TM-132
< SYMPTOM DIAGNOSIS >[CVT: RE0F09B]
SYSTEM SYMPTOM
21
OthersMaximum speed low.ON vehicle1. CVT fluid level and stateTM-142
2. Line pressure testTM-146
3. Accelerator pedal position sensorTM-88
4. CAN communication lineTM-41
5. Stall testTM-144
6. Step motorTM-97
7. Primary speed sensorTM-52
8. Secondary speed sensorTM-55
9. Primary pressure sensorTM-80
10. Secondary pressure sensorTM-74
11. CVT fluid temperature sensorTM-50
OFF vehicle12. Torque converterTM-172
13. Oil pump assembly
TM-168
14. Gear system
15. Forward clutch
16. Control valve
22With selector lever in
“P” position, vehicle
does not enter parking
condition or, with se-
lector lever in another
position, parking con-
dition is not cancelled.ON vehicle1. PNP switchTM-44
2. CVT positionTM-152
OFF vehicle 3. Parking componentsTM-168
23Vehicle drives with
CVT in “P” position.ON vehicle1. PNP switchTM-44
2. CVT fluid level and stateTM-142
3. CVT positionTM-152
OFF vehicle4. Parking components
TM-1685. Gear system
6. Control valve
24Vehicle drives with
CVT in “N” position.ON vehicle1. PNP switchTM-44
2. CVT fluid level and stateTM-142
3. CVT positionTM-152
OFF vehicle4. Gear system
TM-1685. Forward clutch
6. Reverse brake
7. Control valve No. Item Symptom Condition Diagnostic item Reference
SYSTEM SYMPTOM
TM-133
< SYMPTOM DIAGNOSIS >[CVT: RE0F09B]
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OthersEngine stall.ON vehicle1. CVT fluid level and stateTM-142
2. Engine speed signalTM-59
3. Primary speed sensorTM-52
4. Torque converter clutch solenoid valveTM-62
5. CAN communication lineTM-41
6. Stall testTM-144
7. Secondary pressure sensorTM-74
OFF vehicle8. Torque converterTM-1729. Control valveTM-168
26Engine stalls when
selector lever is shift-
ed “N”→“D”or “R”.ON vehicle1. CVT fluid level and stateTM-142
2. Engine speed signalTM-59
3. Primary speed sensorTM-52
4. Torque converter clutch solenoid valveTM-62
5. CAN communication lineTM-41
6. Stall testTM-144
OFF vehicle7. Torque converterTM-1728. Control valveTM-168
27Engine speed does
not return to idle.ON vehicle1. CVT fluid level and stateTM-142
2. Accelerator pedal position sensorTM-88
3. Secondary speed sensorTM-55
4. CAN communication lineTM-41
OFF vehicle 5. Control valveTM-168
28 CVT does not shiftON vehicle1. CVT fluid level and stateTM-142
2. CVT positionTM-152
3. Line pressure testTM-146
4. Engine speed signalTM-59
5. Accelerator pedal position sensorTM-88
6. CAN communication lineTM-41
7. Primary speed sensorTM-52
8. Secondary speed sensorTM-55
9. Step motorTM-97
OFF vehicle10. Control valve
TM-16811. Oil pump assembly
29Engine does not start
in “N” or “P” position.ON vehicle1. Ignition switch and starterPG-55
, STR-6
2. CVT positionTM-152
3. PNP switchTM-44
No. Item Symptom Condition Diagnostic item Reference
TM-136
< PRECAUTION >[CVT: RE0F09B]
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover
INFOID:0000000003897196
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Precaution for On Board Diagnosis (OBD) System of CVT and EngineINFOID:0000000003849068
The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
Be sure to turn the ignition switch OFF and disconnect the battery cable from the negative terminal
before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid
valves, etc. will cause the MI to light up.
Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to an open circuit. (Be sure the connector is free from water, grease, dirt,
bent terminals, etc.)
Be sure to route and secure the harnesses properly after work. Interference of the harness with a
bracket, etc. may cause the MI to light up due to a short circuit.
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to a malfunction of the EVAP system or fuel injection system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and
ECM before returning the vehicle to the customer.
Precaution for TCM and CVT Assembly ReplacementINFOID:0000000003849069
CAUTION:
Check if new data (Unit ID) are entered correctly after replacing CVT assembly and erasing data in
TCM. (Connect CONSULT-III, and then turn ignition switch OFF.)
