A/T Technical Training for SORENTO Subject : OBD-II Fault handling

Auto Transmission Engineering Team

A/T Technical Training for SORENTO

KIA MOTORS

Subject : OBD-II Fault handling


4. TCU Block diagram & Terminal assignment


5. Fault handling

5-1. DTC List

Fault Type MIL

P0707 Transmission range sensor circuit low input B OP0708 Transmission range sensor circuit high input B OP0722 Output speed sensor circuit no signal B OP0727 Engine speed input sensor no signal B OP0740 Torque converter clutch circuit(SL) malfunction B OP0743 Torque converter clutch circuit(SL) electrical B OP0750 Shift solenoid A(S1) malfunction B OP0753 Shift solenoid A(S1) electrical A OP0755 Shift solenoid B(S2) malfunction B OP0758 Shift solenoid B(S2) electrical A OP0748 Pressure solenoid(SLT) electrical A OP1121 Throttle sensor signal invalid B O

Σ3.5 NAS/EUDTC Description


※1 ; Only for 4WD vehicles, “-” ; not be supported

Fault type ; A – DTC stored on the 1st driving cycle

B – DTC stored on the 2nd driving cycle continuously

C – Only Fail-safe (not DTC stored)

MIL ; “○” -- supported(to be performed at the same time as DTC stored)

P0710 ATF sensor circuit malfunction B OP0717 Input speed sensor circuit no signal B OP0716 Input speed sensor circuit range/performance B OP1795 Transfer high/low(L4) switch malfunction ※1 B OP1630 CAN communication BUS OFF B OP1631 No ID from ECU B O

- Vehicle speed signal from Meter set C -- Brake switch malfunction C -


5-5. DTC detection, decision condition & Fail safe SYSTEM

DGCODE

Fail safe cancel conditionWhen TCU judges normal condition

REMARKS If no signal is detected, the position of range sensor is judged to D range. But, A/T is operated mechanically.

To detect no failure more than 2 min.DTC STORE

2 drivingMIL

2 driving

CONDITION

FAILSAFE OPERATION TCU judges the position of range sensor is D range.PASS CRITERIA

DECISIONSame timing of the above detection

DETECTIONTCU detects no signal of range sensor more than 30 sec. with following condition.1. Output revolution is more than 1130 rpm.2. Engine revolution is more than 1500rpm

Transmission range sensor circuit low inputITEM NO signal P0707


SYSTEMDGCODE

Fail safe cancel conditionWhen TCU judges normal condition 2 driving

Transmission range sensor circuit high inputITEM Short P0708

Same timing of the above detection

DETECTIONDetected 2 or more signals more than 10 sec. at same time.

DECISION

CONDITION

FAILSAFE OPERATION TCU judges the position of range sensor with following priority. D>2>L>R>N>P

REMARKS

PASS CRITERIA

DTC STORE MILTo detect no failure more than 2min.

2 driving


SYSTEMDGCODE

Fail safe cancel conditionWhen TCU judges normal, and 0 km/h is detected

REMARKS

PASS CRITERIATo detect output speed more than 400rpm for 70 sec continuously.DTC STORE 2 driving

MIL2 driving

・TCU uses input speed sensor signal as a vehicle speed.

・No Reverse control

・No L-up ・No 4th gear・No throttle pressure reduction at shifting・No torque reduction at shifting

DECISION

・ Output revolution calculated by C0 sensor ≧ 190 rpmFAILSAFE OPERATION

・ D,2,L range ・ 25sec passed after N-D shifting

Output speed sensor circuit malfunctionITEM No pulse P0722

The above detection 500 times continuouslyCONDITION

DETECTIONTCU detects NO pulse of output speed sensor while TCU detects 45 pulses of input speed signal .


SYSTEM


MIL2 driving

Malfunction DGCODE

REMARKS

PASS CRITERIA

DTC STORETo detect F_N_ENG bit OFF for 2.0sec.

