Workshop Manual GALANT - СТО «МСБ» /...

23-1

AUTOMATICTRANSMISSION

CONTENTS 23109000347

SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . . . . .

LUBRICANTS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 4. . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 46. . . . . . . . . . . . . . . . . . .Essential Service 46. . . . . . . . . . . . . . . . . . . . . . . . . . . .

A/T Control Component Location 51. . . . . . . . . . . . .

A/T Control Component Check 52. . . . . . . . . . . . . . .

Torque Converter Stall Test 54. . . . . . . . . . . . . . . . . .

Hydraulic Pressure Test 56. . . . . . . . . . . . . . . . . . . . .

Hydraulic Circuit 61. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Pressure Adjustment 62. . . . . . . . . . . . . . . . . . . .

Selector Lever Operation Check 62. . . . . . . . . . . . . .

TRANSMISSION CONTROL* 63. . . . . . . . . . . . . .

TRANSMISSION ASSEMBLY 66. . . . . . . . . . . . . .

WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICULES

WARNING!(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal

injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (from renderingthe SRS inoperative).

(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorizedMITSUBISHI dealer.

(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - SupplementalRestraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-relatedcomponent.

NOTEThe SRS includes the following components: SRS-ECU, SRSwarning lamp, air bagmodule, clock spring, side impact sensors andinterconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service ormaintenance) are indicated in the table of contents by an asterisk (*).

AUTOMATIC TRANSMISSION -Service Specifications/Lubricants/Special Tools23-2

SERVICE SPECIFICATIONS 23100030222

Items Standard value

Oil temperature sensor kW at 0_C 16.5 - 20.5

at 100_C 0.57 - 0.69

Resistance of damper clutch control solenoid valve coil (at 20_C) W 2.7 - 3.4

Resistance of Low-Reverse solenoid valve coil (at 20_C) W 2.7 - 3.4

Resistance of second solenoid valve coil (at 20_C) W 2.7 - 3.4

Resistance of underdrive solenoid valve coil (at 20_C) W 2.7 - 3.4

Resistance of overdrive solenoid valve coil (at 20_C) W 2.7 - 3.4

Stall speed r/min 2,100 - 2,600

LUBRICANTS 23100040034

Items Specified lubricant Quantity L

Transmission fluid DIA QUEEN ATF SPII or equivalent 7.8

SPECIAL TOOLS 23100060214

Tool Number Name Use

MB991502 MUT-II subassembly

Checking of the diagnosis code

MD998330(includingMD998331)

Oil pressure gauge(2,942 kPa)

Measurement of oil pressure

MD998332 Adapter

MD998900 Adapter

AUTOMATIC TRANSMISSION - Special Tools 23-3

Tool Number Name Use

MB990635 orMB991113

Steering linkagepuller

Ball joint disconnection

MB991610 Oil filter wrench Removal and installation of automatic trans-mission oil filter

GENERALSERVICETOOLMZ203827

Engine lifter Supporting the engine assembly duringremoval and installation of the transmission

MB991453 Engine hangerassembly

Supporting the engine assembly duringremoval and installation of the transmission

AUTOMATIC TRANSMISSION - Troubleshooting23-4

TROUBLESHOOTING 23100760275

STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Gathering information from custom-er.

Check trouble symptoms.

Read the diagnosis code (GROUP 00- How to Use Troubleshooting/In-spection Service Points.)

Communication withMUT-II not possible

Inspection procedure No. 1 inInspection Chart For TroubleSymptoms (Refer to P.23-27.)

Diagnosis codedisplayed

Erase the diagnosis code (GROUP00 - How to Use Troubleshooting/In-spection Service Points.)

No diagnosis code displayed

Carry out the essential service(Refer to P.23-46.)

Road test (Refer to P.23-6.)Abnormality exists (no diagnosis code)

No abnormality

Recheck diagnosis codes whichwere read before the road test.

Abnormality exists(diagnosis codepresent)

Diagnosiscode displayed

No diagnosiscode displayed

To INSPECTION CHART FORDIAGNOSIS CODES(Refer to P.23-14.)

To INSPECTION CHART FORTROUBLE SYMPTOMS(Refer to P.23-26.)

Search for cause.

Found Not found

Repair

Confirmation test (road test)NG

NGINTERMITTENT MALFUNCTION(GROUP 00 - Points to Note forIntermittent Malfunctions.)

OKCompleted

OK

AUTOMATIC TRANSMISSION - Troubleshooting 23-5

DIAGNOSIS FUNCTION 23100770186

1. N range lampThe N range lamp flashes at a frequency of approximately1 Hz if there is an abnormality in any of the items in thetable below which are related to the A/T system. Checkthe diagnosis code output if the N range lamp is flashingat a frequency of approximately 1 Hz.

N range lamp flashing items

Crank angle sensor

Input shaft speed sensor

Output shaft speed sensor

Each solenoid valve

Out of phase at each shift point

CautionIf the N range lamp is flashing at a frequency ofapproximately 2 Hz (faster than at 1 Hz), it means thatthe automatic transmission fluid temperature is too high.Stop the vehicle in a safe place and wait until the N rangelamp switches off.

2. Method of reading the diagnosis codeUse the MUT-II or the N range lamp to take a reading ofthe diagnosis codes. (Refer to GROUP 00 - How to UseTroubleshooting/Inspection Service Points.)


ROAD TEST 23100780271

Check by the following procedure.

No. State prior to testand operation

Test and operation Judgement value Check item Diag-nosiscodeNo.

Inspectionprocedure pageif there is anabnormality

1 Ignition switch:OFF

Ignition switch(1) ON

Data list No. 54Battery voltage [V]

Control relay 54 A/T Controlrelay system(23-25)

2 Ignition switch:ONEngine: StoppedSelector leverposition: P

Selector leverposition(1) P, (2) R,(3) N, (4) D,(5) 3, (6) 2, (7) L

Data list No. 61(1) P, (2) R, (3)N,(4) D, (5) 3, (6) 2,(7) L

Inhibitor switch - Inhibitor switchsystem (23-36)

position: PAccelerator pedal(1) Released(2) Half depressed(3) Depressed

Data list No. 11(1) 400 - 1,000 mV(2) Gradually rises

from (1)(3) 4,500 - 5,000

mV

Throttle posi-tion sensor<Vehicleswithout TCL>Acceleratorpedal positionsensor<Vehicles withTCL>

111214

Throttleposition sensorsystem (23-15)Acceleratorpedal positionsensor system(23-15)

Data list No. 25(1) OFF(2) ON

Wide openthrottle switch

25 Wide openthrottle switchsystem (23-17)

Brake pedal(1) Depressed(2) Released

Data list No. 26(1) ON(2) OFF

Stop lampswitch

26 Stop lamp switchsystem (23-18)

3 Ignition switch:STEngine: Stopped

Starting test withlever P or N range

Starting should bepossible

Startingpossible orimpossible

- Startingimpossible(23-28)

4 Warming up Drive for 15minutes or more sothat the automaticfluid temperaturebecomes 70 -90_C.

Data list No. 15Gradually rises to70 - 90_C

Oil temperaturesensor

15 Oil temperaturesensor system(23-15)





5 Engine: IdlingSelector leverposition: N

Brake pedal(Retest)(1) Depressed(2) Released


Stop lampswitch

26 Stop lamp switchsystem (23-18)

A/C switch(1) ON(2) OFF


Dual pressureswitch

- Dual pressureswitch system(23-37)

Accelerator pedal(1) Released(2) Half depressed


Idle positionswitch

- Idle positionswitch system(23-37)

Data list No. 21(1) 550 - 850 rpmGradually risesfrom (1)

Crank anglesensor

21 Crank anglesensor system(23-16)

Data list No. 57(2) Data changes

Communicationwith engine-ECU<Vehicleswithout TCL>Communicationwith TCL-ECU<Vehicles withTCL>

51 Serialcommunicationsystem (23-25)

Selector leverposition(1) N ® D

Should be noabnormal shiftingshocks

Malfunctionwhen starting

- Engine stallingduring shifting(23-30)(1) N ® D

(2) N ® R Time lag should be

within 2 seconds

- Shocks whenchanging from Nto D and largetime lag (23-30)

- Shocks whenchanging from Nto R and largetime lag (23-31)

- Shocks whenchanging from Nto D,N to R andlarge time lag(23-32)

Drivingimpossible

- Does not moveforward (23-28)

- Does notreverse (23-29)

- Does not move(forward orreverse) (23-29)





6 Selector leverposition: N(Carry out on a

Selector leverposition andvehicle speed

Data list No. 63(2) 1st, (4) 3rd, (3)2nd, (5) 4th

Shift condition - -

flat and straightroad.)

(1) Idling inL range(Vehiclestopped)

(2) Driving at

Data list No. 31(2) 0 %, (4) 100 %,(3) 100 %, (5) 100%

Low and reversesolenoid valve

31 Low and reversesolenoid valvesystem (23-18)

constant speedof10 km/h inL position

Data list No. 32(2) 0 %, (4) 0 %,(3) 0 %, (5) 100 %

Underdrivesolenoid valve

32 Underdrivesolenoid valvesystem (23-18)

(3) Driving atconstant speedof30 km/h in

Data list No. 33(2)100 %, (4) 100%, (3) 0 %, (5) 0 %

Secondsolenoid valve

33 Second solenoidvalve system(23-18)

2 position(4) Driving at

50 km/h in3 position withaccelerator fully

Data list No. 34(2) 100 %, (4) 0 %,

(3) 100 %, (5) 0 %

Overdrivesolenoid valve

34 Overdrivesolenoid valvesystem (23-18)

closed(5) Driving at

constant speedof

Data list No. 29(1) 0 km/h(4) 50 km/h

Vehicle speedsensor

- Vehicle speedsensor system(23-38)

50 km/h inD position(Eachcondition

Data list No. 22(4) 1,800 - 2,100

rpm

Input shaftspeed sensor

22 Input shaft speedsensor system(23-16)

should bemaintained for10 seconds ormore.)

Data list No. 23(4) 1,800 - 2,100

rpm

Output shaftspeed sensor

23 Output shaftspeed sensorsystem (23-17)

7 Selector leverposition: 3(Carry out on aflat and straightroad.)

Selector leverposition andvehicle speed(1) Release the ac-

celerator pedal

Data list No. 36(1) 0 %(2) Approx. 70 - 90

%

Damper clutchcontrol solenoidvalve

3652

Damper clutchcontrol solenoidvalve system(23-19)

fully while driv-ing at 50 km/hin 3rd gear.

(2) Driving atconstant speedof 50 km/h in3rd gear.

Data list No. 52(1) Approx.

100 - 300 rpm(2) Approx.

0 - 10 rpm





8 Use the MUT-II tostop the INVECS-II function.

Monitor data listNo. 11, 23, and 63with the MUT-II .

For (1), (2) and (3),the reading shouldbe the same as the

Malfunctionwhen shifting

- Shocks andrunning up(23-32)

Selector lever (1) Accelerate to specified output Displaced - All points (23-33)position: D(Carry out on a flatand straight road.)

4th gear at athrottleposition

shaft speed and noabnormal shocksshould occur.

shifting points - Some points(23-34)and straight road.) position

sensor outputof 1.5V

should occur.For (4), (5) and (6),downshifting

Does not shift - No diagnosiscode (23-34)

(acceleratoropening angleof 30 %).

(2) Gently

should occurimmediatelyafter the shiftingoperation is made.

