CH-40 CHASSIS – MULTI-MODE MANUAL TRANSMISSION SYSTEM

JSYSTEM RESETTING

1. General
When removing or installing any part related to the multi-mode manual transmission system as shown in the
following table, perform the 5 general service procedures indicated below to reset the system:
D Clutch Position Adjustment (Clutch Clamp Position)
D Clutch Actuator Preload
D Initialization of M-MT ECU
D Learning of M-MT System
D Synchronization Position Calibration

" The Parts that Relate to the M-MT System A

Engine Clutch Transaxle

D Clutch Actuator
D Clutch Stroke Sensor
D Clutch Disc D Shift & Select Actuator
D Flywheel D Clutch Cover D Shift Stroke Sensor
D End Plate D Clutch Release Bearing D Select Stroke Sensor
D Crankshaft D Clutch Release Fork D M-MT ECU
D Clutch Release Fork Lever D Transaxle Assembly
D Transaxle Parts
(inside gear box)

2. General Service Procedures

Target Clutch Clamp Position Control

D The clutch actuator can be adjusted to the clutch clamp position by effecting the clutch position
adjustment. This operation must be performed before removing the clutch actuator.
D Furthermore, when installing a new clutch actuator (service supplied parts), make sure to adjust it to the
clutch clamp position by effecting the clutch position adjustment.
D Other general service procedures (“clutch actuator preload” and “learning of M-MT system”) are to be
performed with the clutch actuator in the clutch clamp position. Therefore, before performing an
operation that involves a general service procedure, make sure to effect the “clutch position adjustment”.
If the “clutch position adjustment” is not effected, it will not be possible to correctly perform other
general service procedures, which could result in a system malfunction.
D Effect “clutch position adjustment” through one of the two ways described below:
– Use an intelligent tester II and connect it to the DLC3.
– Use the SST 09843-18040 and connect it to the Tc and CG terminals of the DLC3, and perform the
brake pedal and shift lever operation that is provided.
For details on the target clutch clamp position control, see the Aygo Repair Manual.
 CHASSIS – MULTI-MODE MANUAL TRANSMISSION SYSTEM CH-41

Adjustment and Initialization

D Perform the 4 general service procedures (“clutch actuator preload”, “initialization of M-MT ECU”,
“learning of M-MT system” and “synchronization position calibration”) upon the completion of the
removal and reinstallation of any part related to the multi-mode manual transmission system.
D For details on the general service procedures, see the Aygo Repair Manual.

General Service Procedure Outline

After touch the push rod of the clutch actuator to the clutch release lever
with the actuator in the clutch clamp position, install the bolts for
Clutch Actuator Preload fixation. In the condition that clutch actuator push rod touches with the
release fork without preload, to fasten three bolts to make sure that the
clutch actuator should be adjusted to the complete engagement position.
M-MT ECU stores the calibrated/learned value for actuators position,
clutch synchronization position etc., the data and DTC. These
information in ECU can be cleared and changed to initial condition.
The initialization of the M-MT ECU can be performed through one of CH
Initialization of M-MT ECU
the two ways described below:
a) Use an intelligent tester II and connect it to the DLC3.
b) Use the SST (09843-18040) and connect it to the Tc and CG terminals
of the DLC3, and operate the brake pedal and shift lever.
Adjusts clutch clamp position accurately including all related parts on
vehicle. Each parts and LCC system have tolerance and are designed to
have certain range of stroke in clamp position, and this operation
calibrates the actual clamp position.
Checks shift & select actuator’s accurate position for shifting by
operating the actuators for shift and select. If initial position is shifted
with designed one, ECU learns actual standard position for shift and
select side.
Learning of M-MT System Before the learning of the M-MT system, the initialization of the M-MT
ECU must be performed first.
The learning of the M-MT system can be performed through one of the
two ways described below:
a) Use an intelligent tester II and connect it to the DLC3. (This will be
used if the initialization of the M-MT ECU is performed with method
“a”.)
b) Turn the ignition switch from OFF to ON, stand by for 40 seconds,
start the engine, and stand by for 10 seconds. (This will be used if the
initialization of the M-MT ECU is performed with method “b”.)
After initialization and learning, the combination of the parts or
characteristic of the parts itself would make the change of clamp
Synchronization position or clutch synchronization position under actual driving. ECU
Position Calibration learns the actual standard position as standard value for smooth shifting.
Drive with M-mode and shift up 1st to 5th, shifts down 5th to 1st in the
specified vehicle speed for each shifting condition.
CH-42 CHASSIS – MULTI-MODE MANUAL TRANSMISSION SYSTEM

Precautions when using shift lock release button

1) When the vehicle is parked with the shift lever in a position other than N:
D If the shift lock is released by the shift lock release button, the engine cannot be started even if the shift
lever is moved to another position as the gear is not in neutral.
D The engine can be started after matching the gear position and shift lever position by moving the shift
lever back to the position the vehicle was parked in, and then moving it to the N position.

2) When the vehicle is parked with the shift lever in the N position:
D If the shift lock is released by the shift lock release button, the engine can be started even if the shift
lever is moved to the positions except N as the gear position is in neutral.
D The M-MT system will not operate, as the gear position and shift lever position do not match.

Other precautions
D When racing engine, make sure that the gear is in neutral.
D If the M-MT system stops with the transmission set in any gear, the vehicle can be moved by
disconnecting the shift & select actuator plug and setting the gear to neutral.