Almera Tino V10 (2003 year). Manual — part 17
TROUBLE DIAGNOSIS — INTRODUCTION
AT-257
[EXC.F/EURO-OBD]
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TROUBLE DIAGNOSIS — INTRODUCTION
PFP:00000
Introduction
ECS0099W
The TCM receives a signal from the vehicle speed sensor, throttle
position sensor or PNP switch and provides shift control or lock-up
control via A/T solenoid valves.
Input and output signals must always be correct and stable in the
operation of the A/T system. The A/T system must be in good oper-
ating condition and be free of valve seizure, solenoid valve malfunc-
tion, etc.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replace-
ment of good parts.
A visual check only, may not find the cause of the problems. A road
test with CONSULT-II or a circuit tester connected should be per-
formed. Follow the “Work Flow”. Refer to
.
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a drive ability complaint. The cus-
tomer can supply good information about such problems, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A “Diagnostic Worksheet” like the exam-
ple (
AT-258, "DIAGNOSTIC WORKSHEET"
) should be used.
Start your diagnosis by looking for “conventional” problems first. This
will help troubleshoot drive ability problems on an electronically con-
trolled engine vehicle.
Also check related Service bulletins for information.
SAT631IA
SAT632I
SEF234G
AT-258
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — INTRODUCTION
DIAGNOSTIC WORKSHEET
Information from Customer
KEY POINTS
●
WHAT. . Vehicle & A/T model
●
WHEN. . Date, Frequencies
●
WHERE. . Road conditions
●
HOW. . Operating conditions, Symptoms
Customer name
MR/MS
Model & Year
VIN
Trans. model
Engine
Mileage
Incident Date
Manuf. Date
In Service Date
Frequency
❏
Continuous
❏
Intermittent (
times a day)
Symptoms
❏
Vehicle does not move.
(
❏
Any position
❏
Particular position)
❏
No up-shift
(
❏
1st
→
2nd
❏
2nd
→
3rd
❏
3rd
→
O/D)
❏
No down-shift
(
❏
O/D
→
3rd
❏
3rd
→
2nd
❏
2nd
→
1st)
❏
Lockup malfunction
❏
Shift point too high or too low.
❏
Shift shock or slip
(
❏
N
→
D
❏
Lockup
❏
Any drive position)
❏
Noise or vibration
❏
No kick down
❏
No pattern select
❏
Others
(
)
O/D OFF indicator lamp
Blinks for about 8 seconds.
❏
Continuously lit
❏
Not lit
TROUBLE DIAGNOSIS — INTRODUCTION
AT-259
[EXC.F/EURO-OBD]
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Diagnostic Worksheet
1.
❏
Read the Fail-safe and listen to customer complaints.
AT-258,
"Information
from Cus-
tomer"
2.
❏
CHECK A/T FLUID
❏
Leakage (Follow specified procedure)
❏
Fluid condition
❏
Fluid level
3.
❏
Perform STALL TEST and LINE PRESSURE TEST.
,
❏
Stall test — Mark possible damaged components/others.
❏
Torque converter one-way clutch
❏
Reverse clutch
❏
Forward clutch
❏
Overrun clutch
❏
Forward one-way clutch
❏
Low & reverse brake
❏
Low one-way clutch
❏
Engine
❏
Line pressure is low
❏
Clutches and brakes except high clutch and
brake band are OK
❏
Line Pressure test — Suspected parts:
4.
❏
Perform all ROAD TEST and mark required procedures.
4-
1.
Check before engine is started.
AT-270, "1.
CHECK
BEFORE
ENGINE IS
STARTED"
❏
SELF-DIAGNOSTIC CONFIRMATION PROCEDURE — Mark detected items.
❏
Vehicle speed sensor·A/T (Revolution sensor),
.
❏
Vehicle speed sensor·MTR,
.
❏
Accelerator pedal position (APP) sensor,
.
❏
Shift solenoid valve A,
.
❏
Shift solenoid valve B,
.
❏
Overrun clutch solenoid valve,
.
❏
Torque converter clutch solenoid valve,
.
❏
A/T fluid temperature sensor and TCM power source,
.
❏
Engine speed signal,
.