22 Input shaftspeed sensorsystem (23-16)(2) Gently

decelerate to astandstill.

(3) Accelerate to

operation is made.23 Output shaft

speed sensorsystem (23-17)

4th gear at athrottlepositionsensor output

Does not shiftfrom 1 to 2 or 2to 1

31 Low and reversesolenoid valvesystem (23-18)

of 2.5 V(acceleratoropening angle

33 Secondsolenoid valvesystem (23-18)

of 50%).(4) While driving at

60 km/h in 4thgear, shift

41 1st gear ratio isnot specified(23-20)

down to3 range.

(5) While driving at

42 2nd gear ratio isnot specified(23-21)40 km/h in 3rd

gear, shiftdown to2 range.



(6) While driving at20 km/h in 2ndgear, shiftdown to

34 Overdrivesolenoid valvesystem (23-18)down to

L range. 42 2nd gear ratio isnot specified(23-21)

43 3rd gear ratio isnot specified(23-22)


32 Underdrivesolenoid valvesystem (23-18)


43 3rd gear ratio isnot specified(23-22)

44 4th gear ratio isnot specified(23-23)





9 Selector leverposition: N(Carry out on a

Monitor data listNo. 22and No. 23 with the

II

The ratio betweendata list No. 22 andNo. 23 should be

Does not shift 22 Input shaftspeed sensorsystem (23-16)(Carry out on a

flat and straightroad.)

MUT-II .(1) Move selector

lever to

the same as thegear ratio whenreversing.

23 Output shaftspeed sensorsystem (23-17)

R range, driveat constantspeed of10 km/h.

46 Reverse gearratio is notspecified (23-24)

SHIFT PATTERN<4G63 engine>UPSHIFT PATTERN

Output shaft speed r/min

Thick line: Standard shift pattern100

Throttle opening %

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000

2® 3movementrange 3® 4

movementrange

Vehicle speed km/h

0

50

0 50 100 150 200

1 2 2 3 3 4

AUTOMATIC TRANSMISSION - Troubleshooting 23-11DOWNSHIFT PATTERN

3 (L,2) 4(L,2,3)

3

Thick line: Standard shift patternThrottle opening %

2¬ 3movementrange

3¬ 4movementrange

100

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000Output shaft speed r/min

Vehicle speed km/h

0

50

0 50 100

1 2 2 3 3 4

200150

1 2 (L) 2

HOLD MODE PATTERN


100

0 2,000 4,000 6,000 8,000Output shaft speed r/min

Vehicle speed km/h

0

50

0 50 100

1 2

2 3 3 4

200150

3 4


<6A13 engine>UPSHIFT PATTERN

Thick line: Standard shift patternThrottle opening %100

Output shaft speed r/min

Vehicle speed km/h

0

50

0 50 100

1 2 2 3 3 4

200150

2® 3movementrange

3® 4movementrange

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000

DOWNSHIFT PATTERN

4(L,2,3)

3


2¬ 3movementrange

3¬ 4movementrange

100

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000Output shaft speed r/min

Vehicle speed km/h

0

50

0 50 100

1 2 2 3 3 4

200150

1 2 (L) 2 3 (L,2)


HOLD MODE PATTERN


100

0 2,000 4,000 6,000 8,000Output shaft speed r/min

Vehicle speed km/h

0

50

0 50 100

3 4

2 3

1 2

200150

3 4


INSPECTION CHART FOR DIAGNOSIS CODE 23100790243

Code Diagnosis item Reference page

11 Throttle position sensor system Short circuit 23-15

12<Vehicles without TCL>Accelerator pedal position sensor system Open circuit 23-15

14

Accelerator pedal position sensor system<Vehicles with TCL> Sensor maladjustment 23-15

15 Oil temperature sensor system Open circuit 23-15

21 Crank angle sensor system Open circuit 23-16

22 Input shaft speed sensor system Short circuit/open circuit 23-16

23 Output shaft speed sensor system Short circuit/open circuit 23-17

25 Wide open throttle switch system Short circuit 23-17

26 Stop lamp switch system Short circuit/open circuit 23-18

31 Low and reverse solenoid valve system Short circuit/open circuit 23-18

32 Underdrive solenoid valve system Short circuit/open circuit 23-18

33 Second solenoid valve system Short circuit/open circuit 23-18

34 Overdrive solenoid valve system Short circuit/open circuit 23-18

36 Damper control clutch solenoid valve system Short circuit/open circuit 23-19

41 1st gear ratio does not meet the specification 23-20

42 2st gear ratio does not meet the specification 23-21

43 3rd gear ratio does not meet the specification 23-22

44 4th gear ratio does not meet the specification 23-23

46 Reverse gear ratio does not meet the specification 23-24

51 Abnormal communication with engine-ECU <Vehicles without TCL>Abnormal communication with TCL-ECU <Vehicles with TCL>

23-25

52 Damper control clutch solenoid valve system Defective system 23-19

54 A/T Control relay system Short circuit to earth/open circuit

23-25

56 N range lamp system Short circuit to earth 23-26

71 Malfunction of A/T-ECU 23-26


INSPECTION PROCEDURES FOR DIAGNOSIS CODES

Code No. 11, 12, 14 Throttle position sensor system<Vehicles without TCL>, accelerator pedal positionsensor <Vehicles with TCL>

Probable cause

If the TPS or APS output voltage is 4.8 V or higher when the engine is idling, theoutput is judged to be too high and diagnosis code No. 11 is output. Code No. 11is also output if there is a problem with the APS and an APS fail-safe signal is receivedfrom the TCL-ECU. If the TPS or APS output voltage is 0.2 V or lower at timesother than when the engine is idling, the output is judged to be too low and diagnosiscode No. 12 is output. If the TPS or APS output voltage is 0.2 V or lower or if itis 1.2 V or higher when the engine is idling, the TPS or APS adjustment is judgedto be incorrect and diagnosis code No. 14 is output.

D Malfunction of the throttle position sensor <Vehicleswithout TCL>

D Malfunction of the accelerator pedal position sensor<Vehicles with TCL>

D Malfunction of connectorD Malfunction of the A/T-ECU

Throttle position sensor check <Vehicles without TCL>(Refer to GROUP 13A - On-vehicle Service.)Accelerator pedal position sensor check<Vehicles with TCL>(Refer to GROUP 13H - On-vehicle Service.)

NGReplace

OK

Check the following connectors:B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29

NGRepair

OK

Harness checkD Between throttle position sensor and A/T-ECU

<Vehicles without TCL>D Between accelerator pedal position sensor and A/T-ECU

<Vehicles with TCL>

NGRepair

OK

Check the trouble symptoms.NG

Replace the A/T-ECU.

Code No. 15 Oil temperature sensor system Probale causeIf the oil temperature sensor output voltage is 2.6 V or more even after driving for10 minutes or more (if the oil temperature does not increase), it is judged that thereis an open circuit in the oil temperature sensor and diagnosis code No. 15 is output.

D Malfunction of the oil temperature sensorD Malfunction of connectorD Malfunction of the A/T-ECU

Oil temperature sensor check (Refer to P.23-52.)NG

Replace

OK

Check the follwing connectors: B-70, C-29NG

Repair

OK

Harness checkD Between oil temperature sensor and A/T-ECU

NGRepair

OK




Code No. 21 Crank angle sensor system Probable causeIf no output pulse is detected from the crank angle sensor for 5 seconds or morewhile driving at 25 km/h or more, it is judged that there is an open circuit in thecrank angle sensor and diagnosis code No. 21 is output.

D Malfunction of the crank angle sensorD Malfunction of connectorD Malfunction of the A/T-ECU

Check the follwing connectors: B-77, C-29NG

Repair

OK

Harness checkD Between crank angle sensor and A/T-ECU

NGRepair

OK

Crank angle sensor system check(Refer to GROUP 13A - Troubleshooting.)

OK



Code No. 22 Input shaft speed sensor system Probable causeIf no output pulse is detected from the input shaft speed sensor for 1 second ormore while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judgedto be an open circuit or short-circuit in the input shaft speed sensor and diagnosiscode No. 22 is output. If diagnosis code No. 22 is output four times, the transmissionis locked into 3rd gear (D range) or 2nd gear as a fail-safe measure, and the Nrange lamp flashes at a frequency of 1 Hz.

D Malfunction of the input shaft speed sensorD Malfunction of the underdrive clutch retainerD Malfunction of connectorD Malfunction of A/T-ECU

L: Refer to the Transmission Workshop Manual.


A/T overhaul KD Replace the underdrive clutch

retainer.


Check the trouble symptoms.

NG

Eliminate the cause of the noise.

NGOK


OK

Check the following harness:D Between the input shaft speed

sensor and the ignition switchD Between the input shaft speed

sensor and A/T-ECU

NGRepair

NGCheck the trouble symptoms.

NGOK


OK

Measure output waveform of the inputshaft speed sensor.(using an oscilloscope)D Engine: 2,000 r/min (approx. 50

km/h)D Transmission: 3rd gear (Voltage)

OK: Conforms to the waveformshown at page 23-45 (Inspec-tion procedure using an oscil-loscope). There is no noisein the output waveform.

NGReplace the input shaft speed sensor.

Measure at the input shaft speed sensorconnector B-71.D Disconnect the connector and

measure at the harness side.(1) Voltage between 3 and earth

(Ignition switch: ON)OK: Battery voltage

(2) Voltage between 2 and earth(Ignition switch: ON)OK approx. 5 V

(3) Continuity between 1 and earthOK: Continuity

NGCheck the following connectors:B-71, C-29

NGRepair


Code No. 23 Output shaft speed sensor system Probable causeIf the output from the output shaft speed sensor is continuously 50% lower than thevehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of30 km/h or more, there is judged to be an open circuit or short-circuit in the outputshaft speed sensor and diagnosis code No. 23 is output.If diagnosis code No. 23 is output four times, the transmission is locked into 3rdgear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashesat a frequency of 1 Hz.

D Malfunction of the output shaft speed sensorD Malfunction of the transfer drive gear or driven gearD Malfunction of connectorD Malfunction of the A/T-ECU


A/T overhaul LD Replace the transfer drive gear and

driven gear.


NG



Replace the A/T-ECU.NG

OK


OK

Check the following harness:D Between the output shaft speed

sensor and the ignition switchD Between the output shaft speed

sensor and A/T-ECU

NGRepair

NGCheck the trouble symptoms.

NGOK


OK

Measure output waveform of the outputshaft speed sensor.(using an oscilloscope)D Engine: 2,000 r/min

(approx. 50 km/h)D Transmission: 3rd gear

(Voltage)OK: Conforms to the waveform

shown at page 23-45 (Inspec-tion procedure using an oscil-loscope). There is no noisein the output waveform.

NGReplace the output shaft speed sensor.

Measure at the output shaft speed sen-sor connector B-68.D Disconnect the connector and

measure at the harness side.(1) Voltage between 3 and earth

(Ignition switch: ON)OK: Battery voltage

(2) Voltage between 2 and earth(Ignition switch: ON)OK: approx. 5 V

(3) Continuity between 1 and earthOK: Continuity

NGCheck the following connectors:B-68, C-29

NGRepair

Code No. 25 Wide open throttle switch system Probable causeIf the wide open throttle switch is on for 1 second or more with the throttle valveopening angle at 70% or less, it is judged that there is a short circuit in the wideopen throttle switch and diagnosis code No. 25 is output.

