Service Bulletin. Subject : DTC P0810 Loss of Drive / Unable to Select Gears

Transcription

1 Service Bulletin Section : Chassis / Power Train Ref. No. : CP-5013 Date : May.,2005 Page : 1 of 8 Area Application : Europe Model Name : COROLLA, COROLLA VERSO Model Code : ZNR11#, NDE120# Subject : DTC P0810 Loss of Drive / Unable to Select Gears This Service Bulletin is issued to inform you of production improvement for TMMT produced Corolla Verso and TMMT/TMUK produced MMC Corolla models with Multi-Mode Manual Transmission. 1. VEHICLE IDENTIFICATION NUMBER (VIN) NOTE This procedure is only applicable to vehicles made at Toyota Motor Manufacturing Turkey (TMMT) and Toyota Motor Manufacturing UK (TMUK). The distinguishing method is by checking the1 st digit of the 17-digit VIN: N = Turkey S = UK A B (a) B083694E02 The VIN is stamped on the cowl panel. It is also stamped on the manufacturer's plate as shown in the illustration. 2. DESCRIPTION OF PHENOMENON Impossible shifting during driving, N light turns ON. Driver unable to select gears, transaxle remains in Neutral. 3. PRODUCTION IMPROVEMENT Change in MMT ECU logic to suit better to high load conditions. 4. FIELD FIX PROCEDURE (a) Symptom Confirmation: 1. Confirm problem symptom and conditions. 2. Check for DTC's "Present Codes" and "History Codes" (see procedure below). 3. If DTC P0810 is present, please repair according to the Repair procedure given at the next page. (b) Checking DTC's If using Intelligent Tester I with software version 10.1 or higher, please check for all codes according to the procedure given in TSB CP-4008.

2 Service Bulletin Ref. No. : CP-5013 Page : 2 of 8 (c) If using Intelligent Tester II, please follow Repair Manual (RM1100E1) page , Multimode transaxle DTC Check / Clear. Without using Intelligent Tester follow the procedure outlined in Repair Manual (RM1100E1) page , Multi-mode transaxle DTC Check / Clear, using service wire. SST Repair procedure: (1) Proceed step-by-step following the Field/fix repair procedure outlined below. 1. Confirm problem conditions. 2. Confirm Freeze-frame data. 3. Confirm clutch actuator rod pre-load. 4. Proceed with Field/fix. Part No. Information : * Prev.Part No New Part No. Part Name COROLLA VERSO - TMMT I Same as previous Computer assembly, Transmission Control LHD I Same as previous Computer assembly, Transmission Control RHD MMC COROLLA - TMMT, TMUK I Same as previous Computer assembly, Transmission Control LHD w/ VSC I Same as previous Computer assembly, Transmission Control LHD w/o VSC I Same as previous Computer assembly, Transmission Control RHD w/ VSC I Same as previous Computer assembly, Transmission Control RHD w/o VSC * : INTERCHANGABILITY CODE Prev. Part New Part PP NP PP NP PP NP I (I) NI (NI) S Interchangeable as a set Prev. Vehicle New Vehicle PV NV PV NV PV NV In order to distinguish old and new parts a discrimination mark is placed on the ECU housing as outlined below.

3 Service Bulletin Ref. No. : CP-5013 Page : 3 of 8 5. DISCRIMINATION MARK ECU: Label: Production Date, Lot No. E110803E02 1. TMMT Corolla Verso If the production date shown on the label is October 13, 2004 or later, this indicates that the ECU was manufactured after the design was changed. Aplicable part No. Part No. Label Color Purple Light Blue 2. MMC Corolla - TMUK & TMMT If the production date shown on the label is November 10, 2004 or later, this indicates that the ECU was manufactured after the design was changed. Aplicable part No. Part No. Label Color Navy Gray Black Green Example: Year Month Date E110804E02 6. HOW TO READ THE LABEL (a) Read the label. Year: Month: 4 '04 year 5 '05 year A January G July B February H August C March J September

4 Service Bulletin Ref. No. : CP-5013 Page : 4 of 8 Production Effective : D April K October E May L November F June M December Model VIN Production Date TMMT Corolla Verso NMTER150-R NMTE16R20R October 22, 2004 TMMT MMC Corolla NMTEC20E80R November 26, 2004 TMUK MMC Corolla SB1KC20E00E November 25, 2004

