FL-20
[YD22DDTi]
FUEL LEVEL SENSOR UNIT
Remove clip by turning it about 90 degrees clockwise.
7. Disconnect harness connector, fuel feed tube, fuel return tube
and fuel hose. (Figure shows left side of fuel tank.)
For the right, disconnect harness connector and fuel hose.
Disconnect quick connector of fuel feed tube and fuel return
tube as follows.
NOTE:
Hold the sides of the connector, push in tubs and pull out the
tube.
If the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them
by pulling.Left hand : Main fuel level sensor unit
Right hand : Sub fuel level sensor unit
SBIA0140E
PBIC2034E
SFE562A
FUEL LEVEL SENSOR UNIT
FL-21
[YD22DDTi]
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CAUTION:
The quick connector can be removed when the tabs are
completely depressed. Do not twist it more than neces-
sary.
Do not use any tools to disconnect quick connector.
Keep the resin tube away from heat. Be especially careful
when welding near the tube.
Prevent acid liquid such as battery electrolyte etc. from
getting on resin tube.
Do not bend or twist the tube during installation and
removal.
Do not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is
replaced.
When resin tube or fuel level sensor unit is replaced, also
replace retainer with a new one.
To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
8. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.
9. Remove main fuel level sensor unit (Left hand) and sub fuel level sensor unit (Right hand).
CAUTION:
Do not bend the float arm during removal.
Avoid impacts such as falling when handling components.
Left hand (main fuel level sensor unit):
If necessary, remove the chamber from the bottom of the fuel tank.
Remove the chamber by sliding toward the rear of the vehicle.Retainer color : Green (Fuel feed tube)
: Gray (Fuel return tube)
SBIA0504E
PBIC0163E
PBIC0240E
FL-22
[YD22DDTi]
FUEL LEVEL SENSOR UNIT
INSPECTION AFTER REMOVAL
Make sure fuel pump strainer is free from foreign materials. If any are found, remove them.
INSTALLATION
Note the following, and install in the reverse order of removal.
Connect quick connector as follows.
1. Check connection for damage and foreign materials.
2. Align the connector with the tube, then insert connector straight into tube until a click is heard.
3. After connecting, make sure that the connection is secure by following the steps below.
Visually confirm that the two tabs are connected to connector.
Pull the tube and connector to make sure they are securely
connected.
Install fuel level sensor unit with mating mark (triangular pro-
trusion) facing between two carved lines on fuel tank. (Figure
shows left side of fuel tank.)
NOTE:
On right side of fuel tank, there are three carved lines on fuel
tank. Set mating mark between two outer carved lines.
Install inspection hole cover with the front mark (arrow) facing front of vehicle (both for RH and LH).
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
Start engine and rev it up and make sure there is no fuel leakage at connections.
PBIC1653E
PBIC2032E
FUEL TANK
FL-23
[YD22DDTi]
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FUEL TANKPFP:17202
Removal and InstallationEBS00BL3
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-16, "
General Precau-
tions" .
1. Perform the procedure from 1 to 7 in “removal” of FL-19, "
FUEL LEVEL SENSOR UNIT" .
2. Drain fuel more from fuel tank if necessary.
CAUTION:
Because fuel tank forwardly inclines and becomes unstable when installing/removing, fuel should
be drained if found the remaining quantity.
3. Remove exhaust center tube and insulator. Refer to EX-2, "
EXHAUST SYSTEM" .
4. Remove propeller shaft. (4WD models) Refer to PR-3, "
REAR PROPELLER SHAFT" .
1. Fuel filler cap 2. Grommet 3. Fuel filler tube
4. Vent hose 5. Vent tube 6. EVAP hose
7. Fuel filler hose 8. Fuel transport pump 9. Fuel hose
10. Fuel tube 11. Fuel tank protector 12. Fuel tank band
13. Fuel tank
PBIC2033E
FL-24
[YD22DDTi]
FUEL TANK
5. Using a transmission jack, support the bottom of final drive
assembly (4WD models) or rear suspension member (2WD
models).