D Malfunction of the wide open throttle switchD Malfunction of connectorD Malfunction of A/T-ECU

Wide open throttle switch check (Refer to P.23-64).NG

Replace

OK

Check the following connectors: C-18, C-30, C-83NG

Repair

OK

Harness checkD Between the wide open throttle switch and the A/T-ECU.

NGRepair

OK




Code No. 26 Stop lamp switch system Probable causeIf the stop lamp switch is on for 5 minutes or more while driving, it is judged thatthere is a short circuit in the stop lamp switch and diagnosis code No. 26 is output.

D Malfunction of the stop lamp switchD Malfunction of connectorD Malfunction of the A/T-ECU

Stop lamp switch check (Refer to GROUP 35 - Brake Pedal.)NG

Replace

OK

Check the following connectors: C-02, C-30, C-65, C-83NG

Repair

OK

Harness checkD Between stop lamp switch and A/T-ECU

NGRepair

OK



Code No. 31 Low and reverse solenoid valve system Probable cause

Code No. 32 Underdrive solenoid valve system

Code No. 33 Second solenoid valve system

Code No. 34 Overdrive solenoid valve systemIf the resistance value for a solenoid valve is too large or too small, it is judgedthat there is a short-circuit or an open circuit in the solenoid valve and the respectivediagnosis code is output. The transmission is locked into 3rd gear as a fail-safemeasure,and the N range lamp flashes at a frequency of 1 Hz.

D Malfunction of solenoid valveD Malfunction of connectorD Malfunction of the A/T-ECU

Solenoid valve check (Refer to P.23-54.)NG

Replace

OK

Check the following connectors: B-70, C-28, C-30, C-41NG

Repair

OK

Harness checkD Between solenoid valve and A/T-ECU

NGRepair

OK

Replace the solenoid valve.




Code No. 36, 52 Damper clutch control solenoid valvesystem

Probable cause

If the resistance value for the damper clutch control solenoid valve is too large ortoo small, it is judged that there is a short-circuit or an open circuit in the damperclutch control solenoid valve and diagnosis code No. 36 is output. If the drive dutyrate for the damper clutch control solenoid valve is 100 % for a continuous periodof 4 seconds or more, it is judged that there is an abnormality in the damper clutchcontrol system and diagnosis code No. 52 is output. When diagnosis code No. 36is output, the transmission is locked into 3rd gear as a fail-safe measure, and theN range lamp flashes at a frequency of 1 Hz.

D Malfunction of the damper clutch control solenoid valveD Malfunction of connectorD Malfunction of the A/T-ECU

Damper clutch control solenoid valve check (Refer to P.23-54.)NG

Replace

OK

Check the following connectors: B-70, C-28, C-41NG

Repair

OK

Harness checkD Between damper clutch control solenoid valve and A/T-ECU

NGRepair

OK

Replace the damper clutch control solenoid valve.




Code No. 41 1st gear ratio does not meet the specification Probable causeIf the output from the output shaft speed sensor multiplied by the 1st gear ratio isnot the same as the output from the input shaft speed sensor after shifting to 1stgear has been completed, diagnosis code No. 41 is output. If diagnosis code No.41 is output four times, the transmission is locked into 3rd gear as a fail-safe measure,and the N range lamp flashes at a frequency of 1 Hz.

D Malfunction of the input shaft speed sensorD Malfunction of the output shaft speed sensorD Malfunction of the underdrive clutch retainerD Malfunction of the transfer drive gear or driven gearD Malfunction of the low and reverse brake systemD Malfunction of the underdrive clutch systemD Noise generated


MUT-II Self-Diag codeIs the diagnosis code No. 22 output?

YesCode No. 22 Input shaft speed sensor system check(Refer to P.23-16.)

No


YesCode No. 23 Output shaft speed sensor system check(Refer to P.23-17.)

No

Measure output waveform from the input shaft speed sensor. (usingan oscilloscope)D Connect the connector B-71 and measure voltage between

31 and 43 at the A/T-ECU.D Engine: 2,000 r/min (approx. 50 km/h)D Selector lever position: 3

(Voltage)OK: Awaveform suchas theone shownonP.23-45 (Inspection

Procedure Using an Oscilloscope) is output (flalshingbetween 0 ¬® 5V) and there is no noise appearingin the waveform.



NG

A/T overhaul LD Replace the underdrive clutch retainer.


NG


OK

Measure output waveform from the output shaft speed sensor.(using an oscilloscope)D Connect the connector B-68 and measure voltage between






NG

A/T overhaul LD Replace the transfer drive gear and driven gear.


NG


OK

A/T overhaul LD Underdrive clutch system check

(No. 42, No. 43, or no diagnosis code is output).D Low and reverse brake system check

(No. 46 or no diagnosis code is output).


Code No. 42 2nd gear ratio does not meet the specification Probable causeIf the output from the output shaft speed sensor multiplied by the 2nd gear ratiois not the same as the output from the input shaft speed sensor after shifting to2nd gear has been completed, diagnosis code No. 42 is output. If diagnosis codeNo. 42 is output four times, the transmission is locked into 3rd gear as a fail-safemeasure, and the N range lamp flashes at a frequency of 1 Hz.

D Malfunction of the input shaft speed sensorD Malfunction of the output shaft speed sensorD Malfunction of the underdrive clutch retainerD Malfunction of the transfer drive gear or driven gearD Malfunction of the second brake systemD Malfunction of the underdrive clutch systemD Noise generated




No



No







NG



NG


OK







NG



NG


OK


(No. 41, No. 43, or no diagnosis code is output).D Second brake system check



Code No. 43 3rd gear ratio does not meet the specification Probable causeIf the output from the output shaft speed sensor multiplied by the 3rd gear ratio isnot the same as the output from the input shaft speed sensor after shifting to 3rdgear has been completed, diagnosis code No. 43 is output. If diagnosis code No.43 is output four times, the transmission is locked into 3rd gear as a fail-safe measure,and the N range lamp flashes at a frequency of 1 Hz.

D Malfunction of the input shaft speed sensorD Malfunction of the output shaft speed sensorD Malfunction of the underdrive clutch retainerD Malfunciton of the transfer drive gear or driven gearD Malfunction of the underdrive clutch systemD Malfunction of the overdrive clutch systemD Noise generated




No



No







NG



NG


OK







NG



NG


OK


(No. 41, No. 42, or no diagnosis code is output).D Overdrive clutch system check



Code No. 44 4th gear ratio does not meet the specification Probable causeIf the output from the output shaft speed sensor multiplied by the 4th gear ratio isnot the same as the output from the input shaft speed sensor after shifting to 4thgear has been completed, diagnosis code No. 44 is output. If diagnosis code No.44 is output four times, the transmission is locked into 3rd gear as a fail-safe measure,and the N range lamp flashes at a frequency of 1 Hz.

D Malfunction of the input shaft speed sensorD Malfunction of the output shaft speed sensorD Malfunction of the underdrive clutch retainerD Malfunction of the transfer drive gear or driven gearD Malfunction of the second brake systemD Malfunction of the overdrive clutch systemD Noise generated




No



No




Procedure Using an Oscilloscope) is output (flashing be-tween 0 ¬® 5V) and there is no noise appearing inthe waveform.



NG



NG


OK







NG



NG


OK

A/T overhaul LD Second brake system check

(No. 42 or no diagnosis code is output).D Overdrive clutch system check



Code No. 46 Reverse gear ratio does not meet thespecification

Probable cause

If the output from the output shaft speed sensor multiplied by the reverse gear ratiois not the same as the output from the input shaft speed sensor after shifting toreverse gear has been completed, diagnosis code No. 46 is output. If diagnosis codeNo. 46 is output four times, the transmission is locked into 3rd gear as a fail-safemeasure, and the N range lamp flashes at a frequency of 1 Hz.

D Malfunction of the input shaft speed sensorD Malfunction of the output shaft speed sensorD Malfunction of the underdrive clutch retainerD Malfunciton of the transfer drive gear or driven gearD Malfunction of the low and reverse brake systemD Malfunction of the reverse clutch systemD Noise generated




No



No







NG



NG


OK







NG



NG


OK

A/T overhaul LD Low and reverse brake system check

(No. 41 or no diagnosis code is output).D Reverse clutch system check (No diagnosis code is output).


Code No. 51 Abnormal communication with engine-ECU<Vehicles without TCL>Abnormal communication with TCL-ECU<Vehicles with TCL>

Probable cause

If normal communication is not possible for a continuous period of 1 second or morewhen the ignition switch is at the ON position, the battery voltage is 10 V or moreand the engine speed is 450 r/min or more, diagnosis code No. 51 is output. Diagnosiscode No. 51 is also output if the data being received is abnormal for a continuousperiod of 4 seconds under the same conditions.

D Malfunction of connectorD Malfunction of the engine-ECU<Vehicles without TCL>D Malfunction of the TCL-ECU <Vehicles with TCL>D Malfunction of the A/T-ECU

Replace the A/T-ECU.NG


NG

Replace the engine-ECU.<Vehicles without TCL>Replace the TCL-ECU.<Vehicles with TCL>

OK


OK

Harness checkD Between engine-ECU and A/T-ECU

<Vehicles without TCL>D Between TCL-ECU and A/T-ECU

<Vehicles with TCL>

NGRepair

Check the following connectors:D C-30, C-34, C-38

<4G6-vehicles without TCL>D C-30, C-37

<6A1-vehicles without TCL>D C-10, C-30, C-51

<Vehicles with TCL>

NGRepair

Code No. 54 A/T control relay system Probable causeIf the A/T control relay voltage is less than 7 V after the ignition switch has beenturned ON, it is judged that there is an open circuit or a short-circuit in the A/T controlrelay earth and diagnosis code No. 54 is output.Then the transmission is locked into 3rd gear as a fail-safe measure, and the Nrange lamp flashes at a frequency of 1 Hz.

D Malfunction of the A/T control relayD Malfunction of connectorD Malfunction of the A/T-ECU

Check the A/T control relay. (Refer to P.23-53.)NG

Replace

OK

Check the following connectors: B-30, C-28, C-30, C-41, C-45NG

Repair

OK

Harness checkD Between control relay and body earthD Between control relay and batteryD Between control relay and A/T-ECU

NGRepair

OK




Code No. 56 N range lamp system Probable causeIf the N range signal is off after an N range lamp illumination instruction (ON instruction)has been given, it is judged that there is a short-circuit in the N range lamp earthand diagnosis code No. 56 is output.

D Malfunction of the N range lamp bulbD Malfunction of connectorD Malfunction of the A/T-ECU

Check the N range lamp bulb(Refer to GROUP 52A - Instrument Panel.)

NGReplace

OK

Check the following connectors: C-30, C-90, D-02NG

Repair

OK

Harness checkD Between N range lamp bulb and A/T-ECU

NGRepair

OK



Code No. 71 Malfunction of A/T-ECU Probale causeThere is an abnormality in the A/T-ECU. The transmission is locked into 3rd gearas a fail-safe measure.

D Malfunction of the A/T-ECU


INSPECTION CHART FOR TROUBLE SYMPTOMS 23100800267

Trouble symptom Inspectionprocedure No.