When replacing CVT assembly or TCM, refer to the pattern table below and erase the EEPROM in the
TCM if necessary.
EEPROM ERASING PATTERNS
Removal and Installation Procedure for CVT Unit ConnectorINFOID:0000000003849070
REMOVAL
PIIB3706J
CVT assembly TCM Erasing EEPROM in TCM Remarks
Replaced Replaced Not requiredNot required because the EEPROM in the TCM is in
the default state. (CVT assembly must be replaced
first.)
Not replaced Replaced Not requiredNot required because the EEPROM in the TCM is in
the default state.
Replaced Not replaced RequiredRequired because data has been written in the EE-
PROM in the TCM and because the TCM cannot write
data from the ROM assembly in the transmission.
LINE PRESSURE TEST
TM-147
< ON-VEHICLE MAINTENANCE >[CVT: RE0F09B]
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Judgment Possible cause
Idle speedLow for all positions
(“P”, “R”, “N”, “D”, “L”)Possible causes include malfunctions in the pressure supply system and low oil pump output.
For example
Oil pump wear
Pressure regulator valve or plug sticking or spring fatigue
Oil strainer ⇒ oil pump ⇒ pressure regulator valve passage oil leak
Engine idle speed too low
Only low for a specific
positionPossible causes include an oil pressure leak in a passage or device related to the position after
the pressure is distributed by the manual valve.
HighPossible causes include a sensor malfunction or malfunction in the line pressure adjustment
function.
For example
Accelerator pedal position signal malfunction
CVT fluid temperature sensor malfunction
Pressure control solenoid A (line pressure solenoid) malfunction (sticking in OFF state, filter
clog, cut line)
Pressure regulator valve or plug sticking
Sta ll sp ee dLine pressure does not
rise higher than the line
pressure for idle.Possible causes include a sensor malfunction or malfunction in the pressure adjustment func-
tion.
For example
Accelerator pedal position signal malfunction
TCM malfunction
Pressure control solenoid A (line pressure solenoid) malfunction (shorting, sticking in ON
state)
Pressure regulator valve or plug sticking
The pressure rises, but
does not enter the
standard position.Possible causes include malfunctions in the pressure supply system and malfunction in the pres-
sure adjustment function.
For example
Accelerator pedal position signal malfunction
Pressure control solenoid A (line pressure solenoid) malfunction (sticking, filter clog)
Pressure regulator valve or plug sticking
Only low for a specific
positionPossible causes include an oil pressure leak in a passage or device related to the position after
the pressure is distributed by the manual valve.
SECONDARY SPEED SENSOR
TM-161
< ON-VEHICLE REPAIR >[CVT: RE0F09B]
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SECONDARY SPEED SENSOR
Exploded ViewINFOID:0000000003849097
Removal and InstallationINFOID:0000000003849098
REMOVAL
1. Disconnect the battery cable from negative terminal.
2. Remove air duct (inlet) and air cleaner case. Refer to EM-26, "
Exploded View".
3. Disconnect secondary speed sensor connector.
4. Remove secondary speed sensor (1) and shim (2).
CAUTION:
Never lose the shim.
5. Remove O-ring (3) from secondary speed sensor.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Never reuse O-ring.
Apply CVT fluid to O-ring.
InspectionINFOID:0000000003849099
After completing installation, check for CVT fluid leakage and check CVT fluid level. Refer to TM-142, "Inspec-
tion".
1. Secondary speed sensor 2. Shim 3. Transaxle assembly
4. O-ring
: Apply CVT Fluid NS-2.
Refer to GI-4, "
Components" for symbols not described above.
JPDIA0687GB
JPDIA0617ZZ
TRANSAXLE ASSEMBLY
TM-169
< REMOVAL AND INSTALLATION >[CVT: RE0F09B]
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3. Remove air breather hose. Refer to TM-164, "Exploded View".
4. Disconnect secondary speed sensor connector. Refer to TM-161, "
Exploded View".
5. Disconnect CVT unit connector.
6. Disconnect air fuel ratio sensor 1 (bank 2). Refer to EM-34, "
Exploded View".
7. Remove crankshaft position sensor (POS). Refer to EM-38, "
Exploded View".
8. Remove CVT fluid charging pipe from transaxle assembly.
9. Remove transaxle assembly fixing bolts with power tool.
10. Remove transaxle assembly from engine assembly with a hoist.
11. Remove fluid cooler hose from transaxle assembly.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Check fitting of dowel pins ( ) when installing transaxle
assembly to engine assembly.
