AUTOMATIC TRANSMISSION INTRODUCTION INSTRUCTION ON AUTOMATIC TRANSMISSION VEHICLES BASIC CHECKS AND ADJUSTMENT TESTING HYDRAULIC PRESSURE TES’ REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION REMOVAL OF OIL PAN AND OIL STRAINER REMOVAL/INSTALLATION OF VALVE BODY REMOVAL AND INSTALLATION OF TURBINE REVOLUTION SENSOR AND OUTPUT REVOLUTION SENSOR AT-25 ELECTRONIC CONTROL SYSTEM ... AT-26 LOCATION OF COMPONENTS (VALVE BODY SECTION) .. AT-30 DIAGRAM SHOWING ARRANGEMENT OF VEHICLE HARNESS SIDE CONNECTOR TERMINALS AT-31 ARTICLES TO BE PREPARED TROUBLE-SHOOTING -_ TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE «1. TROUBLE SHOOTING TABLE ACCORDING TO PHENOMENA UNIT CHECK AT-31 AT-37 AT-40 AT-66 AT-77AT-2 INTRODUCTION This manual describes the checking and servicing procedures for the automatic transmission which | mounted on the vehicle. As for tne checking end servicing procedures for the unit itself, refer to the unit section Service Manual Unit Section: No. 9735 INSTRUCTION ON AUTOMATIC TRANSMISSION VEHICLES +. When towing the automatic transmission vehicles with a wrecker, be sure to use a towing dolly. 2. Instruction on installation and removal of parts (1) Remove completely sands and dirt which have adhered to the external surface so that no foreign matters can enter the transmission. (2) The disassembling should be performed at a clean place free of dust and Girt. (3) When disassembling, do not use gloves or cloth. (4) Before disassembling, be sure to check for oil leakage. (5) Carefully consider the contents of malfunction so as to avoid unnecessary removing of parts. (6) When disassembling connected paris, such as the case, lightly tap them with a plastic hammer or the like, not prying with a screwdriver. (7) Be sure to apply automatic transmission fluid to sliding sections. (8) When gaskets, O-rings, etc. have been removed, be sure to install new ones. ssseeeonecnen wreceenconee BASIC CHECKS AND ADJUSTMENT 1. Preparation prior to check (1) Park the vehicle on a flat place. Apply the parking brake. (2) Confirm safety before and after the vehicle. 2. Check of transmission fluid level and its condition (1) Check the idle speed. NOTE: + The check should be performed with the engine fully warmed up. Specified Value: 650-750 rpm (During ISC operation, accessory switch turned OFF] If the measured value does not comply with the specifica tion, refer to the EM section (2) With the engine idling, move the shift lever slowly from the P to L, passing through each range. Then, return the lever to the P range. (8) Pull out the transmission fluid level gauge and wipe out the oil with a cloth. Remove lint, etc. by blowing compressed ait (4) Push it back fully into the tube.(5) Pull it out and check that the fiuid level is in the HOT range. NOTE: + Ifit necessary to check the fiuid level at low tempera ture (20 - 30°C), e.g. at the time of fluid change, first adjust the fluid level so that it may become within the COLD level. Then, recheck the fluid level under the hot conditions. ‘+ If the fluid level fails to reach the COLD level on the fluid level gauge, be sure to check the transaxle for fluid leakage. (6) Check the fluid condition If the fluid smelis burning or it presents a black ap- pearance, change the fluid Change the transmission fiuid (1) Remove the transmission oil by removing the drain plug with the gasket (2) Drain the fluid. WARNING: Be careful not to scald yourself. (3) With the new gasket interposed, tighten the drain plug securely, Tightening Torque: 19.6 -29.4.N-m NOTE: + Never reuse the removed gasket. (4) Add the new fluid through the oi filler tube. Specified Value: 1.5 litter (Drain and refill) (6) Adjust the fluid level. (Refer to page AT-2.) Check of shift lever position (1) Move the shift lever from the N range to each range. Ensure that the shift lever button and shift lever can be operated smoothly with a positive detent feeling at each range. Check that the position indicator functions properly. (2) Start the engine. Ensure that the vehicle moves. for- ward when you move the shift lever from the N range to the D, 2 and L ranges, respectively. Make sure that the vehicle moves backward when you move the shift lever to the R range (3) With the ignition switch set to the ON position, move the shift lever from the P to Fl range and from the N to R range while depressing the brake pada. => mark: Shift can be made only while shift lever but- ton is being pushed > mark: Shift can be made without pushing shift lever bution HoT_COLD TESAT-4 ee 5. Adjustment of control cable (1) Check the connecting section between the control cable and the control shaft lever for wear, Check other connections for wear and deformation. (2) Remove the attaching volts of the control cable and control cable shaft lever, (3) Turn the control shaft lever to the vehicle front direction until it stops (P range). Then, back off two notches. (N range). (4) Place the control shaft lever in the N range. Without al- lowing any slack of the control cable, tighten the at- taching bolts to the specified torque Tightening Torque: 6.9- 9.8 Nem (5) After completion of adjustment, check the operating condition and function. 6. Check of neutral start switch (1) Apply parking brake (2) Ensure that the engine can start only when the shift lever is placed in the P or N range. Ensure that the en- gine will not start in other ranges. (3) Ensure that the backup lamp goes on only when the shift lever is placed in the R range. (4) With the ignition switch turned ON, move the shift lever. Ensure that the shift position indicator in the ‘combination meter goes on correctly according to the shift lever position. (6) If any abnormality is encountered, disconnect the con- nector of the neutral start switch. Using an ohmmeter, perform continuity check according to the table given below. ery e |e =le|s fo] =| Range P eer 1 T R [ loto] I I N jot —t—}—to I D a 2 [o7;—- + OL L i ft if the continuity does not conform to the specifications, replace the switch. recrnaeee wronsr2cooneAdjustment of neutral start switch (1) Remove 2 bolt of the contro! cable assembly. (2) Remove a nut of the transmission control shaft lever assembly, (3) Back off the manual lever shaft two notches from the parking position and remove the manual lever. (4) Place the SST and tighten the screw. SST: 09302-87201-000 (6) Loosen the tightening bolt (6) Align the groove with the basic line. (7) Tighten the bolt Tightening Torque: 14.7 - 21.6 Nm NOTE: * Make sure that the bolt is tightened to the specified tightening torque. (8) Install the transmission contro! shaft lever assembly and tighten it with the nut. Tightening Torque: 9.8- 15.7 N-m NOTE: + Make sure that the nut is tightened to the specified tightening torque. (8) Tighten the control cable assembly with the bolt. Tightening Torque: 6.9- 9.8 Nm (10) Check the continuity of the terminals in the neutral start switch connector (11) Inspection of shift lever position (42) Inspection of engine idling speed (Refer to the EM section.) Basic line THT RTAT-6 ON TESTING STALL TEST The purpose of this testis to check the overall performance of the automatic transmission and engine by measuring the maximum engine speeds in the D and R ranges. ‘CAUTION: + Perform the stall test at the normal fluid operating temperature (70 - 90°C). * Donot conduet this test continuously for more than five seconds. 2 Wait at least one minute before the switching is made from the D range to the R range. «Be sure to turn OFF the air conditioner (if equipped so on). Measurement of stall speed Place chocks at the four wheels. Install an engine tachometer. Fully apply the parking brake. Keep depressing the brake pedal firmly by your left foot during the test Start the engine. Move the shift lever to the D range. Depress the accelerator pedal fully by your right foot, Quickly read the highest engine rpm at this time. Stall Speed: 2100 - 2600 rpm oopens 7. Perform the same test in the R range. Evaluation 1. If the engine speed is the same for both ranges (D, R) but lower than specified value: (1) Engine output probably insufficient (2) Torque convertor malfunctioning 2. Ifthe stall speed at the D range is higher than specified value: (1) Line pressure too low (2) Forward clutch slipping (3) Torque convertor malfunctioning 3. Ifthe stall speed in the R range is higher than specified value: (1) Line pressure too low (2) Direct clutch sipping (8) First & reverse brake slipping 4, Ifthe stall speed in the R and D ranges is higher than specified value: (1) Line pressure too low (2) Fluid level improper ob TTT.AT-7 SS TIME LAG TEST When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before you can feel a shock. This time lag can be used for checking those conditions of the forward clutch, the direct clutch and the first & reverse brake. CAUTION: + Perform the time lag test at the normal fluid operating temperature (70 - 90°C). «Be sure to allow one minute intervals between tests. Conduct the measurement three times and take the average value. Measurement of time lag 1. Place chocks at the four wheels. 2. Fully apply the parking brake. 3. Start the engine and check the idle speed. (Refer to the EM Section.) 