Referencepage

Communication with MUT-II is not possible 1 23-27

Driving impossible Starting impossible 2 23-28

Does not move forward 3 23-28

Does not reverse 4 23-29

Does not move (forward or reverse) 5 23-29

Malfunction when starting Engine stalling when shifting 6 23-30

Shockswhenchanging fromN toDand large time lag 7 23-30

Shockswhenchanging fromN toRand large time lag 8 23-31

Shocks when changing from N to D, N to R and largetime lag

9 23-32

Malfunction when shifting Shocks and running up 10 23-32


Trouble symptom Referencepage

Inspectionprocedure No.

Displaced shifting points All points 11 23-33

Some points 12 23-34

Does not shift No diagnosis codes 13 23-34

Malfunction while driving Poor acceleration 14 23-35

Vibration 15 23-35

Inhibitor switch system 16 23-36

Mode control switch system 17 23-36

Idle position switch system 18 23-37

Dual pressure switch system 19 23-37

Vehicle speed sensor system 20 23-38

Auto-cruse-ECU signal system 21 23-38

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMSINSPECTION PROCEDURE 1

Communication with MUT- II is not possible Probable causeIf communication with the MUT-II is not possible, the cause is probably a defectivediagnosis line or the A/T-ECU is not functioning.

D Malfunction of diagnosis lineD Malfunction of connectorD Malfunction of the A/T-ECU

Is communication with other systemspossible using the MUT-II?

NoCheck the diagnosis line with MUT-II ,and repair if necessary.

Yes

Check the continuity and voltage of theA/T-ECU connector.D Disconnect the connector C-28 and

check at harness side.D Voltage between terminals No. 11,

24 and earthOK: Battery voltage

D Voltage between C-28 terminalsNos.12, 13, 25, 26, C-30 terminalNo. 72 and earthOK: Continuity

NGCheck the following connectors:C-28, C-30, C-45, C-83, C-131, C-134

NGRepair

OK

Harness checkD Between power supply and

A/T-ECUD Between earth and A/T-ECU

NGRepair

OK


NG

Repalce the A/T-ECU.

OK

Check the following connectors:C-20, C-28, C-30, C-49, C-66, C-83

NGRepair

OK

Harness checkD Between diagnosis connector and

A/T-ECU

NGRepair

OK




INSPECTION PROCEDURE 2

Starting impossible Probable causeStarting is not possible when the selector lever is in P or N range.In such cases,the cause is probably a defective engine system, torque converter or oil pump.

D Malfunction of the engine systemD Malfunction of the torque converterD Malfunction of the oil pump


Check the engine system.D Control system, ignition system, fuel system, main engine

system

NGRepair, replace

OK

Torque converter checkD Check for incorrect installation (inserted at an angle, etc.) and

for damaged splines.

NGRepair if possible. If the splines are damaged and repairs are notpossible, replace the torque converter assembly.

OK

Repalce the oil pump assembly. L(The oil pump cannot be disassembled.)


Does not move (forward) Probable causeIf the vehicle does not move forward when the selector lever is shifted from N toD, 3, 2 or L range while the engine is idling, the cause is probably abnormal linepressure or a malfunction of the underdrive clutch or valve body.

D Abnormal line pressureD Malfunction of the underdrive solenoid valveD Malfunction of the underdrive clutchD Malfunction of the valve body


MUT-II Actuator testD No. 2 Underdrive solenoid valve

OK: Sound of operation can be heard.

NGReplace the solenoid valve. L

OK

Hydraulic pressure test (Refer to P.23-56.)D Measure the hydraulic pressure for each element when in L

range.Standard value: Refer to P.23-57.

NGValve body disassembly, cleaning and reassembly LD Pay particular attention to loosening of bolts, and to damage

and slippage of O-rings, valves and valve bodies.D If the damage cannot be repaired, replace the valve body

assembly.OK

Underdrive clutch system check LD Remove the transmission assembly, valve body cover and valve

body.D Pistons should operate and pressure should be maintained

when air is blown through the underdrive clutch oil hole in thetransmission case.

OK

NGUnderdrive clutch check LD Check for burning of the facing, defective piston seal rings

and interference at the retainer.



Does not reverse Probable causeIf the vehicle does not reverse when the selector lever is shifted from N to R rangewhile the engine is idling, the cause is probably abnormal pressure in the reverseclutch or low and reverse brake or a malfunction of the reverse clutch, low and reversebrake or valve body.

D Abnormal reverse clutch pressureD Abnormal low and reverse brake pressureD Malfunction of the low and reverse solenoid valveD Malfunction of the reverse clutchD Malfunction of the low and reverse brakeD Malfunction of the valve body


MUT-II Actuator testD No. 1 Low and reverse solenoid valve


NGReplace the low and reverse solenoid valve. L

OK

Hydraulic pressure check (Refer to P.23-56.)D Measure the reverse clutch pressure in R range.

Standard value: Refer to P.23-57.

NG

OK

Hydraulic pressure check (Refer to P.23-56.)D Measure the low and reverse brake pressure in R range.


NG

OK

Reverse clutch system and low and reverse brake system checkLD Remove the transmission assembly, valve body cover and valve


when air is blown through the reverse clutch oil hole and thelow reverse brake oil hole in the transmission case.

OK

NGReverse clutch and low and reverse brake check LD Check for burning of the facing, defective piston seal rings


Valve body disassembly, cleaning and reassembly LD Pay particular attention to loosening of bolts, and to damage


assembly.


Does not move (forward or reverse) Probable causeIf the vehicle does not move forward or reverse when the selector lever is shiftedto any position while the engine is idling, the cause is probably abnormal line pressure,or a malfunction of the power train, oil pump or valve body.

D Abnormal line pressureD Malfunction of power trainD Malfunction of the oil pumpD Malfunction of the valve body


Hydraulic pressure check (Refer to P.23-56.)D Measure the hydraulic pressure for each element when moving

forward and back.Standard value: Refer to P.23-57.

OKPower train check LD Disassemble the transmission, check the condition of the

planetary carrier, output shaft and differential, etc.

NG

Replace the oil pump assembly. L(The oil pump cannot be disassembled.)



assembly.



Engine stalling when shifting Probable causeIf the engine stalls when the selector lever is shifted from N to D or R range whilethe engine is idling, the cause is probably a malfunction of the engine system, damperclutch solenoid valve, valve body or torque converter (damper clutch malfunction).

D Malfunction of the engine systemD Malfunction of the damper clutch control solenoid valveD Malfunction of the valve bodyD Malfunction of the torque converter (Malfuction of the

damper clutch)


Engine system checkD Check the control system, ignition system, fuel system and

main system.

NGRepair, replace

OK

Replace the damper clutch control solenoid valve.



assembly.

NGRepalce the torque converter.


Shocks when changing from N to D and large time lag Probable causeIf abnormal shocks or a time lag of 2 seconds or more occur when the selectorlever is shifted from N to D range while the engine is idling, the cause is probablyabnormal underdrive clutch pressure or a malfunction of the underdrive clutch, valvebody or idle position switch.

D Abnormal underdrive clutch pressureD Malfunction of the underdrive solenoid valveD Malfunction of the underdrive clutchD Malfunction of the valve bodyD Malfunction of the idle position switch


MUT-II Actuator testD No. 2 Underdrive solenoid valve


NGReplace the underdrive solenoid valve. L

OK

When does the shock occur?

When starting

Shocks sometimes occur

No Yes

MUT-II Data listD No. 64 Idle position switch

OK: Turns from on to off when the accelerator pedal is slightlydepressed from the fully closed position.

OK NG

Idle position switch checkD INSPECTION PROCEDURE 18 - Idle position switch system

check (Refer to P.23-37.)



assembly.

When shifting

Hydraulic pressure test (Refer to P.23-56.)D Measure the underdrive clutch pressure when shifting from

N to D.Standard value: Refer to P.23-57.

NG

OK

Underdrive clutch system check LD Remove the transmission assembly, valve body cover and valve


when air is blown through the underdrive clutch oil hole in thetransmission case.

OK

NG

Underdrive clutch check LD Check for burning of the facing, defective piston seal rings




Shocks when changing from N to R and large time lag Probable causeIf abnormal shocks or a time lag of 2 seconds or more occurs when the selectorlever is shifted from N to R range while the engine is idling, the cause is probablyabnormal reverse clutch pressure or low and reverse brake pressure, or a malfunctionof the reverse clutch, low and reverse brake, valve body or idle position switch.

D Abnormal reverse clutch pressureD Abnormal low and reverse brake pressureD Malfunction of the low and reverse solenoid valveD Malfunction of the reverse clutchD Malfunction of the low and reverse brakeD Malfunction of the valve bodyD Malfunction of the idle position switch


MUT-II Actuator testD No. 1 Low and reverse solenoid valve


NGReplace the low and reverse solenoid valve. L

OK


When starting

Shocks sometimes occur

No Yes

MUT-II Data listD No. 64 Idle position switch

OK: Turns from on to off when the accelerator pedal is slightlydepressed from the fully closed position.

OK NG

Idle position switch checkD INSPECTION PROCEDURE 18 - Idle position switch system

check (Refer to P.23-37.)



assembly.

When shifting

Hydraulic pressure test (Refer to P.23-56.)D Measure the reverse clutch pressure in R range.


NG

OK

Hydraulic pressure test (Refer to P.23-56.)D Measure the low and reverse brake pressure in R range.


NG

OK

Reverse clutch system and low reverse brake system check LD Remove the transmission assembly, valve body cover and valve


when air is blown through the reverse clutch oil hole and lowand reverse brake oil hole in the transmission case.

OK

NG

Reverse clutch and low reverse brake check LD Check for burning of the facing, defective piston seal rings




Shocks when changing from N to D, N to R and large timelag

Probable cause

If abnormal shocks or a time lag of 2 seconds or more occur when the selectorlever is shifted from N to D range and from N to R range while the engine is idling,the cause is probably abnormal line pressure or a malfunction of the oil pump orvalve body.

D Abnormal line pressureD Malfunction of the oil pumpD Malfunction of the valve body

OK


Whenstarting Valve body disassembly, cleaning and reassembly L

D Pay particular attention to loosening of bolts, and to damageand slippage of O-rings, valves and valve bodies.

D If the damage cannot be repaired, replace the valve bodyassembly.


Hydraulic pressure test (Refer to P.23-56.)D Measure the hydraulic pressure for each element when in D

range and R range.Standard value: Refer to P.23-57.

NGAdjust the line pressure. (Refer to P.23-62.)

NG

When shifting



Shocks and running up Probable causeIf shocks occur when driving due to upshifting or downshifting and the transmissionspeed becomes higher than the engine speed, the cause is probably abnormal linepressure or a malfunction of a solenoid valve, oil pump, valve body or of a brakeor clutch.

D Abnormal line pressureD Malfunction of each solenoid valveD Malfunction of the oil pumpD Malfunction of the valve bodyD Malfunction of each brake or each clutch


MUT-II Actuator testD No. 1 Low and reverse solenoid valveD No. 2 Underdrive solenoid valveD No. 3 Second solenoid valveD No. 4 Overdrive solenoid valve


NGReplace the solenoid valve.

OK

Adjust the line pressure. (Refer to P.23-62.)NG


NG



assembly.

OK

Clutch and brake check LD Check for burning of the facing, defective piston seal rings




All points (Displaced shifting points) Probable causeIf all shift points are displaced while driving, the cause is probably a malfunctionof the output shaft speed sensor, TPS or of a solenoid valve.

D Malfunction of the output shaft speed sensorD Malfunction of the throttle position sensorD Malfunction of each solenoid valveD Abnormal line pressureD Malfunction of the valve bodyD Malfunction of the A/T-ECU


MUT-II Data listD No. 23 Output shaft speed sensor

OK: Increases in proportion to vehicle speed.