5 Service Bulletin Ref. No. : CP-5013 Page : 5 of 8 Chassis & Power Train MMT F/Fix method for DTC P0810 on MMT for Corolla and Corolla Verso 1. Problem conditions (a) There are 4 possible cases. The repair method is different for each case as the cause is different. case Problem occurs during clutch pre-load on the clutch actuator rod is 1 disengagement correct (no clearance) 2 disengagement not correct (some clearance) and 3 engagement correct 4 engagement not correct 2. Problem Condition Confirmation Method: (a) Judge the problem condition by confirming problem condition (cases 1, 2, 3 or 4) using the following flow chart (refer to method described in next sheets to determine Clutch (dis)engagement - by "Freeze frame data" - and "Pre-load" condition): 1) Check DTC NO 2) Are there freeze frame data of P0810? YES 3) During clutch disengagement? NO YES 4) Is the pre-load on the clutch rod correct? NO 4) Is the pre-load on the clutch rod correct? NO YES YES Case 1 Case 2 Case 3 Case 4 E110748E02 1) Confirm DTC. Is there DTC P0810? 2) Are there freeze frame data of P0810? 3), 4) Which case is the problem vehicle? Note: If Freeze Frame data cannot be checked, handle as cases 1 or 2 depending on Pre-load

6 Service Bulletin Ref. No. : CP-5013 Page : 6 of 8 If Pre-load cannot be judged clearly, handle as case Confirmation Method of Freeze Frame Data P0810: Clutch Position Control Freeze Frame Data Item Data Unit Item Data Unit Engine Coolant Temperature 86 Engine Revolution rpm Vehicle Speed 40 Accelerator Pedal Angle 10.8 % Theoretical Engine Torque 17 Nm Clutch Position (Current) mm Shift Position (Current) mm Select Position (Current) mm Clutch Motor Current MMT 24 A Shift Motor Current MMT 0 A Select Motor Current MMT 0 A Gear Position (Current) 3 Gear Position (Target) 3 Shift Lever Position Judge E Cold Condition Judgement 69 Shift Lever Switch Signal 1 Open Shift Lever Switch Signal 2 Open Shift Lever Switch Signal 3 Gnd Shift Lever Switch Signal 4 Open Shift Lever Switch Signal 5 Open Shift Lever Check Signal 1 Open Shift Lever Check Signal 2 Gnd Shift Lever Check Signal 3 Open T/M Reverse Switch Signal Open Ignition Signal #NAME? Steering Switch Signal Up Gnd Steering SW Signal Down Gnd Brake Switch Signal 1 Open Brake Switch Signal 2 Open STP Switch Signal OFF STA Switch Signal OFF Mode Changes 38 Possibility of T/M Uplock No Learn-Clutch Standby Point Exec Learning-T/M Exec Learn-Clutch Stopper Point Exec Check "Clutch Motor Current MMT" whether "more than 22A" or "less than-22a". And also please check both "Shift Motor Current MMT" and "Select Motor Current MMT" are "0A". HINT: When "Clutch Motor Current MMT" is "more than 22A", Problem condition is "during clutch engagement". When "Clutch Motor Current MMT" is "less than -22A", Problem condition is "during clutch disengagement". The example shown above is "during clutch engagement". 4. Confirmation method of the pre-load on the clutch actuator rod (a) Checking method: (1) Turn the ignition switch to OFF and keep it there.

7 Service Bulletin Ref. No. : CP-5013 Page : 7 of 8 (2) As shown in the illustrations below, put the finger lightly on the clutch actuator rod nut and apply small load in Up & Down direction. (Load applied by the finger is approx. 2N.) Check whether or not the rod moves in between the fork hook. Fork Rod nut Fork hook E110751E02 Judgement: If the rod nut does not move in Up & Down direction with approx. 2N load Pre-load adjustment on the clutch actuator rod is correct. If the rod nut moves in Up & Down direction with approx. 2N load Pre-load adjustment on the clutch actuator rod is incorrect. HINT: On the normal nominal condition, the load in the clutch actuator rod direction is 96N. 5. Field /Fix repair Case Problem Condition Cause F/Fix parts F/Fix procedure 1 1. During the clutch disengagement 2. The pre-load on the clutch actuator rod is correct During the clutch disengagement 2. The pre-load on the clutch actuator rod is not correct. 1. Decreasing of clutch release efficiency 1. Decreasing of clutch release efficiency 2. Too much LCC adjustment due to the low clutch release efficiency 1. MMT-ECU 2. Grease 1. MMT-ECU 2. Grease 3. LCC 4. Clutch Disc 1. Replace the MMT-ECU by C/M one. 2. Clean the clutch release support and apply the grease. 3. MMT-ECU initialization 1. Replace the MMT-ECU by C/M one. 2. Clean the clutch release support and apply the grease. 3. Replace the clutch disc and the clutch cover. 4. MMT-ECU initialization

8 Service Bulletin Ref. No. : CP-5013 Page : 8 of 8 Case Problem Condition Cause F/Fix parts F/Fix procedure 3 1. During the clutch engagement 2. The pre-load on the clutch actuator rod is correct During the clutch engagement 2. The pre-load on the clutch actuator rod is not correct. 1. Clutch actuator internal lock 1. Clutch actuator internal lock 2. Not correct installation of the clutch actuator at a vehicle factory 1. MMT-ECU 1. Replace the MMT-ECU by C/M one. 2. MMT-ECU initialization 1. MMT-ECU 1. Replace the MMT-ECU by C/M one. 2. Reinstall the clutch actuator according to the repair manual. 3. MMT-ECU initialization