❏
Line pressure solenoid valve,
.
❏
CAN communication line,
.
❏
Control unit (RAM), control unit (ROM),
.
❏
Control unit (EEP ROM),
.
❏
PNP & overdrive control switches, and throttle position sensor,
.
❏
Battery
❏
Others
4-
2.
Check at idle
❏
1. O/D OFF Indicator Lamp Does Not Come On,
.
❏
2. Engine Cannot Be Started In “P” And “N” Position,
.
❏
3. In “P” Position, Vehicle Moves Forward Or Backward When Pushed,
.
❏
4. In “N” Position, Vehicle Moves,
.
❏
5. Large Shock. “N”
→
“R” Position,
.
❏
6. Vehicle Does Not Creep Backward In “R” Position,
.
❏
7. Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position,
.
AT-260
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — INTRODUCTION
4.
4-
3.
Cruise test
AT-277,
"Cruise Test
— Part 1"
Part-1
❏
8. Vehicle Cannot Be Started From D
1
,
.
❏
9. A/T Does Not Shift: D
1
→
D
2
Or Does Not Kickdown: D
4
→
D
2
,
.
❏
10. A/T Does Not Shift: D
2
→
D
3
,
.
❏
11. A/T Does Not Shift: D
3
→
D
4
,
.
❏
12. A/T Does Not Perform Lock-up,
.
❏
13. A/T Does Not Hold Lock-up Condition,
.
❏
14. Lock-up Is Not Released,
.
❏
15. Engine Speed Does Not Return To Idle (Light Braking D
4
→
D
3
),
.
Part-2
AT-280,
"Cruise Test
— Part 2"
❏
16. Vehicle Does Not Start From D
1
,
.
❏
9. A/T Does Not Shift: D
1
→
D
2
Or Does Not Kickdown: D
4
→
D
2
,
.
❏
10. A/T Does Not Shift: D
2
→
D
3
,
.
❏
11. A/T Does Not Shift: D
3
→
D
4
,
.
Part-3
AT-282,
"Cruise Test
— Part 3"
❏
17. A/T Does Not Shift: D
4
→
D
3
When Overdrive Control Switch “ON”
→
“OFF”,
.
❏
15. Engine Speed Does Not Return To Idle (Engine Brake In D
3
),
.
❏
18. A/T Does Not Shift: D
3
→
2
2
, When Selector Lever “D”
→
“2” Position,
.
❏
15. Engine Speed Does Not Return To Idle (Light Braking D
4
→
D
3
),
.
❏
19. A/T Does Not Shift: 2
2
→
1
1
, When Selector Lever “2”
→
“1” Position,
.
❏
20. Vehicle Does Not Decelerate By Engine Brake,
.
❏
21. TCM Self-diagnosis Does Not Activate (PNP & Overdrive Control Switches, and throttle position sen-
sor Circuit Checks),
.
❏
SELF-DIAGNOSTIC PROCEDURE — Mark detected items.
❏
Vehicle speed sensor·A/T (Revolution sensor),
.
❏
Vehicle speed sensor·MTR,
.
❏
Accelerator pedal position (APP) sensor,
.
❏
Shift solenoid valve A,
.
❏
Shift solenoid valve B,
.
❏
Overrun clutch solenoid valve,
.
❏
Torque converter clutch solenoid valve,
.
❏
Batt/fluid temp sen (A/T fluid temperature sensor and TCM power source),
.
❏
Engine speed signal,
.
❏
Line pressure solenoid valve,
.
❏
CAN communication line,
.
❏
Control unit (RAM), control unit (ROM),
.
❏
Control unit (EEP ROM),
.
❏
PNP & overdrive control switches, and throttle position sensor,
.
❏
Battery
❏
Others
5.
❏
For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.
AT-252,
"SELF-DIAG-
NOSTIC
PROCE-
DURE
(WITHOUT
CONSULT-
II)"
6.
❏
Perform all ROAD TEST and re-mark required procedures.
TROUBLE DIAGNOSIS — INTRODUCTION
AT-261
[EXC.F/EURO-OBD]
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Work Flow
ECS0099X
HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In
general, each customer feels differently about a problem. It is important to fully understand the symptoms or
conditions for a customer complaint.