4. Move the shift lever from the N to the D range. Using a stopwatch, measure the time required from the lever shifting to the time when you feel a shock. Time Lag: Not to exceed 1.0 second 5. Inthe same manner, measure the time lag when shifting is made from the N to the R range. Time Lag: Not to exceed 1.0 second Evaluation 1. If the Neto-D time lag is longer than the specified value: (1) Line pressure too low (2) Forward clutch worn 2. If the N-to-F time lag is longer than the specified value’ (1) Line pressure too low (2) Direct clutch worn (8) First & reverse brake worn (ovterpease (0-20)AT-8 HYDRAULIC PRESSURE TEST ARTICLES TO BE PREPARED Shape Partnumber, part name I Use 09325-87201.000 For checking hycrauic pressure of eRe AUT pressure gauge No. 1 adapter automatic transmission = Oipressue gauge lor AT | Forhycraul resus Instrument 3 = reste gauge adnir | rors ubrisant | DENRON® Hl or DEXRON'E = POSITION OF HYDRAULIC PRESSURE TEST PLUG LUG ON pressure / epressuce C2 pressure paced Caorssuce Bi pressure! PRESSURE GAUGE INSTALLATION PROCEDURE NOTE: * Be sure to use the new gaskets for the SST and instrument. The test plug is a non-reusable part. 1, Remove the test plug. Install the pressure gauge. SST; 09325-87201-000 NOTE: © Be very careful not to allow the pressure gauge to interfere with the front propeller shaft. 2. Start the engine and warm up the transmission (fluid temperature 70 - 90°C), Check the fiuid level Check each section for fiuid leakage. ptAT-9 ee eeeSeSeSeSSeSNSSSSFSS— HYDRAULIC PRESSURE MEASURING PROCEDURE Pressure C2 1. Apply the parking brake. Place chocks. 2. Start the engine. 3. While depressing the brake pedal strongly by your left foot, move the shift lever to the D range. Operate the accelerator pedal with your right foot and measure the hydraulic pressure Pressure C1, pressure B2 4. Apply the parking brake. Place chocks. 2. Start the engine. 3. While depressing the brake pedal strongly by your lett foot, move the shift lever to the R range. Operate the accelerator pedal with your right foot and measure each hydraulic pressure Pressure B1 1. Jack up the four wheels. Support the vehicle with rigid racks. 2. Start the engine. 3. Place the shift lever in the D range. Depress the accelerator pedal gradually so that a shitting to the 2nd gear takes place, Measure the hydraulic pressure at the engine speed of 2000 rom. Pressure C3 1. Jack up the four wheels, Support the vehicle with rigid racks. 2. Start the engine. 3. Place the shift lever in the Drange. Depress the accelerator pedal gradually so that a shifting to the 3rd gear takes place. Measure the hydraulic pressure when you release the accelerator pedal. LUC OFF pressure 1. Jack up the four wheels. Support the vehicle with rigid racks. 2. Start the engine. 3. Place the shift lever in the D range. Measure the hydraulic pressure. (Hydraulic pressure when lock up is OFF) 4, Depress the accelerator pedal gradually so that a shifting to the Grd gear takes place. Further acceler- ate gradually. Measure the vehicle hydraulic pressure at the time when the Jock up takes place. (Hydraulic pressure when lock up is ON) NOTE: «The lock up in the 3rd gear takes place when the vehicle speed is about 47 km/h and the throttle opening is 6 - 25%, Specifications Measuring condition tem Specitied value (kPa) oo | Running condition ca Do ‘Stal revolving conaiion 930-1120 C1, 82 T a Stall revolving condition 1820-2110 3 [0 | Sra gear. accelerator OFF (When lock unis OFF) | 440-640) BI ° ‘2nd gear, engine revolution 2000 pm | 980-1130 ay hen loc up is OFF | 590.750 When lock up is ON | 20 or essAT-10 Inspection of line (Ci, C: and B) and throttle pressure Gradually depress the accelerator pedal so that a shifting to 3rd gear may take place. AL this time, measure the hycraulc pressure (Hycraulc pressure after the accelerator pedal is released)AT-11 ne RUNNING TEST ‘tems to be observed NOTE: Assure thoroughly the safety on the road during the tests. = The fluid should be at the normal running temperature. (70 - 80°C) Drange test 1. Move off with the D range. Check to see if upshifts and downshifts take place between the 1st «> 2nd, 2nd «9 3rd, 3rd «> 4th (O/D) gears, and if those shitting points comply with the specifications. Moreover, check that there is no abnormal shocks, slipping, etc. 2. While driving with the D range, 4th (O/D), 3rd and 2nd gears, perform kickdown operations. Check fo se¢ if a kickdown takes place from the 4th (Q/D) to 3rd gear, from 3rd to 2nd gear, from 2nd to 1st gear, ‘Also ensure that the limit vehicle speed at which kickdown is possible complies with the specification. Moreover, check that there is no abnormal shacks, slipping, etc. 3. While running with the 4th gear (O/D), ensure that a downshift from the 4th gear (O/D) to the 3rd gear takes place when the O/D switch is turned OFF. 2range test 1. Move off with the 2 range. Check to see if an upshift and a downshift take place between the 1st «> 2nd gears, and if those shifting points comply with the specifications. Moreover, check that there is no ab- normal shocks, slipping, etc 2. Move off with the 2 range. Ensure that an upshift of the 1st to 2nd gear takes place, and no upshift to the 3rd gear takes place. 3. While driving with the 2 range, 2nd gear, perform a kickdown operation. Check to see if @ kickdown takes place from the 2nd to 1st gear. Also ensure that the limit vehicle speed at which kickdown is pos- sible complies with the specification. Moreover, check that there is no abnormal shocks, slipping, etc. 4. While driving with the D range, 3rd gear, move the shift lever to the 2 range. Ensure that a downshitt takes place from the 3rd gear to 2nd gear, and the engine brake is working. Also ensure that the shifting point complies with the specification. Lrange test 1. Move off with the L range. Ensure that no upshift to the 2nd gear takes place. 2. While driving with the D range, 3rd gear, move the shift lever to the L range. Ensure that downshifts take place from the 3rd gear to 2nd gear, and finally to the 1st gear, and the engine brake is working. Also ‘ensure that the shifting points comply with the specification. Lockup test 1. While running in the 3rd gear, gradually accelerate. Ensure that the vehicle speed at which the lockup is turned ON and the engine speed drops complies with the specified timing of the lockup ON. Also check that no significant change in engine speed occurs when you depress lightly the accelerator pedal. 2. Perform the same test for the 4th gear. P range test 1. Park the vehicle at an uphill (about 5° or more). Move the shift lever to the P range and release the park- ing lever. At this time, ensure that the vehicle will not move because of the parking lock mechanism. 2. Perform the same test when the vehicle is parked at a downhill 3. Under the conditions above, check to see if the vehicle moves when the shift lever is moved from the P range to other range - G aToon24-20000AT-12 fl EEE SPECIFICATIONS Shift point speeds Vehicle sent Trot opening dees] Range | Gear siting 2 -anD Teonony mode Gagan | Powermode agra | Exnony node diagram | Pow ode dagen od 6-5 & [Les = Bd ted | 0-88 = [= = » [saosin | e818 © [ie « a ° ain > 3nd 108-118. 113 - 128 100-115 10-125 3nd —> 2nd 5-80 5-60 62-77 + and 15 | 5-40 0-45 5-40 l - yd 20-38 en ee ee % @ [saan 5B * a | 6-21 2d 18 5-8 = oa | 6-21 | anand 122-137 + m5 | . 0- 100%. @DO | sor 200 | 79-4 + T-9 | = teat | A= 88 2 jun aes, © ‘Tne shi point speats ne 152d gs lhe @ range wi the thc opening eo 100% ard ae he sews wt he {the sonomy mec agra or pont ede agra atomalicaly sted, depending upc te vote opening sped, Hence, eval shal be made sed on eer shi poi seed. SPECIFICATIONS Lockup vehicle speed Throttle opening degree | Gear position | Lockup Vehicle speed 1 ac | on 42-57 a i rere BON 2-77 { 3a | oFF 38 ~ 53 At I OFF 58-73 The accelerator pedal should be depressed gradually.AT-13 REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION ARTICLES TO BE PREPARED ‘Shape I Part number. part name Use (09994-87201-000 3 removail instalation of engine tr ee. For removal installation of engine trame sst Z ae 9210-87701-000 Forremoval/instalation of deve Flywnee! holder | ls ng goa High transmission jack Banzai HMJ-450-TW For removal/ installation of transaxle Iyaseka ML450 Engine suppor bridgs Tools ‘Sonied by Banza For suspending engine and transmission r | & | Engine support bridge it nding engine and transmission Vistumen | Torque wrench, dial gauge Libieant_| DEXRON* lor DEXRON? OPERATIONS PRIOR TO REMOVAL, 1. Disconnect the negative (-) terminal of the battery. NOTE: «It must be remembered that, when disconnecting the negative (-) terminal of the battery, the dlagno- ssis contents and memories of the radio, etc. will be erased at the same time. Remove the air cleaner assembly. Remove the intake manifold. Remove the starter assembly. Drain automatic transmission fluid. Remove the propeller front shaft. (4WD vehicles) Remove the propeller shaft Remove the front exhaust pipe. Disconnect the control cable at the transmission side. Disconnect the neutral start switch connector and solenoid wire connector from the transmission. Remove the earth wire. tgomrocsenAT-14 12. Install the engine hanger No. 2 to the engine. NOTE: «The engine hanger No. 2 and attaching bolts are re- placement parts, 413. Hang the front part of the engine assembly, using the en- gine support bridge.AT-15 i REMOVAL AND INSTALLATION PROCEDURES @ Ol evel gauge @ Vacuum hose Engine mounting rear insulator Engine rear suspor member SIA Transmission Ay with wanster Ay © Torque converter Ay © Drive plate & ring gear SiA 2: Tightening torque Non-reusable parts Nm FOEAT-16 MAIN POINTS OF REMOVAL 4. While holding the front of the engine with the engine sup- port bridge, remove the engine mounting rear insulator. 