NGCodeNo. 23 - Output shaft speed sensor system (Refer to P.23-17.)

OK

MUT-II Data listD No. 11 TPS/APS

OK: Increases in proportion to accelerator pedal opening angle

NGCode No. 11, 12, 14 TPS/APS system check (Refer to P.23-15.)

OK

MUT-II Data listD No. 31 Low and reverse solenoid valve duty %D No. 32 Underdrive solenoid valve duty %D No. 33 Second solenoid valve duty %D No. 34 Overdrive solenoid valve duty %

OK: Refer to the table below.

NGReplace the solenoid valve. L

NG


OK

Adjust the line pressure. (Refer to P.23-62.)NG



assembly.

No. 31 No. 32 No. 33 No. 34

Driving at constant speed in 1st gear 0 % 0 % 100 % 100 %

Driving at constant speed in 2nd gear 100 % 0 % 0 % 100 %

Driving at constant speed in 3rd gear 100 % 0 % 100 % 0 %

Driving at constant speed in 4th gear 100 % 100 % 0 % 0 %



Some points (Displaced shifting points) Probable causeIf some of the shift points are displaced while driving, the cause is probably amalfunctionof the valve body, or it is related to control and is not an abnormality.

D Malfunction of the valve body

L: Refer to the Transmission Workshop Manual.INVECS-II CANCEL COMMANDD Use the MUT-II to stop the

INVECS-II function.

Does standard shifting occur normally?No

Does the problem occur only when theautomatictransmissionfluidtemperatureis -29_C or lower or 125_C or higher?

NoValve body disassembly, cleaning andreassembly LD Pay particular attention to loosening

of bolts, and to damage and slippageof O-rings, valves and valve bodies.

D If the damage cannot be repaired,replace the valve body assembly.

Yes

It is related to control and is not an ab-normality.

Yes


No diagnosis codes (Does not shift) Probable causeIf shifting does not occur while driving and no diagnosis codes are output, the causeis probably a malfunction of the inhibitor switch, or A/T-ECU.

D Malfunction of the inhibitor switchD Malfunction of the A/T-ECU

Does the transmission remain in 3rdgear with selector lever in positionD ?

NoMUT-II Data listD No. 61 Inhibitor switch

OK: A/T-ECU input signal and se-lector lever position shouldmatch.

NGInhibitor switch checkD INSPECTION PROCEDURE 16 -

Inhibitor switch system check.(Refer to P.23-36.)

OK

Yes

Is backup power being supplied to theA/T-ECU?

No Yes

Is power being supplied to theA/T-ECU?

Yes

No

Power supply circuit checkD Pay particular attention to open

circuits in the harnesses, poorconnector connections and opencircuits in fuses.

D If there is a blown fuse, investigatewhy a short-circuit has occurred andthen replace the fuse.

OK


MUT-II Data listD No. 62 Hold mode signal

OK: The signal should changewhen the mode control switchposition is changed.

NGMode control switch checkD INSPECTION PROCEDURE 17 -

Mode control switch system check(Refer to P.23-36.)



Poor acceleration Probable causeIf acceleration is poor even if downshifting occurs while driving, the cause is probablya malfunction of the engine system or of a brake or clutch.

D Malfunction of the engine systemD Malfunction of the brake or clutch


Engine system checkD Check the control system, ignition system, fuel system and

main system.

NGReplace, repair

OK

Brake or clutch check LD Check for burning of the facing, defective piston seal rings



Vibration Probable causeIf vibration occurs when driving at constant speed or when accelerating and decelerationin top range, the cause is probably abnormal damper clutch pressure or a malfunctionof the engine system, damper clutch control solenoid valve, torque converter or valvebody.

D Abnormal damper clutch pressureD Malfunction of the engine systemD Malfunction of the damper clutch control solenoid valveD Malfunction of the torque converterD Malfunction of the valve body


MUT-II Actuator testD No. 6 Damper clutch control solenoid valve


NGReplace the damper clutch control solenoid valve. L

OK

Does the problem occur even when the oil temperature sensorconnector is disconnected?

YesEngine system checkD Check the control system, ignition system, fuel system and

main system.No

Hydraulic pressure test (Refer to P.23-56.)D Measure the damper clutch pressure.




assembly.OK

Replace the torque converter assembly.



Inhibitor switch system Probable causeThe cause is probably a malfunction of the inhibitor switch circuit, ignition switchcircuit or a defective A/T-ECU.

D Malfunction of the inhibitor switchD Malfunction of the ignition switchD Malfunction of connectorD Malfunction of the A/T-ECU

Inhibitor switch check (Refer toP.23-49.)NG

Replace

OK

Check the voltage of the inhibitor switchconnector B-72.D Disconnect the connector and

measure at the harness side.D Voltage between terminal No. 8 and

earthOK: Battery voltage

NGCheck the following connectors:C-49, C-83, C-131, C-134

NGRepair

OK

Harness checkD Between inhibitor switch and

ignition switch

NGRepair

OK


NG

Ignition switch check(Refer to GROUP54 - Ignition Switch.)

OK

Check the following connectors:B-72, C-30, C-47, C-48

NGRepair

OK

Harness checkD Between inhibitor switch and

A/T-ECU connector

NGRepair

OK




Mode control switch system Probable causeThe cause is probably a defective mode control switch circuit or a defective A/T-ECU. D Malfunction of the mode control switch


OK

Check the following the connector:C-30

OK



NGRepair

NGRepair

NG

Ignition switch check (Refer to GROUP54 - Ignition Switch.)

OK


OK

Harness checkD Between mode control switch and

ignition switch

OK

Harness check.D Between mode control switch and

A/T-ECU

OK

Check the voltage of the A/T-ECU con-nector C-30.D Disconnect theconnector andcheck

at the harness side.D Ignition switch: OND Select the HOLD mode.D Voltage between terminalNo. 70and

earthOK: Battery voltage

NGCheck the following connectors:C-49, C-83, C-89, C-131, C-134

NGRepair

Mode control switch check(Refer to P.23A-65.)

NGReplace



Idle position switch system Probable causeThe cause is probably a defective idle position switch circuit or a defective A/T-ECU. D Malfunction of the idle position switch


Idle position switch check(Refer to GROUP 13A - On-vehicle Service.)

NGReplace the throttle position sensor.

OK

Check the following connectors:B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29

NGRepair

OK

Harness checkD Between idle position switch and A/T-ECU

NGRepair

OK




Dual pressure switch system Probable causeThe cause is probably a defective dual pressure switch circuit or a defective A/T-ECU. D Malfunction of the dual pressure switch

D Malfunction of connectorD Malfunction of A/C systemD Malfunction of the A/T-ECU

Dual pressure switch check (Refer toGROUP 55 - On-vehicle service.)

NGReplace

OK

Check the voltage of the A/T-ECU con-nector C-28.D Disconnect the connector and

check at the harness side.D Ignition switch: OND A/C switch: OND Voltage between terminal No. 10

and earthOK: Battery voltage

OKCheck the following connectors:B-30, C-28

NGRepair

OK


NGNG

Check the A/C system. (Refer toGROUP 55 - Troubleshooting.)

Repair

OK


NG

A/C system check (Refer to GROUP55 - Troubleshooting.)



Vehicle speed sensor system Probable causeThe cause is probably a defective vehicle speed sensor circuit or a defective A/T-ECU. D Malfunction of the vehicle speed sensor


2. NG

3. NG

OK

Check the ignition switch. (Refer to GROUP 54 - Ignition switch.)

NG

OK

OK

Replace the engine-ECU.

OK

Replace the engine-ECU.

Check the harness wire between the vehicle speed sensor andthe earth, and repair if necessary.

NG

Check the harness wirebetween the engine-ECUand the vehicle speedsensor connector.

NGRepair

Check trouble symptom.

Check the followingconnectors:C-30, C-48

NGRepair

NG

Check the harness wirebetween the vehiclespeed sensor and ignitionswitch connector.

NGRepair

OK


Check the harness wirebetween the engine-ECUand the vehicle speedsensor connector.

NGRepair

OK


OK

Check the followingconnector:B-67

NGRepair

OK

Measure at the vehicle speed sensor connector B-67.D Disconnect the connector, and measure at the harness side.1. Voltage between 1 and earth (Ignition switch: ON)

OK: Battery voltage2. Voltage between 3 and earth (Ignition switch: ON)

OK: 4.8 - 5.2 V3. Continuity between 2 and earth

OK: Continuity

1. NGCheck the followingconnectors:C-90, C-131, C-135

NGRepair

Check the vehicle speed sensor.(Refer to GROUP 54 - Combination Meters.)

NGReplace


Auto-cruise-ECU signal system Probable causeThe cause is probably a defective auto-cruise signal line circuit or a defective A/T-ECU. D Malfunction of connector

D Malfunction of the A/T-ECUD Malfunction of the auto-cruise-ECU

Auto-cruise system check (Refer to GROUP 17 - Troubleshooting.)NG

Repair

OK

Check the following connectors: C-28, C-82, C-83NG

Repair

OK

Harness checkD Between auto-cruise-ECU and A/T-ECU

OKReplace the A/T-ECU.

NG

Repair


DATA LIST REFERENCE TABLE 23100810208

Item No. Check item Check requirement Normal value

11 Throttle position sensor<Vehicles without TCL>

Engine: StoppedSelector lever

Accelerator pedal:Released

400 - 1,000 mV

Accelerator pedalposition sensor<Vehicles with TCL>

position: PAccelerator pedal:Halfly depressed

Gradually rises from theabove value

Accelerator pedal:Depressed

4,500 - 5,000 mV

15 Oil temperature sensor Warming up Drive for 15 minutes ormore so that theautomatic transmissionfluid temperaturebecomes 70 - 90 _C.

Gradually rises to70 - 90 _C

21 Crank angle sensor Engine: IdlingSelector lever


550 - 900 rpm

position: PAccelerator pedal:Halfly depressed

Gradually rises from theabove value

22 Input shaft speedsensor

Selector leverposition: 3

Driving at constant speedof 50 km/h in 3rd gear

1,800 - 2,100 rpm

23 Output shaft speedsensor



1,800 - 2,100 rpm

25 Wide open throttle Accelerator pedal Released OFFswitch position

Depressed ON

26 Stop lamp switch Ignition switch: ON Brake pedal: Depressed ONEngine: Stopped

Brake pedal: Released OFF

29 Vehicle speed sensor Selector leverposition: 3

Idling with 1st gear(Vehicle stopped)

0 km/h


50 km/h

31 Low and reversesolenoid valve duty %

Selector leverposition: L, 2, 3, D

10 km/h in 1st gear No. 31: 0 %, No. 32: 0%, No. 33: 100 %,No. 34: 100%

32 Underdrive solenoidvalve duty %

30 km/h in 2nd gear No. 31: 100 %, No. 32:0 %, No. 33: 0 %,No. 34: 100%

33 Second solenoid valveduty %

50 km/h in 3rd gear No. 31: 100 %, No. 32:0 %, No. 33: 100 %,No. 34: 0%

34 Overdrive solenoid valveduty %

70 km/h in 4th gear No. 31: 100 %, No. 32:100 %, No. 33: 0 %,No. 34: 0%


Item No. Normal valueCheck requirementCheck item

36 Damper clutch controlsolenoid valve duty %


Driving at 50 km/h in3rd gear with acceleratorreleased

0 %


Approx. 70 - 90 %

52 Amount of damperclutch slippage


Driving at 50 km/h in 3rdgear with acceleratorfully closed

Approx. 100 - 300 rpm*


Approx. 0 - 10 rpm

54 Control relay outputvoltage

Ignition switch : OFF Ignition switch:ON® OFF

Battery voltage (mV)®0 mV

57 Engine volumetricefficiency

Selector leverposition: N

N range with acceleratorpedal released®depressed.