2 driving

DECISION

CONDITION

FAILSAFE OPERATION TCU detects that Engine rev. is 7000rpm. And the Line pressure to be maxium value.

Engine speed input sensor signal malfunctionITEM P0727

The above detection is continued for 2.0 sec.

DETECTIONTCU detects F_N_ENG bit ON in EMS1 signal from ECU for 0.2sec.


SYSTEMDG S1 P0750CODE S2 P0755

SL P0740


REMARKS

Refer to next PageDTC STORE

2 drivingMIL

2 driving

FAILSAFE OPERATION [S1 STUCK ON] TCU prohibits to shift to 4th gear, when detection counter is 1.PASS CRITERIA

CONDITION

WT sig./ Solenoid Electrical/Range sensor / Throttle sig./ L4 sw.

Shift solenoid A (S1)/ B(S2) ,Torque converter system (SL) Malfunction

DECISION

DETECTION

ITEM STUCK OFF / ON

・after 20 sec. after P,R,N,2,L→ D ・[only for SL stuck off]C0 cylinder is stopping.・During no failure of Output Speed sensor /Input Speed sensor/ Engine Rev./

Refer to next Page.

・D range ・L4 sw off ・ENG rev. ≧ 600 rpm.・Engine water normal temperature

Refer to next page


METHOD OF SOLENOID MALFUNCTION DETECTION

Gear Ratio1st: 2.8262nd: 1.4933rd: 1.004th: 0.73

L-up off: freeL-up on: 1.00

GEAR(Ex. 30-40LE)

T.C.C.ENGINE

Input Rev.: NiEngine Rev.: Ne Output Rev.: No

Gear SLSTCUK ON

SLSTCUK OFF

1st ○ × 1 ○ × 4 × × 2 ○ ○ 1 ○ × 1 12nd ○ ○ 2 ○ ○ 3 × ○ 2 ○ ○ 1 ○ × 2L (2) 23rd × ○ 2 ○ ○ 3 × ○ 3 × ○ 4 × × 3L (3) 34th × × 1 ○ × 4 × × 3 × ○ 4 × × 4L 4 (4L)

Normal S1STCUK ON

S1STCUK OFF

S2STCUK ON

S2STCUK OFF

※Detection of Gear position …

※Ex) Detection of S1 STUCK ON failure : TCU detects 2nd gear ratio in case that TCU shifts to 3rd gear.


*1 ; The prohibition time is started when shift changes.

*2 ; It is necssary to get the failure detection in both gear position , due to failure decision.

where, Vehicle speed(rpm) ; output shaft speed

Condition of SHIFT SOLENOID Malfunction

Min Max Min MaxStuck onFailure 3rd 2nd 2

Stuck onNormal 3rd 3rd 1

1st 4th 22nd 3rd 2

Stuck offNormal 2nd 2nd 1

1st 2nd 24th 3rd 2

Stuck onNormal 4th 4th 1

2nd 1st 23rd 4th 2

Stuck offNormal 3rd 3rd 1

DetectionTime(sec)*1

Decisioncounter

8 100 175 65535 12

Stuck offFailure *2

Gearposition

(Sol.Output)

Prhbt.Time(sec)*1

Gearposition

ofdetection *1

8 100 175 65535 2S2

Stuck onFailure *2

1

S1 Stuck offFailure *2

ThrottleOpenings(%)

Vehiclespeed( rpm )


*1 ; The prohibition time is started when shift changes or L/Up is full engaged.