2. Lower the transmission assembly with the transfer assem- bly, which are supported by the transmission jack, until they are brought into contact with the engine rear support member S/A. Under this condition, remove the bolts (two bolts, engine x upper part of transmission), working from the back of the transmission using a long extension bar. Tools: High transmission jack 3. While supporting securely with a transmission jack, etc., remove the engine rear support member S/A. 4, Remove the transmission assembly with the transfer as- sembly, while supporting them with @ high transmission jack, ete. NOTE: © Be careful not to deform the oil pan. 5. Remove the drive plate & ring gear S/A while preventing them from turning using the SST. SST; _09210-87701-000 CHECK 4. Check the drive plate for run-out. Limit: 0.25. mm.2 Install the torque converter to the drive plate. Check the axial runout, using a dial gauge. Limit: 0.3mm NOTE: ‘+ Be careful not to drop the torque converter. MAIN POINTS OF INSTALLATION i- e install the drive plate & ring gear S/A while preventing them from turning by means of the SST. SST: 09210-87701-000 Insert the torque converter assembly to the transmission assembly. Ensure that the insertion has been made posi- tively Specified Value: Dimension A = 16.5 mm or more (Dimension A: Distance between housing end surface and drive plate installation seat of torque converter) REFERENCE: « Ifany difficulty is encountered in inserting the assembly to the specified dimension, slightly lift or lightly push the torque converter repeatedly. Apply Ammix MP grease to the forward end of the torque converter. Grease: MP grease Install the transmission assembly with transfer. (1) Set the engine support bridge in such @ way that the front end of the engine is raised (2) Clean the seal bolt hole of the engine block. NOTE: + The seal bolts are non-reusable parts.AT-18 5. While supporting the transmission assembly with a trans- mission jack or the like, connect the engine. NOTE: © Be careful not to dent the oil pan. '* Before tightening the bolts (engine x transmission) se- curely, confirm that you can lightly turn the torque con- verter by your finger. If not, the torque converter has deviated from the specified position. Remove the trans- mission and insert securely the torque converter to the specified position (Dimension A at page AT-17). (If the bolts are tightened securely with the torque converter deviating from the specified position, the oil pump may be damaged.) 6. Install the bolts (torque converter x drive plate). (1) First tighten the reference bolt of the drive plate. NOTE: + Do not use bolts other than those shown in the right fig ure. (If unspecified bolts are used, it will cause improp- €r tightening or deform the inner shape of the convert- er, thus impairing the functions.) 7. Install the vacuum hose as shown at the right figure. (A to @ Bt0®) OPERATIONS AFTER INSTALLATION 4, Install the earth wire. 2. Install the control cable at the transmission side. 3. Install the front exhaust pipe. 4._ Install the propeller shatt 5. Install the propeller front shaft 6. Fill automatic transmission fluid. 7. Fill oll tothe transfer assembly. (4WD vehicle) 8 Remove the engine support bridge, 9. Install the starter assembly. 10. Install the intake manifold, 11. Install the air cleaner. 12. Perform the basic check and adjustment. 19. Erase the learning values of the A/T ECU, (Refer to AT-35.) saroces ontAT-19 i REMOVAL OF OIL PAN AND OIL STRAINER ARTICLES TO BE PREPARED instrument Torque wrench Lubricant DEXRON® Ml or, Three bond 12818 OPERATIONS PRIOR TO REMOVAL. 1. Drain automatic transmission fluid. REMOVAL AND INSTALLATION PROCEDURES [2 Tightening torque %_ : Non-reusable parts Unit : Nem 1smission oil pan S/A ‘smission magnet trainer SIA roeAT-20 MAIN POINTS OF REMOVAL 1 Remove the attaching bolts of the oil pan. While holding the oil pan with your hand, remove the oll pan flange sec- tion by tapping it lightly with a plastic hammer. Remove the oll strainer. NOTE: ‘« The oil strainer is installed to the valve body by means of a pawl at the position shown in the figure. Therefore, carefully remove the oll strainer by widening the pawl in such a way that no excessive force is applied to the oil strainer. MAIN POINTS OF INSTALLATION 1 Clean and degrease the mating surface. Apply liquid gas- ket to the oil pan at the sections indicated at the right fig- ure. Grease: Three Bond 1281B NOTE: * Be careful not to apply the liquid gasket excessively, (If a large amount of liquid gasket dissolves to the ATF, it may deteriorate the ATF.) Apply the ATF to the O-ring and assemble it to the oil strainer. NOTE: ‘+ The O-ting is a non-reusable part. OPERATIONS AFTER INSTALLATION 1 Fill automatic transmission fluidAT-21 REMOVAL/INSTALLATION OF VALVE BODY ARTICLES TO BE a I Shape Part number, part name I Use + 09350-97201-000 For preventing manual vaive idler Manual valve idier shafiholder | shaft ram cropping Sst | osas0.87202-000 For hysraulic pressure test ‘Automatic transmission set too} Inatrument| Torque wrench Lubricant | DEXRON® tor The "#" mark shows @ newly provided part OPERATIONS PRIOR TO REMOVAL 1, Remove the oil pan. 2. Remove the oil strainer.AT-22 fl REMOVAL AND INSTALLATION PROCEDURES NOTE: ‘+ Prior to the operations, be sure to completely remove sands and mud that have adhered to the exter- ral of the transaxle so that no foreign matters enter the transaxle, + Perform the operations at a clean place free of dirt and dust + perform the operations with bare hands or by wearing vinyl gloves. Do not use working gloves nor cloth to prevent admission of lints. (Use nylon cloth, or paper cloth.) Place removed parts in order at all times. Take a measure to keep them away from dust. Thoroughly wash the removed parts before assembling. After drying, apply automatic transmission fluid (DEXRON? Il or 1), However, do not wash aluminum and rubber parts with alkali chemicals. Never wash rubber parts, such as O-rings, gaskets, oil seals, with cleaning oil (white gasoline or the like). @ (CO: Tightening torque F—: Nonreusable parts Unit: Nem { Manual detent spring & Transmission vaive Bocy Ay & Clutch corwral solenoid Ay No. 3 (C9 & BZ solenai) (Write connector) @ Clutch contral solenoid Ay No.2 (B1 solenoid) (Black connector) & Curch corel solenoid Ay No, 1 (C2 slencic) White connector) @ Transmission Sway solenoid Ay (Soienoi relay solenoid) g O-ring & Transmission 2-way solenoid Ay (Leckup clutch shit solenoid) ning & Owing @ Lookup clutch conto solenois Ay 4 Solenaia wire Ay TORTSMAIN POINTS OF REMOVAL 1. Remove the valve body. (1) Disconnect the solenoid connector and solenoid wire connector. (2) Support the manual valve idler shaft, using the follow- ing SST. SST; 09350-97201-000 NOTE: + Ifthe SST is not used, the manual valve idler shaft will drop when the valve body is removed. As a result, it will be difficult to perform re-assembling on the vehicle. (3) Remove the manual detent spring by loosening the two bolts evenly. (4) Remove the valve body assembly by loosening the six bolts evenly, NOTE: ‘+ Care must be exercised as to the possibility that the 2nd & 4th brake cylinder seal may fall during the re- moval of the valve body. (5) Remove gently the manual valve from the valve body assembly. SIG) “Manual Valve Idler Shaft a eyAT-24 MAIN POINTS OF INSTALLATION 4, Ifthe solenoid wire has been removed, be sure to connect each connector positively until you hear a clicking sound. 2. Install the valve body assembly. (1) Apply ATF to the manual valve. Gently assemble the manual valve to the valve body by letting the manual valve drop by its own weight, After assembling, ensure that there is no abnormal sticking when you move the manual valve back and forth. (2) Make sure that the 2nd & 4th breke cylinder seal has been assembled (3) While aligning the protrusion of the manual valve lever with the groove of the manual valve, assemble them in the transmission case. (4) After temporarily attaching the six bolts, tighten the two reference bolts (* marks in the figure) to the spec- ified torque. Tightening Torque: 6.9- 9.8N-m NOTE: «Before assembling, clean the bolts with compressed air. Be sure to assemble the clamp for the solenoid wire. Be sure to clamp the solenoid wire to the clamp men- tioned above. (6) Tighten the remaining boits to the specified torque. Tightening Torque: 6.9 - 9.8 Nm 3. While aligning the groove of the manual valve with the hole of the valve Body (N range position), by using the follow- ing SST, assemble the manual detent spring, Tighten the bolt @ first, then, the bolt ®. SST: 09351-87211-000 (09350-87202-000) Tightening Torque: 6.9- 9.8.N-m OPERATIONS AFTER INSTALLATION 1. Install the oil strainer. 