Data changes

61 Inhibitor switch Ignition switch: ON Selector lever position: P PEngine: Stopped

Selector lever position: R R

Selector lever position: N N

Selector lever position: D D

Selector lever position: 3 3

Selector lever position: 2 2

Selector lever position: L L

62 HOLD mode signal Mode control switch HOLD ONposition

AUTO OFF

63 Shift position Selector lever posi-tion: L, 2, 3, D

Driving at constant speedof 10 km/h in 1st gear

1st

Driving at constant speedof 30 km/h in 2nd gear

2nd


3rd

Driving at constant speedof 70 km/h in 4th gear

4th

64 Idle position switch Engine: IdlingSelector lever posi-


ON

tion: NAccelerator pedal:Halfly depressed

OFF

65 Dual pressure switch Engine: Idling A/C switch: ON ONSelector lever posi-tion: N A/C switch: OFF OFF


Item No. Normal valueCheck requirementCheck item

66 Auto-cruse-ECU signal While auto-cruise Plain road OFFoperating

Sloping road ON

NOTE*: The damper clutch is released when the accelerator is fully closed (Idle position switch: ON).

ACTUATOR TEST JUDGEMENT VALUE 23100820065

Item No. Check item Test content Check requirement Normal value

1 Low reverse solenoid valve Drive the solenoid Ignition switch: ON The operation sound should

2 Underdrive solenoid valvevalve specified bythe MUT-II at 50 %

Selector leverposition: P

be audible when the solenoidvalve is driven.

3 Second solenoid valveduty for 5 seconds.No other solenoid

Engine: 0 r/minVehicle speed:

4 Overdrive solenoid valvevalve should beenergised.

Vehicle speed:0 km/h

6 Damper clutch controlsolenoid valve

(Vehicle stopped)Throttle(Accelerator)

12 A/T control relay Control relay is OFFfor 3 seconds.

opening voltage:Less than 0 VIdle switch: ON

Data list No. 54(1) During test: 0 mV(2) Normal: Battery voltage

[mV]

INVECS-II CANCEL COMMAND 23100950023

Item No. Item Content Remarks

14 INVECS-II Stop the INVECS-II control and change gearsaccording to the standard shift pattern.

Use this functionwhencarryingout procedure 8 in the roadtests.


CHECK AT A/T-ECU TERMINALS 23100840207

TerminalNo.

Check item Check requirement Standard value

1 Underdrive solenoid valve Selector lever position: D (1st gear) Battery voltage

Selector lever position: P Approx.7 - 9 V

2 Solenoid valve power supply Ignition switch: OFF 0 V

Ignition switch: ON Battery voltage

3 Solenoid valve power supply Ignition switch: OFF 0 V


8 Auto-cruse control unit No OD-OFF request Battery voltage

OD-OFF request 0V

10 A/C compressor load signal A/C switch: OFF 0 V

A/C switch: ON Battery voltage

11 Power supply Ignition switch: OFF 0 V


12 Earth Always 0 V

13 Earth Always 0 V

14 Overdrive solenoid valve Selector lever position: D (3rd gear) Battery voltage

Selector lever position: P Approx. 7 - 9 V

15 Damper clutch control solenoid Selector lever position: L (1st gear) Battery voltagevalve

Selector lever position: 3 (50 km/h in 3rd gear) Other thanbattery voltage

16 Second solenoid valve Selector lever position: 2 (2nd gear) Battery voltage

Selector lever position: P Approx. 7 - 9 V

21 Engine-ECU torque reductionrequest signal<Vehicles with TCL>

Ignition switch: ON (except during shifting) 4 - 5 V


TerminalNo.

Standard valueCheck requirementCheck item

23 Diagnosis control - -

24 Power supply Ignition switch: OFF 0 V


25 Earth Always 0 V

26 Earth Always 0 V

31 Input shaft speed sensor Measure between terminal No. 31 and No. 43 byan oscilloscope.Engine: 2,000 r/minSelector lever position: 3

Refer to P.23-45,Oscilloscopeinspectionprocedure.

32 Output shaft speed sensor Measure between terminal No. 32 and No. 43 byan oscilloscope.Engine: 2,000 r/minSelector lever position: 3

Refer to P.23-45,Oscilloscopeinspectionprocedure.

33 Crank angle sensor Engine: Idling 2.0 - 2.4 V

36 Idle position switch Engine: Idling 0 V

Engine: Other than idling 5 V

38 Back up power suuply Ignition switch: OFF Battery voltage

43 Sensor earth Always 0 V

44 Oil temperature sensor ATF temperature: 25 _C 3.8 - 4.0 V

ATF temperature: 80 _C 2.3 - 2.5 V

45 Throttle position sensor (TPS)<Vehicles without TCL>

Accelerator pedal: Released (Engine stopped) 0.5 - 1.0 V

Accelerator pedal position sensor(APS) <Vehicles with TCL>

Accelerator pedal: Depressed (Engine stopped) 4.5 - 5.0 V

53 Communication with engine-ECU<Vehicles without TCL>Communication with TCL-ECU<Vehicles with TCL>

Engine: IdlingSelector lever position: D

Other than 0 V

54 Communication with engine-ECU<Vehicles without TCL>Communication with TCL-ECU<Vehicles with TCL>

Engine: IdlingSelector lever position: D

Other than 0 V

55 Inhibitor switch P Selector lever position: P Battery voltage

Selector lever position: Other than above 0 V

56 Inhibitor switch N Selector lever position: N Battery voltage


57 Inhibitor switch 3 Selector lever position: 3 Battery voltage



TerminalNo.

Standard valueCheck requirementCheck item

58 Inhibitor switch L Selector lever position: L Battery voltage


59 Stop lamp switch Brake pedal: Depressed Battery voltage

Brake pedal: Released 0 V

62 Low and reverse solenoid valve Selector lever position: D (1st gear) Battery voltage

Selector lever position: D (2nd gear) Approx. 7 - 9 V

63 Diagnosis output Normal (No diagnosis code output) 0® 5 V flashing

65 Wide open throttle switch Accelerator pedal: Released 4.5 - 5.5 V

Accelerator pedal: Depressed Less than 0.4 V

66 Inhibitor switch R Selector lever position: R Battery voltage


67 Inhibitor switch D Selector lever position: D Battery voltage


68 Inhibitor switch 2 Selector lever position: 2 Battery voltage


69 Vehicle speed sensor When stopped 0 V

Move forward slowly 0® 5 V flashing

70 Mode control switch Select HOLD mode Battery voltage

Select AUTO mode 0V

71 A/T control relay Ignition switch: OFF 0 V


72 Earth Ignition switch: ON 0 V


OSCILLOSCOPE INSPECTION PROCEDURE 23100850064

Check item Check requirement Normal condition(Waveform sample)

Crank angle sensor Selector lever position: N Idling (Vehicle stopped) Waveform A

Input shaft speedsensor

Selector lever position: 3 Driving at constant speed of 50km/h in 3rd gear

Waveform B

Output shaftspeed sensor

(Engine: 1,800 - 2,100 r/min)

Vehicle speed sensor

Low reversesolenoid valve

Ignition switch: ONSelector lever position: P

Force drive each solenoid valve(Actuator test)

Waveform C

Underdrive solenoidvalve

Engine: 0 r/minVehicle speed: 0 km/h(Vehicle stopped)

Second solenoidvalve

(Vehicle stopped)Throttle (Accelerator) openingangle: Less than 1 V

Overdrive solenoidvalve

Idle switch: ON

Damper clutchcontrol solenoidvalve

Waveform sample

Waveform A

(ms)

(V)

0

5

Waveform B

(ms)

(V)

0

5

Waveform C

(ms)

(V)60

40

20

0

AUTOMATIC TRANSMISSION - On-vehicle Service23-46

ON-VEHICLE SERVICE 23100090237

ESSENTIAL SERVICEAUTOMATIC TRANSMISSION FLUID CHECK1. Drive the vehicle until the fluid temperature rises to the

normal temperature (70-80_C).2. Park the vehicle on a level surface.3. Move the selector lever through all positions to fill the

torque converter and the hydraulic circuits with fluid, andthen move the selector lever to the N position.

4. After wiping off any dirt around the oil level gauge, removethe oil level gauge and check the condition of the fluid.

NOTEIf the fluid smells as if it is burning, it means that thefluid has been contaminated by the particles from thebushes and friction materials, a transmission overhauland flushing the cooler line may be necessary.

5. Check that the fluid level is at the HOT mark on theoil level gauge. If the fluid level is lower than this, pourin more fluid until the level reaches the HOT mark.

Automatic transmission fluid:

Dia Queen ATF SP II or equivalent

NOTEIf the fluid level is low, the oil pump will draw in air alongwith the fluid, which will cause bubbles to form insidethe hydraulic circuit. This will in turn cause the hydraulicpressure to drop, which will result in late shifting andslipping of the clutches and brakes.If there is too much fluid, the gears can churn it up intofoam and cause the same conditions that can occur withlow fluid levels.In either case, air bubbles can cause overheating andoxidation of the fluid which can interfere with normal valve,clutch, and brake operation. Foaming can also result influid escaping from the transmission vent, in which caseit may be mistaken for a leak.

6. Securely insert the oil level gauge.7. The fluid and oil filters should always be replaced in the

following conditions:When troubleshooting the transmissionWhen overhauling the transmissionWhen the oil is noticeably dirty or deteriorates (drivingunder the severe condition)Furthermore, the oil filters are special filters which areonly to be used for the automatic transmission.

AUTOMATIC TRANSMISSION - On-vehicle Service 23-47

AUTOMATIC TRANSMISSION FLUID REPLACEMENT23100100251

If you have a fluid changer, use this changer to replace thefluid. If you do not have a fluid changer, replace the fluidby the following procedure.1. Disconnect the hose shown in the illustration which

connects the transmission and the oil cooler (inside theradiator).

2. Start the engine and let the fluid drain out.

Running conditions: N range with engine idling

CautionThe engine should be stopped within one minute afterit is started. If the fluid has all drained out beforethen, the engine should be stopped at that point.

Discharge volume: Approx. 3.5 L

3. Remove the drain plug from the bottomof the transmissioncase to drain the fluid.

Discharge volume: Approx. 2.0 L

4. Replace the oil filters. (Refer to P.23-48.)5. Install the drain plug via a new gasket, and tighten it

to the specified torque.

Tightening torque: 32 Nm

6. Pour the new fluid in through the oil filler tube.

Adding volume: Approx. 5.5 L

CautionStop pouring if the full volume of fluid cannot bepoured in.

7. Repeat the procedure in step 2.

NOTEDrain the fluid from the cooler hose 7 L at least. Thendrain the fluid a little and check the fluid for dirt.If it has been contaminated, repeat the steps 6 and 7.