6. Remove the mounting nuts on the rear suspension member, and
lower the transmission jack carefully until just before the rear
suspension member is removed from the stud bolts on the vehi-
cle.
7. Disconnect fuel filler hose, EVAP hose and vent hose at fuel
tank side.
Instruction for quick connector of EVAP hose. Refer to FL-19,
"FUEL LEVEL SENSOR UNIT" .
8. Disconnect connector of fuel transport pump and remove bolts
for bracket.
9. Remove fuel tank protector.
10. Remove fuel tank band mounting bolts while supporting fuel
tank.
CAUTION:
Sustain the bottom of the tank by using plate or anything
same.
11. Remove fuel tank.
CAUTION:
Pay attention not to fall fuel tank because it forwardly
inclines and becomes unstable.
NOTE:
It is desirable that more than two technicians work together.
After lifting down the front portion of fuel tank, remove the fuel tank by pulling it from the upper front of
final drive assembly, so that the fuel tank can move forwardly.
INSTALLATION
Note the following, and install in the reverse order of removal.
Surely clamp fuel hoses and insert hose to the length below.
Be sure hose clamp is not positioned on swelled area of fuel tube.
Tighten fuel hose clamp so that the distance between its lugs becomes to the following.
Fit mounting band pin to the vehicle side securely.
Before fixing the fuel tank, temporarily install the fuel filler tube.
CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the speci-
fied torque.
To connect quick connector. Refer to FL-19, "FUEL LEVEL SENSOR UNIT" .
KBIA0285E
PBIC2035E
KBIA0290E
Fuel filler hose : 35 mm (1.38 in)
The other hose : 25 mm (0.98 in)
Fuel tank side : 5 - 9 mm (0.20 - 0.35 in)
Fuel filler tube side : 7 - 11 mm (0.28 - 0.43 in)
ACC-2
ACCELERATOR CONTROL SYSTEM
ACCELERATOR CONTROL SYSTEMPFP:18005
Removal and InstallationEBS00KP5
REMOVAL
1. Disconnect accelerator pedal position sensor harness connector.
2. Loosen nuts, and remove accelerator pedal assembly.
CAUTION:
Do not disassemble accelerator pedal assembly. Do not remove accelerator pedal position sen-
sor from accelerator pedal assembly.
Avoid impact from dropping etc. during handling.
Be careful to keep accelerator pedal assembly away from water.
Do not adjust adjusting screw (painted white).
INSTALLATION
Installation is the reverse order of removal.
INSPECTION AFTER INSTALLATION
Make sure that accelerator pedal moves smoothly within the whole operation range.
Make sure that accelerator pedal securely returns to the original position.
For the electrical inspection of accelerator pedal position sensor, refer to EC-409, "DTC P2122, P2123
APP SENSOR" (QR20DE and QR25DE) or EC-1099, "DTC P0122, P0123 APP SENSOR" (YD22DDTi).
CAUTION:
When the harness connector of the accelerator pedal position sensor is disconnected, perform
“Accelerator Pedal Released Position Learning”. (QR20DE and QR25DE) Refer to EC-46, "
Acceler-
ator Pedal Released Position Learning" (WITH EURO-OBD) or EC-559, "Accelerator Pedal
Released Position Learning" (WITHOUT EURO-OBD).
NOTE:
In the case of YD22DDTi, it is unnecessary to perform “Accelerator Pedal Released Position Learning”
even when disconnecting the harness connector of the accelerator pedal position sensor.
1. Accelerator pedal assembly
PBIC2412E
MT-18
AIR BREATHER HOSE
AIR BREATHER HOSEPFP:31098
Removal and InstallationECS008BW
Refer to the figure for air breather hose removal and installation information.
QR engine models
YD engine models
CAUTION:
Make sure there are no pinched or restricted areas on air breather hose caused by bending or
winding when installing it.