2. Install the transaxle oil pan. 3. Erase the learning values of the AT ECU. ) C) LB opt Reference hole aeAT-25 REMOVAL AND INSTALLATION OF TURBINE REVOLUTION SENSOR AND OUTPUT REVOLUTION SENSOR Articles to be prepared Lubricant [ DEXRON® mor REMOVAL AND INSTALLATION PROCEDURES: (O: Tightening torque 4: Non-reusable parts Unit : Nem ) Turbine revolution sensor Outgut revolution sensor @OrngAT-26 ELECTRONIC CONTROL SYSTEM HANDLING INSTRUCTION OF ELECTRONIC CONTROL SYSTEM 1, The computer unit and sensors are precision parts. Be very careful not to apply great shocks to these parts during the removal and installation Do not use any part which has been subjected to a great shock, such as the one which was dropped onto a floor. 2. Care must be exercised as to admission of water during the check on @ rainy day or during car wash ing, Be caretul not to allow water to get to the computer unit, sensors, etc. 3, When the computer unit was judged to be abnormal and the vehicle resumes the normal condition after the unit has been replaced, once again install the computer unit which was judged to be abnormal, if you can confirm that the malfunction originally observed Is reproduced, you can make a final judgment that the computer unit is malfunctioning. 4, When a wireless set is mounted on the vehicle, pay attention to the following points. (1) The antenna should be as far away as possible from the computer unit. (2) The antenna feeder should be routed as far away as possible from the computer unit and wire har- ness (minimum distance 30 cm), The antenna feeder should not run parallel to the computer unit ‘and wire harness over a long distance. NOTE: * Anantenna well matched should be used. CAUTION: « Awiteless radio set with a great output should not be mounted. Failure to observe this caution may cause wrong operation of the AT-ECU due to strong effect of the electric waves, resulting in the vehi- cle's failure to run. regoAT-27 i CHECK OF CONNECTORS, ETC. system description 1. System wiring diagram Shift postion Vinaieator Solenoid No; 1 Solenoici No. 2 0 620 2 38. @ a Luce Shit position indicator (R) OD OFF switch —$$€) 010 Check terminal = yr Obtemperature sensor 3 @one § Turgine revolution sensor ee Ss {ofp 4 Garon § Output revoluion sensor }-———“Ovi2_ : Lio) sosed meter @)rort SS Brake etch BFK | 310 Oft-board diagnosis ip, OMG EFI commurication como@® z Banery ae coke = 2 ‘s 0 {ol FENG. IG swier BACK UP Engine revoution sanaor Ohl BAT = an et eee iissAT-28 Diagram showing connector terminal arrangement of transmission control computer ereeles ealealorlealool oh ali) e] is] elusalishole Le Tz seein Fe SN OE | eS | EE TEESE Connector at computer side The terminal numbers shown above are the same as those for he sub-hamess and EF! computer check, ae ECU connection connectors at vehicle hamess side [ko] Symbar Connected 10 hol Smo Connected to O|__ Bt SaROENG. 1+) @l Br | Solenoid No.1) @| cas ‘Solenoid No. 2(+) |2 co | Solenoig No. 2 (-) @|_cae2~ Solenoid No. 3(+) | caBe- | Solenoid No. 3 (-) @[ wee Duy solencie @ ae = ® UCR | LUC solenoid 2) £02 Earn @| sour [ Switch solenci¢ 3] 01 Earn @| Ror ‘Quipat revolution sensor al m I = @|__RENG Engine evolution signal is — ul = ® = - (s. al = | _SPDO___| Vehicle speed signal @ nell = ove INT sensor power 3 £2 __| Sensor eanh ® = = a E___| Signe! earth | = | = [@|___ GTP __| Fuvia temperature sensor al = = a ATEN | Turbine revolution sensor al = | = [2 Come _| EF\seriel communication shield el OL OD OFF lam |e = - 2 P Neutral start switch (P) 3 COMO, EFI serial communication output @ = = @|___ COMI __| EFlserial communication input 3 = = @ SIO___| Diagnosis tester 2) = = 2 L [ Neutral stan switch (L) a] T ‘Check terminal @ 2 [Neutral stan ewiten (2) 2) OID O/D cut switch e D | Neutral start switch (0) @| BRK Brake lamp switch |g N Neutral start switch (N) a = ‘Ss = a | Neutra! stant switch (R) | _Bar Battery power a SEL___| Shitlamp urinated 2 +82 Battery power S RNG2 | Shift range signal 2 @ Bi Battery power &)__ANG?__| Shiftrange signal 1AT-29 LOCATION OF COMPONENTS OD OFF lamp * ‘Check connector Nautral stant switch '\ Engine contro! computer fic temperature sasor ‘Switch solencig f LUC solenoie Duty solenoia_/ NOTE: M Ghihe LHD vehicles, as for the asterisk-marked parts, they are installed symmetrically between the right and left sides.AT-30 LOCATION OF COMPONENTS (VALVE BODY SECTION) ‘Switch solenoid \ LUC solenoid \, Solencial wire oO Solenoid No. 2 Duy solensid | (ig temprature sensor Solenoid No, 3 ‘Solenoid No. 1AT-31 DIAGRAM SHOWING ARRANGEMENT OF VEHICLE HARNESS SIDE CONNECTOR TERMINALS For the terminal names of the vehicle harness side connector of the transmission control computer, refer to the system wiring diagram. czy = = og piste apap peya ve] fos)vafer| ola [or] eel] ase fefalsiists} [sizlelvlalnisie) [elole[alslolslere ssa] ss 54 og ae ol . armtcomy ATNE(RENG) STEEN parentheses) are tbe poiion of A/T EGU nee oo — = tee) erated ee ered ole) eee ast astele|s| fabeeor la] [alelslelelsla7e) [oisistetssieere tse 1 exes Tees Tee Torl es) [eslrotn Xela) [re rele 7s “aTRX(COMO} luce LueR, SOR ta 2 via RR 2 OPT RTBN Turbine revolution sensor Output revolution sensor Neutral start switch Solenoid wire paar = sip OD OFF switch Brake switch oon = on. 2 PN AP Telslelreleen] [els Tete [riots hal glrel se! arta} Dol belsle| ss] ee) 7] 3 Se (Combination meter 8) ARTICLES TO BE PREPARED Tee Pan number, part name Use 09842.97205-000 Transmission control computer check sub-harness Transmission control computer check (09991-87404-000 Engine contro system inspection wire Start and erasure of diagnosis ss nae a aGee tartand erasure of diagnosis Diagnosis check wire Sea eraseye roe | (09990-97201.000 For in-vehicle check of solenoid wires AMT solenoid wire check sub-hamess | instruments Instrument] Tester, Osciloscope, DS-21 clagnosis testerAT-32 OPERATING INSTRUCTIONS Handling of connectors 1. Before disconnecting @ connector from its terminal or connecting it, turn OFF the IG switch or discon- ect the negative (-) terminal of the battery. Otherwise, the computer will judge that an open wire oc- curs in the harness and fail safe function will be applied. 2. When disconnecting a connector, do not pull its harness. Be sure to pull it with the connector unlocked. When connecting a connector. push it securely until a clicking sound is emitted and the lock is applied, 3, When applying a tester probe to the connector, insert the tester probe from the back of the coupler (harness side) Incases where the tester probe can not be inserted from the back, for example, in waterproof couple's, apply the tester probe, being very caretul not to deform the cennector terminal. 4, Donot touch directly the connector terminal by hand. Wire hamess and connector checking procedure When checking wire harnesses and connectors during a system check, follow the procedure given below. CONTINUITY CHECK 1. Disconnect the connectors at both ends of the harness concerned. 2. Measure the resistance between the terminals concerned of the connectors at both ends. Specified Value: 10 Q or less NOTE: ‘© Measure the resistance while lightly shaking the wire harness In up-and-down and right-and-left di- rections. Open wires hardly take place at the center of the wiring of the vehicle. Rather, most open wires take place at connectors. Special care must be paid as to the connectors of the sensors, etc, CHECK OF SHORT 4. Disconnect the connectors at both ends of the harness concerned, 2. Measure the resistance between the terminals concerned of the connectors at both ends Specified Value: 1 MQ or more NOTE: © Measure the resistance while lightly shaking the wire harness in up-and-down and right-and-left di- rections. 3. Measure the resistance between the terminal of the connector concerned and a terminal which is in the same connector as that one (except between the power systems, or between earth systems). Perform the check at the connectors at both ends. Specified Value: 1 MQ or more NOTE: ‘= Some short circuits are produced by wires of the vehicle interior which are caught by the body, or by faulty clamps. sareoorr 0002AT-33 i VISUAL INSPECTION AND CONTACT PRESSURE CHECK ‘Disconnect the connectors at both ends of the harness concerned 2. Visually check that there is no rust formation nor admission of foreign matters at the connector termi- nals. 3, Engure that staked sections exhibit no looseness nor damage. Also ensure that the wire harness will not be pulled off when you pull lightly the wire hamess from the coupler. 