8. Pour the new fluid in through the oil filler tube.

Adding volume: Approx. 3.5 L


9. Reconnect the hose which was disconnected in step 1above, and firmly replace the oil level gauge.

10. Start the engine and run it at idle for 1 - 2 minutes.11. Move the selector lever through all positions, and then

move it to the N position.

12. Check that the fluid level is at the COLD mark on theoil level gauge. If the level is lower than this, pour inmore fluid.

13. Drive the vehicle until the fluid temperature rises to thenormal temperature (70 - 80_C), and then check thefluid level again.The fluid level must be at the HOT mark.

NOTEThe COLD level is for reference only; the HOT level shouldbe regarded as the standard level.

14. Firmly insert the oil level gauge into the oil filler tube.OIL FILTER REPLACEMENT 23101050067

1. Use the special tool (MB991610) to remove the automatictransmission oil filter.

2. Clean the filter bracket side mounting surface.3. Apply a small amount of automatic transmission fluid to

the O-ring of the new oil filter.4. Use the special tool (MB991610) to install the automatic

transmission oil filter.

NOTETightening torque: 12 Nm

5. Check the quantity of the automatic transmission fluid.(Refer to P.23-46.)

THROTTLE POSITION SENSOR ADJUSTMENT<Vehicles without TCL> 23100190142

Refer to GROUP 13A - On-vehicle Service.

ACCELERATOR PEDAL POSITION SENSORADJUSTMENT <Vehicles with TCL> 23100250048


Apply ATFto O-ring


INHIBITOR SWITCH CONTINUITY CHECK 23100140345

Items Terminal No.

1 2 3 4 5 6 7 8 9 10

P

R

N

D

3

2

L

INHIBITOR SWITCH AND CONTROL CABLEADJUSTMENT 23100150096

1. Set the selector lever to the �N� position.2. Loosen the control cable to manual control lever coupling

nut to free the cable and lever.3. Set the manual control lever to the neutral position.

Inhibitor switch

PR

N

D

L

2

3

Transmissioncontrol cable

Adjusting nut

Manualcontrollever


4. Loosen the inhibitor switch body mounting bolts and theturn the inhibitor switch body so the hole in the end ofthe manual control lever and the hole (cross section A-Ain the figure on the left) in the flange of the inhibitorswitch body flange are aligned.

5. Tighten the inhibitor switch body mounting bolts to thespecified torque. Be careful at this time that the positionof the switch body is not changed.

6. Gently pull the transmission control cable in the directionof the arrow, and then tighten the adjusting nut.

7. Check that the selector lever is in the �N� position.8. Check that each range on the transmission side operates

and functions correctly for each position of the selectorlever.

10 - 12 Nm

Mounting bolts

Manualcontrol lever

Section A-A

Hole in end

Hole inflange

Manual controllever

Inhibitorswitch body

A

A

Adjusting nut

12 Nm

Manual control lever


A/T CONTROL COMPONENT LOCATION 23100860234

Name Symbol Name Symbol

Accelerator position sensor (with idle positionswitch) <Vehicles with TCL>

C Mode control switch L

A/T control relay M Oil temperature sensor G

A/T-ECU K Output shaft speed sensor E

Crank angle sensor B Shift indicator lamp I

Diagnosis connector O Solenoid valve G

Dual pressure switch A Stop lamp switch P

Engine ECU K TCL-ECU J

Inhibitor switch F Throttle position sensor (with idle positionswitch) <Vehicles without TCL>

C

Input shaft speed sensor H Vehicle speed sensor D

Wide open throttle switch N

A

B

C D

E

F

G

HI

JK

LMN

O

P


A/T CONTROL COMPONENT CHECK 23100900011

CRANK ANGLE SENSOR CHECKRefer to GROUP 13A - Troubleshooting.

THROTTLE POSITION SENSOR CHECK<Vehicles without TCL> 23100390030


ACCELERATOR PEDAL POSITION SENSOR CHECK<Vehicles with TCL> 23100420029

Refer to GROUP 13H - On-vehicle Service.

OIL TEMPERATURE SENSOR CHECK 23100450035

1. Remove the oil temperature sensor.

2. Measure the resistance between terminals No. 1 andNo. 2 of the oil temperature sensor connector.

Standard value:

Oil temperature (_C) Resistance (kW)

0 16.7-20.5

100 0.57-0.69

INHIBITOR SWITCH CHECK 23100140352

Refer to P.23A-49.

STOP LAMP SWITCH CHECK 23100910014

Refer to GROUP 35 - Brake Pedal.

VEHICLE SPEED SENSOR CHECK 23100460038

Refer to GROUP 54 - On-vehicle Service.

Oil temperature sensor

ATF


DUAL POSITION PRESSURE SWITCH CHECK23100470031

Refer to GROUP 55 - On-vehicle Service.

IDLE POSITION SWITCH CHECK 23100410033


MODE CONTROL SWITCH CHECK 23100920048

Refer to P.23-65.

WIDE OPEN THROTTLE SWITCH CHECK 23100890080

Refer to P.23-64.

A/T CONTROL RELAY CHECK 23100930065

1. Remove the A/T control relay.

2. Use jumper wires to connect A/T control relay terminal2 to the battery (- ) terminal and terminal 4 to the battery(+) terminal.

3. Check the continuity between terminal 1 and terminal3 of the A/T control relay when the jumper wires areconnected to and disconnected from the battery.

Jumper wire Continuity between terminals No. 1and No. 3

Connected Continuity

Disconnected No continuity

4. If there is a problem, replace the A/T control relay.


SOLENOID VALVE CHECK 23100940013

1. Remove the valve body cover.2. Disconnect the connectors of each solenoid valve.

3. Measure the resistance between terminals 1 and 2 ofeach solenoid valve.

Standard value:

Name Resistance

Damper clutch solenoid valve 2.7 - 3.4 W

Low and reverse solenoid valve (at 20_C)

Second solenoid valve

Underdrive solenoid valve

Overdrive solenoid valve

4. If the resistance is outside the standard value, replacethe solenoid valve.

TORQUE CONVERTER STALL TEST 23100540206

This test measures the maximum engine speed when theselector lever is at the D or R position and the torque converterstalls to test the operation of the torque converter, startermotor and one-way clutch operation and the holdingperformance of the clutches and brakes in the transmission.

CautionDo not let anybody stand in front of or behind the vehiclewhile this test is being carried out.

1. Check the automatic transmission fluid level andtemperature and the engine coolant temperature.D Fluid level: At the HOT mark on the oil level gaugeD Fluid temperature: 80 - 100_CD Engine coolant temperature: 80 - 100_C

Overdrivesolenoidvalve

Low andreversesolenoidvalve

Secondsolenoidvalve

Damperclutchsolenoidvalve

Underdrivesolenoidvalve

Reverseclutch Low-reverse

brakeUnderdriveclutch

Torqueconverter


2. Check both rear wheels (left and right).3. Pull the parking brake lever on, with the brake pedal

fully depressed.4. Start the engine.5. Move the selector lever to the D position, fully depress

the accelerator pedal and take a reading of the maximumengine speed at this time.

Caution1. The throttle should not be left fully open for any

more than eight seconds.2. If carrying out the stall test two or more times,

move the selector lever to the N position and runthe engine at 1,000 r/min to let the automatictransmission fluid cool down before carrying outsubsequent tests.

Standard value

Stall speed: 2,100 - 2,600 r/min

6. Move the selector lever to the R position and carry outthe same test again.

Standard value

Stall speed: 2,100 - 2,600 r/min

TORQUE CONVERTER STALL TEST JUDGEMENTRESULTSa. Stall speed is too high in both D and R ranges

D Low line pressureD Low & reverse brake slippage

b. Stall speed is too high in D range onlyD Underdrive clutch slippage

c. Stall speed is too high in R range onlyD Reverse clutch slippage

d. Stall speed too low in both D and R rangesD Malfunction of torque converterD Insufficient engine output


HYDRAULIC PRESSURE TEST 23100550216

1. Warm up the engine until the automatic transmission fluidtemperature is 80 - 100_C.

2. Jack up the vehicle so that the wheels are free to turn.3. Connect the special tools (2,942 kPa oil pressure gauge

[MD998330] and joints [MD998332, MD998900]) to eachpressure discharge port.

4. Measure the hydraulic pressure at each port under theconditions given in the standard hydraulic pressure table,and check that the measured values are within thestandard value ranges.

5. If a value is outside the standard range, correct theproblem while referring to the hydraulic pressure testdiagnosis table.


STANDARD HYDRAULIC PRESSURE TEST<4G63>

Measurement condition Standard hydraulic pressure kPa

Selectorleverposition

Shift posi-tion

Enginespeed(r/min)

Under-driveclutchpressure

Reverseclutchpressure

Overdriveclutchpressure

Low andreversebrakepressure

Secondbrakepressure

Torqueconverterpressure

P - 2,500 - - - 310 - 390 - 310 - 390

R Reverse 2,500 - 1,320 -1,720

- 1,320 -1,720

- 500 - 700

N - 2,500 - - - 310 - 390 - 310 - 390

D 1st gear 2,500 1,010 -1,050

- - 1,010 -1,050

- 500 - 700

2nd gear 2,500 1,010 -1,050

- - - 1,010 -1,050

500 - 700

3rd gear 2,500 590 - 690 - 590 - 690 - - 450 - 650

4th gear 2,500 - - 590 - 690 - 590 - 690 450 - 650

<6A13>

Measurement condition Standard hydraulic pressure kPa

Selectorleverposition

Shift posi-tion

Enginespeed(r/min)

Under-driveclutchpressure

Reverseclutchpressure

Overdriveclutchpressure

Low andreversebrakepressure

Secondbrakepressure

Torqueconverterpressure

P - 2,500 - - - 260 - 340 - 260 - 340

R Reverse 2,500 - 1,320 -1,720

- 1,320 -1,720

- 500 - 700

N - 2,500 - - - 260 - 340 - 260 - 340

D 1st gear 2,500 1,010 -1,050

- - 1,010 -1,050

- 500 - 700

2nd gear 2,500 1,010 -1,050

- - - 1,010 -1,050

500 - 700

3rd gear 2,500 780 - 880 - 780 - 880 - - 450 - 650

4th gear 2,500 - - 780 - 880 - 780 - 880 450 - 650


HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom Probable cause

All hydraulic pressures are high. Incorrect transmission control cable adjustment

Malfunction of the regulator valve

All hydraulic pressures are low. Incorrect transmission control cable adjustment

Malfunction of the oil pump

Clogged internal oil filter

Clogged external oil filter

Clogged oil cooler


Malfunction of the relief valve

Incorrect valve body installation

Hydraulic pressure is abnormal Malfunction of the regulator valvein �R� range only.

Clogged orifice


Hydraulic pressure is abnormal Malfunction of the overdrive solenoid valvein �3� or �4� range only.

Malfunction of the overdrive pressure control valve


Malfunction of the switch valve

Clogged orifice


Only underdrive hydraulic Malfunction of the oil seal Kpressure is abnormal.

Malfunction of the oil seal L

Malfunction of the oil seal M

Malfunction of the underdrive solenoid valve

Malfunction of the underdrive pressure control valve

Malfunction of check ball

Clogged orifice


Only reverse clutch hydraulic Malfunction of the oil seal Apressure is abnormal.

Malfunction of the oil seal B

Malfunction of the oil seal C

Clogged orifice



Trouble symptom Probable cause

Only overdrive hydraulic Malfunction of the oil seal Dpressure is abnormal.