*2 ; It is necssary to get the failure detection in both gear position , due to failure decision.

where, Ne ; Engine speed

Ni ; Turbine speed

L/U ; Lock up

Vehicle speed(rpm) ; Output shaft speed

Condition of DCC SOLENOID Malfunction

Min Max Min Max2nd

L/U off 25 100 175 3200 2 [Ne-Ni]＜ 100rpm 1 2

3rdL/U off 25 100 175 1500 2 [Ne-Ni]

＜ 100rpm 2 1

Stuck onNormal

2nd or3rd

L/U off8 100 175 65535 2 [Ne-Ni]

＞150rpm 1 1

Stuck offNormal 3rd 25 100 175 300 2 [Ne-Ni]

＜ 100rpm 1 1

13rd 8 100

SL

Stuck onFailure *2

175 65535 2 [Ne-Ni]＞150rpm 2Stuck off

Failure *2

Gearposition

(Sol.Output)

Prhbt.Time(sec)*1

Relationshipbetween

Ne and Ni

ThrottleOpenings(%)

DetectionTime(sec)

Decisioncounter

Vehiclespeed( rpm )


SYSTEMDGCODE

OPEN / +B SHORT : To detects the “ON “ signal of SL monitor during 500msec when SL driver outputs the “OFF” signal.


REMARKS

DTC STORE 2 driving

MIL2 driving

GND SHORT : To detects no fail for 1 sec. when L-up on.OPEN / +B SHORT : To detects no fail for 1 sec. when L-up off.

CONDITION

* L-up sol off * 1st gear fixed under the 375 rpm in case of +B short / open.PASS CRITERIA

FAILSAFE OPERATION

GND SHORT : The above detection 1 times at shifting continuously

DECISIONOPEN/+B SHORT : The above detection 2 times at shifting continuously

DETECTIONGND SHORT : To detects the “OFF “ signal of SL monitor during 300msec when SL driver outputs the “ON” signal.

Torque converter clutch system (SL) electricalITEM GND SHORT / OPEN /+B SHORT P0743


S Y S T E MD GC O D E

O P E N / + B S H O R T : T o d e t e c t s t h e “ O N “ s i g n a l o f S 1 m o n i t o r d u r i n g 5 0 0 m s e c w h e n S 1 d r i v e r o u t p u t s t h e “ O F F ” s i g n a l .

F a i l s a f e c a n c e l c o n d i t i o nA f t e r I . G O F F - > O N

1 d r i v i n gM I L

1 d r i v i n gR E M A R K S

O P E N : T o d e t e c t n o f a i l f o r 1 s e c . w h e n S o l . o f f . ( 3 r d , 4 t h )D T C S T O R E

A f t e r f a i l u r e d e c i s i o n : E m e r g e n c y M o d eP A S S C R I T E R I AG N D S H O R T : T o d e t e c t n o f a i l f o r 1 s e c . w h e n S o l . o n . ( 1 s t , 2 n d )

S h i f t s o l e n o i d S 1 e l e c t r i c a lI T E M G N D S H O R T / O P E N / + B S H O R T P 0 7 5 3

D E C I S I O NT h e a b o v e d e t e c t i o n 2 t i m e s a t s h i f t i n g c o n t i n u o u s l y

D E T E C T I O NG N D S H O R T : T o d e t e c t s t h e “ O F F “ s i g n a l o f S 1 m o n i t o r d u r i n g 3 0 0 m s e c w h e n S 1 d r i v e r o u t p u t s t h e “ O N ” s i g n a l .

C O N D I T I O N

A f t e r f a i l u r e d e t e c t i o n ; T C U o p e r a t e s s h i f t i n g a s r i g h t t a b l e . S L O F F .

F A I L S A F E O P E R A T I O N

GEAR S1 FAIL S2 FAIL S1 &S2 FAIL1 3 1 42 3 4 43 3 4 44 4 4 4Emergency mode ; fixed at 4th gear, Lock up off and Line pressure is max


S Y S T E MD GC O D E

O P E N / + B S H O R T : T o d e t e c t s t h e “ O N “ s i g n a l o f S 2 m o n i t o r d u r i n g 5 0 0 m s e c w h e n S 2 d r i v e r o u t p u t s t h e “ O F F ” s i g n a l .

F a i l s a f e c a n c e l c o n d i t i o nA f t e r I . G O F F - > O N

C O N D I T I O N

A f t e r f a i l u r e d e t e c t i o n ; T C U o p e r a t e s s h i f t i n g a s r i g h t t a b l e . S L O F F .