4. Prepare the same terminal as the male terminal of the connector terminal. Insert this terminal into the fe- male terminal. Check the pulling force. When some terminals have a smaller pulling force compared with other terminals, these terminals may have poor contact NOTE: «When terminals have rust formation, admission of foreign matters, or poor contact due to @ drop of the contact pressure between the male and female terminals, such problems sometimes are solved by removing the connectors and installing them again. Hence, first check the wire harnesses and connectors. If they are normal, confirm the malfunction phenomenon again. If the malfunction is no longer reproduced, you may conclude that the wire harnesses and connectors were causing the problem. POWER SUPPLY CIRCUIT CHECK Checking procedure Perform the power supply circuit check during the check according the system, following the procedure given below. Repair any faulty circuit or connector. If they are normal, replace the computer unit 4. Visual check and contact pressure check of computer unit connectors Check the connectors of the computer unit. 2. Earth circuit check of computer unit Disconnect the connector of the computer unit. Measure the resistance between each earth terminal and the body earth Specified Value: 10 Qor less 3. Power supply circuit check of computer unit Disconnect the connector of the computer unit. Measure the voltage between each power supply termi- nal and the body earth. Specified Value: Battery voltage NOTE: «During the check of the computer unit, some problems are solved by disconnecting connectors, for this operation can change the contact state of the terminals. Therefore, if the check results of the ‘computer unit circuit suggest the possibility of the computer units fault, first connect the computer unit connector again and see if the problem stil persists. Then, consider whether the computer unit is normal or malfunctioning. * Measurements by the diagnosis tester are also possible, sxresrsoatcoAT-34 DIAGNOSIS CHECK When any malfunction takes place in the input or output sys- tem of the computer, the O/D OFF light flashes. In this case, you can know the content of the malfunction in the following way. Checking method without using diagnosis tester (1) How to display diagnosis codes With the ignition switch turned ON, short the test termi- nal of the DLC (data link connector) located under the glove box with the earth terminal. Then, the O/D OFF light flashes in a certain pattern according to the con- tent of the maifunction. ‘You can know the diagnosis codes from that flashing pattern by referring to the attached table. ‘When there are more than one diagnosis codes, these codes are repeatedly displayed one by one. CAUTION: «Never short an undesignated terminal, for it will cause maitunction, «When the check terminal is shorted, the warning lamps other than that of the electronically-controlled A/T sys- tem will flash. However, it does not mean that the sys- tem is matfunctioning. ry J DLC (Datalink) ON Data ink connector terminal terminal Terminal T During normal period (Flashing) [0/0 OFF} lamp During abnormal period (in case of codes 13and 31) ore IMlustration 1 [ne on Terminal T OFF- During normal period [0/0 OFF] lamp O59 oN During abnormal OF ! period a see Ilustration 2 (Warning function) Tea(2) How to erase diagnosis code To erase the diagnosis codes after completion of re- pair, turn OFF the ignition switch and keep the backup fuse removed at least 30 seconds. (\llustration 2) NOTE: + When the backup fuse is removed, the memories in the radio and clock are reset. You need to set them again. Checking method bby using diagnosis tester (1) How to display diagnosis codes Connect the DS-21 diagnosis tester or general ciagno- sis tester to the DLC (Data link connector) located under the glove box. When you select the diagnosis code display menu of the diagnosis tester, the diagnosis code will be dis- played. CAUTION: «Before connecting/disconneeting the DLC with/from the diagnosis tester, be sure to turn OFF the ignition switch and switch off the power of the diagnosis tester. If con- nection/disconnection is made with the power switched ‘on, the diagnosis tester may be damaged. NOTE: * As for how to use the diagnosis tester, see the instruc- tion manual of the diagnosis tester. (2) How to erase diagnosis code You can erase the diagnosis codes after completion of repair, by going to the diagnosis code erasing menu. For further details, see the instruction manual of the di- agnosis tester, AT-35AT-36 em ERASING LEARNING VALUES OF TRANSMISSION CONTROL COMPUTER Erasing memory without using diagnosis tester When the automatic transaxle assembly and valve body assembly (including the solenoid valve) have bee: replaced. it is necessary to erase the learning values of the transmission control computer. To erase the learning values, follow the procedure given below. Erasing memory without using diagnosis tester 1. Short the terminal ECUT with the terminal E in the check connector. (Refer to page AT-34) 2. Depress the brake pedal within three seconds aiter the ignition switch is set to the ON position (without starting the engine). Keep the brake depressed, until the operations in the steps 3 and 4 are complet- ed, 3. Move the shift lever from P + R + P within one second. (The time spent for moving from P + R — P should be within one second.) 4, Repeat the step 3 above eight times. 5. Set the ignition switch to the OFF position. Set the ignition switch to the ON position again. 6. Run the vehicle in an urban area for about fifteen minutes. (Go through all operations, such as shifting to each gear and kickdown operations.) g memory by using diagnosis tester 1. Connect the diagnosis tester to the vehicle. Set the ignition key to the ON position. 2. Execute Erasing memory from the individual function of the diagnosis tester. 3. Set the ignition switch to the OFF position. Remove the diagnosis tester. Set the ignition switch to the ON position. 4, Run the vehicle in an urban area for about fitteen minutes, (Go through all operations, such as shifting to each gear and kickdown operations.)AT-37 TT TROUBLE-SHOOTING TROUBLE-SHOOTING PROCEDURES The engine control system is equipped with the diagnosis function which diagnoses the malfunctioning points. This gives important clues when performing the trouble shooting. ‘The diagnosis of this system is provided with the battery backup function (function which supplies power for the diagnosis memory even when the ignition switch is turned OFF), Refer to AT-34 Reconfitmation of malfunctioning phenomenon Preliminary check Reconfirmation of diagnosis cove ‘Abnormal Normal Trauble-shooting according to Manual shitting test”) Refer to AT-3 ‘agnosis code* Refer to AT=40 Check of trouble shooting Function test* according to maifunction (Stall test, time lag test, nycraulic ‘phenomenon fest, roaditest) Rafer to AT-66 Rater toAT-6 ‘Troubleshooting table according to phenomena Paster 10 AT-68 Repair or replace. ‘Confirmation test (Has vehicle resumed its normal operations?) *: Rafer to “INSPECTION”,AT-38 fl LUE EEE DIAGNOSIS THROUGH QUESTION-AND-ANSWER When you try to remove the cause of a malfunction that is occurring in the vehicle, it you have not con- firmed the malfunction phenomenon, you can not pinpoint the cause and the vehicle may not resume the normal condition in spite of your efforts. The purpose of diagnosis through question-and-answer is to.col- lect information from the customer before you confirm the malfunction phenomenon. The diagnosis through question-and-answer gives you an important clue to reproducing the malfunction phenomenon. Furthermore, the information obtained in the diagnosis through question-and-answer will be very helpful in the trouble-shooting process. Therefore, rather than merely performing diagnosis through question-and-an- swer, itis necessary to get information specifically regarding the malfunction. The following is an example of the diagnosis through question-end-answer sheet which you will surely find it very useful. If you make the most of this sheet, it wll avoid failing to ask important questions. (The diagno- sis through question-and-answer sheet of JIS A4 size has been provided at this page. You may photocopy and use it.) [Diagnosis through question-and-answer Sheet) Diagnosis through cussion and-answer shest Name of customer Vericie model Engine: K3VE Transmission: 4WD, 2WD “g] Frame Ne Date ofregsiation Date when railuncion tok pace | Mieage kn 3 3 | Equipment: Te (Bs. racial, srow, spike omer Wheel {steel aluminum] B) (Sex of customer (ariver). | (Age) [Occupation] | [Pincgalareawnerevetceis used] | [Parking lt) 3B) Male Famala | about Towntubussashoimaunainiter | Outceorindoor Phenomena Conerete contents «= Wil not move forwara Vehicle wit not run ‘= Will not move backward, 1 Poor engine starting ane = Clutch slips 5 poslecidaningian = Moves off at F or W range. 