION
Ensure the connector slot lock at transmis-
sion case.
DOINT23CR11005

TRANSMISSION / 21
9. Install the main connector clip properly.
DOINT23CR11006
10. Lay-out the input speed sensor harness con-

nector to it position as shown in the illustra-
tion.
DOINT23CR11007
11. Slot in the output speed sensor bracket

properly as shown in the illustration.
DOINT23CR11008
12. Tighten the output speed sensor bracket

bolt.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs)
DOINT23CR10021

/ 22 TRANSMISSION
13. Connect all the connectors at the cpl valve

body.
DOINT23CR11009
14. Install the valve body and fit the special tool
P480142.
CAUTION
Make sure that the valve body metal slide
is fitted in the pin of the rooster cam plate.
DOINT23CR11039

TRANSMISSION / 23
15. Install the valve body bolts and tighten the

bolts.
Remove the special tool P480142.
CAUTION
Torque the bolts in order number as shown
in the illustration.
Specified torque:
1.1 kgm (11 Nm, 7.96 ft.lbs) ± 0.1 kgm (1 Nm,
0.72 ft.lbs)
DOINT23CR11038
16. Connect the position switch connector to the

main cable harness and lock it by pushing
the gray button.
CAUTION
Ensure the harness connector is properly
locked.
DOINT23CR11042

/ 24 TRANSMISSION
17. Place position switch to the metal slide, with

the guiding pin on the back of the position
switch locked in the metal slide groove.
Align the position switch so the screw holes
lign-up, tighten the position switch bolts.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs)
DOINT23CR11012
18. Fix the oil filter with new O-ring.
DOINT23CR11034
19. Install the oil pan with gasket and magnet.
DOINT23CR11033

TRANSMISSION / 25
20. Tighten the oil pan bolts.

Specified torque:
0.72 ft.lbs)
CAUTION
DOINT23CR11043
21. Install the secondary cover with the new O-

ring.
DOINT23CR10018
22. Tighten the countersunk head screw (torx

type).
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs)
CAUTION
DOINT23CR11041

/ 26 TRANSMISSION
23. Install the input speed sensor and tighten

the bolt.
Specified torque:
0.85 kgm (8.5 Nm, 6.15 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
DOINT23CR10020
24. Use the special tools P480137 and MB998350

to install the primary ball bearing.
DOINT23CR11024
25. Use an air impact wrench to tighten the

primary nut.
Specified torque:
19.75 kgm (197.5 Nm, 142.85 ft.lbs) ± 1.75
kgm (17.5 Nm, 12.66 ft.lbs)
DOINT23CR11014
26. Install the belle-ville washer as shown in the

illustration.
DOINT23CR11015

TRANSMISSION / 27
27. Install the oil pump properly.

CAUTION
Ensure the oil pump oil-ring not protrude.
DOINT23CR11016
28. Tighten the oil pump bolts.

Specified torque:
0.72 ft.lbs)
CAUTION
DOINT23CR11040
29. Install new big O-ring to the transmission

case properly.
DOINT23CR11026

/ 28 TRANSMISSION
30. Clean the primary cover and fix it the trans-

mission housing.
DOINT23CR11017
31. Tighten the primary cover bolts with clamp.

Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.25 kgm (2.5
Nm, 1.81 ft.lbs)
DOINT23CR10006

TRANSMISSION / 29
32. Replace with a new oil seal differential

(RH/LH) sides and put it in the housing, place
the special tool P480143 on the seal and use
a rubber hammer to knock oil seal into the
transmission housing.
DOINT23CR11028

/ 30 TRANSMISSION
NOTE

CVT Model YR 2011 English Edition RDCE-11PNCH080-00 July 2011 Printed in Malaysia

CVT - VT3

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WORKSHOP MANUAL

TRANSMISSION & CLUTCH OVER-

00 GENERAL ..................................................................................... 00/1 - 00/6

Printed in Malaysia 12 July 2011 Eng

Printed in Malaysia 12 July 2011 Eng

Printed in Malaysia 12 July 2011 Eng

HOW TO USE THIS MANUAL WTC000READS11001

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

Printed in Malaysia 12 July 2011 Eng

EXPLANATION OF MANUAL CONTENTS WTC000READS11002

Printed in Malaysia 12 July 2011 Eng

Grease (multipurpose grease unless there is a brand

Brake fluid or automatic transmission fluid

Engine oil, gear oil or air condition compressor oil

Adhesive tape or butyl rubber tape.

Printed in Malaysia 12 July 2011 Eng

Indicates that there are essentials point for removal

Indicates that there are essential point for installation

Indicates that there are essential points for both

M Operating procedures, caution etc. on removal, installation disassembly and reassembly

Printed in Malaysia 12 July 2011 Eng

Printed in Malaysia 12 July 2011 Eng

23C CONTINUOUSLY VARIABLE TRANSMISSION <CVT2 & CVT3>

SPECIFICATIONS ....................................................................... 23C/4

SPECIAL TOOLS ........................................................................ 23C/5

TRANSMISSION ........................................................................ 23C/8

Printed in Malaysia 12 July 2011 Eng

GENERAL INTRODUCTION WTC23CGINFO001

The transmission's continuously variable ratio is achieved by means of a variator.

Printed in Malaysia 12 July 2011 Eng

CVT CROSS-SECTION VIEW WTC23CGINFO002

Printed in Malaysia 12 July 2011 Eng

Items 6. Steel belt

Printed in Malaysia 12 July 2011 Eng

SPECIAL TOOLS WTC23CSTOOL001

P480125 Stamp Oil seal selector shaft

Printed in Malaysia 12 July 2011 Eng

Tool Number Name Use

MD998350 Stamp Primary bearing installer

MD998348 Puller assembly Primary bearing re-

MB991202 Primary bearing re-

P480130 Stamp Oil seal input shaft in-

P480129 Centering bush Oil seal input shaft in-

P480127 Removing tool Oil seal selector shaft

Printed in Malaysia 12 July 2011 Eng

Tool Number Name Use

P480143 Stamp Install oil seal differen-

Printed in Malaysia 12 July 2011 Eng

DISASSEMBLY AND REASSEMBLY

Printed in Malaysia 12 July 2011 Eng

— Non- reusable part

Printed in Malaysia 12 July 2011 Eng

DISASSEMBLY SERVICE POINTS

1. Use the screw driver to pinch out the oil dif-

2. Use the screw driver pinch out the oil seal

3. Remove the self locking nut shift lever.

Printed in Malaysia 12 July 2011 Eng

4. Then remove the shift lever.

5. Place special tool P480127 on the selector

6. Rotate the screw to remove the oil seal.