C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf

8/10/2019 C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf

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MULTI-MODE MANUAL

TRANSAXLE SYSTEM >

PRECAUTION

1.IGNITION SWITCH EXPRESSIONS

1. The type of ignition switch used on this model differs according to thespecifications of the vehicle. The expressions listed in the table below are used in

this section.

ExpressionIgnition Switch

(position)

Engine Switch

(condition)

Ignition Switch off LOCK Off

Ignition Switch on (IG) ON On (IG)

Ignition Switch on (ACC) ACC On (ACC)

Engine Start START Start

2.PRECAUTION REGARDING ON-VEHICLE INSPECTION

1. When revving the engine, make sure that the gear is in neutral.

3.PRECAUTION REGARDING PARTS REMOVAL AND INSTALLATION

1. When removing or installing parts related to the multi-mode manual transmissionsystem, perform [Clamp Position Adjustment], [Initialization and Learning]

and/or [Synchronization Position Calibration]. In addition, the required operations

differ according to the parts to be removed and installed. Proceed with theoperation in the order shown in the table below.

Before removal

Parts to be removed Operation order See



procedure

• Clutch actuator

• Transmissionassembly

• Transmission parts

(inside gear box)• Clutch disc and clutch

cover

• Clutch release bearing

• Clutch release fork

• Clutch release lever

• Flywheel

• End plate (2SZ-FEonly)

• Crankshaft

• Shift and select

actuator (with clutch actuator)

• CLAMP

POSITION

ADJUSTMENT

2.

Before installation

Parts to be installed Operation orderSee

procedure

• New clutch

actuator

• CLAMP POSITION

ADJUSTMENT

3. NOTICE:

4. Push rods of brand new clutch actuators (service supply parts) are not set in theclutch clamp position. Therefore, adjust the clamp positions before installing new

clutch actuators.5.

After installation

Parts installed Operation orderSee

procedure1. INITIALIZATION OF MULTI-MODE MANUAL

TRANSMISSION SYSTEM

[Initialization of ECU]

• Transmissionassembly


(inside gear box)

• Shift and selectactuator (with clutch

actuator) 2. LEARNING OF MULTI-

MODE MANUAL



TRANSMISSION SYSTEM• Transmission

control ECU 3. SYNCHRONIZATION

POSITION CALIBRATION

1. INITIALIZATION OF MULTI-MODE MANUAL

TRANSMISSION SYSTEM

[Initialization of transmission]

2. LEARNING OF MULTI-

MODE MANUAL

TRANSMISSION SYSTEM

• Shift stroke sensor

• Select stroke sensor

3. SYNCHRONIZATIONPOSITION CALIBRATION

1. INITIALIZATION OF MULTI-

MODE MANUAL

TRANSMISSION SYSTEM[Initialization of clutch]

• Clutch actuator

• Clutch stroke

sensor

• Clutch disc and

clutch cover




• Flywheel

• End plate (2SZ-FE

only)

• Crankshaft

2. LEARNING OF MULTI-

MODE MANUAL

TRANSMISSION SYSTEM

6. NOTICE:

• Replace the clutch disc and clutch cover together. If only one is replaced,

the adjustment system of the clutch cover does not function properly. This

may cause clutch drag or clutch slippage, which may result indeterioration of drivability or malfunctions of the system parts.

• After replacing any system components, perform initialization and

learning of related components (refer to the operations listed above). Ifinitialization and learning are not performed, the transmission system will

not function properly.

• Before proceeding with learning of the multi-mode manual transmissionsystem, clear (initialize) the previously stored learning values. Since the

multi-mode manual transmission system does not have an overwrite

function, clearing (initializing) stored data is necessary before the new

data can be stored.

4.TROUBLESHOOTING INITIALIZATION AND LEARNING (ENGINE DOES NOT



START)

HINT:

If any malfunctions are suspected in the transmission control system afterreassembling or repairing transmission system components, perform

troubleshooting in accordance with the following chart.

1.Check for DTC output

1. Using an intelligent tester, check for output DTCs.1. Connect the intelligent tester to the DLC3.

2. Turn the ignition switch on (IG) and the tester ON.

3. Select the following menu items: Powertrain / Multi-Mode M/T / DTC.

4. Read any DTCs.

Result:

Result Proceed To

No DTC output A

DTC output B

B. Go to DTC Chart

A

2.Check clutch position learning condition

1. Check that the clutch position learning has been completed.

1. Connect the intelligent tester to the DLC3.2. Turn the ignition switch on (IG) and the tester ON.

3. Select the following menu items: Powertrain / Multi-Mode M/T / Data

List.

4. Read the Learn-Clutch Stopper Point result.

Result:

Result Proceed To

Exec (Executed) A

Notexec (Not executed) B

Fail (Failure) C



B. Execute learning again ()

C. Check clutch system

A

3.Check T/M gear position learning condition

1. Check that the T/M gear position learning has been completed.1. Connect the intelligent tester to the DLC3.



List.4. Read the Learn-T/M results.

Result:

Result Proceed To

Exec (Executed) A


Fail (Failure) C


C. Go to step 6

A

4.Check whether gear is in neutral

1. Referring to the shift slit position of the shift and select actuator, check whether

the actual transmission gear position is in neutral.



Result:

Result Proceed To

Neutral A

Other than Neutral B

B. Check transmission assembly

A

5.Check whether park/neutral position switch is ON



1. Check whether the park/neutral position switch is ON ().

Result:

Result Proceed To

ON A

OFF B

B. Check park/neutral position switch

A

Check starter system and brake system

6.Check whether T/M up-lock has occurred during gear position learning

1. Check whether T/M up-lock has occurred during gear position learning.1. Connect the intelligent tester to the DLC3.


3. Select the following menu items: Powertrain / Multi-Mode M/T / DataList.

4. Read the Possibility of T/M Uplock results.

HINT:

T/M up-lock: The transmission gear momentarily cannot be engaged due tomechanical reasons during gear position learning.Result:

Result Proceed To

No (Not occurred) A

Yes (Occurred) B

B. Perform initialization and learning ag

learning fails twice or more, check tr

A

Check transmission assembly



5.TROUBLESHOOTING INITIALIZATION AND LEARNING (VEHICLE DOES NOT START OFF)

HINT:If any malfunctions are suspected in the transmission control system after

reassembling or repairing transmission system components, perform

troubleshooting in accordance with the following chart.

1.Check for DTC output

1. Using an intelligent tester, check for output DTCs.1. Connect the intelligent tester to the DLC3.

2. Turn the ignition switch on (IG) and the tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T / DTC.

4. Read any DTCs.

Result:

Result Proceed To

No DTC output A

DTC output B

B. Go to DTC Chart

A

2.Check clutch position learning condition

1. Check that the clutch position learning has been completed.1. Connect the intelligent tester to the DLC3.



4.

Read the Learn-Clutch Stopper Point results.

Result:

Result Proceed To

Exec (Executed) A




Fail (Failure) C



A

3.Check T/M gear position learning condition

1. Check that the T/M gear position learning has been completed.1. Connect the intelligent tester to the DLC3.

2.

Turn the ignition switch on (IG) and the tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T / DataList.

4. Read the Learning-T/M results.

Result:

Result Proceed To

Exec (Executed) A


Fail (Failure) C


C. Go to step 8

A

4.Check clutch standby point learning condition

1. Check that the clutch position learning has been completed.1. Connect the intelligent tester to the DLC3.



4. Read the Learn-Clutch Standby Point results.



Result:

Result Proceed To

Exec (Executed) A


Fail (Failure) C

B. Execute learning again (Ignition switstart engine)


A

5.Confirm that gear position in [1st] or [R] when shift lever in [E], [M] or [R]

1. Start the engine.

2. Referring to the shift slit position of the shift and select actuator, check that the

actual transmission gear position is in the 1st or R position when the shift lever position is changed from N to E, M or R.



NG. Go to step 9

OK

6.Inspect accelerator pedal position sensor signal

1. Check the accelerator pedal position sensor signal circuit.1. Connect the intelligent tester to the DLC3.



List.



4. Check that value of the Accelerator Pedal Angle changes in accordance

with the accelerator pedal operation ().

2. Check the CAN communication circuit ().

Standard (1KR-FE):Accelerator Pedal

Operation

Tester

Display

Fully depressed 60 to 100 %

Fully released 0 to 25 %

Standard (2SZ-FE):

Accelerator Pedal

Operation

Tester

Display

Fully depressed 52 to 100 %

Fully released 0 to 22 %

NG. Check engine control system and CAsystem

OK

7.Rev up engine with transmission in neutral

1. Check that the engine can be revved up when the transmission gear is in neutral.

Result:

Result Proceed To

Possible A

Impossible B

B.

Check engine control system

A

Check clutch system and transmission control ECU



8.Check whether T/M up-lock has occurred during gear position learning

1. Check whether T/M up-lock has occurred during gear position learning.

1. Connect the intelligent tester to the DLC3.2. Turn the ignition switch on (IG) and the tester ON.

3.

Select the following menu items: Powertrain / Multi-Mode M/T / DataList.

4. Read the Possibility of T/M Uplock result.

HINT:T/M up-lock: The transmission gear momentarily cannot be engaged due to

mechanical reasons during gear position learning.Result:

Result Proceed To

No (Not occurred) A

Yes (Occurred) B

B. Perform initialization and learning ag

learning fails twice or more, check tr

A


9.Check whether clutch disengaged when shift lever in [E], [M] or [R]

1. Check the actual clutch state when the shift lever is in the E, M or R position.

Result:

Result Proceed To

Disengaged A

Not disengaged B

B. Check clutch system

A




6.PRECAUTIONS REGARDING USE OF SHIFT LOCK RELEASE BUTTON

1. When the vehicle is parked with the shift lever in any position other than N:

•

The engine cannot be started if the shift lever is moved to any positionother than N by operating the shift lock release button.The shift lever should be moved back to the N position to start the engine.

• The engine cannot be started if the shift lever is in the position it was in

when the vehicle was parked.The shift lever should be moved back to the N position to start the engine.

• When the shift lever is returned to the N position by operating the shift

lock release button, the gear is shifted to neutral when the ignition switch

is turned on (IG) so that the engine can be started.2. When the vehicle is parked with the shift lever in the N position:

• The engine can be started even if the shift lever is moved to any position

other than N by operating the shift lock release button. In this case, thegear is shifted to the position in accordance with the shift lever position

after the engine starts.

Shift lever position when

vehicle parked

Current shiftlever position

Enginecranking

operation

Note

Other than N Other than N* Impossible -

Other than NSame position in

when vehicle parked

Impossible -

Other than N N* PossibleGear shifted to neutral when

ignition switch on (IG)

N Other than N* PossibleGear shifted to position inaccordance with shift lever

position after engine start

N

N

(Same positionin when vehicle

parked)

Possible -

*: The shift lever was moved with the shift lock release button operation.



7.OTHER PRECAUTIONS REGARDING MULTI-MODE MANUALTRANSMISSION SYSTEM

• Set the gear in neutral when revving the engine.

• Set the gear to the neutral position before removing the shift and select actuator. Ifthe gear cannot be shifted to the neutral position due to malfunctions of the

actuator and/or transaxle gear, remove the plug from the shift and select actuator

and observe the position of the shift slit within. If the slit is in any position otherthan neutral, use a screwdriver to set it to neutral.



8.PRECAUTION REGARDING ELECTRONIC THROTTLE CONTROL SYSTEM(FOR 1KR-FE)

1. Perform the electronic throttle learning when the following operations are done ().

• ECM replacement

•

Throttle body assembly replacement

9.PRECAUTION REGARDING USE OF INTELLIGENT TESTER

NOTICE:

Observe the following items for safety reasons:

• Read its instruction books before using the tester.

• Prevent the tester cable from being caught on the pedals, shift lever and steering

wheel when driving with the tester connected to the vehicle.

•

When driving the vehicle for testing purposes using the tester, two people arerequired. One drives the vehicle, and the other operates the tester.



MULTI-MODE MANUALTRANSAXLE SYSTEM > PARTS

LOCATION

for Preparation



1 / 5



2 / 5



3 / 5



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MULTI-MODE MANUAL

TRANSAXLE SYSTEM > SYSTEM

DIAGRAM

for Preparation



MULTI-MODE MANUAL

TRANSAXLE SYSTEM > SYSTEMDESCRIPTION

for Preparation

MULTI-MODE MANUAL TRANSMISSION SYSTEM OUTLINE

1.

The multi-mode manual transmission has been developed from the conventionalmanual transmission by adding actuators that are directly controlled by electric

motors. The transmission control system consists of an electronic throttle control

system, clutch actuator, shift and select actuator, sensors, a shift lever, and atransmission control ECU. The system offers automatic clutch operation and two

driving modes: automatic shifting E mode and manual shifting M mode.



2. The stroke sensors, which are mounted on each actuator and detect the actuator

operating position, are double non-contact type.3. The multi-mode manual transmission is equipped with a clutch actuator, which

has a motor for clutch engagement, and a shift and select actuator, which has two

motors for shifting and selecting gear shafts that have been used on the

conventional manual transmission. Each actuator operates in accordance withsignals from the transmission control ECU. The transmission control ECU

receives information from the ECM and sensors, and controls the engine and

multi-mode manual transmission.4. The shift lever features a Shift-by-Wire System that electrically detects the shift

lever position chosen by the driver and sends a shift lever position signal to the

transmission control ECU to control the transmission.5. The shift lever has an electrical shift lock mechanism. When the ignition switch is

turned off, or the shift lever is in the N position with the engine running and the

brake pedal released, the shift lever is locked in the current shift position.6. The multi-mode manual transmission system has fail-safe functions. When the

transmission control ECU detects a malfunction in the system, the ECUilluminates the Multi-mode Manual Transmission Warning Light (MMT Warning

Light) to inform the driver that a malfunction has occurred. If necessary, the ECUilluminates the Malfunction Indicator Lamp (MIL) and MMT Warning Light

simultaneously. Under such conditions, the fail-safe function allows the vehicle to

be operated in order to avoid emergency situations.

FUNCTIONS OF MAIN COMPONENTS

Components Outlines

Combination

meter (meter ECU)

Controls the operation of the indicator lights, warning light, and

buzzer.

Multi-mode

manual

transmission

warning light(built into

combination

meter)

Illuminates to alert the driver when a malfunction occurs in the

multi-mode manual transmission system.

Gear positionindicator

(built into

combinationmeter)

Indicates the present gear position. The indicator flashes if theactual gear position and the shift lever position do not match.

Mode indicator Indicates E-mode or M-mode.



(built into

combination

meter)

Es indicator light

(built into

combinationmeter)

Illuminates when the sporty [Es] pattern is selected during normal

[E] pattern driving in E-mode. Does not illuminate while thenormal [E] pattern is selected.

Buzzer

(built into

combinationmeter)

Sounds if the following conditions met simultaneously:

Engine is running

Shift lever is in E, M or R positionDriver's door is open

Shift lever position

sensor

(built into shiftlever assembly)

Outputs the shift lever position and shift request (+ or -) throughthe ON/OFF combination of 6-contact switch and 2-contact switch.

Transmission shiftmain switch

(built into shiftlever assembly)

Outputs the shift mode signal (E-mode or M-mode).

Shift lock solenoid

(built into shift

lever assembly)

Actuated by the transmission control ECU. Restricts the movementof the shift lever.

Shift motor

(built into shift and

select actuator)

Actuated by the transmission control ECU. Effects the shiftoperation of the shift and select lever shaft.

*

Shift stroke sensor(built into shift and

select actuator)

Detects the shift and select actuator operation position (shift

direction).*

Select motor

(built into shift andselect actuator)

Actuated by the transmission control ECU. Effects the select

operation of the shift and select lever shaft.*

Select stroke

sensor

(built into shift andselect actuator)

Detects the shift and select actuator operation position (select

direction).*

Clutch motor(built into clutchactuator)

Actuated by the transmission control ECU. Engages and

disengages the clutch.

Clutch stroke

sensor

(built into clutchactuator)

Detects the push rod position of the clutch actuator from therotational angle of the worm wheel in the clutch actuator, and sends

the signal to the transmission control ECU.



LCC (Load

Controlled Clutch

cover)

The diaphragm spring height of the LCC is adjusted to a

predetermined position automatically, in order to apply a constant

load to the clutch motor.

Transmission

revolution sensor

Detects the input shaft speed of the transaxle and transmits it to the

transmission control ECU.