Be sure to insert air breather hose into air breather tube until overlap area reaches the spool.
PCIB0778E
1. Air cleaner case 2. Transaxle assembly 3. Clip
4. Air breather hose 5. Clip 6. PCV hose
7. Resonator
PCIB0779E
1. Air cleaner case 2. Transaxle assembly 3. Clip
4. Clip 5. Air breather hose 6. Clip
7. Bracket 8. Mass air flow sensor
AT-1
AUTOMATIC TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION AT
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AUTOMATIC TRANSAXLE
TROUBLE DIAGNOSIS — INDEX ............................. 6
Alphabetical & P No. Index for DTC ......................... 6
PRECAUTIONS .......................................................... 8
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 8
Precautions for On Board Diagnostic (EURO-OBD)
System of A/T and Engine — Euro-OBD — ............. 8
Precautions for Trouble Diagnosis ........................... 8
Precautions for Harness Repair ............................... 8
Precautions .............................................................. 9
Service Notice or Precautions ................................ 10
Wiring Diagrams and Trouble Diagnosis ................. 11
PREPARATION ......................................................... 12
Special Service Tools ............................................. 12
Commercial Service Tools ...................................... 15
A/T FLUID ................................................................. 16
Checking A/T Fluid ................................................. 16
Changing A/T Fluid ................................................ 17
OVERALL SYSTEM ................................................. 18
Cross-Sectional View ............................................. 18
Hydraulic Control Circuit ........................................ 19
A/T Electrical Parts Location .................................. 20
Circuit Diagram ...................................................... 21
Shift Mechanism ..................................................... 22
TCM Function ......................................................... 31
CAN Communication .............................................. 32
Input/Output Signal of TCM .................................... 34
Line Pressure Control ............................................ 34
Shift Control ........................................................... 35
Lock-Up Control ..................................................... 36
Engine Brake Control (Overrun Clutch Control) ..... 37
Control Valve .......................................................... 39
EURO-OBD
ON BOARD DIAGNOSTIC SYSTEM DESCRIP-
TION .......................................................................... 40
Introduction ............................................................ 40
EURO-OBD Function for A/T System .................... 40One or Two Trip Detection Logic of EURO-OBD .... 40
EURO-OBD Diagnostic Trouble Code (DTC) ......... 40
Malfunction Indicator (MI) ....................................... 44
CONSULT-II ............................................................ 44
Diagnostic Procedure Without CONSULT-II ........... 52
TROUBLE DIAGNOSIS — INTRODUCTION ........... 57
Introduction ............................................................. 57
Work Flow ............................................................... 61
TROUBLE DIAGNOSIS — BASIC INSPECTION .... 64
A/T Fluid Check ...................................................... 64
Stall Test ................................................................. 65
Line Pressure Test .................................................. 68
Road Test ............................................................... 70
TROUBLE DIAGNOSIS — GENERAL DESCRIP-
TION .......................................................................... 85
Symptom Chart ....................................................... 85
TCM Terminals and Reference Value ..................... 94
DTC U1000 CAN COMMUNICATION LINE .............. 97
Description .............................................................. 97
On Board Diagnosis Logic ...................................... 97
Possible Cause ....................................................... 97
DTC Confirmation Procedure ................................. 97
Wiring Diagram — AT — CAN ................................ 98
Diagnostic Procedure ............................................. 99
DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH ..................................................................100
Description ............................................................100
On Board Diagnosis Logic ....................................100
Possible Cause .....................................................100
DTC Confirmation Procedure ...............................100
Wiring Diagram — AT — PNP/SW .......................102
Diagnostic Procedure ...........................................103
DTC P0710 A/T FLUID TEMPERATURE SENSOR
CIRCUIT ..................................................................106
Description ............................................................106
On Board Diagnosis Logic ....................................106
Possible Cause .....................................................106
DTC Confirmation Procedure ...............................106
Wiring Diagram — AT — FTS ..............................108