F A I L S A F E O P E R A T I O N

D E C I S I O NT h e a b o v e d e t e c t i o n 2 t i m e s a t s h i f t i n g c o n t i n u o u s l y

D E T E C T I O NG N D S H O R T : T o d e t e c t s t h e “ O F F “ s i g n a l o f S 2 m o n i t o r d u r i n g 3 0 0 m s e c w h e n S 2 d r i v e r o u t p u t s t h e “ O N ” s i g n a l .

S h i f t s o l e n o i d S 2 e l e c t r i c a lI T E M G N D S H O R T / O P E N / + B S H O R T P 0 7 5 8

O P E N : T o d e t e c t n o f a i l f o r 1 s e c . w h e n S o l . o f f . ( 1 s t , 4 t h )D T C S T O R E

A f t e r f a i l u r e d e c i s i o n : E m e r g e n c y M o d eP A S S C R I T E R I AG N D S H O R T : T o d e t e c t n o f a i l f o r 1 s e c . w h e n S o l . o n . ( 2 n d , 3 r d )

1 d r i v i n gM I L

1 d r i v i n gR E M A R K S

GEAR S1 FAIL S2 FAIL S1 &S2 FAIL1 3 1 42 3 4 43 3 4 44 4 4 4


SYSTEMDGCODE

Fail safe cancel conditionAfter I.G OFF -> ON

CONDITION

To detect the no failure detection for 12.5 sec continuously.

1 driving 1 drivingREMARKS

DTC STORE MIL

PASS CRITERIA

FAILSAFE OPERATION Emergency mode

Pressure solenoid (SLT) electricalITEM GND SHORT / OPEN /+B SHORT P0748

DECISION

DETECTIONGND SHORT / OPEN : To detect that the feed back A/D value is less than 15 for 70msec. continuously.BATTERY SHORT :

To detect that the feed back A/D value is more than 1000 for 500msec. continuously.

GND SHORT / OPEN :

BATTERY SHORT : Same as detection

12.5sec. continuously


DGCODE


2 drivingMIL

2 drivingREMARKS

PASS CRITERIATo detect the oil temp. is between 0℃ and 150℃ for 15 min. continuously.

DTC STORE

CONDITIONSHORT :

FAILSAFE OPERATION * TCU judges the oil temp. is 200℃.

SYSTEMCircuit Malfunction

ITEM SHORT/OPEN P0710

OPEN :

Same as detectionDECISION

OPEN :

Transmission Fluid Temperature Sensor

Fluctuation A/D value is less than 15 and minimum A/D value is more than 1000.

DETECTIONSHORT : TCU detects out of sensor resistance from operating range for 5min. continuously.

* No throttle pressure reduction control at shifting * No L-up control

To detect E/G revolution more than 400 rpm for 15min at D,2,L,R range continuously

No detection of normal condition (between 0℃ and 150℃ for 10sec) after IG ON


DGCODE

*output speed signal over 775 rpm *D,2, L range selected *1st, 2nd, 3rd gear (C0 rotation is stopped at 4th gear) *25 sec. later after changing the range *3.5 sec. later after changing the gear *E/G revolution more than 400 rpm *During No failure of shift solenoid electrical and malfunction *No pulse of 2nd gear for 1 sec. continuously


DETECTION TCU detects no pulse of input speed signal while TCU detects 12 pulses of output speed sensor.

* No throttle pressure reduction control at shifting * No Lock up control

The above detection 1000 times continuously.DECISION

SYSTEM

ITEM No pulse P0717

Input Speed Sensor Circuit No Signal

PASS CRITERIATo detect input speed signal more than 400rpm for 70 sec. continuously.

DTC STORE

CONDITION

FAILSAFE OPERATION * no Engine torque control at shifting.

2 drivingMIL

2 drivingREMARKS


DGCODE


2 drivingMIL

2 drivingREMARKS

PASS CRITERIA0＜ Input rev. ＜ 7000 rpm for 20 sec. continuously.