Park/neutral

position switch(built into

transmission

assembly)

Detects whether the transmission gear is in neutral.

Back-up lightswitch

(built into

transmissionassembly)

Detects whether the transmission gear is in reverse, and illuminatesthe back-up lights.

Stop light switch Detects whether the brake pedal is depressed or released.

Parking brake

switchDetects whether the parking brake lever is applied.

Pattern select [Es]

switch

Outputs the driving pattern (Normal [E] pattern or Sporty [Es] pattern) in E-mode in accordance with the ON/OFF condition to the


Transmission

control ECU

Controls the multi-mode manual transmission system and signals

the ECM to effect engine control during upshifting or downshiftingvia CAN (Controller Area Network) communication.

When the multi-mode manual transmission system malfunctions,

the transmission control ECU diagnoses the malfunctioning areasand stores the data. Furthermore, the multi-mode manual

transmission warning light and malfunction indicator lamp are

illuminated to inform the driver of malfunctions in the system.

Buzzer(built into

transmission

control ECU)

Sounds during system warning.When performing the initialization and learning or the clamp

position adjustment without using intelligent tester, the buzzer

sounds to inform that the ECU mode is changed.

ECM

Outputs sensor information via CAN communication to thetransmission control ECU.

Affects engine control in accordance with signals from thetransmission control ECU.

Accelerator pedal

position sensor

Detects the accelerator pedal position and transmits signals to the

ECM.

Crankshaft

position sensor

Detects the engine speed and transmits signals to the transmission

control ECU via the ECM.



HINT:

*: Shift and select directions are as shown in the illustration.

MULTI-MODE MANUAL TRANSMISSION SYSTEM CONTROL

1. System start:

The multi-mode manual transmission system starts when the ignition switch isturned on (IG). The shift lever can be operated when the ignition switch is on and

the brake pedal is depressed. The engine starts when the ignition switch is turnedto the ST position (the engine switch is operated) with the brake pedal depressed

and the gear in neutral.

2. Take off/reverse assist control:When the brake pedal is not depressed with the gear in 1st, 2nd or reverse, the

clutch is half-engaged, even if the accelerator pedal is not depressed. As a result,

the vehicle can creep slowly like an automatic transmission vehicle. This will

assist the vehicle in preparing to move. The take off assist control is cancelled

while the parking brake switch is ON.

HINT:

When attempting to shift to reverse at a vehicle speed of 6 km/h (3.7 mph) ormore, the reverse warning buzzer sounds, and the gear does not shift to reverse.

3. Shift control:When upshifting with the accelerator pedal depressed, the ECM restrains theengine rev up in accordance with the request signal from the transmission control



ECU.

[Automatic shift control (E and Es modes)]When the shift lever is in the E position, the most appropriate gear is

automatically selected in accordance with the accelerator pedal opening angle and

the vehicle speed. In addition to this automatic shift control, LHD (Left Hand

Drive) vehicles have kick down control. When the accelerator pedal is fullydepressed until a click is felt, the ECM for LHD vehicles interprets this as the

kick down signal being received. Kick down signals affects the transmission shift

control.Shift control can be switched between normal [E] mode and sporty [Es] mode by

pressing the pattern select switch.

Normal [E] mode: Economical automatic shift control with emphasis on fueleconomy

Sporty [Es] mode: Automatic shift control with emphasis on driving performance

[Sequential shift control (M-mode)]Moving the shift lever to the M position enables the driver to select the gear. The

driver can select gears optionally by shifting the lever to the [+] or [-] position.4. Ascent/descent shift control:

While driving in E-mode or Es-mode, the system operates to prevent excessshifting and obtain the proper driving force and engine brake power by estimating

the road inclination based on the vehicle conditions.

[Ascent shift control]On an ascent, upshifting to the 3rd, 4th or 5th gear is prohibited, depending on the

degree of road inclination.

[Descent shift control]On a descent, the current gear position is maintained, depending on the degree of

road inclination, to obtain engine brake power. When the brake pedal isdepressed, the transmission control ECU automatically downshifts to improve the

vehicle (driving force) control performance.

5. AI (Artificial Intelligence) shift control:The AI shift control enables the transmission control ECU to estimate the road

conditions and the driver's intention in order to automatically select the optimal

shift pattern. This improves the ride comfort.

[Accelerator pedal rapid open control]When the accelerator pedal is rapidly depressed, the system interprets it as an

acceleration demand and advances the downshift timing.

[Accelerator pedal sudden close control]When the accelerator pedal is suddenly released, the system interprets it as a

deceleration demand and ensures the engine brake power without changing gear.

This also ensures there is sufficient driving force for the next acceleration stage.6. Control when the vehicle stops (stopping control):

The transmission control ECU automatically disengages the clutch when the input

speed of the transmission revolution sensor falls below a specified speed. Thisenables the vehicle to stop without stalling. If the shift lever is in the E or M

positions, the transmission control ECU shifts the gear to the most appropriate

position when the vehicle speed decreases to less than a specified speed.



HINT:

If the shift lever is kept in the N position for 2 seconds with the brake pedalreleased at a specified vehicle speed or less, the transmission control ECU locks

the shift lever to prevent improper shift lever operation. When depressing the

brake pedal, the shift lever is unlocked.

7. Control when the vehicle is parked (parking control):When the ignition switch is turned off, the transmission control ECU locks the

shift lever in the current position, and 1 second later engages the clutch to park the

vehicle with the gear engaged.

HINT:

The multi-mode manual transmission system does not have a park position. The

vehicle can be parked with the shift lever in any position (N, E, M or R). Whenthe vehicle is parked with the shift lever in a position other than N, the vehicle is

parked with the gear engaged. The vehicle may not be parked with the gear

engaged if the ignition switch is turned off before the gearshift is complete.

MULTI-MODE MANUAL TRANSMISSION SYSTEM REMOVAL ANDINSTALLATION PROCEDURES

The multi-mode manual transmission differs from the conventional manual transmission.

The following operations are necessary when removing and installing the component

parts.

1. CLAMP POSITION ADJUSTMENT

• Preload is applied to the clutch actuator push rod installed on the vehicle.

• Clamp position adjustment is necessary to position the push rod when the

clutch actuator is reinstalled.

• The push rod position of a new clutch actuator is not suitable for clutch

actuator installation. When installing a new clutch actuator, Clamp

Position Adjustment must be performed before the installation.

• The push rod position of a clutch actuator that has been installed on thevehicle is not suitable for clutch actuator reinstallation. Clamp Position

Adjustment must be performed when removing the clutch actuator.

•

For details of replacement, refer to CLAMP POSITION ADJUSTMENT().



• Push rod position A (Stopper position):

The stopper position is where the clutch actuator push rod is fullyretracted. Clearance exists between the release bearing and the diaphragm

spring.

• Push rod position B (Clutch clamp position):

The clutch clamp position is where 0 N [newton] of preload is applied tothe diaphragm spring. Removal or installation of the clutch actuator is

possible at this point. No clearance exists between the release bearing and

the diaphragm spring.

• Push rod position C (Complete engagement position):

During normal clutch operation, the push rod alternates between this

position and the standby position (between C and D). When the system isstopped (while the ignition switch is off), the push rod maintains this

position.

• Push rod position D (Standby position):The standby position is where the clutch actuator push rod is protruded

and the clutch is not engaged.2. REPLACEMENT OR REMOVAL/INSTALLATION OF MULTI-MODE

MANUAL TRANSMISSION SYSTEM PARTSRefer to the respective pages for each part.

3. INITIALIZATION AND LEARNING

1. INITIALIZATION OF TRANSMISSION SYSTEM:

• The transmission control ECU stores information from eachcomponent, such as sensors and motors, to control the system.

• Sensors and motors that comprise the multi-mode manual

transmission system have individual specification values. Thetransmission control ECU learns and stores these values, and

controls the multi-mode manual transmission system. Therefore,the values stored in the transmission control ECU must be cleared

when the sensor or actuator is replaced.

• Learning of the multi-mode manual transmission system can be

performed when there is no learning value in the ECU. It istherefore necessary to perform initialization of the transmission

control ECU before performing learning of the multi-mode manual

transmission system.

• For details of replacement, refer to INITIALIZATION AND

LEARNING ().

2. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM:

•

This operation is performed to store the individual specificationvalues of components, such as sensors and actuators, in the


• For details of replacement, refer to INITIALIZATION AND

LEARNING ().

NOTICE:



Perform this operation after initialization of the multi-mode manual transmission

system.

4. SYNCHRONIZATION POSITION CALIBRATION

• The transmission components have individual specification values. The

transmission control ECU learns and stores those values, and controls thegearshift accurately. Synchronization position calibration corrects andadjusts the shift points appropriately in accordance with the individual

specification values of the components.

• For details of replacement, refer to SYNCHRONIZATION POSITION

CALIBRATION ().

MULTI-MODE MANUAL



TRANSAXLE SYSTEM > HOW TO

PROCEED WITH

TROUBLESHOOTINGfor Preparation

1.VEHICLE BROUGHT TO WORKSHOP

NEXT

2.CUSTOMER PROBLEM ANALYSIS

NEXT

3.CONNECT INTELLIGENT TESTER TO DLC3

HINT:

If the display indicates a communication fault in the tool, inspect the DLC3.

NEXT

4.CHECK CAN COMMUNICATION SYSTEM

1. Check for output DTCs.

HINT:



The ECM of this system is connected to the CAN communication system.

Therefore, before starting troubleshooting, check that there is no trouble in theCAN communication system ().

Result:

Display (DTC Output) Proceed To

CAN communication system DTCs A

No output B

A. PROCEED TO CAN

COMMUNICATION SYSTEM

B. Go to step 5

5.CHECK DTC AND FREEZE FRAME DATA

NOTICE:

Record or print DTCs and freeze frame data, if necessary. Refer to the relevant

pages ().

NEXT

6.CLEAR DTC AND FREEZE FRAME DATA

HINT:

Refer to the relevant pages ().

NEXT

7.VISUAL INSPECTION



NEXT

8.PROBLEM SYMPTOM CONFIRMATION

Result:

Result Proceed To

Symptom does not occur A

Symptom occurs B

A. Go to step 9

B. Go to step 10

9.SYMPTOM SIMULATION

HINT:


NEXT

10.DTC CHECK

HINT:Refer to the relevant pages ().

Result:

Display (DTC Output) Proceed To

Output A



No output B

A. Go to step 11

B. Go to step 12

11.DTC CHART

HINT:


NEXT

Go to step 13

12.PROBLEM SYMPTOMS TABLE

HINT:Refer to the relevant pages ().

NEXT

13.CIRCUIT INSPECTION

HINT:


NEXT

14.IDENTIFICATION OF PROBLEM

NEXT



15.ADJUSTMENT, REPAIR

NEXT

16.CONFIRMATION TEST

NEXT

END



MULTI-MODE MANUAL

TRANSAXLE SYSTEM >INITIALIZATION

for Preparation

INITIALIZATION AND LEARNING USING INTELLIGENT TESTER

HINT:

• By using an intelligent tester, initialization and learning of the multi-mode manual

transmission system can be performed sequentially. Under manual operation (not

using intelligent tester), initialization and learning must be performedindividually.

• The learning values and the DTC history of the multi-mode manual transmission

system are stored in the EEPROM in the transmission control ECU. The storedinformation is not cleared even when the negative terminal of the battery is

disconnected. To clear all the stored information, initialize the transmission

control ECU.

• Perform the procedure below to ensure that the initialized transmission controlECU stores the adjusted clutch position (stopper position, clamp position, and

standby position) or gear position (shift position and select position).

• If the initialization cannot be performed normally, there may be a malfunction in

the shift lever position sensor, NE signals, or CAN communication.

• When replacing the following parts, proceed with the operation in the order listed

in the table below.


procedure1. INITIALIZATION OF MULTI-MODEMANUAL TRANSMISSION SYSTEM


See below

2. LEARNING OF MULTI-MODEMANUAL TRANSMISSION SYSTEM

See below

• Transmission assembly


(inside gear box)

• Shift and select actuator

(with clutch actuator)

• Transmission control3. SYNCHRONIZATION POSITION



ECU CALIBRATION

1. INITIALIZATION OF MULTI-MODE

MANUAL TRANSMISSION SYSTEM


See below


See below



3. SYNCHRONIZATION POSITION

CALIBRATION

1. INITIALIZATION OF MULTI-MODEMANUAL TRANSMISSION SYSTEM

[Initialization of clutch]

See below• Clutch actuator

• Clutch stroke sensor

• Clutch disc and clutch

cover



•

Clutch release lever• Flywheel


only)

• Crankshaft

2. LEARNING OF MULTI-MODE

MANUAL TRANSMISSION SYSTEMSee below

1. Prepare the vehicle:

• Stop the vehicle

• Shift the shift lever to the N position.

• Turn the ignition switch off.

2. Connect the intelligent tester to the DLC3.



3. Turn the ignition switch on (IG).

4. Turn the intelligent tester ON.5. Select the following menu items: Powertrain / Multi-Mode M/T / Utility / Parts

Exchange.

6. Read the information.

7. Press the Next key.


9. After checking the vehicle condition, press the Next key.



10.

Read the information.11. Press the Next key.





14. On the Multi-Mode M/T / Utility screen, select Step 3 Initial Learning.


16. Select the appropriate operation.

HINT:

• Initialization of clutch: when removing and installing the following partsrelated to the clutch system.

Clutch actuator, clutch stroke sensor, clutch disc and clutch cover, clutchrelease bearing, clutch release fork or fork lever, flywheel, and end plate.

• Initialization of transmission: when removing and installing the parts

related to the shift and select operation of the transmission assembly.

• Initialization of ECU: This initializes learned values of both the clutch and

transmission.




18.

Read the information.19. Press the Next key after turning the ignition switch off.

20. Wait 10 seconds.

HINT:Count down the seconds from 10 to 0.




22. Press the Next key after turning the ignition switch on (IG).

23.

Wait 40 seconds.

HINT:

Count down the seconds from 40 to 0.



24. Press the Exit key.25. Complete Initialization and Learning.

26. Turn the intelligent tester OFF and turn the ignition switch off.

27. Wait at least 20 seconds.28. Turn the ignition switch on (IG).

29. Depress the brake pedal with the shift lever position in the N position.

30. Start the engine and wait at least 10 seconds.

31. Shift the gear from neutral to any other position.

HINT:

• When [Initialization of transmission] was selected at step (p), add the

following step between steps (w) and (x).

Additional step: (w') Wait at least 30 seconds.

• If the Initialization and Learning operations fail, perform the operations

again from step (a) more than 15 seconds after turning the ignition switchoff.

• Perform Synchronization Position Calibration after performing

Initialization of transmission or Initialization of ECU.

• Shifting the gear from neutral to any other position at last, the

transmission control ECU learns the standby point. At this time, the value

of Learn-Clutch Standby Point in the Data List changes from [Notexec] to

[Exec].

INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION SYSTEM



WITHOUT USING INTELLIGENT TESTER

HINT:

• The learning values and the DTC history of the multi-mode manual transmissionsystem are stored in the EEP ROM in the transmission control ECU. The stored

information is not cleared even when the negative terminal of the battery isdisconnected. To clear all the stored information, initialize the transmissioncontrol ECU.

• If the initialization of the multi-mode manual transmission system fails, perform

the operation again from step (a) more than 15 seconds after turning the ignitionswitch off.

• If the initialization cannot be performed normally, there may be a malfunction in

the shift lever position sensor, NE signals, or CAN communication.

• When replacing the following parts, proceed with the operations in the order

listed in the table below.


procedure




See below


See below



(inside gear box)

• Shift and select actuator(with clutch actuator)

• Transmission control

ECU 3. SYNCHRONIZATION POSITION

CALIBRATION

1. INITIALIZATION OF MULTI-MODEMANUAL TRANSMISSION SYSTEM


See below


See below



3. SYNCHRONIZATION POSITION

CALIBRATION


MANUAL TRANSMISSION SYSTEM[Initialization of clutch] See below

• Clutch actuator

•

Clutch stroke sensor• Clutch disc and clutch

cover




• Flywheel



See below



only)

• Crankshaft


•

Stop the vehicle.• Shift the lever to the N position.


2. Using SST, connect terminals TC (13) and CG (4) of the DLC3.

SST09843-18040

3. Wait at least 10 seconds.




9.

Depress the brake pedal once.

0. The buzzer sounds at intervals of 0.5 seconds as follows (an interval of 2.5

seconds exists between each cycle).