3 =e | + Shiting wil not take place. | Fev omer eng | s Shiting point deviated. * Big shifing shock Shifting shock, ime lag | « Long time lag att | 1 Engine races up dt omners ‘whan ralnatonteyantwacest | » Since vehicle was new ~Recenty (since month yea ‘Occurrence frequency |< Atalltimes + Under certain circumstance ( )__ + Frequent ‘Meteorological conditions | + Atal times SFing =Cloudy «Rain *Snow —« Others( ) Weather Jeatner __| Temperature (about?C) (Spring, summer, autumn, winter) Temperate Road Town «Suburs «High way» Mountainous road (climbing. downhill) “No relations «+ During running During stating (Wenicle spese: kmh) Driving conditions * During racing {Engine revolution: rpm) During turing (eRighttuming Left tuning) Other situation lncicaldn it ance During checking | +Nermal + Abnormal code ( 2 ‘Second time ‘= Normal» Abnormal code ( )AT-39 ee eeeSeSeSeSeSeSSSNSFSsS ee CONFIRMATION OF PHENOMENON When performing the trouble-shooting, itis impossible to pinpoint the cause, unless first the operator con- firms the phenomenon. In order to confirm the phenomenon. it is indispensable to reproduce the maifunc- tion phenomenon concerned by producing the conditions and environment similar to those where the mal- function took place, based on the information obtained at the time of the diagnosis through question-and- answer. As for the phenomenon which is difficult to reproduce, it js necessary to produce the situation close to the running conditions where the malfunction took place (toad conditions, meteorological conditions and ori- ving conditions), based on the information obtained at the time of the diagnosis through question-and-an- swer. To this end, it is of great importance to produce the phenomenon perseveringly by applying external factors, such as vibration (moving wire harnesses or relays by hands), heat (applying hot wind) and water (giving humidity), RE-CHECK OF DIAGNOSIS CODE Re-check the diagnosis code after confirmation of the malfunction phenomenon. In this way, itis possible to judge whether the system for which the code was indicated before confirmation is now functioning properly or the malfunction stil persists. 1. In.cases where the malfunction takes place at time of re-confirmation and the a’bnormaiity code still per- sists even after the re-confirmation, perform the trouble-shooting according to the codes. 2, Incases where the maifunction took place but the normal code is now indicated after the re-confirma- tion, most likely the malfunction is caused by systems other than the diagnosis system. Therefore, per- form the checks described in the trouble shooting table on the next page or the checks of trouble shooting according to malfunction phenomenon (Refer to AT-68), 3. in-cases where no maltunction took place and the normal code is indicated after the confirmation, most likely the harness or connector sections had malfunctions, such as poor contact in the past, but now those sections are functioning normally ‘Therefore, check the system for which the code was indicated before confirmation of the phenomenon.AT-40 fl Tea TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE LIST OF DIAGNOSIS CODES Pacer Sera ore. Contents of malfunction ne aaigist | 2 ciate [Pdication] memory page po70s | 8 | © | x | Nonoutal sar switch input Arse POTOS 56 ° oO ‘Multi input of neutral start switch AT-44 pari | 738] | 0] Onen wire or shor of fluid tomperature sensor eeu ATO pari | 738 | 0 | O| Abnormal rising characteristics of fui temperature of hid temperature sensor | AT-60 pois | a7 | | 0 _| Nowurbine revolution input [ar62 por20 42 | 0 | 0 _| Neoutputrevoluion input [aT Pores 86 o fo No engine revolution input | ATs pores [61 | 0 | 0 | Open wire or short f solndid Ne. 1(B1) oreut [ata sores | 62] 0 | 0 | Open wire or short f solenoid No. 2 (C2) circuit [aso sores | 63 | 0 | 0 | Open wire or shart af solnaid No. 3 (63/82) cireut [ars pores | «| O | 0 | Onen wie or short of duty solenoid cireut [LATeSe por7a| 65 | 0 | _O | Open wie or short ofLUC solenoid creut ATS Prez | 62 ° © _| Fauity communication with EFLECU [Arse P1703 72 o[| 6 Lookup revolution speed not matching | AT-41 P1780 56 oo} 0 ‘Open wire or short of switch solenoid circuit | AT-64 * Denoies those output code when the DS-21 in used saver ansAT-41 DIAGNOSIS CODE NO. P1703 4. The diagnosis code No. P1703 is outputted from the A/T ECU if the engine revolution speed differs greatly from the turbine revolution speed when the torque converter is operating in the direct lockup state. Checking points 1. Isthe valve body assembly normal? 2. Isthe torque converter assembly normal? sees Checking method Li up the vehicle ‘Start the engine. With the shift lever placed in the D range, depress the accelerator pedal gradually, unt an upshit to the 3rd gear lakes place. Further, accelerate the Senicie gradually. Measure the LUC ON pressure ang LUC OFF pressure wren the direct lockup takes place Specified Value: ‘LUC ON pressure - LUG OFF pressure = 6.0- 7.0 kale? NOTE: + In cases where the hydraulic pressure is measured again after the indication of & waming has been made, stop the vehicle. Proceed to put the shift lever in the N range. ‘Then, place the shift laver to the D range again before the measurement. ener ee ee ed oK Ne ‘Torque converter malfunctioning peices | RET [Wave body matunotoning SS a anceAT-42 en ———— DIAGNOSIS CODE NO. P0720 1, The diagnosis code No. P0720 is outputted when ECU of A/T evaluates that malfunction has occurred in the output rotation sensor. Evaluation Conditions: ‘When the vehicle is running at a speed of 5 km/h or more, the present vehicle speed is compared with that 16 ms before. If deceleration exceeds a certain level, itis evaluated that the output revo- lution sensor is malfunctioning, thereby outputting the diagnosis code No. P0720. sntoras acco Checking points 1. Is the neutral start switch maifunctioning? NOTE: When the neutral start switch is matfunetioning, the diagnosis code P0720 may also be outputted. 2. Is the signal from the output revolution sensor inputted to the ECU? 3. Is the harness between the output revolution sensor and the ECU normal? 4, Is the output of the output revolution sensor normal? ‘Arrangement of ‘connecior terminals @Gnd. Bvout. Ove yMi2__/ ROPT eroe|os|ealeaezle eohohenzfeps] fshsharvolstel7|(6[s]s]ale[y fsa) als rTsol-5]eale71olasl2a|-a|42] [ar aolsofaelsrIsel=sle4 (33|32151|50]29}23] 2 Arrangement of SST terminals odar an Wher IG switch is umed ON. is the voltage between @ (E2) and O)(V12) of SST about 12V7 Yes, NO ‘When the vehicle sions is the volage between @ and @ (ROPT and E2) of SST about § V7 xo |_—_J Gheckthe power supaly creut Yes ‘Ghack continuity ofthe harness ofthe output revoluion sensor. '*@ (GND) of sensor side connector and 8 (E2) of ECL side comector * @IVOUT of sensor side connector and @) (ROPT) of ECU side connector +# DIVOC) of sensor sie connector and (D)(V12) of ECU side connector ves Trcreckal oso rerio sense alr ATT?) orem eee ‘Check each connector for connecting state, ‘Output revolution sensor fauty Waveform of volage between E2 and ROPT ‘dung eutout revolutionAT-44 ON DIAGNOSIS CODE NO. P0705 1. The vehicle can resume to the normal condition. The diagnosis code No. P0705 is outputted from the A/T ECU when abnormality takes place in the input from the neutral start switch. Evaluation Conditions: “The diagnosis code No. P0705 is outputted when no signal is available from the neutral start switch for 2 seconds or more, or when more than one signals are inputted from the neutral start switch for 2 seconds or more. NOTE: «The diagnosis code No. P0705 is not memorized in the ECU, It is erased when the neutral start switch resumes the normal condition. Checking points 1. Is the harness between the ECU and the neutral start switch normal? 2. Is the output of the neutral start switch normal? ct Shit postion indicator Neural star switch connector fa2|31 [20] zo] 2a] | (vehicienarness sige) ae 3 else es] pelesliel hols [ST EE 4 sea solalalatelsel) 2] alot sli WT -li l } RND2ZL Arrangament of SST terminalsAT-45 eS INSPECTION PROCEDURE ‘Connect SST to between ECU and harness at vehicle side Aa ‘wit ignition switch tured ON. measure vokage between SST terminals 19 and body earth. NG “Tum OFF the engine swiich. Disconnect the connectors of the ECU and neutral start switch. ‘Specified Vottage: ‘During P range: 0.5 Vor less During range other than P range: Battery voltage OK ——_— Se ‘With ignition switch tured ON, measure voltage ‘between SST terminals $} and bey earth, NG Specified Voltage: During R range: Battery voltage | During range other than R range: 0.5 Vorless | OK | v Win ignition switch tuned ON. measure voltage between SST tarminals £8 and body earth No 1 ¥ Perform unit check of newtral start switch. Wen shiting is mage to each range, ensure that continuity exists Between the following terminals and no ‘continuity axists benieen other terminals, During P range: Terminal (P-£)@ -® During R range: Terminal (R - AB) D 2 During N range: Terminal (N-E)3)- 6 During Drange: Terminal (O-)2- © During 2 nga: Terminal (2 During L range: Terminal (LE) OK Tne uk seo ae ese seeeeeSeece ir Or replace shitt postion switch, Specified Voltage: ‘During N range: 0.5 V or less During range other than N range: Battery voltage qos start switch EGU News sa sien ¥ @- oP Win ignition swich turned ON, measure vollage a - De) Detween SST toeminals @ and booy earth ie a: bw ‘Spectied Voltage: g- 30 ‘Dunng D range: 0.5 Vor less > 2@ During range other than D range: Battery votage ou OK OK [NG eee eee x [ Repaircr repiece ‘Wn ignition switch turned ON, measure vattage hamess. between SST terminals & and boay earth a 4 Ensure thet continuity exists between the following ‘conneetor terminal at newral siart switch side and Connector terminal at ECU side. ECU harness Neutral Specified