DTC STORE

CONDITION

FAILSAFE OPERATION

SYSTEM

ITEM High range P0716

Input speed sensor circuit range / performance

DETECTION TCU detects Input revolution ≥ 7000 rpm.

The above detection is continued for 10.0 sec.DECISION


SYSTEMDGCODE

Fail safe cancel condition-

REMARKS

PASS CRITERIA To detect no failure for 10 sec. continuously

DTC STORE 2 driving

MIL2 driving

DETECTION OPEN (transfer low, L4 switch off ) : N1/N2 ≥ X

Transfer High/Low(L4) Switch MalfunctionITEM OPEN/SHORT P1795

N2 : Output revolution calculated by speed meter sensor X : ( T/F gear ratio – 1.0 ) / 2 +1.0 = (2.48 – 1) / 2 + 1.0 = 1.74

N1 : Output revolution calculated by output speed sensor

SHORT (transfer High, L4 switch on ) : N1/N2 ＜ X

*TH' OPENING ≥ 2 %

DECISION The above detection is continued for 20.0 sec.CONDITION

FAILSAFE OPERATION

*Vehicle speed ≥ 1500 rpm *D range *No Output speed and SPM failure


SYSTEM


*Line pressure is almost max.

*TCU judges throttle opening is 0% for shifting. *No throttle pressure reduction control at shifting and N-D,N-R. *No engine torque control at shifting and N-D,N-R

FAILSAFE OPERATION

DECISION The above detection is continued for 2.0 sec.CONDITION

DETECTION TCU detects TPS data is FFh for 0.2sec via ECU message.

TPS signal malfunction from ECU to TCUITEM P1121Malfunction DG

CODE

REMARKS

PASS CRITERIA To detect no failure for 10 sec. continuously

DTC STORE 2 driving

MIL2 driving


SYSTEM


PASS CRITERIA

DTC STORE MIL2 driving

To detect the BUS normal signal for 2.0sec continuously

2 drivingREMARKS

DETECTION

CAN communication BUS OFFITEM P1630Malfunction DG

CODE

After 0.2sec. passed from IG ON.

To detect the BUS OFF signal in CPU.

DECISION The above detection is continued for 0.2sec.

CONDITION

FAILSAFE OPERATION *Throttle pressure is full. *No torque control


SYSTEMDGCODE


REMARKS

To detect ID of both EMS1 and EMS2 on CAN BUS for 2.0sec continuously

DTC STORE 2 driving

MIL2 driving

Malfunction

To detect the nothing of EMS1 or EMS2 signal on CAN BUS for 0.2 sec.

DECISION The above detection is continued for 2.0 sec.

FAILSAFE OPERATION

CONDITION After 0.2sec. passed from IG ON.

DETECTION

ECU No IDITEM P1631

*Throttle pressure is full. *No torque control

PASS CRITERIA


SYSTEM

Fail safe cancel condition －

CONDITION

FAILSAFE OPERATION

DTC STORE －

MIL－

TCU detects VS signal is FFh for 0.2sec.

Vehicle speed signal from meter setITEM －

DETECTION

DG CODEMalfunction

DECISION

REMARKS

The above detection 2.0sec continuously

TCU detects VS signal is between 00h and FEh for 2.0sec continuously.PASS CRITERIA


SYSTEMDG CODE －CODE

Fail safe cancel condition －

REMARKS

2. Throttle angle is more than 5%.

Same as detection

PASS CRITERIA

3. Brake Switch on time is more than 10 second.

DECISION

Cancel the judgment of Brake Switch “ON”, and allow the L-up control.FAILSAFE OPERATION

To detect Brake Switch off signal.

－－

1. Vehicle speed is more than 2260rpm.

Brake SwitchITEM

TCU detects following conditions at the same time.

Malfunction

DETECTION

CONDITION

DTC STORE MIL


6. TCU Circuit diagram

A/T Technical Training for SORENTO Subject : OBD-II Fault handling

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Transcript of A/T Technical Training for SORENTO Subject : OBD-II Fault handling