• Twice when initializing the ECU (one cycle)

• Three times when initializing the clutch (one cycle)

• Four times when initializing the transmission (one cycle)

HINT:

• If the buzzer does not sound as specified, wait at least 15 seconds

after turning the ignition switch off. Then, perform the procedurefrom step (a) again.

• If the buzzer sounds at intervals of 1 second (not at intervals of 0.5

seconds), wait at least 15 seconds after turning the ignition switch

off. Then, perform the procedure from step (a) again.10. Depress the brake pedal 3 times or more within 2 seconds.

0. The buzzer sounds twice with an interval of 0.25 seconds.11. Turn the ignition switch off and wait at least 10 seconds.

12. The initialization is complete.

13. Disconnect the SST from terminals TC and CG of the DLC3.

LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM WITHOUTUSING INTELLIGENT TESTER

HINT:



• Perform the procedure below to ensure that the initialized transmission control

ECU stores the adjusted clutch position or gear position.

• If the learning of the multi-mode manual transmission system fails, perform the

operation again from step (a) more than 15 seconds after turning the ignition

switch off.


• Stop the vehicle.

• Shift the shift lever to the N position.

• Turn the ignition switch off.2. Turn the ignition switch on (IG).

3. Wait at least 40 seconds.

4. Turn the ignition switch off.5. Wait at least 20 seconds.


7. Start the engine under the following conditions:

•

Shift lever is in the N position.• Brake pedal is depressed.

HINT:

The shift N position indicator blinks when the engine starts.

8. Wait at least 10 seconds.9. Check that the shift N position indicator turns on continuously (stops blinking).

10. The learning is complete.



MULTI-MODE MANUAL

TRANSAXLE SYSTEM >

CALIBRATIONfor Preparation

SYNCHRONIZATION POSITION CALIBRATION

For smoother shifting, the transmission control ECU learns the synchronization position

of the transmission gears. Perform the synchronization position calibration of the multi-

mode manual transmission while driving the vehicle after repairing system components.

HINT:When replacing the following parts, proceed with the operation in the order listed

in the table below.


procedure


MANUAL TRANSMISSION SYSTEM[Initialization of ECU]



• Transmission parts(inside gear box)

•

Shift and select actuator(with clutch actuator)

• Transmission control

ECU 3. SYNCHRONIZATION POSITIONCALIBRATION

See below

• Shift stroke sensor1. INITIALIZATION OF MULTI-MODE






MANUAL TRANSMISSION SYSTEM• Select stroke sensor

3. SYNCHRONIZATION POSITIONCALIBRATION

See below


MANUAL TRANSMISSION SYSTEM[Initialization of clutch]

• Clutch actuator

• Clutch stroke sensor

• Clutch disc and clutch

cover




• Flywheel

• End plate (2SZ-FEonly)

•

Crankshaft



1. While driving the vehicle in M-mode, shift up and down between 1st and 5th at

the vehicle speeds specified below.2. Check that the gears shift smoothly.

Recommended Gear Shifting Speeds

Gear Change Gear Position Vehicle Speed

1st→2nd 25 to 40 km/h (15.5 to 24.8 mph)

2nd→3rd 45 to 80 km/h (27.9 to 49.7 mph)

3rd→4th 60 to 110 km/h (37.2 to 68.3 mph)Up shift

4th→5th 75 to 140 km/h (46.6 to 86.9 mph)

Down shift 2nd→1st 25 to 35 km/h (15.5 to 21.7 mph)

3. HINT:

• Leave an interval of more than 2 seconds between gear changes.

• If there is a shock when changing gears after the synchronization position

calibration, perform the synchronization position calibration again.



MULTI-MODE MANUAL

TRANSAXLE SYSTEM > PROBLEMSYMPTOMS TABLE

for Preparation

HINT:

• When a malfunction cannot be confirmed by conducting a DTC check and the

cause of the problem cannot be identified through a basic inspection, troubleshootin accordance with the priority order indicated in the table below.

• Inspect the fuse and relay before confirming the suspected areas as shown in the

chart below.

NOTICE:When removing the following parts, perform the operations correctly by

following the precautions on the relevant pages.



Problem Symptoms for Multi-Mode Manual Transmission

Symptom Suspected areaSee

page

1. Transmission unit (Gears, bearings,

shift fork, synchronizer ring, shift key,etc.)

2. Clutch disk (Clutch cover)

3. Clutch stroke sensor

4. Clutch actuator assembly

5. Shift stroke sensor

6. Select stroke sensor

7. Shift and select actuator

8. Shift lever position sensor

9. Shift lever assembly

10. Speed signal circuit

No up-shift, No down-shift

11. Transmission control ECU

1. Multi-mode manual transmissionwarning light circuit

2. IG signal circuit

3. ECU power source circuit

Multi-mode manual transmission

warning light defective

4. Transmission control ECU1. Multi-mode manual transmission

warning light circuit

2. IG signal circuitShift position indicator light defective


Buzzer does not sound when incorrect

operation occurs (built into transmissioncontrol ECU)


1. Multi-mode manual transmission

warning light circuit

2. IG signal circuit

3. Front door courtesy switch

4. Combination meter

Buzzer does not sound when incorrectoperation occurs (built into combination

meter)


Shift impossible to any gear1. Transmission unit (Gears, bearings,shift fork, synchronizer ring, shift key,



2. Transmission shift main switch


down during E mode driving


1. Transmission shift main switch

2. Shift lever assemblyMode switch impossible (E to M)


1. Shift lever position sensorSetting to 1st or R positions impossible


1. Accelerator pedal position sensor

(1KR-FE)

2. Accelerator pedal position sensor(2SZ-FE)

Shift timing delays occur during M

mode driving


1. Parking brake switch circuitAssist control does not operate when

engine started 2. Transmission control ECU

1. SFI system (1KR-FE)

2. SFI system (2SZ-FE)

3. Starter signal circuit

4. Stop light switch circuit


6. Starter (for 1KR-FE 0.9 kW)

7. Starter (for 1KR-FE 1.3 kW)8. Starter (for 2SZ-FE)

Engine does not crank


1. Oil (level low)

2. Oil (Wrong)

3. Gear (Worn or damaged) Noise

4. Bearing (Worn or damaged)

1. Oil (Level too high)

2. Gasket (Damaged)

3. Oil seal (Worn or damaged)Oil leakage

4. O-ring (Worn or damaged)



MULTI-MODE MANUALTRANSAXLE SYSTEM >

TERMINALS OF ECU

for Preparation

Transmission Control ECU:



Symbols(Terminal

No.)

WiringColor

Terminal Description ConditionSpecifiedCondition

+B - GND

(D79-1 -D79-6)

B - W-BBattery (ECU power

source)Always 10 to 14 V

IG - GND

(D79-3 -

D79-6)

O - W-B Ignition switchIgnition switch off →

on (IG)Below 1 V→

10 to 14 V

PKB - GND(D79-4 -

D79-6)

P - W-B Parking brake switch

Ignition switch on(IG),

Parking brake switch

OFF→ ON

(Parking brake leverreleased→ pulled)

10 to 14 V →

Below 1 V

SLS - GND

(D79-5 -

D79-6)

LG - W-

BShift lock solenoid

Ignition switch on

(IG),Brake pedal depressed

→ Released

10 to 14 V →

Below 1 V

GND - Body

ground(D79-6 -

Body

ground)

W-B -

Bodyground

Ground Always Below 1 Ω

MDSW -

GND

(D79-10 -

D79-6)

L - W-BTransmission shift

main switch

Ignition switch on

(IG),

Shift lever position E→ M

10 to 14 V → Below 1 V

LS4C -

GNDB - W-B


sensor

Ignition switch on

(IG),

10 to 14 V →

Below 1 V



(D79-11 -

D79-6)

Shift lever position N→ except N

LS3C -GND

(D79-12 -

D79-6)

W - W-BShift lever position

sensor


Shift lever position E

or M→ R or N

10 to 14 V →

Below 1 V

LS2C -GND

(D79-13 -

D79-6)

LG - W-

B


sensor


Shift lever position R→ Except R

10 to 14 V →

Below 1 V

LSW5 -GND

(D79-15 -

D79-6)

R - W-BShift lever position

sensor



except [-] → [-]

10 to 14 V →

Below 1 V

LSW4 -

GND(D79-16 -

D79-6)

G - W-B Shift lever positionsensor

Ignition switch on

(IG),Shift lever position

except N→ N


LSW3 -

GND(D79-17 -

D79-6)

B - W-BShift lever position

sensor

Ignition switch on

(IG),

Shift lever position R

or N→ Except R and N


LSW2 -

GND

(D79-18 -D79-6)

W - W-BShift lever position

sensor

Ignition switch on

(IG),

Shift lever positionexcept R→ R

10 to 14 V →

Below 1 V

LSW1 -

GND(D79-19 -

D79-6)

GR - W-

B


sensor

Ignition switch on

(IG),Shift lever position

except [+] → [+]

10 to 14 V →

Below 1 V

PWR - GND

(D79-23 -

D79-6)

GR - W-

BPattern select switch

Ignition switch on

(IG),Pattern select switch

OFF→ ON

10 to 14 V →

Below 1 V

DG - GND(D79-25 -D79-6)

P - W-B Terminal TC of DLC3 Ignition switch on (IG)→ Connect terminalsTC and CG of DLC3


INDC -

GND

(D79-29 -D79-6)

R - W-BCommunication line

with combination

meter

Always Below 1.44 V



INDA -

GND

(D79-31 -D79-6)

Y - W-B

Communication line

with combinationmeter

Ignition switch on (IG)

Pulse

generation

(See waveform1)

STP - GND

(D79-34 -D79-6)

G - W-B Stop light switch Brake pedal depressed→ Released 10 to 14 V → Below 1 V

ST1- - GND(D79-35 -

D79-6)

Y - W-B Stop light switch

Ignition switch on

(IG),

Brake pedal released→ depressed


CAN+ -

CAN-

(A38-1 -A38-2)

W - B CAN communication Ignition switch on (IG)

Pulse

generation

(See waveform2)

MREL -GND

(A38-5 -D79-6)

LG - W-

B

AMT relay (motor

power source)

Ignition switch off →

on (IG)

Below 1 V→

10 to 14 V

STA - GND(A38-6 -

D79-6)

SB - W-BStarter relay operation

signal

(input)

Ignition switch off,

Brake pedal depressed,

Shift lever position N→ Starter operates

Below 1 V→

10 to 14 V

RSW - GND

(A38-9 -

D79-6)

R - W-B Back-up light switch

Ignition switch on

(IG),

Shift lever positionexcept R→ R

Below 1 V→

10 to 14 V

NE - GND

(A38-10 -

D79-6)

L - W-BEngine speed signal

from ECMIdling

Pulse

generation(See waveform

3)

NIP- - NIP+

(A38-15 -

A38-16)

V - PTransmission

revolution sensor

Engine running,

Clutch engaged

(during driving)

Pulse


4)

E2S1 - GND(A38-17 -D79-6)

P - W-B Shift stroke sensorground(main)

Always Below 1Ω

VSS1 -

GND

(A38-18 -D79-6)

B - W-BShift stroke sensor

voltage monitor

(main)

Ignition switch on (IG) 0.5 V to 4.5 V



VCS1 -

GND

(A38-19 -D79-6)

W - W-BShift stroke sensor

power source (main)Ignition switch on (IG) 4.5 V to 5.5 V

VCL1 -

GND(A38-20 -

D79-6)

O - W-B Select stroke sensor power source (main)


VSL1 -

GND(A38-21 -

D79-6)

V - W-B

Select stroke sensor

voltage monitor

(main)


E2L1 -

GND(A38-22 -

D79-6)

Y - W-BSelect stroke sensor

ground (main)Always Below 1 Ω

SPD - GND

(A38-23 -

D79-6)

V - W-B Vehicle speed signal

Ignition switch on

(IG),

during driving

Pulse


5)

E2L2 -

GND(A38-24 -

D79-6)

GR - W-

B


ground (sub)Always Below 1 Ω

E2R1 -

GND(A38-25 -

D79-6)

LG - W-B Clutch stroke sensorground (main) Always Below 1 Ω

VSR1 -GND

(A38-26 -

D79-6)

B - W-B

Clutch stroke sensor

voltage monitor

(main)


VCR1 -GND

(A38-27 -

D79-6)

W - W-BClutch stroke sensor

power source (main)Ignition switch on (IG) 4.5 V to 5.5 V

E2S2 - GND(A38-28 -

D79-6)

GR - W-

B

Shift stroke sensor


VSS2 -

GND(A38-29 -

D79-6)

BR - W-

B

Shift stroke sensor

voltage monitor (sub)Ignition switch on (IG) 0.5 V to 4.5 V



VCS2 -

GND

(A38-30 -D79-6)

R - W-BShift stroke sensor

power source (sub)Ignition switch on (IG) 4.5 V to 5.5 V

VCL2 -

GND(A38-31 -

D79-6)

L - W-B Select stroke sensor power source (sub)


VSL2 -

GND(A38-32 -

D79-6)

LG - W-

B



E2R2 -

GND(A38-33 -

D79-6)

GR - W-

B



VSR2 -

GND(A38-34 -

D79-6)

BR - W-

B



VCR2 -

GND(A38-35 -

D79-6)

G - W-BClutch stroke sensor

power source (sub)Ignition switch on (IG) 4.5 V to 5.5 V

MSF+ -

GND(A37-1 -

D79-6)

B - W-B Shift motor

Ignition switch on

(IG),motor not operating→

operating

Pulse

generation()

+BM - GND(A37-2 -

D79-6)

B - W-B Motor power sourceIgnition switch off →

on (IG)

Below 1 V→

10 to 14 V

MSF- -

GND(A37-3 -

D79-6)

W - W-B Shift motor

Ignition switch on


operating

Below 1 V→

Pulsegeneration

()

MSL- -GND(A37-4 -

D79-6)

L - W-B Select motorIgnition switch on(IG),

motor not operating→

operating

Below 1 V→ Pulsegeneration

()

MSL+ -

GND(A37-5 -

D79-6)

B - W-B Select motor

Ignition switch on


operating

Below 1 V→

Pulsegeneration

()



MCL- -

GND

(A37-6 -D79-6)

GR - W-

BClutch motor

Ignition switch on

(IG),

motor not operating→ operating

Below 1 V→

Pulse

generation()

MCL+ -

GND(A37-7 -

D79-6)

G - W-B Clutch motor

Ignition switch on


operating

Below 1 V→

Pulsegeneration

()

PGND -

Bodyground

(A37-8 -

Bodyground)

W-B -

Bodyground

Ground Always Below 1 Ω

1. Waveform 1:

Communication with Combination Meter

Terminal INDA - GND

Gauge set 2 V/DIV, 500 μs/DIV

Condition Ignition switch on (IG)

2.



3. Waveform 2:

CAN Communication Terminal

Terminal CAN+ - CAN-



4.

5. Waveform 3:

Engine speed signal from ECM

Terminal NE - GND

Gauge set 5 V/DIV, 5 ms/DIV

Condition Engine idling



6.

7. Waveform 4:

Transmission Revolution Sensor Terminal

Terminal NIP- - NIP+

Gauge set 500 mV/DIV, 500 μs/DIV

ConditionVehicle speed of

approximately 30 km/h (19

mph)

8.



9. Waveform 5:

Vehicle Speed Signal Terminal

Terminal SPD - GND


ConditionVehicle speed of

approximately 20 km/h (12

mph)

ECM:

Symbols

(Terminal No.)Wiring Color

Terminal

DescriptionCondition

Specified

Condition

CAN+ - CAN-

(A32-34 - A32-

26)

W - BCAN

Communication

Ignition switch

on (IG)

Pulse


1)

NEO - E1(C33-64 - A32-

1)

L - W-BEngine speed

signalEngine idling

Pulse


2)

E1 - Body

ground(A32-1 - Body

ground)

W-B - Body

groundGround Always Below 1 Ω



1. Waveform 1:

CAN Communication Terminal

Terminal CAN+ - CAN-



2.

3. Waveform 2:

Engine speed signal

Terminal NEO - E1




Condition Engine idling

MULTI-MODE MANUAL

TRANSAXLE SYSTEM >

DIAGNOSIS SYSTEMfor Preparation



DESCRIPTION

• The transmission control ECU has a self-diagnosis system. If the ECU, the multi-mode manual transmission system or any components fail to operate correctly, the

ECU detects the malfunction, and illuminates the multi-mode manualtransmission warning light on the combination meter.