When installing transaxle assembly to the engine assembly, attach
the fixing bolts in accordance with the following.
JPDIA0598ZZ
JPDIA0602ZZ
JPDIA0600ZZ
Insertion direction Transaxle assembly to engine assemblyEngine assembly to tran-
saxle assembly
Bolt position A B C D
Number of bolts 1 2 2 4
Bolt length mm (in) 55 (2.17) 39 (1.54) 108 (4.25) 40 (1.57)
Tightening torque
N·m (kg-m, ft-lb)74.5 (7.6, 55) 50 (4.3, 31)
SERVICE DATA AND SPECIFICATIONS (SDS)
TM-175
< SERVICE DATA AND SPECIFICATIONS (SDS) [CVT: RE0F09B]
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Solenoid ValvesINFOID:0000000003849119
CVT Fluid Temperature SensorINFOID:0000000003849120
Primary Speed SensorINFOID:0000000003849121
Secondary Speed SensorINFOID:0000000003849122
Step MotorINFOID:0000000003849123
Torque ConverterINFOID:0000000003849124
Name Resistance (Approx.)
Pressure control solenoid valve B (secondary pressure solenoid valve)
3.0 – 9.0 Ω Pressure control solenoid valve A (line pressure solenoid valve)
Torque converter clutch solenoid valve
Lock-up select solenoid valve6.0 – 19.0 Ω
Name ConditionCONSULT-III “Data Monitor”
(Approx.)Resistance (Approx.)
CVT fluid temperature sensorWhen CVT fluid temperature is 20°C (68°F) 1.9 – 2.2 V 6.5 kΩ
When CVT fluid temperature is 80°C (176°F) 0.8 – 1.1 V 0.9 kΩ
Name Condition Data (Approx.)
Primary speed sensorWhen driving at 20 km/h (12 MPH) in “L” position, use the
CONSULT-III pulse frequency measuring function.680 Hz
Name Condition Data (Approx.)
Secondary speed sensorWhen driving at 20 km/h (12 MPH) in “D” position, use the
CONSULT-III pulse frequency measuring function.400 Hz
Name Resistance (Approx.)
Ste p mo tor A15.0 Ω
Ste p mo tor B15.0 Ω
Ste p mo tor C15.0 Ω
Ste p mo tor D15.0 Ω
Distance between end of converter housing and torque converter 14.0 mm (0.55 in)
TM-176
< BASIC INSPECTION >[CVT: RE0F10A]
DIAGNOSIS AND REPAIR WORK FLOW
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORK FLOW
Work FlowINFOID:0000000003806344
INTRODUCTION
The TCM receives signals from the vehicle speed sensor and PNP switch. Then it provides shift control or
lock-up control via CVT solenoid valves.
The TCM also communicates with the ECM by means of signals
sent from sensing elements used with the OBD-related parts of the
CVT system for malfunction-diagnostic purposes. The TCM is capa-
ble of diagnosing malfunctioning parts while the ECM can store mal-
functions in its memory.
Input and output signals must always be correct and stable in the
operation of the CVT system. The CVT system must be in good
operating condition and be free of valve seizure, solenoid valve mal-
function, etc.
It is much more difficult to diagnose a malfunction that occurs inter-
mittently rather than continuously. Most intermittent malfunctions 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 malfunctions. A
road test with CONSULT-III (or GST) or a circuit tester connected
should be performed. Follow the “DETAILED FLOW”.
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a driveability complaint. The cus-
tomer can supply good information about such malfunctions, espe-
cially intermittent ones. Find out what symptoms are present and
under what conditions they occur. A “Diagnostic Work Sheet” as
shown on the example (Refer to TM-177
) should be used.
Start your diagnosis by looking for “conventional” malfunctions first.
This will help troubleshoot driveability malfunctions on an electroni-
cally controlled engine vehicle.
Also check related Service Bulletins.
DETAILED FLOW
1.COLLECT THE INFORMATION FROM THE CUSTOMER
Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) using the diagnosis work sheet. Refer to TM-177, "
Diagnostic Work Sheet".
>> GO TO 2.
2.CHECK SYMPTOM 1
Check the following items based on the information obtained from the customer.
Fail-safe. Refer to TM-283, "
Fail-safe".
CVT fluid inspection. Refer to TM-304, "
Inspection".
Line pressure test. Refer to TM-308, "
Inspection and Judgment".
SAT631IB
SAT632I
SEF234G