Voltage: During 2 range: 0.8 V or less During range other than 2 ranger Battery voltage Ensure tnat no continuity exists between the body earth ‘and the following terminals of the harness. ECU Newwal ar swith 4 Br) - Ow) gh Om) ¥ m- Om ‘Win ignition teh turned ON, measure vatlage 80 - do ‘between SST terminals @ and booy earn aa BQ) - 22 ‘Species Votage: i! saa ‘During L range: 0.5 V or less oa "7 During range other than L range: Battery votage t ¥ {= a ssepeeeeeO estes tee ¥SOOepeS Ee eeseneeneESEEEE (Chack powerline of ECU, (Check each connector for connecting condition. Repair or replace the harness. . as iS Replace the EOU. Repair or replace the connector. TaeAT-46 ae DIAGNOSIS CODE NO. P0725 1. The diagnosis code No. P0725 is outputted when ECU evaluates that malfunction has occurred in the engine rotation signal. Evaluation Conditions: ‘When no engine revolution signal is inputted from the EFI-ECU after the engine has started, this code is outputted. swseooseanonn Checking points 1, Is the signal from EFI-ECU inputted to the ECU? 2. Is the harness between the EFI-ECU and ECU normal? EFI cou TNE PENG ecu Fsfelpols ie] [Tes] <[s] 2 [z2[ai[eolsolselo7] (2slss| 4131321 si|s0l23} Psl2b D) Gear shi shock and tne ag oo large (MR) fanges oer han P and N anges Peaking wilt work ete Peaking cannot be released q 3 1 No tr shiting (ve at he ‘Aer siting fo parking, sipping culo gear orcs ils ql i z i y Shi can not be made opasking No gsr shiting (bed at 1 gear) Engine can sta 3AT-67 Causes a vein side “aneing3 ]0 0] OT OT OOO Tame adoro ree UNOR CLI moj ooraii ||) alee [ala ANS 1 pap SAU OSS Head AAA ‘avOYs 10 ‘papaUUOOSIP 1ORURS UONMIONS) BUGHAL | DaERUUOESp OAaUED HOLES | oid) Opava pins VRS ana | pe A ANG wae OND 00109 300 aE BAO © High passivity © Average possibly. Low posibily The unt proper Daub ou WARIS ay Dua fine Gunde vos Buea “ne nds wap Boe aubye ou pos wo Bueg os wed eg paige vow) ay TUN pe Aveo VSWAS VES MAN Bu Ba pm ap Oda abe “ana ona Rew 300 ‘ejauiasse Jou aipeau Aleiautig ‘Aue yous apaWAW Aine; 2 uns wos | re eS oes | ne Ou eos yeUS fu G95 18S Pape hadoxiur evan 28 vis as vad 2a | june ze | una 386 Za pare Ado eoveRaR 1 00S WSL “Rie yung 260 18 e RacorG Ue ED re ano onbIOL Hydraulic pressure conta sytem Ton 0 wi) Baro US <<[1) ‘ r time lag too tare | i ‘ ine ime Ge shit sock and Gear shit shock and Gear shit shock and Gear sit shock and Gear sti shock and ‘p08 Ou noise related to engine revolution trom parking section NP) fom converter housing 5 ea sh 00 large to a pan Creep, ie wrt oo age os (a tine of lookup uncon) noise Vibration ai noe Engine revs up dutng pear shi (23) Engine rvs up cutng gear shit (3 > 4) Lockup mil not union. Por hel economy and poo unning Vibration during running to age Gear sits nly in t= 3 yeas, Atom ‘Aoxa ono Abo 1 A Sumas 3AT-68 ————— CHECKING PROCEDURE (1) Starter will not operate. 1. Check and adjustment of control cable (Refer to AT-4.) 2. Check and adjustment of neutral start switch (Refer to AT-4.) 3. Check of engine cranking system (2) Vehicle will not move forward nor backward. 1. Check of oil level (Refer to AT-2.) IFitis OK, go to step 2. Ititis NG, adjust the oil level. 2. Check and adjustment of control cable (Refer to AT-4.) Ifitis OK, goto step 3. itis NG, adjust the control cable. 3. Manual running test Disconnect the connector of the A/T ECU. Check the gear position of each range. Ifitis OK, goto step 4 IFitis NG, go to step 5. Specifications Range Bw | oBu ® ‘Gear postion Neutral 3d Reverse 4. Check of ECU power supply circuit (Refer to AT-33.) ititis OK, replace the A/T ECU, If the malfunction still persists after replacement, go to step 5. Ifit is NG, repair the connectors or circuits concerned, 5. Remove the oil pan. In the N range, ensure that the manual valve groove is aligned with the hole at the valve body side. (Refer to the AT Unit service manual.) It itis OK, go to step 6. Ifitis NG, adjust the manual valve. 6. Replace the valve body. If the malfunction stil persists, go to step 6. 7. Measure the LUC OFF pressure at time of lockup OFF. (Refer to AT-8.) Ifitis OK, replace the torque converter assembly. Itit is NG, go to step 7. 8. Remove the automatic transmission from the vehicle. Check it for cracks of the drive plate and loose bolts. Itit is OK, go to step 8. Itit is NG, replace the drive plate or tighten the bolts. 9. Replace the oil pump assembly,AT-69 SSS (2) Vehicle will not move forward. 1. Check and adjustment of control cable (Refer to AT-4.) Ititis OK, go to step 2. fit is NG, adjust the control cable. 2. Manual running test Disconnect the connector of the A/T ECU. Check the gear position of each range. Ifitis OK, goto step 3. IFitis NG, go to step 4. Specifications Range L et O20 @ Gear postion | __Newtral 316 Reverse 3. Check of ECU power supply circuit (Refer to AT-33.) Ifitis OK, replace the A/T ECU. If the maifunction stil persists after replacement, go to step 5. If itis NG, repair the connectors or circuits concerned. 4. Remove the oil pan. In the N range, ensure that the manual valve groove is aligned with the hole at the valve body side. If it is OK, go to step 5. If it is NG, adjust the manual valve. (Refer to the AT Unit service manual.) 5. Unit check of solenoid No. 2 (Operation) (Refer to AT-77.) If it is OK, go to step 6. If it is NG, replace the solenoid No. 2. 6. Replace the valve body. If the malfunction still persists, replace the automatic transmission assembly. (4) Vehicle will not move backward. 1. Check and adjustment of control cable (Refer to AT-4.) Ifitis OK, go to step 2 Ititis NG, adjust the control cable. 2, Manual running test Disconnect the connector of the A/T ECU. Check the gear position of each range. Ifitis OK, go to step 3 Ifitis NG, goto step 4 Specifications Range ew | | B Gear pos! Neutral | [Reverse 3. Check of ECU power supply circuit (Refer to AT-33.) ifit is OK, replace the AT ECU. If the malfunction stil persists after replacement, go to step 5. Ifitis NG, repair the connectors or circuits concerned. 4. Remove the oil pan. In the N range, ensure that the manual valve groove is aligned with the hole at the valve body side. (Refer to the AT Unit service manual.) Ifitis OK, replace the automatic transmission assembly. Ifitis NG, adjust the manual valveAT-70 a a (6) Engine stalls when shift is made from N to D-R. 1. Check idle speed. (Refer to AT-2.) Ifitis OK, go to step 2. It itis NG, repair the engine idling system 2. Unit check of LUC solenoid (Operation) (Refer to AT-77.) Ifitis OK, goto step 3. Ifitis NG, replace the LUC solencid, 3. Replace the valve body. Ifthe malfunction stil persists, replace the torque converter assembly. (6) Clutch slip takes place in 1st g 4, Check of oll level (Refer to AT-2.) Ifitis OK, go to step 2. if itis NG, adjust the oil level. 2. Check and adjustment of control cable (Refer to AT-4.) Ifitis OK, goto step 3. is NG, adjust the control cable. 3. Manual running test Disconnect the connector of the A/T ECU. Check the gear position of each range. IFitis OK, go to step 4. IFitis NG, go to step 5. Specifications Range ®-s) oO | @ ‘Gear postion Neutral 3d___|__Feverse 4. Check of ECU power supply circuit (Refer to AT-33.) ffitis OK, replace the A/T ECU. If the malfunction stil persists after replacement, go to step 5. if it is NG, repair the connectors or circuits concerned. 5. Remove the oil pan and strainer. Check the strainer for cut or wear of the O-ring Ifitis OK, go to step 6. Ititis NG, replace the O-ring of the strainer. 6. Inthe Nrange, ensure that the manual valve groove is aligned with the hole at the valve body side. Itit is OK, go to step 7. Ifit is NG, adjust the manual vaive. (Refer to the AT Unit service manual.) 7. Unit check of solenoid No. 2 (Operation) (Refer to AT-77.) Ititis OK, goto step 8 It it is NG, replace the solenoid No. 2. 8. Replace the valve body. if the maifunetion stil persists, replace the automatic transmission assembly. vaooiss0m0AT-71 FSF (7) Clutch slip takes place in 2nd gear. 1. Check of oil level (Refer to AT-2.) Ifit is OK, go to step 2. Ifitis NG, adjust the cil level 2. Manual running test Disconnect the connector of the A/T ECU. Check the gear position of each range. Ifitis OK, goto step 3. If itis NG, goto step 4 Specifications Range Ow | O80 | B (Gear position Neural | ad [Reverse 3. Check of ECU power supply circuit (Refer to AT-33.) Ifitis OK, replace the A/T ECU. If the malfunction stil persists after replacement, go to step 4. If itis NG, repair the connectors or circuits concerned. 4, Remove the oil pan and strainer. Check the strainer for cut or wear of the O-ring. If itis OK, go to step § Ifitis NG, replace the O-ring of the strainer. 5. In the N range, ensure that the manual valve groove Is aligned with the hole at the valve body side (Refer to the AT Unit service manual.) If itis OK, go to step 6 Ifitis NG, adjust the manual vaive. 6. Unit check of solenoid No. 2 and duty solenoid (Operation) (Refer to AT-77.) Iitis OK, go to step 7. Ititis NG, replace the solenoid concerned. 