The multi-mode manual transmission warning light is illuminated when the multi-

mode manual transmission system malfunctions.

•

• When troubleshooting Euro-OBD vehicles, the only difference from the usualtroubleshooting procedure is that an OBD scan tool (complying with ISO 15765-

4) or an intelligent tester is connected to the vehicle, and various data output fromthe vehicle ECU is read.

• Euro-OBD regulations require that the vehicle's on board computer illuminates

the MIL (Malfunction Indicator Lamp) on the combination meter when the ECM(Engine Control Module) detects a malfunction in: 1) the emission control

systems and components, or 2) the powertrain control components (which affect

vehicle emissions), or 3) the ECM. Therefore, the transmission control ECU



illuminates the MIL and multi-mode manual transmission warning light together

if malfunctions related to these systems or components are detected.

• If the malfunction does not recur on 3 consecutive trips, the MIL goes out

automatically. However, the DTCs remain recorded in the transmission control

ECU memory.

•

• To check DTCs, connect the OBD scan tool or intelligent tester to the DLC3(Data Link Connector 3) on the vehicle. The OBD scan tool or intelligent tester

also enables the DTCs to be erased and the freeze frame data and various forms of

engine data to be checked. See the instruction manual of the OBD scan tool orintelligent tester for details.

• The DTCs include ISO controlled codes and manufacturer controlled codes. ISO

controlled codes must be set as prescribed by the ISO, while manufacturer

controlled codes can be set by the manufacturer within prescribed limits ().

FREEZE FRAME DATA

• Freeze frame data record the vehicle conditions (engine speed, vehicle speed,

transmission gear position, shift position, etc.) when malfunctions are detected.When troubleshooting, the freeze frame data can help determine if the vehicle was

moving or stationary, if the engine was warmed up or not, the transmission gearwas in neutral or not, and other data, from the time the malfunction occurred.

DLC3 (Data Link Connector 3)



1. The ECU uses ISO 15765-4 for communication. The terminal arrangement of theDLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format.

SymbolTerminal

No. Name

Reference

terminalResult Condition

SIL 7 Bus "+" line5-Signal

ground

Pulse

generation

During

transmission

CG 4Chassisground

Body ground 1 Ω or less Always

SG 5Signal

groundBody ground 1 Ω or less Always

BAT 16 Battery positive

Body ground 9 to 14 V Always

14 - CANL 54 to 69 Ω Ignition switch

off *

Battery positive

1 MΩ orhigher

Ignition switchoff *

CANH 6CAN "High"

line

4 - CG1 k Ω or

higher

Ignition switch

off *

Battery

positive

1 MΩ or

higher

Ignition switch

off *

CANL 14

CAN "Low"

line4 - CG

1 k Ω or

higher

Ignition switch

off *

2.

NOTICE:

3. *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and

do not operate the ignition switch, any other switches or the doors.

4. HINT:



5. The DLC3 is the interface prepared for reading various data from the vehicle's

ECU. After connecting the cable of an intelligent tester or OBD scan tool, turn theignition switch on (IG) and turn the tester or scan tool ON.

6. If a communication failure message is displayed on the tester or scan tool screen

(on the tester: no information available), a problem exists in either the vehicle or

tester. In order to identify the location of the problem, connect the tester toanother vehicle.

If communication is normal: Inspect the DLC3 on the original vehicle.

If communication is impossible: The problem is probably with the tester itself.

Consult the service department listed in the instruction manual.

CHECK MULTI-MODE MANUAL TRANSMISSION WARNING LIGHT


2. Check that the warning light illuminates for 5 seconds. If the warning light does

not illuminate, proceed to troubleshooting the multi-mode manual transmissionwarning light circuit ().

BATTERY VOLTAGE

1. Measure the voltage of the battery.

Standard voltage:

11 to 14 V

If the voltage is below 11 V, recharge the battery before proceeding.



2. Inspect the battery, fuses, fusible links, wiring harness, connectors and ground.

MULTI-MODE MANUAL

TRANSAXLE SYSTEM > DTC

CHECK / CLEAR

for Preparation

HINT:



DTCs which are stored in the transmission control ECU can be displayed on the

intelligent tester.

CHECK DTC (Using intelligent tester)


2. Turn the ignition switch on (IG) and turn the intelligent tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T.

4. Check DTCs and freeze frame data, and write them down.

5. See DTC chart to confirm the details of the DTCs ().

HINT:Intelligent testers can display current DTC data, pending DTC data and historical

DTC data. Touch the [Current], [Pending] or [History] button on the DTC displayscreen.

[Current]: Displays the current DTC data.

[Pending]: Displays the pending DTC data

[History]: Displays the historical DTC data (past codes).

FREEZE FRAME DATA

1.

Connect the intelligent tester to the DLC3.2. Turn the ignition switch on (IG) and turn the intelligent tester ON.3. Read DTCs by selecting the following menu items: Powertrain / Multi-Mode M/T

/ DTC.4. Select the parameter(s) to check the freeze frame data.

5. Note down the DTC(s) and freeze frame data.

HINT:



• A "!" displayed to the left of DTC data shown in red indicates that freeze

frame data has been recorded for that parameter.

• For further information about using the intelligent tester, refer to the

instruction manual.

CLEAR DTCs AND FREEZE FRAME DATA (Using intelligent tester)

1. Connect the intelligent tester to the DLC3.2. Turn the ignition switch on (IG) and turn the intelligent tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T / DTC / Clear.

4. Erase DTCs and freeze frame data by pressing the YES button on the tester.

HINT:

For further information about using the intelligent tester, refer to the instruction

manual.



MULTI-MODE MANUAL

TRANSAXLE SYSTEM > FAIL-SAFE CHART

for Preparation

FAIL-SAFE CHART

1.

If any of the following codes is recorded, the transmission control ECU enters thefail-safe mode.

DTC No. Malfunction Areas Fail-safe Functions Fail-safe D

• P0806

• P0807

• P0808

• P0810

• P0900

• Clutch stroke

sensor or its circuit

• Clutch

actuator assembly or

its circuit

• Gear does

not change

• Vehicle doesnot start moving

again after stopping

Either (a) or

10. cond

•

•

•

•

11.

dete

off

• P0807

• P0808

• P0906

• P0907

• P0916

• Clutch stroke


• Select stroke


• Shift stroke

• Limit to 3rd

gears or lower

Either of (a)

22. follo

•



• P0917 sensor or its circuit

•

•

•

23. dete

off

• P0905

•

P0906• P0907

• P0909

• P0910

• P0915

• P0916

• P0917

• P0919

• P0920

• Shift stroke

sensor or its circuit• Shift


its circuit

• Select stroke


• Select


its circuit

• Gear does

not change

• Vehicle does

not start moving

again after stopping

Either (a) or

40. cond

•

•

•

41.

dete

off

• P0725• Engine speed

input circuit

• Convert

engine revolutionsignals into CAN

communication

signals

• No effect

Either (a) or

46. cond

•

•

•

47.

dete

off

• P0500

• P0715

• Vehicle

speed sensor or its

circuit

• Gear does

not shift down while

driving

Either (a) or

54.



• Transmission

revolution sensor or

its circuit

• Only

possible to drive in

1st or reverse gears

after vehicle stops

cond

•

•

•

•

55.

dete

off

• P0603

• P0885

• Transmission

control ECU• Clutch

actuator, shiftactuator, select

actuator power

source circuit

• Gear doesnot change

•

Enginecannot be started

• Transmissioncontrol ECU stops

engine when vehicle

stops

Pass conditi

ignition swi

• P0820

• Shift lever

position sensor or itscircuit

•

Transmissionshift main switch orits circuit

• Impossibleto enter M-mode

• Gear does

not shift to 1st orreverse (and forward

or backward gears)

Pass conditi

ignition swi

• P0335

• P0339

• Crankshaft

position sensor or its

circuit

• Gear does

not changePass conditi

ignition swi

• U0100• CAN

communication

signal circuit

• Gear doesnot change

• Only

possible to drive in1st or reverse gears

after vehicle stops

Either (a) or

76. cond

•

•

•

•



77.

dete

off

HINT:

• *: Transmission gear: Actual transmission gear position

• The transmission control ECU identifies the actual transmission gear

position through the signals from the shift stroke sensor and select stroke

sensor.

• The transmission control ECU identifies the shift lever position through

the signal from the shift lever position sensor.

MULTI-MODE MANUAL



TRANSAXLE SYSTEM > DATA

LIST / ACTIVE TEST

for Preparation

DATA LIST

HINT:

By reading the Data List displayed on an intelligent tester, you can check values,

including those of the switches, sensors, and actuators, without removing any parts. Reading the Data List as the first step of troubleshooting is one method of

shortening diagnostic time. NOTICE:

In the table below, the values listed under Normal Conditions are for referenceonly. Do not depend solely on these values when determining whether or not a

part is faulty.

1. Warm up the engine.

2. Turn the ignition switch off.3.

Connect an intelligent tester to the DLC3.

4. Turn the ignition switch on (IG) and turn the tester ON.

5. Select the following menu items: Powertrain / Multi-Mode M/T / Data List.

6. Check the values by referring to the table below.

Items[Abbreviation]

MeasurementItems: Display

NormalConditions

Diagnostic Notes

MIL Status

[MIL Status]

MIL status:

OFF or ON

ON: MIL

comes on-

CalculatedEngine Load

[Calc E/G

Load]

Load calculated by ECM:

Min.: 0 %, Max.:

100 %

1KR-FE:

11 to 25 %:Idling

15 to 35 %:Runningwithout load

(2,500 rpm)

2SZ-FE:12.8 to 19.2 %:

Idling

-



10.3 to 17.9 %:

Running

without load(2,500 rpm)

Engine

CoolantTemperature

[Coolant

Temp]

Coolanttemperature:

Min.: -40°C,

Max.: 140°C

1KR-FE:

75 to 95°C (167to 203°F):

After engine

warmed up

2SZ-FE:80 to 100°C

(176 to 212°F):

After enginewarmed up

• If value -40 °C(-40 °F): sensor circuit

open

• If value 140 °C(284 °F): sensor circuit

shorted

Engine Run

Time

[Eng RunTime]

Engine run time:

Min.: 0 s, Max.:65535 s

Time since

engine start -

Engine

Revolution

[Engine Rev]

Engine

revolutions per

minute:Min.: 0 rpm,

Max.: 16,383.75

rpm

1KR-FE:

730 to 830 rpm:

Idling2SZ-FE:

600 to 700 rpm:

Idling

If NE signal circuit has a short

or open circuit, back-up engine

speed data from CANcommunication displayed

Vehicle Speed

[Vehicle Spd]

Vehicle speed:Min.: 0 km/h,

Max.: 255 km/h

0 km/h (0 mph):

Vehicle

stationaryApproximatelysame value as

combination

meter display

When vehicle speed signalmalfunctions, speed value

calculated from input

revolution signal displayed

Battery

Voltage

[Batt]

Battery voltage:

Min.: 0 V, Max.:

65.535 V

10 to 15 V:

Idling-

Drive Mile

afterMalfunction

[Driving

Mileage]

Accumulateddriving mileage

sincemalfunction

detection:Min.: 0 km/h,

Max.: 65,535

km/h

0 km/h (0 mph):

System normal

Distance driven sinceoccurrence of diagnosis

malfunction displayed

Running Time

from MIL ON

Running time

from MIL ON:

Equivalent to

running time-



[MIL On Run

Time]

Min.: 0 min,

Max.: 65535 min

since MIL ON

WarmupCycle Cleard

DTC

[Wu Cyc DTCclear]

Warm-up cyclesince DTC

cleared:

Min.: 0 , Max.:255

- Number of warm-up cycles

since DTC cleared

Distance from

DTC Cleared

[Dist DTCClear]

Distance since

DTC cleared:

Min.: 0 Km,Max.: 65535 Km

Equivalent to

drive distance

since DTCserased

-

Time after

DTC Cleared

[Time DTCClear]

Time since DTC

cleared:

Min.: 0 min,Max.: 65535 min

Equivalent totime since

DTCs erased

-

Vehicle SpeedSignal

[Vehicle Spd

Sig]

Vehicle speedsignal:

Min.: 0 km/h,Max.: 327.675

km/h

0 km/h (0 mph):

Vehicle

stationary

When vehicle speed signalmalfunctions, speed value

calculated from input

revolution signal displayed

Input

Revolution[Input Rev.]

Transmission

input revolution:Min.: 0 rpm,

Max.: 12,800

rpm

0 rpm: Vehicle

stationary

When input revolution signal

malfunctions, value calculated

from vehicle speed signaldisplayed

BackupEngine Speed

[Bacup Engin

Spd]

Back-up enginespeed from CAN

communication:

Min.: 0 rpm,

Max.: 8,160 rpm

Approximatelysame as

tachometer

reading: Enginerunning

0 rpm: Engine

stopped

0 rpm displayed when CAN

communication malfunctions

AcceleratorPedal Angle

[Accel Pedl

Angl]

Accelerator pedal angle:

Min.: 0 %, Max.:

100 %

0 %:

Accelerator pedal released

0 % displayed when CANcommunication malfunctions

TheoreticalEngine Torque

[Theoretic

Torq]

Theoreticalengine torque:

Min.: 0 N*m,

Max.: 255 N*m

0 N*m: Idling -

Clutch

Position

(Current)

Current clutch

position:

Min.: 0 mm,

19.0 mm (0.74

in.) to 44.0 mm

(1.73 in.)

Current clutch position

displayed



[Clutch Pos-

Cur]

Max.: 127.998

mm

Shift Position

(Current)

[Shift Pos-Cur]

Current shift position:

Min.: 0 mm,

Max.: 127.998mm

5.0 mm (0.20

in.) to 31.9 mm

(1.25 in.)

Current shift position value

displayed (1st, 3rd, 5th, or

Neutral, or 2nd, 4th, Reverse)

Select Position(Current)

[Select Pos-

Cur]

Current select

position:

Min.: 0 mm,Max.: 127.998

mm

3.0 mm (0.11in.) to 29.0 mm

(1.14 in.)