Make good use of the two sheets provided, “Information From Customer” (
) and “Diagnostic Work-
sheet” (
), to perform the best troubleshooting possible.
7.
❏
Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts.
Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible
symptoms and the component inspection orders.)
AT-285,
"TROUBLE
DIAGNOSIS
— GEN-
ERAL
DESCRIP-
TION"
8.
❏
Erase self-diagnosis code from TCM memories.
AT-251,
"HOW TO
ERASE
SELF-DIAG-
NOSTIC
RESULTS
(WITH CON-
SULT-II)"
256, "HOW
TO ERASE
SELF-DIAG-
NOSTIC
RESULTS
(WITHOUT
CONSULT-
II)"
AT-262
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — INTRODUCTION
WORK FLOW CHART
*1
*2
*3
*4
*5
*6
*7
*8
*9
*10
*11
*12
*13
*14
*15
*16
*17
*18
*19
SAT097KC
TROUBLE DIAGNOSIS — BASIC INSPECTION
AT-263
[EXC.F/EURO-OBD]
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TROUBLE DIAGNOSIS — BASIC INSPECTION
PFP:00000
A/T Fluid Check
ECS0099Y
FLUID LEAKAGE CHECK
1.
Clean area suspected of leaking. — for example, mating surface
of converter housing and transmission case.
2.
Start engine, apply foot brake, place selector lever in “D” posi-
tion and wait a few minutes.
3.
Stop engine.
4.
Check for fluid leakage.
FLUID CONDITION CHECK
FLUID LEVEL CHECK
Refer to
.
SAT767B
SAT288G
Fluid color
Suspected problem
Dark or black with burned odor
Wear of frictional material
Milky pink
Water contamination — Road water
entering through filler tube or breather
Varnished fluid, light to dark brown and
tacky
Oxidation — Over or under filling, —
Overheating
SAT638A
AT-264
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — BASIC INSPECTION
Stall Test
ECS0099Z
STALL TEST PROCEDURE
1.
Check A/T fluid and engine oil levels. If necessary, add.
2.
Drive vehicle for approx. 10 minutes or until fluid and oil reach
operating temperature.
3.
Set parking brake and block wheels.
4.
Install a tachometer where it can be seen by driver during test.
●
It is good practice to mark the point of specified engine
rpm on indicator.
5.
Start engine, apply foot brake, and place selector lever in D
position.
6.
Accelerate to wide open throttle gradually while applying foot
brake.
7.
Quickly note the engine stall revolution and immediately release
throttle.
●
During test, never hold throttle wide open for more than 5
seconds.
Stall revolution:
8.
Move selector lever to “N” position.
9.
Cool off ATF.
●
Run engine at idle for at least one minute.
10. Repeat steps 5 through 9 with selector lever in “2”, “1” and “R”
positions.
ATF operating temperature:
50 - 80
°
C (122 - 176
°
F)
SAT647B
SAT513G
SAT514G
QG18DE
2,300 - 2,750 rpm
SAT771B
TROUBLE DIAGNOSIS — BASIC INSPECTION
AT-265
[EXC.F/EURO-OBD]
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JUDGEMENT OF STALL TEST
The test result and possible damaged components relating to each result are shown in the illustrations on next
page.
In order to pinpoint the possible damaged components, follow the WORK FLOW shown in
.
NOTE:
Stall revolution is too high in “D”, “2” or “1” position:
●
Slippage occurs in 1st gear but not in 2nd and 3rd gears. .. Low one-way clutch slippage
●
Slippage occurs in the following gears:
1st through 3rd gears in “D” position and engine brake functions with overdrive control switch set to
“OFF”.
1st and 2nd gears in “2” position and engine brake functions with accelerator pedal released (fully closed
throttle). .. Forward clutch or forward one-way clutch slippage
Stall revolution is too high in R position:
●
Engine brake does not function in “1” position. .. Low & reverse brake slippage
●
Engine brake functions in “1” position. .. Reverse clutch slippage
Stall revolution within specifications:
●
Vehicle does not achieve speed of more than 80 km/h (50 MPH). .. One-way clutch seizure in torque
converter housing
CAUTION:
Be careful since automatic fluid temperature increases abnormally.