7. Replace the valve body. If the matfunction still persists, replace the automatic transmission assembly. (8) Clutch slip takes place in 3rd gear. 1. Check of oil level (Refer to AT-2.) Ifitis OK, goto step 2. Ifitis NG, adjust the oil level 2. Manual running test Disconnect the connector of the A/T ECU. Check the gear position of each range. IWitis OK, go to step 3, Ititis NG, go to step 4 Specifications Range | ew | oe @ Gear position [newtal 30 Reverse 3. Check of ECU power supply circuit (Refer to AT-33.) Ifitis OK, replace the A/T ECU. If the malfunction still persists after replacement, go to step 4, If itis NG, repair the connectors or circuits concerned, 4, Remove the oil pan and strainer. Check the strainer for cut or wear of the O-ring, If itis OK, go to step 5 It itis NG, replace the O-ring of the strainer. 5. In the N range, ensure that the manual valve groove is aligned with the hole at the valve body side, (Refer to the AT Unit service manual.) Iritis OK, go to step 6. Itt is NG, adjust the manual valve. swrcotoceoonAT-72 i 6. Unit check of solenoid No. 2, solenoid No. 3 and switch solenoid (Operation) (Refer to AT-77,) Ifitis OK, goto step 7. Itt is NG, replace the solenoid concerned, 7. Replace the valve body. If the malfunction still persists, replace the automatic transmission assembly. (9) Clutch slip takes place in 4th gear. 1. Check of oil level (Refer to AT-2.) Ifitis OK, goto step 2. Ifit is NG, adjust the oil level. 2. Manual running test Disconnect the connector of the A/T ECU. Check the gear position of each range. itis OK, go to step 3. Ifitis NG, go to step 4. Specifications Range [ ow |] OU @ Seeaie add a Reverse 3. Check of ECU power supply circuit (Refer to AT-33.) Ifitis OK, replace the A/T ECU. If the matfunction still persists after replacement, go to step 4. If itis NG, repair the connectors or circuits concerned 4, Remove the oll pan and strainer. Check the strainer for cut or wear of the O-ring, Ifitis OK, goto step 5. If itis NG, replace the O-ring of the strainer. 5. Inthe N range, ensure that the manual valve groove is aligned with the hole at the valve body side IF itis OK, goto step 6. Ifitis NG, adjust the manual valve. (Refer to the AT Unit service manual.) 6. Unit check of solenoid No. 2, solenoid No. 3 and switch solenoid (Operation) Ifitis OK, go to step 7. ifit is NG, replace the solenoid concerned. (Refer to AT-77.) 7. Replace the valve body. Ifthe malfunction still persists, replace the automatic transmission assembly, sone. 0099AT-73 Neen eee EEE EEE ESSE (10) Clutch slip takes place in R range. 1. Check of oil level (Reter to AT-2.) If itis OK, go to step 2. IFitis NG, adjust the oil level. 2. Check and adjustment of control cable (Refer to AT-4.) IFitis OK, go to step 3. If itis NG, adjust the control cable 3. Manual running test Disconnect the connector of the A/T ECU. Check the gear position of each range. Ifitis OK, go to step 4 Ifitis NG, goto step 5. Specifications Range Ow | oH | ® ‘Gear positon Neural ara] _—~Reverse 4, Check of ECU power supply circuit (Refer to AT-33,) Ifitis OK, replace the A/T ECU. If the malfunction stil persists after replacement, go to step 5. It itis NG, repair the connectors or circuits concerned. 5. Remove the oil pan and strainer. Check the strainer for cut or weer of the O-ring. Ifitis OK, go to step 6. Ifitis NG, replace the O-ring of the strainer. 6. In the N range, ensure that the manual valve groove is aligned with the hole at the valve body side. (Refer to the AT service manual.) Ititis OK, go to step 7 Ifitis NG, adjust the manual valve. 7. Unit check of solenoid No. 3 and duty solenoid (Operation) (Refer to AT-77.) IFitis OK, go to step 8. If itis NG, replace the solenoid concemed. 8. Replace the valve body. If the malfunction still persists, replace the automatic transmission assembly. (11) Vehicle starts to move in P or N range. 1. Check and adjustment of control cable (Refer to AT-4.) is OK, go to step 2. Hf itis NG, adjust the control cable. 2. Remove the oil pan. In the N range, ensure that the manual valve groove is aligned with the hole at the valve body side. ITitis OK, replace the automatic transmission assembly. Ifitis NG, adjust the manual valve. (Refer to the AT service manual.) (12) Vehicle starts to move when engine revolution is raised in N range. 1. Replace the automatic transmission assembly. (13)_ Engine starts in a range other than P and N 1. Check and adjustment of neutral start switch (Refer to AT-4.) IFitis OK, go to step 2 IFitis NG, adjust the position of the neutral start switch. 2. Check and adjustment of contro! cable (Refer to AT-4.) (14) No gear shift takes place. (1st gear fixed) 4. Unit check of duty solenoid (Operation) (Refer to AT-77.) Ifitis OK, replace the valve body. If itis NG, replace the duty solenoid, sronunoiz00AT-74 (15) No gear shift takes place. (3rd gear fixed) 1. Check of ECU power supply circuit (Refer to AT-33.) Ifitis OK, replace the AT ECU. Ifitis NG, repair the connectors or circuits concerned (16) Vehicle moves off in 2nd gear. Check of input/output signals of transmission control computer (Brake switch system) (Refer to AT-77.) IFitis OK, goto step 2. Ifitis NG, check and repair the brake switch system. 2, Check of ECU power supply circuit Ifitis OK, replace the A/T ECU. Ifitis NG, repair the connectors or circuits concerned, (17) Gear shift shock and time lag too large (N - D) 1. Check of oil level (Refer to AT-2,) Ifit is OK, go to step 2. ititig NG, adjust the oil level 2. Check of inout/output signals of transmission control computer (Brake switch system) (Refer to AT-77.) Itit is OK, go to step 2. It it is NG, check and repair the brake switch system. 3. Check of ECU power supply circuit (Refer to AT-33.) iFitis OK, replace the A/T ECU. If the malfunction stil persists after replacement, go to step 4 If itis NG, repair the connectors or circuits concerned. 4, Remove the oil pan and strainer. Check the strainer for cut or wear of the O-ring. Ifit is OK, goto step 5. if itis NG, replace the O-ring of the strainer 5. Unit check of solencid No, 2 and duty solenoid (Operation) (Refer to AT-77.) Ifit is OK, go to step 6. Ifitis NG, replace the solenoid concerned. 6. Replace the valve body. |f the malfunction still persists, replace the automatic transmission assembly. (18) Gear shift shock and time lag too large (N- R) 1. Check of oil level (Refer to AT-2.) Ifitis OK, go to step 2, Ititis NG, adjust the oil level 2. Check of ECU power supply circuit (Refer to AT-33.) Ifitis OK, replace the A/T ECU. If the malfunction still persists after replacement, go to step 3. if itis NG, repair the connectors or circuits concerned 3. Remove the oil pan and strainer. Check the strainer for cut or wear of the O-ring. If itis OK, goto step 4. Ifitis NG, replace the O-ring of the strainer. 4, Unit check of solenoid No. 3 and duty solenoid (Operation) (Refer to AT-77.) Fit is OK, go to step 5. Ifit is NG, replace the solenoid concerned. 5. Replace the valve body. If the malfunction still persists, replace the automatic transmission assembly.AT-75 nD (19) Gear shift shock and time lag too large (1 - 2) 4. Check of oil level (Refer to AT-2.) IFit is OK, go to step 2. Itt is NG, adjust the oil level 2. Check of ECU power supply circuit (Refer to AT-33.) Ifitis OK, replace the A/T ECU. If the malfunction still persists after replacement, go to step 3 Ifitis NG, repair the connectors or circuits concerned. 3, Remove the oil pan and strainer. Check the strainer for cut or wear of the O-ring. If itis OK, goto step 4 if itis NG, replace the O-ring of the strainer. 4, Unit check of solenoid No. 1 (Operation) (Refer to AT-77.) Ifitis OK, go to step 5. Ifitis NG, replace the solenoid No. 1 5. Replace the vaive body. Ifthe malfunction still persists, replace the automatic transmission assembly. (20) Gear shift shock and time lag too large (2-3) 1. Check of oil level (Refer to AT-2.) Itt is OK, go to step 2. ititis NG, adjust the oil level. 2. Check of ECU power supply circuit (Refer to AT-33.) itis OK, replace the A/T ECU. If the malfunction still persists after replacement, go to step 3. Itit is NG, repair the connectors or circuits concerned. 3. Remove the cil pan and strainer. Check the strainer for cut or wear of the O-ring. Itit is OK, go to step 4 if itis NG, replace the O-ring of the strainer. 4. Unit check of solenoid No. 3 and solenoid No. 1 (Operation) (Refer to AT-77.) IFitis OK, go to step 5. Ifitis NG, replace the solenoid concerned. 5, Replace the valve body. IF the maifunetion stil persists, replace the automatic transmission assembly. (21) Gear shift shock and time lag too large (3 - 4) 1. Check of oil level (Refer to AT-2,) IF itis OK, go to step 2. Ifit is NG, adjust the oil level. 2. Check of ECU power supply circuit (Refer to AT-33.) itis OK, replace the A/T ECU. If the malfunction stil persists after replacement, go to step 3. Ifit is NG, repair the connectors or circuits concerned. 3. Remove the oil pan and strainer. Check the strainer for cut or wear of the O-ring. Ifitis OK, go to step 4. if itis NG, replace the O-ring of the strainer. 4. Unit check of solenoid No. 3 and solenoid No. 1 (Operation) (Refer to AT-77.) Ifitis OK, go to step 5. Ifitis NG, replace the solenoid concerned. 5, Replace the valve body. {f the malfunction still persists, replace the automatic transmission assembly. :