Current select position valuedisplayed (gear shift fork shaft

No. 1, No. 2 or No. 3)

Shift Lever

Position Judge

[Shift Pos

Judge]

Shift lever

position:INVALID

POSITION, P,R, N, E, M

Actual shift

lever position

displayed

-

Calculated AT

OilTemperature

[AT Oil

Temp]

Transmissionfluid temperature

calculated by

ECU:Min.: -128°C,

Max.: 127°C

Equivalent to

actualtransmission

fluid

temperature

-

Shift Lever

SwitchSignal1

[Shift SW

Sig1]

Shift lever

switch signal

(+):OFF or ON

ON: Shift lever

position in (+)

OFF: Otherthan above

LSW1(LSW+) terminal signal

of transmission control ECU

Shift LeverSwitch

Signal2

[Shift SWSig2]

Shift lever

switch signal(R):

OFF or ON

ON: Shift lever

position in (R)OFF: Other

than above

LSW2 (LSWR) terminal signalof transmission control ECU

Shift LeverSwitch

Signal3

[Shift SWSig3]

Shift lever

switch signal

(M) or (E):OFF or ON

ON: Shift lever

position in (E),

(M), (+) or (-)

OFF: Shift lever position in (R)

or (N)

LSW3 (LSWS) terminal signal


Shift LeverSwitch

Signal4

[Shift SW

Shift leverswitch signal

(N):

OFF or ON

ON: Shift lever position in (N)

OFF: Other

than above

LSW4 (LSWN) terminal signalof transmission control ECU



Sig4]

Shift Lever

SwitchSignal5

[Shift SW

Sig5]

Shift lever

switch signal (-):

OFF or ON

ON: Shift lever

position in (-)

OFF: Other

than above

LSW5 (LSW-) terminal signal


Shift Lever

Check Signal1[Shift Chek

Sig1]

Check signal of

shift lever switchsignal 2:

OFF or ON

OFF: Shift lever

position in (R)ON: Other than

above

LS2C (LSRC) terminal signalof transmission ECU

Reversal signal of LSW2

(LSWR) (ON and OFFreversed)

Shift LeverCheck Signal2

[Shift Chek

Sig2]

Check signal ofshift lever switch

signal 3:

OFF or ON

OFF: Shift lever

position in (E),

(M), (+) or (-)ON: Shift lever

position in (R)or (N)

LS3C (LSSC) terminal signalof transmission control ECU


(LSWS) (ON and OFF

reversed)

Shift Lever

Check Signal3[Shift Chek

Sig3]

Check signal of

shift lever switchsignal 4:

OFF or ON

OFF: Shift lever

position in (N)ON: Other than

above

LS4C (LSNC) terminal signalof transmission ECU


(LSWN) (ON and OFFreversed)

T/M ReverseSwitch Signal

[T/M R SW

Sig]

Transmissionreverse switch

signal:

OFF or ON

ON:

Transmission

gear in reverseOFF: Other

than above

During malfunctions, indicatorshows either OFF or ON

continuously, regardless of

gear position

Ignition Signal

[Ignition Sig]

Ignition switch

signal:OFF or ON

ON: Ignition

switch on (IG)-

Mode Switch

Signal

[Mode SWSig]

Transmission

shift main switch

signal:OFF or ON

ON: Sequential

shift control

(M-mode)selected

-

Es Mode

Switch Signal[Es SW Sig]

Es Mode Switch

Signal:OFF or ON

ON: Sporty [Es]

mode selected

(Automaticshift control)

-

Parking Brake

Signal

[Pkb Sig]

Parking brake

switch signal:

OFF or ON

ON: Parking

brake appliedOFF: Parking

brake released

-

Brake Switch Brake switch OFF: Brake ST1- terminal signal of



Signal2

[Brake SW

Sig2]

signal (ST1-):

OFF or ON

pedal depressed

ON: Brake

pedal released

transmission control ECU

Brake Switch

Signal1

[Brake SWSig1]

Brake switch

signal (STP):OFF or ON

ON: Brake

pedal depressed

OFF: Brake pedal released

STP terminal signal of

transmission control ECU

STA Switch

Signal

[STA SW Sig]

STA signal:OFF or ON

ON: Duringcranking

-

Gear Position(Current)

[Gear Pos-

Cur]

Current gear position:

Min.: 0, Max.:

255

Actual gear

positiondisplayed

0 = Non1 to 6 = 1st to 6th

254 = Neutral

255 = Reverse

Gear Position

(Target)

[Gear Pos-Tar]

Target gear position:

Min.: 0, Max.:

255

When shift

lever notoperated:

Target gear position equals

current gear

position

0 = Non1 to 6 = 1st to 6th

254 = Neutral

255 = Reverse

Clutch

Position(Target)

[Clutch Pos-

Tar]

Target clutch

position:Min.: 0 mm,

Max.: 127.998

mm

Difference between actual

and target

clutch positions:

Maximum of 15

mm during gearchange control

operation

(varies withvehicle

condition)

-

Shift Position

(Target)

[Shift Pos-Tar]

Target shift position:

Min.: 0 mm,

Max.: 127.998mm

Difference

between actualand target shift

positions:Maximum of 15


operation

(varies withvehicle

condition)

-



Select Position

(Target)[Select Pos-

Tar]

Target select

position:

Min.: 0 mm,Max.: 127.998

mm

Difference

between actual

and target select positions:

Maximum of 15


operation

(varies withvehicle

condition)

-

Clutch Motor

Current Req

[Clutch MotorReq]

Requested clutch

motor currentfrom CPU:

Min.: -50 A,

Max.: 50 A

-20 to 20 AInstruction (calculated) current

value from CPU

Clutch MotorCurrent MMT

[Clutch

Motor]

Actual clutchmotor current:

Min.: -50 A,

Max.: 50 A

-20 to 20 A0 A: When clutch motor not in

operation

Shift Motor

Current Req[Shift Motor

Req]

Requested shiftmotor current

from CPU:

Min.: -50 A,Max.: 50 A

-40 to 40AInstruction (calculated) currentvalue from CPU

Shift MotorCurrent MMT

[Shift Motor]

Actual shift

motor current:Min.: -50 A,Max.: 50 A

-40 to 40A 0 A: When shift motor not inoperation

Select MotorCurrent Req

[Select Motor

Req]

Requested select

motor currentfrom CPU:

Min.: -50 A,

Max.: 50 A

-25 to 25 AInstruction (calculated) current

value from CPU

Select Motor

Current MMT

[Select Motor]

Actual selectmotor current:

Min.: -50 A,Max.: 50 A

-25 to 25 A0 A: When select motor not in

operation

Base Clutch

Load[Base Clutch

Load]

Base clutch load:

Min.: -1000 N,Max.: 1000 N

Learning valueshown

Base clutch load:Calculated from average clutch

motor current when ECU

performing initialization andlearning of clutch system



Current ClutchLoad

[Current

Clutch Load]

Current clutchload (calculated

value):

Min.: -1000 N,

Max.: 1000 N

Reference value

(varies with

vehiclecondition)

39.33 to 45.29:

Stopper position

37.07 to 43.03:

Completeengagement

position

24.5 to 35.25:Standby

position

Current clutch load:Calculated from average clutch

motor current

Difference between BaseClutch Load and Current

Clutch Load increases as clutch

disks wear away

After performing LCCadjustment, difference

decreases (Almost same as

Base Clutch Load value)

Clutch AdjustCount

[Clutch AdjCnt]

Number of LCC

(Load Controlled

Clutch cover)adjustment

performed:Min.: 0 , Max.:

255

-When clutch motor strokeamount reaches certain value,the count increases by 1

Clutch Adjust

Fail Count[Clutch Adj

Fail]

Number of LCC

(Load ControlledClutch cover)

adjustment

judged

unnecessary:Min.: 0 , Max.:

255

-

When difference between Base

Clutch Load and CurrentClutch Load exceeds threshold,

the count increases by 1

Clutch Adjust

Detection[Clutch Adj

Detect]

Number of LCC(Load Controlled

Clutch cover)

adjustment

required:Min.: 0 , Max.:

255

-

When difference between Base

Clutch Load and CurrentClutch Load exceeds threshold,

the count increases by 1

Mode Changes

[Mode

Changes]

System controlmode:

Min.: 0, Max.:

255

-

11: System wake-up control

mode12: Vehicle driving control

mode

13: System end control mode14: System initialization mode

17: Engine starting control

mode20: Fixed gear shift control



mode

21: Gear shift control mode

22: Shift lever lock controlmode

25: Shut-down control mode

26: Vehicle stationary controlmode

27: Vehicle start off control

mode

Gear Mode

Changes[Gear Mode]

Gear changemode indication:

Min.: 0, Max.:

255

- -

1st Uplock

Signal

[1st Uplock

Sig]

1st gear up-lock

signal:

OFF or ON

2nd Uplock

Signal

[2nd Uplock

Sig]

2nd gear up-lock

signal:OFF or ON

3rd Uplock

Signal

[3rd UplockSig]

3rd gear up-locksignal:

OFF or ON

4th Uplock

Signal

[4th UplockSig]

4th gear up-locksignal:

OFF or ON

5th Uplock

Signal

[5th UplockSig]

5th gear up-locksignal:

OFF or ON

Rev Uplock

Signal

[Rev Uplock

Sig]

Reverse gear up-lock signal:

OFF or ON

-

If gear shift fails, uplock signal

indicates whether transmission

up-lock has occurred or notUp-lock:

Transmission gear momentarily

cannot be engaged due tomechanical reasons (notmalfunction)

Vehicle Speed

Signal Open

[Vehicle SpdOpen]

Vehicle speed

signal circuit

open judgement:OFF or ON

OFF: During

vehicle running

ON: When momentarilyinterruption in vehicle speed

signal

Input Rev

Signal Open

Input revolution

signal circuit

OFF: During

engine running

ON: When abnormal pulse

interval detected



[In Rev Open] open judgement:

OFF or ON

Creep Control

[Creep Ctrl]

Vehicle creep

control mode:

OFF or ON

ON: Clutch partial

engagement

continues forlong time

Clutch partially engaged whenfollowing conditions met:

•

Engine running• Transmission

gear in 1st, 2nd or

Reverse

• Brake pedal not

depressed

• Parking brakereleased

• Accelerator

pedal released

Low Voltage

Signal[Low Volt]

+B terminal lowvoltage

judgement:

OFF or ON

OFF: +B

terminal voltage8 V or more

-

Run Off

Signal[Run Off Sig]

Vehicle run-off

judgementOFF or ON

OFF: Whilevehicle running

ON: High differential spinoccurred sharply at differential

gear

When following conditionsmet, transmission control ECU

detects run-off in vehicle and

restricts gear shift:

• Accelerator pedal angle exceeds

threshold

• SPD signalchange rate above

threshold

• Shift position in

1st, 2nd or 3rd

Clutch Heat

[Clt Heat]

Clutch heat

judgement:OFF or ON

OFF: Engine

idling, gear inneutral

ON: Calculated clutchtemperature 280°C (536°F) or

moreClutch temperature calculated

from relative revolution speed

between engine andtransmission input shaft, clutch

torque, heat radiation, heat



conduction, sum of current

clutch temperature and

variation in clutch temperature,etc.

Clutch Heat

and Overuse[Clt Heat

Overuse]

Clutch heat and

overuse judgement:

OFF or ON

OFF: Engineidling, gear in

neutral

ON: Calculated clutchtemperature 330°C (626°F) or

more

Clutch Motor

CurrentEnable

[Clt Curr Ena]

Clutch motor

current enabledOFF or ON

OFF: Target

clutch motorcurrent less than

1 A

ON: OFFcondition not

met

-

Motor Relay

Signal

[Mot RelaySig]

AMT relay drive

signal:

OFF or ON

ON: Ignitionswitch on (IG)OFF: Ignition

switch off and

after system

shut-down

-

Shift LeverLock Solenoid

[SLS]

Shift lever lock

solenoid

operation:OFF or ON

OFF: Shift leverlocked

-

Clutch TouchPosition

[Clt Touch

Pos]

Clutch touch

position:

Min.: 0 mm,Max.: 127.998

mm

Learning value

shown

Difference between ClutchTouch position and Clutch

Clamp Position within 4.0 mm

(0.16 in.) to 16.0 mm (0.63 in.)

Clutch Clamp

Position

[Clt ClampPos]

Clutch clamp

position:Min.: 0 mm,

Max.: 127.998

mm

Learning value

shown

Difference between Clutch

Touch position and Clutch

Clamp Position within 4.0 mm(0.16 in.) to 16.0 mm (0.63 in.)

Neutral

Position(Shift)

[N Pos (Shift)]

Neutral position

(shift position):Min.: 0 mm,

Max.: 127.998mm

Learning valueshown

Median value between [3rd Pos(Shift)] and [4th Pos (Shift)]displayed

Neutral

Position

(Select)

Neutral position

(select position):

Min.: 0 mm,

Learning valueshown

Median value between [1st Pos

(Sel)] and [5th Pos (Sel)]

displayed



[N Pos (Sel)] Max.: 127.998

mm

1st Gear

Position(Shift)

[1st Pos

(Shift)]

1st gear position


Max.: 127.998

mm

Learning valueshown

• Difference between [1st Pos

(Shift)] and [2nd Pos

(Shift)] within 15.0 mm(0.59 in.) to 19.5 mm

(0.77 in.)

• Difference

between [1st Pos(Shift)] and [3rd Pos

(Shift)] within 1.5 mm

(0.06 in.)

1st Gear

Position(Select)[1st Pos (Sel)]

1st gear position

(select position):Min.: 0 mm,

Max.: 127.998

mm

Learning valueshown

Difference between [1st Pos

(Sel)] and [3rd Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5mm (0.33 in.)

2nd Gear

Position

(Shift)[2nd Pos

(Shift)]

2nd gear position

(shift position):

Min.: 0 mm,Max.: 127.998

mm

Learning value

shown

Difference between [1st Pos(Shift)] and [2nd Pos (Shift)]

within 15.0 mm (0.59 in.) to

19.5 mm (0.77 in.)

2nd Gear

Position(Select)[2nd Pos (Sel)]

2nd gear position(select position):

Min.: 0 mm,Max.: 127.998

mm

Learning valueshown

Difference between [2nd Pos

(Sel)] and [4th Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5mm (0.33 in.)

3rd Gear

Position(Shift)

[3rd Pos

(Shift)]

3rd gear position


Max.: 127.998

mm

Learning value

shown

• Difference

between [3rd Pos

(Shift)] and [4th Pos


(0.77 in.)

• Difference between [5th Pos

(Shift)] and [3rd Pos(Shift)] within 1.5 mm

(0.06 in.)

3rd Gear

Position

(Select)

3rd gear position

(select position):

Min.: 0 mm,

Learning valueshown

Difference between [3rd Pos

(Sel)] and [5th Pos (Sel)]

within 5.5 mm (0.22 in.) to 8.5



[3rd Pos (Sel)] Max.: 127.998

mm

mm (0.33 in.)

4th Gear

Position(Shift)

[4th Pos

(Shift)]

4th gear position


Max.: 127.998

mm

Learning valueshown

• Difference between [3rd Pos

(Shift)] and [4th Pos


(0.77 in.)

• Difference

between [R Pos (Shift)]and [4th Pos (Shift)]

within 1.5 mm (0.06

in.)

4th Gear

Position(Select)[4th Pos (Sel)]

4th gear position

(select position):Min.: 0 mm,

Max.: 127.998

mm

Learning valueshown

Difference between [R Pos

(Sel)] and [4th Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5mm (0.33 in.)

5th GearPosition

(Shift)

[5th Pos

(Shift)]

5th gear position(shift position):

Min.: 0 mm,

Max.: 127.998

mm

Learning value

shown

• Difference

between [R Pos (Shift)]

and [5th Pos (Shift)]within 15.0 mm (0.59

in.) to 19.5 mm (0.77

in.)

• Difference

between [3rd Pos(Shift)] and [5th Pos(Shift)] within 1.5 mm

(0.06 in.)

5th Gear

Position(Select)

[5th Pos (Sel)]

5th gear position

(select position):

Min.: 0 mm,

Max.: 127.998mm

Learning valueshown

Difference between [5th Pos

(Sel)] and [3rd Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5

mm (0.33 in.)

Reverse GearPos (Shift)

[R Pos (Shift)]

Reverse gear position (shift position):

Min.: 0 mm,

Max.: 127.998mm

Learning valueshown

• Difference

between [R Pos (Shift)]and [5th Pos (Shift)]

within 15.0 mm (0.59in.) to 19.5 mm (0.77

in.)

• Difference

between [R Pos (Shift)]



and [4th Pos (Shift)]

within 1.5 mm (0.06

in.)

Reverse Gear

Pos (Select)[R Pos (Sel)]

Reverse gear

position (select position):

Min.: 0 mm,

Max.: 127.998mm

Learning valueshown

Difference between [R Pos(Sel)] and [4th Pos (Sel)]within 5.5 mm (0.22 in.) to 8.5

mm (0.33 in.)

Possibility of

T/M Uplock

[T/M Uplock]

Possibility oftransmission up-

lock:

No or Yes

No:Initialization

and learning

complete

Yes: Transmission gear

temporarily could not be

engaged due to mechanicalreasons during gear position

learning

Learn-ClutchStandby Point

[Lern-Stby_Pnt]

Clutch actuatorstandby position

learning:

Notexec, Fail orExec

Exec:Initialization

and learningcomplete

-

Learning-T/M

[Lern-T/M]

Learning T/M

system: Notexec, Fail or

Exec

Exec:

Initializationand learning

complete

-

Learn-Clutch

Stopper Point[Lern-Stppr_Pnt]

Clutch actuator

stopper positionlearning:

Notexec, Fail or

Exec

Exec:

Initializationand learningcomplete

-

# Codes

[# Codes]

Number ofcodes:

Min.: 0, Max.:

255

- Number of detected DTCs

Check Mode[Check Mode]

Check mode:OFF or ON

ON: Checkmode ON

-

ACTIVE TEST

HINT:

Performing an Active Test enables components including the relays, VSV

(Vacuum Switching Valve), and actuators, to be operated without removing any parts. The Active Test can be performed with an intelligent tester. Performing an



Active Test as the first step of troubleshooting is one method of shortening

diagnostic time.Data List can be displayed during Active Tests.

1. Connect an intelligent tester to the DLC3.

2.

Turn the ignition switch on (IG) and turn the tester ON.3. Select the following menu items: Powertrain / Multi-Mode M/T / Active Test.4. Perform the Active Test by referring to the table below.