Malfunction of the oil seal E

Malfunction of the oil seal F

Malfunction of the overdrive solenoid valve

Malfunction of the overdrive pressure control valve

Malfunction check ball

Clogged orifice


Only low and reverse hydraulic Malfunction of the oil seal Ipressure is abnormal.

Malfunction of the oil seal J

Malfunction of the low and reverse solenoid valve

Malfunction of the low and reverse pressure control valve

Malfunction of the switch valve

Malfunction of the fail safe valve A


Clogged orifice


Only second hydraulic pressure Malfunction of the oil seal Gis abnormal.

Malfunction of the oil seal H

Malfunction of the oil seal O

Malfunction of the second solenoid valve

Malfunction of the second pressure control valve

Malfunction of the fail safe valve B

Clogged orifice


Only torque converter pressure Malfunction of the oil cooleris abnormal.

Malfunction of the oil seal N

Malfunction of the damper clutch control solenoid valve

Malfunction of the damper clutch control valve

Malfunction of the torque converter pressure control valve

Clogged orifice


Pressure applied to non Incorrect transmission control cable adjustmentoperating element.

Malfunction of the manual valve




OIL SEAL LAYOUT

O

A

H

B

C

D

E F G I J K L M N


HYDRAULIC CIRCUIT 23100880070

PARKING AND NEUTRAL

1 2 3 4 5

6 7

8

9 10

1112

13

14 15 16 17 18

19 20 21 22 23

2425

26

27

28 2930

32

31

6 6 6

RNDP3

2L

1. Reverse clutch2. Low-reverse brake3. Second brake4. Underdrive clutch5. Overdrive clutch6. Accumulator7. Check ball8. Damper clutch9. Fail safe valve A10. Fail safe valve B11. Damper clutch control valve12. Switch valve13. Automatic transmission fluid cooler14. Lubrication15. Low-reverse pressure control valve16. Second pressure control valve17. Underdrive pressure control valve

18. Overdrive pressure control valve19. Damper clutch control solenoid

valve20. Low-reverse solenoid valve21. Second solenoid valve22. Underdrive solenoid valve23. Overdrive solenoid valve24. Torque converter pressure control

valve25. Regulator valve26. Manual valve27. Oil filter28. Oil pump29. Oil strainer30. Oil filter (Built in type)31. Relief valve32. Oil pan


LINE PRESSURE ADJUSTMENT 23100170122

1. Discharge the automatic transmission fluid, and thenremove the valve body cover.

2. Turn the adjusting screw shown in the illustration at leftto adjust the underdrive pressure to the standard value.The pressure increases when the screw is turned to theleft.

NOTEWhen adjusting the underdrive pressure, adjust to themiddle of the standard value range.

Standard value: 1,010 - 1,050 kPa

Change in pressure for each turn of the adjusting screw:35 kPa

3. Install the valve body cover, and pour in the standardvolume of automatic transmission fluid.

4. Carry out a hydraulic pressure test. (Refer to P.23-56.)Readjust the line pressure if necessary.

SELECTOR LEVER OPERATION CHECK23100130090

1. Shift selector lever to each range and check that levermoves smoothly and is controlled. Check that positionindicator is correct.

2. Check the selector lever can be moved to each position(by button operation as shown in the illustration).

3. Start the engine and check if the vehicle moves forwardwhen the selector lever is moved from N or D, and movesbackward when moved to R.

4. When the shift lever malfunctions, adjust control cableand selector lever sleeve. Check for worm shift leverassembly sliding parts.

Adjustingscrew

Push button

Button not pressed

Button pressed

AUTOMATIC TRANSMISSION - Transmission Control 23-63

TRANSMISSION CONTROL 23100660247

REMOVAL AND INSTALLATION

Pre-removal and Post-installation OperationD Air Cleaner Assembly Removal and InstallationD Battery and Battery Tray Removal and InstallationD Lower Cover and Side Cover Removal and

Installation (Refer to GROUP 52A - InstrumentPanel.)

D Floor Console Box Removal and Installation(Refer to GROUP 52A.)

Caution: SRSBe careful not to subject the SRS -ECU to anyshocks during removal and installation of thetransmission control cable and selector leverassembly.

12 Nm

12 Nm

12 Nm

1

2

3

4

5

6

7

8

9

7

Transmission control cable removalsteps1. Foot rest <R.H. drive vehicles>2. Engine-ECU, A/T-ECU and A/T

control relay assembly"AA 3. Nut

4. Adjuster5. Transmission control cable connec-

tion6. Transmission control cable assem-

bly

Selector lever assembly removalsteps5. Transmission control cable connec-

tion7. Wiring harness connector8. Selector lever assemblyA/T-ECU removal steps1. Foot rest <R.H. drive vehicles>2. Engine-ECU, A/T-ECU and A/T

control relay assemblyWide open throttle switch removalstep9. Wide open throttle switch

AUTOMATIC TRANSMISSION - Transmission Control23-64

INSTALLATION SERVICE POINT"AANUT INSTALLATION1. Put the selector lever in the �N� position.2. Loosen the adjusting nut, gently pull the transmission

control cable in the direction of the arrow and tightenthe nut.

INSPECTION 23100890097

WIDE OPEN THROTTLE SWITCH CHECK

Switch position Terminal No.

1 2

OFF

ON

Manual control lever

Nut

OFFON

AUTOMATIC TRANSMISSION - Transmission Control 23-65

SELECTOR LEVER ASSEMBLY 23100680168

DISASSEMBLY AND REASSEMBLY

11

2 Nm

1

234

5

6

8

9

10

1114

13

2 Nm

13 Nm

12

15

7

Disassembly steps1. Push button2. Spring3. Bumper4. Adjuster5. Shift knob6. Indicator panel assembly7. Switch holder8. A/T mode changeover switch

9. Bolt10. Shift lever assembly11. Bushing12. Detent spring13. Pipe14. Position indicator lamp assembly15. Bracket assembly

INSPECTION 23100670059

A/T MODE CHANGEOVER SWITCH CHECK

Switch position Terminal No.

1 2 4 3 5

OFF

ON

AUTOMATIC TRANSMISSION - Transmission Assembly23-66

TRANSMISSION ASSEMBLY 23100570274

REMOVAL AND INSTALLATION

Pre-removal OperationD Carry out the essential service for the

troubleshooting (Refer to P.23-46.)D Transmission Fluid Draining (Refer to P.23-47.)D Under Cover RemovalD Battery and Battery Tray RemovalD Air Cleaner Assembly Removal

Post-installation OperationD Air Cleaner Assembly InstallationD Battery and Battery Tray InstallationD Under Cover InstallationD Transmission Fluid Supplying <Supplying should

be done before starting the engine>(Refer to P.23-47.)

D Check the Dust Cover for Cracks or Damage byPushing it with Finger.

D Selector Lever Operation CheckD Speedometer Operation CheckD Wheel Alignment Adjustment

(Refer to GROUP 33A - On-vehicle Service.)

88 Nm*1

98 - 118 Nm*1

12 Nm103 Nm

44 Nm

81 Nm

67 - 78 Nm

24 - 33 Nm

81 Nm

98 - 118 Nm88 Nm

30 Nm30 Nm

10 - 12 Nm

1

23 4

5

6

7

8

9

10

11

12

13 14

1516

17

17

Removal steps1. Transmission control cable connec-

tion2. Transmission fluid cooler hoses

connection3. Bolt4. Input shaft speed sensor connector5. Output shaft speed sensor

connector6. Inhibitor switch connector7. A/T control solenoid valve assem-

bly connector8. Vehicle speed sensor connector9. Starter motor <6A1>

AA" 10. Tie rod end connection11. Stabilizer link connection12. Damper fork13. No. 2 stay14. Lateral lower arm connection

AB" 15. No. 3 stay16. Compression lower arm connection

AC" 17. Drive shaftCaution*1: Indicates parts which should be temporarily

tightened, and then fully tightened with thevehicle on the ground in the unladen condition.

AUTOMATIC TRANSMISSION - Transmission Assembly 23-67

7 Nm

44 Nm

18

57 Nm

57 Nm*2

69 Nm

10 Nm <Flange bolts>9 Nm <Washer assembled bolts>

20

21

21

2223

93 Nm

49 Nm

27

26

49 Nm

30 Nm

69 - 78 Nm

10 - 12 Nm

24 25 Nm

25

81 Nm*2

49 Nm26

1945 - 52 Nm

18. Starter motor <4G6>19. Transmission assembly upper part

coupling boltsAD" 20. Transmission mount bracket

"BA 21. Transmission mount stopperAE" D Engine and transmission assembly

supporting22. Centermember assembly23. Rear roll stopper24. Bell housing cover <4G6>

25. Cover <6A1>AF" 26. Transmission assembly lower part

coupling boltsAF" "AA 27. Transmission assembly

CautionMounting locations marked by *2 should beprovisionally tightened, and then fully tightened afterplacing the vehicle horizontally and loading the fullweight of the engine on the vehicle body.

AUTOMATIC TRANSMISSION - Transmission Assembly23-68

REMOVAL SERVICE POINTSAA" TIE ROD END DISCONNECTION

Caution1. Use the special tool to loosen the tie rod end mounting

nut. Only loosen the nut; do not remove it from theball joint.

2. Support the special tool with a cord, etc. not to letit come off.

AB"NO.3 STAY REMOVALNo.3 stay is tightened together with the crossmember.Therefore, after removing No.3 stay, install the nut and boltto the crossmember provisionally.

AC"DRIVE SHAFT DISCONNECTION1. Insert a pry bar between the transmission case and the

drive shaft as shown to remove the drive shaft.

NOTEDo not remove the hub and knuckle from the drive shaft.

CautionAlways use a pry bar, or the TJ will be damaged.

2. Suspend the removed drive shaft with a wire so thatthere are no sharp bends in any of the joints.

3. Use a shop towel to cover the transmission case notto let foreign material get into it.

AD" TRANSMISSION MOUNT BRACKET REMOVALJack up the transmission assembly gently with a garage jack,and then remove the transmission mount bracket.

Cord

Ball joint

MB990635 orMB991113

Nut

No.3 stay Crossmember

Pry bar

Trans-missionside

AUTOMATIC TRANSMISSION - Transmission Assembly 23-69

AE" ENGINE AND TRANSMISSION ASSEMBLYSUPPORTING

Set the special tool to the vehicle to support the engine andtransmission assembly.

AF" TRANSMISSION ASSEMBLY LOWER PARTCOUPLING BOLTS/TRANSMISSION ASSEMBLYREMOVAL

1. Support the transmission assembly by using atransmission jack.

2. Remove the drive plate bolts while turning the crank shaft.3. Press in the torque converter to the transmission side

so that the torque converter does not remain on the engineside.

4. Remove the transmission assembly lower bolts and lowerthe transmission assembly.

INSTALLATION SERVICE POINTS"AA TRANSMISSION ASSEMBLY INSTALLATIONAfter securely inserting the torque converter into thetransmission side so that the value shown in the illustrationbecomes the reference value, install the transmissionassembly to the engine.

Reference value (A): Approx. 12.2 mm

"BA TRANSMISSION MOUNT STOPPERINSTALLATION

Install the transmission mount stopper so that the arrow pointsas shown in the illustration.

MZ203827

MB991453

Drive plate bolts

A

Transmis-sion mountstopper

Engine side

Arrow

Transmissionmount bracket

NOTES

Date post:	18-Mar-2018
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