●
Slippage occurs in 3rd and 4th gears in “D” position. .. High clutch slippage
●
Slippage occurs in 2nd and 4th gear in “D” position. .. Brake band slippage
●
Engine brake does not function in 2nd and 3rd gears in “D” position, 2nd gear in “2” position, and 1st gear
in “1” position with overdrive control switch set to “OFF”.
Stall revolution less than specifications:
●
Poor acceleration during starts. .. One-way clutch seizure in torque converter
AT-266
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — BASIC INSPECTION
SCIA0707E
TROUBLE DIAGNOSIS — BASIC INSPECTION
AT-267
[EXC.F/EURO-OBD]
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Line Pressure Test
ECS009A0
LINE PRESSURE TEST PORTS
Location of line pressure test ports are shown in the illustration.
●
Always replace pressure plugs as they are self-sealing
bolts.
LINE PRESSURE TEST PROCEDURE
1.
Check A/T fluid and engine oil levels. If necessary, add fluid or
oil.
2.
Drive vehicle for approx. 10 minutes or until engine oil and ATF
reach operating temperature.
3.
Install pressure gauge to corresponding line pressure port.
4.
Set parking brake and block wheels.
●
Continue to depress brake pedal fully while line pressure test is being performed at stall speed.
5.
Start engine and measure line pressure at idle and stall speed.
●
When measuring line pressure at stall speed, follow the
stall test procedure.
Line pressure: Refer to
AT-519, "SERVICE DATA AND SPECIFI-
.
SAT561J
ATF operating temperature:
50 - 80
°
C (122 -176
°
F)
SAT647B
UAT008
SAT493G
AT-268
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — BASIC INSPECTION
JUDGEMENT OF LINE PRESSURE TEST
Road Test
ECS009A1
DESCRIPTION
●
The purpose of the test is to determine overall performance of A/
T and analyze causes of problems.
●
The road test consists of the following three parts:
1.
Check before engine is started
2.
Check at idle
3.
Cruise test
●
Before road test, familiarize yourself with all test procedures and
items to check.
●
Conduct tests on all items until specified symptom is found.
Troubleshoot items which check out No Good after road test.
Refer to the following items.
Judgement
Suspected parts
At idle
Line pressure is low in all positions.
●
Oil pump wear
●
Control piston damage
●
Pressure regulator valve or plug sticking
●
Spring for pressure regulator valve damaged
●
Fluid pressure leakage between oil strainer and pressure regulator valve
●
Clogged strainer
Line pressure is low in particular posi-
tion.
●
Fluid pressure leakage between manual valve and particular clutch
●
For example, line pressure is:
−
Low in “R” and “1” positions, but
−
Normal in “D” and “2” positions.
Therefore, fluid leakage exists at or around low and reverse brake circuit.
Refer to
AT-18, "CLUTCH AND BAND CHART"
.
Line pressure is high.
●
Maladjustment of throttle position sensor
●
A/T fluid temperature sensor damaged
●
Line pressure solenoid valve sticking
●
Short circuit of line pressure solenoid valve circuit
●
Pressure modifier valve sticking
●
Pressure regulator valve or plug sticking
●
Open in dropping resistor circuit
At stall
speed
Line pressure is low.
●
Maladjustment of throttle position sensor
●
Line pressure solenoid valve sticking
●
Short circuit of line pressure solenoid valve circuit
●
Pressure regulator valve or plug sticking
●
Pressure modifier valve sticking
●
Pilot valve sticking
SAT786A
SAT496G
TROUBLE DIAGNOSIS — BASIC INSPECTION
AT-269
[EXC.F/EURO-OBD]
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ON BOARD DIAGNOSTIC SYS-
TEM DESCRIPTION
TROUBLE DIAGNOSES FOR
SYMPTOMS
Except for
Euro-OBD
to
to
Does Not Activate (PNP & Over-
AT-270
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — BASIC INSPECTION
1. CHECK BEFORE ENGINE IS STARTED
1.
CHECK O/D OFF INDICATOR LAMP
1.
Park vehicle on flat surface.
2.
Turn ignition switch to “OFF” position.
3.