ItemsTest Details/Vehicle

conditionsDiagnosis Notes

Target Gear

PositionControl

[Test Details]

Target gear position control

(Gear position) N, 1st, 2nd, 3rd, 4th, 5th, R

[Vehicle Conditions]Ignition switch on (IG),

Engine stopped, Vehicle

stationary, Shift lever N position

If shift and select actuator does not

shift to the gear indicated, there

could be some malfunctions in the

following parts:Shift stroke sensor


Shift and select actuator assemblyAMT relay

Transmission assembly

Transmission control ECU

TargetClutchControl

[Test Details]

Target clutch controlStandby position: Standby

Clamp position: Clamp[Vehicle Conditions]Ignition switch on (IG),

Engine stopped, Vehicle

stationary, Shift lever N

position

If clutch actuator does not operate tothe position indicated, there could be

some malfunctions in the following

parts:Clutch stroke sensor

Clutch actuator assembly

AMT relayClutch release bearing

Clutch release fork

Transmission control ECU



MULTI-MODE MANUAL

TRANSAXLE SYSTEM >

ADJUSTMENT

for Preparation

1. USING INTELLIGENT TESTER: CLAMP POSITION ADJUSTMENT (CLUTCH

POSITION ADJUSTMENT)

HINT:

• The multi-mode manual transmission system has a load controlled clutch cover(adjustment system). The pressure plate moves depending on the wear condition

of the clutch disc lining.

•

When removing or installing any parts related to the multi-mode manual

transmission system, move the clutch actuator to the clutch clamp position. This is

for normal operation of the load controlled clutch cover (adjustment system).

• If the clutch position adjustment operation input fails, perform the operation again

from step (a) more than 15 seconds after turning the ignition switch off.

NOTICE:



Do not depress the brake pedal while performing the clamp position adjustment

using an intelligent tester.



•

Shift the lever into the N position.• Turn the ignition switch off.

• Apply the parking brake.



4. Turn the intelligent tester ON.

5. Select the following menu items: Powertrain / Multi-Mode M/T / Utility / Parts

Exchange.






9. After checking the vehicle condition, press the Next key.



14. On the Multi-Mode M/T / Utility screen, select Step 1 Clutch Position Adjustment

(Clamp Position Adjustment).

15.

Press the Next key.



18. Complete Clutch Position Adjustment.

19. Turn the intelligent tester OFF.

20. Turn the ignition switch off.

21. Replace the malfunctioning parts.



HINT:

Perform [Initialization and Learning] after repairing the multi-mode manualtransmission control system ().

2. WITHOUT USING INTELLIGENT TESTER: CLAMP POSITION ADJUSTMENT

(CLUTCH POSITION ADJUSTMENT)

HINT:

• The multi-mode manual transmission system has a load controlled clutch cover(adjustment system). The pressure plate moves depending on the wear condition

of the clutch disc lining.

• When removing or installing any parts related to the multi-mode manualtransmission system, move the clutch actuator to the clutch clamp position. This is

for normal operation of the load controlled clutch cover (adjustment system).

•

If the clutch position adjustment operation input fails, perform the operation againfrom step (a) more than 15 seconds after turning the ignition switch off.

1. Prepare the vehicle.


• Shift the lever into the N position.


• Apply the parking brake.

2. Using SST, connect terminals TC (13) and CG (4) of the DLC3

SST

09843-18040



3. Turn the ignition switch on (IG) with the brake pedal released.

4. Depress the brake pedal 7 times or more within 3 seconds.

1. The buzzer sounds twice with an interval of 0.25 seconds.

5. Depress the brake pedal.

6.

Shift the shift lever in the following sequence with the brake pedal depressed: N→E→M→+→M→+→M→+→M→+→M→E→ N.



7. Release the brake pedal.

8. Depress the brake pedal again.

1. The buzzer sounds once at intervals of 2.5 seconds.

HINT:

If the buzzer does not sound at this time, wait at least 15 seconds after turning the

ignition switch off. Then, perform the procedure from step (a) again.

9. Depress the brake pedal 3 times or more within 2 seconds.

1.

The buzzer sounds twice with an interval of 0.25 seconds.

10. Depress the brake pedal.

11. Shift the shift lever to the [-] position with the brake pedal depressed.

12. Release the brake pedal.

13. Complete clutch position adjustment.

14. Turn the ignition switch OFF and wait at least 10 seconds.

15. Disconnect the SST from terminals TC and CG of the DLC3.

16. Repair the malfunctioning parts.

HINT:Perform [Initialization and Learning] after repairing the multi-mode manual

transmission control system ().



MULTI-MODE MANUAL TRANSAXLE SYSTEM > Starter SignalCircuit

for Preparation

DESCRIPTION

In this vehicle, since the starter motor control depends on the ECM due to cranking

holding function, the ST relay that supplies power to the starter motor is operated by the



ECM. When the appropriate vehicle conditions are satisfied (the brake pedal is depressed

and the transmission gear is in neutral) the engine can be cranked. If the brake pedal isnot depressed or the transmission gear is not in neutral, the engine cannot be cranked.

During cranking, the ST relay operation signal (STA signal) is input into the STA

terminal of the transmission control ECU, and is used to control the multi-mode manual

transmission system.

WIRING DIAGRAM



INSPECTION PROCEDURE

1.READ VALUE USING INTELLIGENT TESTER

1.

Connect an intelligent tester to the DLC3.


3. Select the following menu items: Powertrain / Multi-Mode M/T / Data List / STA

Switch Signal.

4.

Check the value displayed on the tester when the ignition switch is turned on (IG)and the engine starts.

Items

[Abbreviation]

Measurement Items:

Display Normal Conditions

Diagnostic

Notes

STA Switch

Signal[STA SW Sig]

STA signal:ON or OFF

ON: Duringcranking

-

5. OK:

6.

[ON] displays in the STA Switch Signal during cranking.



OK

PROCEED TO NEXT CIRCUIT

INSPECTION SHOWN IN PROBLEMSYMPTOMS TABLE

NG

2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU -

ECM)



1.

Disconnect the transmission control ECU connector.

2. Disconnect the ECM connector.

3. Remove the ST relay from the engine room relay block.

4. Check the resistance.



Standard resistance:

Tester ConnectionsSpecified

Conditions

1KR-FE:

STA (A32-27) -

STA (A38-6)2SZ-FE:

STA (A21-48) -

STA (A38-6)

Below 1 Ω

STA (A38-6) - Bodyground

10 k Ωor higher

5. Reconnect the transmission control ECU connector.

6. Reconnect the ECM connector.

7. Reinstall the ST relay.



NG

REPAIR OR REPLACE HARNESS OR

CONNECTOR

OK

GO TO STARTER SIGNAL CIRCUIT (ENGINE CONTROL SYSTEM)



MULTI-MODE MANUAL TRANSAXLE SYSTEM > Pattern SelectSwitch Circuit

for Preparation

DESCRIPTION

While the vehicle is driven with the shift lever in the E position, the most appropriate

gear is automatically selected in accordance with the accelerator pedal opening angle andvehicle speed. In this time, shift control can be switched between normal mode (E) and

sports mode (Es) by pressing the pattern select switch.

WIRING DIAGRAM




1.INSPECT PATTERN SELECT SWITCH ASSEMBLY

1. Remove the pattern select switch.

2. Check the resistance of the pattern select switch terminals.




Tester

Connections

Switch

Conditions

Specified

Conditions

1 - 4 ON Below 1 Ω

1 - 4 OFF10 k Ω or

higher

3. Reinstall the pattern select switch.

NG REPLACE PATTERN SELECTSWITCH ASSEMBLY



OK


BODY GROUND)

1. Disconnect the transmission control ECU connector.



Tester

Connections

Switch

Conditions

Specified

Conditions

PWR (D79-

23) - Body

ground

OFF10 k Ω or

higher

PWR (D79-23) - Body

ground

ON Below 1 Ω




NG


CONNECTOR

OK

3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY (PWR TERMINAL

VOLTAGE)




2. Measure the voltage between the terminal of the transmission control ECU

connector and the body ground when the pattern select switch is ON and OFF.

Standard voltage:

Tester

Connections

Switch

Conditions

Specified

Conditions

PWR (D79-

23) - Body

ground

Pattern

selectswitch

OFF

10 to 14 V

PWR (D79-

23) - Bodyground

Pattern

selectswitch ON

Below 1 V



NG

REPLACE TRANSMISSION

CONTROL ECU ASSEMBLY

OK

PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS

TABLE




1.READ VALUE USING INTELLIGENT TESTER

1. Connect the intelligent tester to the DLC3




3. Select the following menu items: Powertrain / Multi-Mode M/T / Data List /

Ignition Signal.

4.

Read the value.

Items[Abbreviation]

Measurement Items:Display

Normal ConditionsDiagnostic

Notes

Ignition

Signal

[Ignition Sig]

Ignition switch signal:OFF or ON

ON: Ignition switch on(IG)

-

5. OK:6. [ON] displays in the item [Ignition Signal] when the ignition switch is turned on

(IG).






connector and the body ground.

Standard voltage:

Tester

Connections

IgnitionSwitch

Conditions

Specified

Conditions

IG (D79-3) -Body ground

Ignitionswitch off

Below 1 V

IG (D79-3) -Body ground

Ignition

switch on

(IG)

10 to 14 V




OK



NG

3.INSPECT INTEGRATION RELAY



1. Remove the integration relay from the engine room relay block.

2.

Measure the voltage between the terminal of the integration relay and the body

ground.

Standard voltage:


Conditions

Integration relay (1C-

1) - Body ground10 to 14 V

3. Reinstall the integration relay.



NG


CONNECTOR (INTEGRATIONRELAY - BATTERY)

OK

4.INSPECT INTEGRATION RELAY (AM2 FUSE AND IG2 RELAY)



1. Inspect the AM2 fuse.1. Remove the AM2 fuse.

2. Check the fuse resistance.

Standard resistance:Below 1 Ω

3. Reinstall the fuse.

2. Inspect the relay.

1. Check the relay resistance.


Tester

Connections

Specified

Conditions

1C-1 - 1B-4 10 k Ω or higher

1C-1 - 1B-4

Below 1 Ω

(When battery

voltage applied toterminals 1B-2 and

1B-3)



NG REPLACE INTEGRATION RELAY

OK

5.INSPECT FUSE (IGN FUSE)



1. Remove the IGN fuse from the main body ECU.

2. Check the fuse resistance.


Below 1 Ω

3. Reinstall the IGN fuse.



NG

CHECK FOR SHORT IN ALL

HARNESSES AND CONNECTORS

CONNECTED TO FUSE ANDREPLACE FUSE

OK


INTEGRATION RELAY)



1.

Remove the integration relay.



Standard resistance (Check for open):




Conditions

Integration relay (1B-4) - IG (D79-3)

Below 1 Ω

Standard resistance (Check for short):


Conditions

IG (D79-3) - Bodyground

10 k Ω or higher

4. Reinstall the integration relay.

5. Reconnect the ECU connector

Result:

ResultProceed

To

Outside normal range A

Within normal range (with

Entry and Start System)B

Within normal range(without Entry and Start

System)

C



B Go to step 7



C Go to step 8

A

REPAIR OR REPLACE HARNESS OR CONNECTOR

7.CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - MAIN BODYECU)



NG


CONNECTOR

OK

CHECK ENTRY AND START SYSTEM

8.CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - IGNITIONSWITCH)



1.

Remove the integration relay.

2. Disconnect the ignition switch connector.


Standard resistance (Check for open):



NG


CONNECTOR

OK

9.INSPECT IGNITION SWITCH



NG REPLACE IGNITION SWITCH

OK

REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION SWITCH -BATTERY)



MULTI-MODE MANUAL TRANSAXLE SYSTEM > Shift LockSolenoid Circuit

for Preparation

DESCRIPTION

The shift lock solenoid is built into the shift lever assembly. When the ignition switch isturned off, or when the shift lever is in the N position without depressing the brake pedalalthough the ignition switch is turned on (IG), the shift lock solenoid restricts the shift

lever movement.

The transmission control ECU sends the shift lock cancellation signal to the shift locksolenoid to cancel the shift lock when the multi-mode manual transmission system

conditions are satisfied.



WIRING DIAGRAM


1.INSPECT SHIFT LOCK SOLENOID

1. Disconnect the shift lever assembly connector.

2. Measure the shift lock solenoid resistance.




Tester

Connections

Specified

Conditions

IG (D81-2) - E

(D81-6)

30 to 35 Ω at 20°C

(68°F)

NG REPLACE SHIFT LOCK SOLENOID

OK

2.CHECK HARNESS AND CONNECTOR (SHIFT LOCK SOLENOID -



E (D81-6) - Body

groundBelow 1 Ω

SLS (D79-5) - Bodyground

10 k Ω or higher

4.

Reconnect the transmission control ECU connector.

5. Reconnect the shift lever assembly connector.

NG REPAIR OR REPLACE HARNESS ORCONNECTOR



OK

3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY


2. Measure the voltage between the terminal of the transmission control ECU and

the body ground when the brake pedal is operated.

Standard voltage:

Pedal

Conditions

Tester

Connections

Specified

Conditions

Brake

pedaldepressed

SLS (D79-5)

- Bodyground

10 to 14 V

Brake

pedal

released

SLS (D79-5)Body ground

Below 1 V



NG



OK

PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS

TABLE



MULTI-MODE MANUAL TRANSAXLE SYSTEM > Multi -ModeManual Transmission Warning Light Circuit

for Preparation

DESCRIPTION

The combination meter interprets the multi-mode manual transmission system conditionthrough information from the INDC and INDA circuits, and if necessary, illuminates

(blinks) the multi-mode manual transmission warning light and sounds the buzzer.

• INDC Terminal Circuit:The battery voltage is constantly supplied to the INDC circuit. If the INDC circuit

is open, the combination meter detects a malfunction in the circuit and illuminates

the multi-mode manual transmission warning light. The INDC circuit is used tosend the multi-mode manual transmission warning light signal to the combination

meter when the ignition switch is off.



meter)

Shift

positionindicator

*1

ON

depends oncommunication

signal

ON

depends oncommunication

signal

OFF OFF OFF OFF

Multi-mode

manualtransmission

warning

light

ON

depends on

communicationsignal

ON

depends on

communicationsignal

ON ON OFF ON

*1: when shift position indicator ON, the number or letter segments are illuminated.

WIRING DIAGRAM




HINT:

• Check that the multi-mode manual transmission warning light and shift position

indicator light come on.Under normal conditions, the shift position indicator indicates the current gear

position while the ignition switch is turned on (IG), and the multi-mode manual

transmission warning light comes on for a bulb check for approximately 5seconds when the ignition switch is turned from off to on (IG).

If the shift position indicator light does not come on, the INDA circuit may bemalfunctioning. If the multi-mode manual transmission warning light does not

come on, the INDA and/or INDC circuits may be malfunctioning.

• The buzzer built into the combination meter sounds when the followingconditions are met:

• The shift lever is in any position except N.

•

The driver's door is open.• Vehicle speed is 10 km/h (6.21 mph) or less.

• Engine speed is 400 rpm or more.


COMBINATION METER ASSEMBLY)




2. Disconnect the combination meter connector




Conditions

INDC (D79-29) -BRQ (D1-13)

Below 1 Ω

INDA (D79-31) -

TX+ (D1-8)Below 1 Ω



NG

REPLACE PARKING BRAKE

SWITCH ASSEMBLY

OK


BODY GROUND)



NG


CONNECTOR

OK

3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY





connector and the body ground when the parking brake switch is ON and OFF.

Standard voltage:

Tester

Connections

Switch

Conditions

Specified

Conditions

PKB (D79-

4) - Body

ground

Parking

brakeswitch

OFF

10 to 14 V

PKB (D79-

4) - Bodyground

Parking

brakeswitch

ON

Below 1 V



MULTI-MODE MANUAL TRANSAXLE SYSTEM > TC and CGTerminal Circuit

for Preparation

DESCRIPTION

Terminal TC and CG are located in the DLC3. When performing [Clamp PositionAdjustment] and [Initialization and Learning] without using an intelligent tester,

connecting terminals TC and CG is necessary. If the TC terminal circuit is open, thesecalibration procedures cannot be performed without using an intelligent tester.

WIRING DIAGRAM





DLC3)






Tester Connections

Specified

Conditions

DG (D79-25) - TC

(D15-13)Below 1 Ω

DG (D79-25) -Body ground

10 k Ωor higher

3.

Reconnect the transmission control ECU connector.