Move selector lever to “P” position.
4.
Set overdrive control switch to “ON” position.
5.
Turn ignition switch to “ON” position. (Do not start engine.)
6.
Does O/D OFF indicator lamp come on for about 2 seconds?
Yes or No
Yes
>> GO TO 2
No
>> Stop ROAD TEST. GO TO
.
2.
CHECK O/D OFF INDICATOR LAMP
Does O/D OFF indicator lamp flicker for about 8 seconds?
Yes or No
Yes
>> Perform self-diagnosis and check NG items on the
DIAGNOSTIC WORKSHEET. Refer to
and
252, "SELF-DIAGNOSTIC PROCEDURE (WITHOUT
CONSULT-II)"
.
No
>> 1. Turn ignition switch to “OFF” position.
2. Perform self-diagnosis and note NG items.
Refer to
AT-252, "SELF-DIAGNOSTIC PROCEDURE
.
3. GO TO
.
SAT774B
MCIA0066E
MCIA0066E
TROUBLE DIAGNOSIS — BASIC INSPECTION
AT-271
[EXC.F/EURO-OBD]
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2. CHECK AT IDLE
1.
CHECK ENGINE START
1.
Park vehicle on flat surface.
2.
Turn ignition switch to “OFF” position.
3.
Move selector lever to “P” or “N” position.
4.
Turn ignition switch to “START” position.
5.
Is engine started?
Yes or No
Yes
>> GO TO 2
No
>>
●
Mark the box on the DIAGNOSTIC WORKSHEET.
●
GO TO
AT-313, "2. Engine Cannot Be Started In “P”
.
●
Continue ROAD TEST. Refer to
.
2.
CHECK ENGINE START
1.
Turn ignition switch to “OFF” position.
2.
Move selector lever to “D”, “1”, “2” or “R” position.
3.
Turn ignition switch to “START” position.
4.
Is engine started?
Yes or No
Yes
>>
●
Mark the box on the DIAGNOSTIC WORKSHEET.
●
GO TO
AT-313, "2. Engine Cannot Be Started In “P”
.
●
Continue ROAD TEST. Refer to
.
No
>> GO TO 3
3.
CHECK VEHICLE MOVE
1.
Turn ignition switch to “OFF” position.
2.
Move selector lever to “P” position.
3.
Release parking brake.
4.
Push vehicle forward or backward.
5.
Does vehicle move when it is pushed forward or backward?
Yes or No
Yes
>>
●
Mark the box on the DIAGNOSTIC WORKSHEET.
●
GO TO
AT-313, "3. In “P” Position, Vehicle Moves
Forward Or Backward When Pushed"
.
●
Continue ROAD TEST. Refer to
.
No
>> GO TO 4
SAT769B
SAT770B
SAT768B
SAT796A
AT-272
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — BASIC INSPECTION
4.
CHECK VEHICLE MOVE
1.
Apply parking brake.
2.
Move selector lever to “N” position.
3.
Turn ignition switch to “START” position and start engine.
4.
Release parking brake.
5.
Does vehicle move forward or backward?
Yes or No
Yes
>>
●
Mark the box on the DIAGNOSTIC WORKSHEET.
●
GO TO
AT-315, "4. In “N” Position, Vehicle Moves"
.
●
Continue ROAD TEST. Refer to
.
No
>> GO TO 5
5.
CHECK SHIFT SHOCK
1.
Apply foot brake.
2.
Move selector lever to “R” position.
3.
Is there large shock when changing from “N” to “R” position?
Yes or No
Yes
>>
●
Mark the box on the DIAGNOSTIC WORKSHEET.
●
GO TO
.
●
Continue ROAD TEST. Refer to
.
No
>> GO TO 6
6.
CHECK VEHICLE MOVE
1.
Release foot brake for several seconds.
2.
Does vehicle creep backward when foot brake is released?
Yes or No
Yes
>> GO TO 7
No
>>
●
Mark the box on the DIAGNOSTIC WORKSHEET.
●
GO TO
AT-317, "6. Vehicle Does Not Creep Back-
.
●
Continue ROAD TEST. Refer to
.
SAT771B
SAT797A
SAT772B
SAT799A
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