NGREPAIR OR REPLACE HARNESS OR

CONNECTOR

OK

2.CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND)





Tester Connections SpecifiedConditions

CG (D15-4) - Body

groundBelow 1 Ω



NG


CONNECTOR

OK

REPLACE TRANSMISSION CONTROL ECU ASSEMBLY



MULTI-MODE MANUAL

TRANSAXLE OIL > ON-VEHICLE

INSPECTION

for Preparation

1. INSPECT TRANSAXLE OIL



1. Stop the vehicle on a level place.

2. Remove the filler plug and gasket.

3.

Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of thefiller plug opening.

NOTICE:

• An excessively large or small amount of oil may cause problems.

• After replacing the oil, drive the vehicle and check the oil level again.

4. When the oil level is low, check for oil leakage.

5. Install the filler plug and a new gasket.

Torque:

39 N*m 400 kgf*cm , 29 ft.*lbf



1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. DRAIN TRANSAXLE OIL


2. Remove the drain plug and gasket, and drain the oil.

3. Install the drain plug with a new gasket.

Torque:


3. REMOVE FRONT WHEELS

4. REMOVE FRONT AXLE SHAFT LH NUT

1. Using SST and a hammer, release the staked part of the axle hub nut.

SST

09930-00010



NOTICE:

• Insert SST into the groove with the flat surface facing up.

• Do not damage the tip of SST using grinders.

• Completely unstake the staked part before removing the axle hub nut.

•

Do not damage the threads of the drive shaft.

2. Using a 30 mm socket wrench, remove the axle hub nut.

5. REMOVE FRONT AXLE SHAFT RH NUT

HINT:The removal procedure for the RH side is the same as that for the LH side.

6. SEPARATE SPEED SENSOR FRONT LH

1. Remove the bolt and separate the speed sensor and flexible hose.



2. Remove the bolt and separate the speed sensor from the steering knuckle.

NOTICE:

• Keep the speed sensor tip and installation portion free of foreign matter.

• Remove the speed sensor without turning it from its original installation

angle.

7. SEPARATE SPEED SENSOR FRONT RH

HINT:

The separation procedure for the RH side is the same as that for the LH side.

8. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH



1. Remove the clip and castle nut.

2. Using SST, separate the lower arm.

SST

09628-00011 NOTICE:

• Do not damage the lower ball joint dust cover.

• Suspend SST with a piece of string or the equivalent.

9. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT:


10. SEPARATE TIE ROD END SUB-ASSEMBLY LH

1.

Remove the cotter pin and castle nut.



2. Using SST, separate the tie rod end from the steering knuckle.

SST

09628-62011 NOTICE:

Do not damage the tie rod end dust cover.

11. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT:


12. REMOVE FRONT STABILIZER LINK ASSEMBLY LH

1. Remove the nut and separate the stabilizer link from the shock absorber.



HINT:

If the ball joint turns together with the nut, use a socket hexagon wrench 6 to holdthe stud.

13. REMOVE FRONT STABILIZER LINK ASSEMBLY RH

HINT:


14. REMOVE FRONT AXLE ASSEMBLY LH

1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting

between the drive shaft and front axle.

HINT:

If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass bar and hammer.

2. Push the front axle out of the vehicle to remove the drive shaft from the front

axle.

NOTICE:

• Do not push the front axle further out of the vehicle than is necessary.

•

Do not damage the outboard joint boot.• Do not damage the speed sensor rotor.

• Suspend the drive shaft with a piece of string or the equivalent.

15. REMOVE FRONT AXLE ASSEMBLY RH

HINT:

The removal procedure for the RH side is the same as that for the LH side.

16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH



1. Using SST, remove the drive shaft.

SST09520-01010

09520-24010 (09520-32040)

NOTICE:

• Do not damage the oil seal.

• Do not damage the inboard joint boot.

• Do not drop the drive shaft.

17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

1. Using a screwdriver and hammer, remove the drive shaft.



DIFFERENTIAL OIL SEAL >

INSTALLATIONfor Preparation

1. INSTALL TRANSAXLE CASE OIL SEAL

1. Coat a new oil seal lip with MP grease.

2. Using SST and a hammer, install the oil seal.

SST

09636-20010Drive in depth:

1.7 to 2.7mm (0.067 to 0.106 in.)

NOTICE:Do not damage the oil seal lip.

2. INSTALL TRANSMISSION CASE OIL SEAL



1. Coat a new oil seal lip with MP grease.

2. Using SST and a hammer, install the oil seal.

SST

09316-60011 (09316-00011)Drive in depth:

2.1 to 3.1mm (0.083 to 0.122 in.)

NOTICE:

Do not damage the oil seal lip.

3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

1. Coat the spline of the inboard joint with gear oil.



6. INSTALL FRONT AXLE ASSEMBLY RH

HINT:

The installation procedure for the RH side is the same as that for the LH side.

7. INSTALL FRONT STABILIZER LINK ASSEMBLY LH

1. Install the stabilizer link with the nut.

Torque:


HINT:If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold

the stud.

8. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT:


9. INSTALL TIE ROD END SUB-ASSEMBLY LH



1. Install the tie rod end onto the steering knuckle with a new castle nut.

Torque:

49 N*m 500 kgf*cm , 36 ft.*lbf NOTICE:

If the holes for the clip are not aligned, tighten the nut by a further turn of up to

60°.

2. Install a new cotter pin.

10. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT:


11. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH



1. Install the lower arm onto the steering knuckle with a new castle nut.

Torque:98 N*m 1,000 kgf*cm , 72 ft.*lbf

NOTICE:

If the holes for the clip are not aligned, tighten the nut by a further turn of up to

60°.

2. Install a new clip.

12. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: The installation procedure for the RH side is the same as that for the LH side.

13. INSTALL SPEED SENSOR FRONT LH



1. Install the speed sensor onto the steering knuckle with the bolt.

Torque:

8.5 N*m 87 kgf*cm , 75 in.*lbf NOTICE:

• Check that the speed sensor tip and installation portion are free of foreign

matter.

• Install the speed sensor without turning it from its original installation

angle.

2. Install the flexible hose and speed sensor with the bolt.

Torque:29 N*m 300 kgf*cm , 22 ft.*lbf

NOTICE:

Install the flexible hose and speed sensor without twisting them.



14. INSTALL SPEED SENSOR FRONT RH

HINT:


15. INSTALL FRONT AXLE SHAFT LH NUT

1. Using a 30 mm socket wrench, install a new axle hub nut.

Torque:

216 N*m 2,203 kgf*cm , 160 ft.*lbf

2. Using a chisel and hammer, caulk the axle hub nut.

16. INSTALL FRONT AXLE SHAFT RH NUT

HINT:


17. INSTALL FRONT WHEELS



18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:

5.4 N*m 55 kgf*cm , 48 in.*lbf

19. ADD TRANSAXLE OIL

20. INSPECT AND ADJUST TRANSAXLE OIL

1.

Stop the vehicle on a level place.


3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the

filler plug opening.

NOTICE:





Torque:




21. INSPECT ABS SPEED SENSOR SIGNAL

()

22. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

()

23. CHECK FOR TRANSAXLE OIL LEAKAGE



1 / 2



1. INSPECT SHIFT LOCK SOLENOID

1. Disconnect the indicator light wire connector.

2. Using an ohmmeter, measure the resistance between terminals 2 and 6.

Standard Resistance:

30 to 35 Ω at 20°C (68°F)

If the resistance is not as specified, replace the shift lever assembly.



4. Move the shift lever to the E position.

5. Using an ohmmeter, measure the resistance according to the value in the table

below.


Shift position

TerminalsSpecifiedcondition

E 4 - 810 k Ω or

higher

If the result is not as specified, replace the shift lever assembly.

6. Connect the indicator light wire connector.

3. INSPECT SHIFT LEVER POSITION SENSOR



SHIFT LEVER > REMOVAL

for Preparation

1. REMOVE REAR CONSOLE BOX COVER



2. Disengage the 4 claws and remove the position indicator light guide from the shiftlever assembly.

3. Disengage the 4 claws and remove the position indicator housing from the position indicator light guide.

3. REMOVE POSITION INDICATOR SLIDE COVER

4. REMOVE POSITION INDICATOR SLIDE COVER NO. 2



3. Using a screwdriver with its tip wrapped in protective tape, release the secondary

lock.



1. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY

1.

Connect marked wire harnesses 2 and 4 to the indicator light wire connector asshown in the illustration.

2. Connect wire harnesses 6 and 8 to the indicator light wire connector as shown in

the illustration.

3. Lock the secondary lock.

4. Install the bulb onto the indicator light wire.

5. Connect the indicator light wire connector onto the shift lever assembly.



2. INSTALL SHIFT LOCK RELEASE BUTTON

1. Apply MP grease to the shift lock release button and spring.

2. Install the shift lock release button and spring onto the shift lever.

3. INSTALL POSITION INDICATOR SLIDE COVER NO. 2

4. INSTALL POSITION INDICATOR SLIDE COVER

5. INSTALL POSITION INDICATOR LIGHT GUIDE



3. Connect the indicator light wire onto the shift lever assembly.

6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY



SHIFT LEVER > INSTALLATION

for Preparation

1. INSTALL SHIFT LEVER ASSEMBLY

1. Install the shift lever assembly with the 4 bolts.

Torque:12 N*m 122 kgf*cm , 8.9 ft.*lbf

2. Connect the 2 connectors.

2. INSTALL REAR CONSOLE BOX ASSEMBLY



MULTI-MODE MANUAL

TRANSAXLE ASSEMBLY >

COMPONENTS

for Preparation



1 / 10



2 / 10



3 / 10



6 / 10



7 / 10



8 / 10



9 / 10



10 / 10

MULTI-MODE MANUAL

TRANSAXLE ASSEMBLY >

REMOVAL

for Preparation



1. CLUTCH POSITION ADJUSTMENT

()


3. REMOVE COLUMN HOLE COVER SILENCER SHEET

1. Remove the floor carpet and 2 clips and remove the column hole cover silencer.

4. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY



1. Use a seat belt to fix the steering wheel assembly, in order to avoid breakage of

the spiral cable.

2. Place matchmarks on the sliding yoke of the steering intermediate shaft assembly

and the power steering.

3. Loosen bolt A, remove bolt B and separate the steering intermediate shaft

assembly.

5. REMOVE FRONT WHEELS

6. REMOVE ENGINE UNDER COVER LH



2. Remove the nut and front wiper arm.

11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RHHINT:

Use the same procedure as for the LH side.

12. REMOVE HOOD TO COWL TOP SEAL

1. Disengage the 7 clips and remove the hood to cowl top seal.

13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for LHD)



1. Disengage the 2 hooks and remove cowl top ventilator louver center No. 1.

2. Disconnect the washer hose.

3. Disengage the 11 claws and clip.



4. Disconnect the washer hose and remove the cowl top ventilator louver sub-assembly.

14. REMOVE COWL TOP VENTILATOR LOUVER LH (for LHD)

1. Remove the 2 clips.

2.

Disengage the 4 claws and remove the cowl top ventilator louver LH.

15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for RHD)



1. Disconnect the washer hose.

2. Disengage the 10 claws and clip and remove the cowl top ventilator louver sub-

assembly.

16. REMOVE COWL TOP VENTILATOR LOUVER LH (for RHD)

1. Remove the clip.

2. Disengage the 4 claws and remove the cowl top ventilator louver LH.



17. REMOVE WINDSHIELD WIPER MOTOR AND LINK

1. Remove the 2 bolts.

2. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the

connector and remove the front wiper motor and link.

18. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2



1. Disengage the claws and remove cowl to resister duct No. 2.

19. REMOVE COWL TOP PANEL OUTER



1. Disengage the clamp and separate the wiper motor connector.

2. Remove the 9 bolts and the cowl top panel outer.

20. REMOVE AIR CLEANER INLET NO.1 (for 2SZ-FE)



1. Remove the air cleaner inlet No. 1.

21. REMOVE BATTERY HOLD DOWN CLAMP

22. REMOVE BATTERY CLAMP SUB-ASSEMBLY

23. REMOVE BATTERY

24. REMOVE BATTERY TRAY

25. REMOVE BATTERY CARRIER (for 1KR-FE)



1. Remove the 4 bolts and the battery carrier.

26. REMOVE BATTERY CARRIER (for 2SZ-FE)


27. REMOVE CLUTCH ACTUATOR ASSEMBLY



1. Remove the bolt and separate the wire harness bracket.

2. Disconnect the clutch stroke sensor connector and motor connector.

NOTICE:

Do not forcibly pull the connector as this may damage the wire harness.



3. Remove the 3 bolts and clutch actuator assembly.

NOTICE:

• Loosen the bolts slowly, and be careful not to get your fingers caught as

the clutch actuator assembly moves due to the reaction force from theclutch cover.

• Do not drop the removed clutch actuator assembly or subject it to any

impacts.

28. DISCONNECT WIRE HARNESS

1. Remove the bolt, then disconnect the wire harness.



29. DISCONNECT CONNECTOR

1.

Disconnect the shift stroke sensor connector.

2. Disconnect the select stroke sensor connector.

3. Disconnect the transmission revolution sensor connector.

4. Disconnect the back-up light switch connector.

5. Disconnect the neutral start switch connector.

6. Disconnect the shift and select motor connectors.

30. REMOVE STARTER ASSEMBLY (for 1KR-FE)

1. Remove the terminal cap.

2. Separate the harness clamp.

3. Remove the nut and disconnect terminal 30.

4. Disconnect the connector.

5. Remove the 2 bolts and remove the starter assembly.



31. REMOVE STARTER ASSEMBLY (for 2SZ-FE)

1. Remove the terminal cap.

2. Remove the nut and disconnect terminal 30.

3. Disconnect the connector.

4. Remove the 2 bolts and remove the starter assembly.

32. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 1KR-FE)

1. Remove the 4 bolts and 4 compression springs.

2. Remove exhaust pipe support No. 4 and the exhaust front pipe assembly.



3. Remove the 2 exhaust pipe gaskets.

33. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2SZ-FE)

1. Remove the 2 bolts and 2 compression springs.



2. Remove the 3 No. 4 exhaust pipe supports and remove the exhaust pipe assembly

front.

34. REMOVE FRONT AXLE SHAFT LH NUT



1. Using SST and a hammer, release the staked part of the axle hub nut.

SST09930-00010

NOTICE:

• Insert SST into the groove with the flat surface facing up.

• Do not damage the tip of SST using grinders.

• Completely unstake the staked part before removing the axle hub nut.

• Do not damage the threads of the drive shaft.

2. Using a 30 mm socket wrench, remove the axle hub nut.

35. REMOVE FRONT AXLE SHAFT RH NUT

HINT:The removal procedure for the RH side is the same as that for the LH side.

36. SEPARATE SPEED SENSOR FRONT LH



1. Remove the bolt and separate the speed sensor and flexible hose.

2. Remove the bolt and separate the speed sensor from the steering knuckle.

NOTICE:

• Keep the speed sensor tip and installation portion free of foreign matter.

• Remove the speed sensor without turning it from its original installation

angle.

37. SEPARATE SPEED SENSOR FRONT RH

HINT:The separation procedure for the RH side is the same as that for the LH side.



38. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH

1. Remove the clip and castle nut.

2. Using SST, separate the lower arm.

SST

09628-00011 NOTICE:

• Do not damage the lower ball joint dust cover.

• Suspend SST with a piece of string or the equivalent.



39. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT:


40. SEPARATE TIE ROD END SUB-ASSEMBLY LH

1. Remove the cotter pin and castle nut.

2. Using SST, separate the tie rod end from the steering knuckle.

SST

09628-62011

NOTICE:Do not damage the tie rod end dust cover.

41. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT:


42. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH



1. Remove the nut and separate the stabilizer link from the shock absorber.

HINT:

If the ball joint turns together with the nut, use a socket hexagon wrench 6 to holdthe stud.

43. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT:


44. REMOVE FRONT AXLE ASSEMBLY LH

1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting between the drive shaft and front axle.

HINT:

If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass bar and hammer.

2. Push the front axle out of the vehicle to remove the drive shaft from the frontaxle.

NOTICE:


• Do not damage the outboard joint boot.



• Do not damage the speed sensor rotor.

• Suspend the drive shaft with a piece of string or the equivalent.

45. REMOVE FRONT AXLE ASSEMBLY RH

HINT:

The removal procedure for the RH side is the same as that for the LH side.

46. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

1. Using SST, remove the drive shaft.

SST09520-01010

09520-24010 (09520-32040)

NOTICE:



•

Do not drop the drive shaft.

47. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH



1.

Using a screwdriver and hammer, remove the drive shaft.

NOTICE:



• Do not drop the drive shaft.

48. SUSPEND ENGINE ASSEMBLY (for 1KR-FE)

1. Install the 2 hangers in the correct direction.



Parts No.:

No. 1 engine hanger 12281-40030 No. 2 engine hanger 12282-40010

Bolt 91671-80820

Torque:


2. Attach the engine chain hoist to the hangers.

NOTICE:

Do not attempt to hang the engine by hooking the chain to any other part.

49. SUSPEND ENGINE ASSEMBLY (for 2SZ-FE)

1. Install the 2 hangers in the correct direction.

Parts No.:

No. 1 engine hanger 12281-23021 No. 2 engine hanger 12282-23010

Bolt 91671-80820

Torque:


2. Attach the engine chain hoist to the hangers.

NOTICE:

Do not attempt to hang the engine by hooking the chain to any other part.



50. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

1. Remove the bolt and separate the engine moving control rod.

2. Support the front suspension crossmember with a transmission jack.



3. Remove the 6 bolts and remove the suspension crossmember.

51. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET

1. Remove the 3 bolts and the engine moving control rod bracket.

52. SUPPORT MULTI-MODE MANUAL TRANSAXLE ASSEMBLY

1. Support the multi-mode manual transaxle with a transmission jack.

53. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for1KR-FE)



1. Remove the bolt and nut, then separate the engine mounting insulator LH.

2. Remove the 4 bolts and the engine mounting insulator LH.

54. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZ-

FE)



55. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-



FE)

1. Remove the 4 bolts and the engine mounting bracket LH.

56. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-FE)


57. REMOVE MULTI-MODE MANUAL TRANSAXLE ASSEMBLY



1. Remove the 9 bolts and multi-mode manual transaxle from the engine.



MULTI-MODE MANUALTRANSAXLE ASSEMBLY >

INSTALLATION

for Preparation

1. INSTALL MULTI-MODE MANUAL TRANSAXLE ASSEMBLY



1. Align the input shaft with the clutch disc and install the manual transaxle onto the

engine.

2. Install the 9 bolts.

Torque:

64 N*m 653 kgf*cm , 47 ft.*lbf for bolt A39 N*m 398 kgf*cm , 29 ft.*lbf for bolt B

NOTICE:

• Insert dowel pins into dowel holes securely so that the end face of

transaxle assembly fits close against engine assembly before tightening the

bolts between the engine and transaxle.

•

Make sure that the dowel pins are not loose, bent, damaged or scratched

and then install the transaxle onto the engine with the contact surfaces of

the engine and transaxle flat against each other.



2. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-FE)

1. Install the engine mounting bracket LH with the 4 bolts.

Torque:


3. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-FE)


Torque:




4. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KR-

FE)

1.

Install the engine mounting insulator LH with the 4 bolts.

Torque:52 N*m 530 kgf*cm , 38 ft.*lbf for bolt A

64 N*m 653 kgf*cm , 47 ft.*lbf for bolt B

2. Install the engine mounting bracket LH and engine mounting insulator LH with

the bolt and nut.

Torque:52 N*m 530 kgf*cm , 38 ft.*lbf for nut C

5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZ-

FE)



1. Install the engine mounting insulator LH with the 5 bolts.

Torque:



the bolt and nut.

Torque:


6. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET

1. Install the engine mounting control bracket with the 3 bolts.

Torque:




7. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

1. Support the front suspension crossmember with a transmission jack.

2. Provisionally install the front suspension crossmember onto the body with the 6 bolts.

Bolt Underhead Length (mm)A 38

B 99

C 45

3. By inserting SST into the datum holes in the front suspension crossmembers RHand LH alternately, tighten bolts A, B and C on both sides to the specified torque,

in several steps.

SST

09670-00011Torque:

70 N*m 714 kgf*cm , 52 ft.*lbf for Bolt A

160 N*m 1,631 kgf*cm , 118 ft.*lbf for Bolt B95 N*m 969 kgf*cm , 70 ft.*lbf for Bolt C



NOTICE:

• Insert SST into the datum hole in a vertical orientation.

• If SST can not be inserted into the datum hole vertically, loosen all the

bolts and then insert SST again.



4. Install the engine moving control rod with the bolt.


8. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

1. Coat the spline of the inboard joint with gear oil.

2. Align the inboard joint splines and install the drive shaft with a screwdriver and

hammer.

NOTICE:

• Face the cut area of the front drive inboard joint hole snap ring downward.





HINT:

Confirm whether the drive shaft is securely driven in by checking the reaction

force and sound.

9. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

HINT:


10. INSTALL FRONT AXLE ASSEMBLY LH

1. Push the front axle out of the vehicle to align the spline of the drive shaft with the

front axle and insert the front axle.

NOTICE:


• Do not damage the outboard joint boot.

• Check for any foreign matter on the speed sensor rotor and insertion part.

• Do not damage the speed sensor rotor.

11. INSTALL FRONT AXLE ASSEMBLY RH

HINT:


12. INSTALL FRONT STABILIZER LINK ASSEMBLY LH



1. Install the stabilizer link with the nut.


HINT:

If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold

the stud.

13. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT:


14. INSTALL TIE ROD END SUB-ASSEMBLY LH



1. Install the tie rod end onto the steering knuckle with a new castle nut.


NOTICE:

If the holes for the clip are not aligned, tighten the nut by a further turn of up to60°.

2. Install a new cotter pin.

15. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT:


16. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH

1. Install the lower arm onto the steering knuckle with a new castle nut.


NOTICE:

If the holes for the clip are not aligned, tighten the nut by a further turn of up to60°.

2. Install a new clip.



17. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT:


18. INSTALL SPEED SENSOR FRONT LH

1. Install the speed sensor onto the steering knuckle with the bolt.

Torque:

8.5 N*m 87 kgf*cm , 75 in.*lbf NOTICE:

• Check that the speed sensor tip and installation portion are free of foreignmatter.

• Install the speed sensor without turning it from its original installation

angle.



2. Install the flexible hose and speed sensor with the bolt.

Torque:


Install the flexible hose and speed sensor without twisting them.

19. INSTALL SPEED SENSOR FRONT RH

HINT:


20. INSTALL FRONT AXLE SHAFT LH NUT

1. Using a 30 mm socket wrench, install a new axle hub nut.



Torque:

216 N*m 2,203 kgf*cm , 160 ft.*lbf

2. Using a chisel and hammer, caulk the axle hub nut.

21. INSTALL FRONT AXLE SHAFT RH NUT

HINT:The installation procedure for the RH side is the same as that for the LH side.

22. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 1KR-FE)

1. Using vernier calipers, measure the free length of the compression spring.

Minimum length (Front Side):

40.5 mm (1.594 in.)Minimum length (Rear Side):

38.5 mm (1.516 in.)

If the length is not as specified, replace the compression spring.



2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket

until its surface is flush with the exhaust manifold.

NOTICE:

• Install the exhaust pipe gasket in the correct direction.

• Do not damage the outer surface of the exhaust pipe gasket.

• Do not reuse the exhaust pipe gasket.

• Do not push in the gasket with the exhaust pipe when connecting it.

3. Install the 3 exhaust pipe support No. 4.

4. Install the exhaust front pipe assembly and a new exhaust pipe gasket with the 4compression springs and 4 bolts.



Torque:


23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2SZ-FE)



1. Using vernier calipers, measure the free length of the compression spring.

Minimum length:40.5 mm (1.594 in.)

If the length is not as specified, replace the compression spring.

2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket

until its surface is flush with the exhaust manifold.

NOTICE:

•

Install the exhaust pipe gasket in the correct direction.

• Do not damage the outer surface of the exhaust pipe gasket.

• Do not reuse the exhaust pipe gasket.

• Do not push in the gasket with the exhaust pipe when connecting it.

3. Install the 3 No. 4 exhaust pipe supports.



4. Install the exhaust pipe assembly front with the 2 compression springs and 2 bolts.


24. INSTALL STARTER ASSEMBLY (for 1KR-FE)



1. Install the starter assembly with the 2 bolts.

Torque:


2. Connect the connector.

3. Connect terminal 30 with the nut.

Torque:

9.8 N*m 100 kgf*cm , 87 in.*lbf

4. Close the terminal cap.

5.

Install the harness clamp.

25. INSTALL STARTER ASSEMBLY (for 2SZ-FE)



1. Install the starter assembly with the 2 bolts.

Torque:



3. Connect terminal 30 with the nut.

Torque:

9.8 N*m 100 kgf*cm , 87 in.*lbf

4. Close the terminal cap.

26. CONNECT CONNECTOR

1. Connect the shift and select motor connectors.

2. Connect the neutral start switch connector.

3. Connect the back-up light switch connector.

4.

Connect the transmission revolution sensor connector.

5. Connect the select stroke sensor connector.

6. Connect the shift stroke sensor connector.



27. CONNECT WIRE HARNESS

1. Connect the wire harness with the bolt.

Torque:


28. INSTALL CLUTCH ACTUATOR ASSEMBLY NOTICE:

Perform the following procedure ((1) to (5)) to set a new clutch actuator in the

clutch clamp position because it is not originally placed in that position.(1) Connect the clutch stroke sensor connector and motor connector to the clutch

actuator.

(2) Connect the battery negative terminal.(3) Perform clutch position adjustment (clutch clamp position)

()

(4) Disconnect the battery negative terminal.(5) Disconnect the clutch stroke sensor connector and motor connector.



1. Apply grease to the clutch release lever.

Sealant:

Toyota Genuine Release Hub Grease or Equivalent

2. Set the clutch actuator to the transaxle and provisionally tighten the 3 bolts.

NOTICE:

Keep the clearance between the bolt head and actuator flange.



3. Gently hold down the clutch actuator assembly toward flat surface of transmission

assembly and slide it so that the convex portion of the clutch actuator rod comes

into contact with the concave portion of the release lever.

NOTICE:

• Do no apply excessive load to them during the operation.

• Make sure that the convex portion of the clutch actuator rod is securely

fitted into the concave portion of the release lever.

• 1KR-FE and 2SZ-FE clutch actuators have their own discrimination stamp

on the housing upper.

Engine Discrimination Color

1KR-FE Green

2SZ-FE Blue

4. Tighten the 3 bolts by hand while holding the clutch actuator assembly.

NOTICE:

Support the clutch actuator assembly until all the 3 bolts are tightened.

5. Tighten the 3 bolts to the specified torque in the order A, B, and C, as shown.




6. Connect the clutch stroke sensor connector and motor connector.

7. Install the wire harness bracket onto the transaxle with the bolt.

Torque:

13 N*m 131 kgf*cm , 9.5 ft.*lbf

29. INSTALL BATTERY CARRIER (for 1KR-FE)



1. Install the battery carrier with the 4 bolts.


30. INSTALL BATTERY CARRIER (for 2SZ-FE)



31. INSTALL BATTERY TRAY



32. INSTALL BATTERY

33. INSTALL BATTERY HOLD DOWN CLAMP

34. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)

1. Install the air cleaner inlet No. 1.

35. INSTALL COWL TOP PANEL OUTER



1. Engage the 2 claws and install cowl to register duct No. 2.

37. INSTALL FR WIPER MOTOR AND LINK ASSEMBLY




2. Slide the wiper link as shown in the illustration and engage the rubber pin with

the body.

3. Install the front wiper motor and link with the 2 bolts.

Torque:


38. INSTALL COWL TOP VENTILATOR LOUVER LH (for LHD)

1. Engage the 4 claws and install the cowl top ventilator louver LH.

2. Install the 2 clips.



39. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for LHD)

1. Connect the washer hose.

2.

Engage the 11 claws and install the cowl top ventilator louver sub-assembly.

3. Install the clip.




5. Engage the 2 hooks and install cowl top ventilator louver center No. 1.

40. INSTALL COWL TOP VENTILATOR LOUVER LH (for RHD)

1.

Engage the 4 claws and install the cowl top ventilator louver LH.


41. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for RHD)



1. Engage the 10 claws and install the cowl top ventilator louver sub-assembly.



42. INSTALL HOOD TO COWL TOP SEAL

1. Engage the 7 clips and install the hood to cowl top seal.



43. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

1. Scrape any metal powder off the serrated part of the wiper arm with a round file

or the equivalent (when reinstalling).

2. Clean the wiper pivot serrations with a wire brush.

3. Operate the wiper, then stop the windshield wiper motor in the automatic stop

position.



4. Align the blade tip with the mark on the windshield glass, as shown in the

illustration.

5. Tighten the nut of the front wiper arm.

Torque:


44. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH



1. Scrape any metal powder off the serrated part of the wiper arm with a round file

or the equivalent (when reinstalling).

2. Clean the wiper pivot serrations with a wire brush.

3. Operate the wiper, then stop the windshield wiper motor in the automatic stop

position.



4. Align the blade tip with the mark on the windshield glass, as shown in the

illustration.

5. Tighten the nut of the front wiper arm.

Torque:


45. INSTALL HOOD SUB-ASSEMBLY

46. INSPECT HOOD SUB-ASSEMBLY

1.

Check that the clearance measurements are within the standard ranges.



(0.297 to 0.533 in.) (0.079 to 0.197 in.)

F1.65 to 5.65 mm

(0.065 to 0.222 in.)- -

47. ADJUST HOOD SUB-ASSEMBLY

1. Loosen the hood side hinge bolts.

2. Move the hood to adjust the clearance to within the standard range.

3.

Tighten the hood side hinge bolts after the adjustment.

Torque:




4. Adjust the height of the hood front end by turning the cushion rubber.

HINT:The cushion rubber can be raised and lowered by turning it.

5. Adjust the hood lock.

1. Loosen the 3 bolts.

2. Adjust the hood lock position so that the striker can enter it smoothly.

3. Tighten the 3 bolts after the adjustment.

Torque:


48. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY



1. Align the matchmarks and install the sliding yoke onto the intermediate shaft.


2.

Tighten bolt A.

Torque:


49. INSTALL COLUMN HOLE COVER SILENCER SHEET

1. Install the column hole cover silencer sheet with the 2 clips.

2. Install the floor carpet.







3.

Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of thefiller plug opening.

NOTICE:





Torque:


52. INSTALL ENGINE UNDER COVER RH

53. INSTALL ENGINE UNDER COVER LH

54. INSTALL FRONT WHEELS




Torque:


56. INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE ECU

()

57. LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM

()

58. SYNCHRONIZATION POSITION CALIBRATION

()

59. INSPECT ABS SPEED SENSOR SIGNAL

()

60. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

()

61. CHECK FOR EXHAUST GAS LEAKAGE

62. CHECK FOR TRANSAXLE OIL LEAKAGE



MULTI-MODE MANUAL

TRANSAXLE UNIT >COMPONENTS

for Preparation



1 / 3



2 / 3



3 / 3

MULTI-MODE MANUAL

TRANSAXLE UNIT >

DISASSEMBLY

for Preparation



1. REMOVE SHIFT STROKE SENSOR

2. REMOVE CLUTCH RELEASE FORK

3. REMOVE CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

4. INSPECT NEUTRAL POSITION

1. Remove the plug from the shift and select actuator.

2. Look through the plug and check that the slit of the shift and select shaft is in the position shown in the illustration.

If not, turn it with a screwdriver.

5. REMOVE LOCK BALL ASSEMBLY NO.1



1. Using an 18 mm socket wrench, remove the lock ball assembly from the transaxle

case.

6. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

1. Using SST, remove the park/neutral position switch with the gasket from the

transaxle case.

SST

09817-16011

7. REMOVE SHIFT AND SELECT ACTUATOR ASSEMBLY



1.

Remove the 6 bolts.

2. Tap the actuator flange with a plastic hammer to remove it.

8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

1. Using SST, remove the back-up light switch with the gasket from the transaxle

case.

SST

09817-16011



9. REMOVE TRANSMISSION REVOLUTION SENSOR

1. Remove the bolt and transmission case protector.

2. Remove the bolt and transmission revolution sensor.

3. Using a small screwdriver, remove the O-ring from the transmission revolution

sensor.

10. REMOVE REVERSE IDLER GEAR SHAFT BOLT



3. Remove gear shift head No.1 and gear shift fork No. 1.

4. Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork

shaft No. 1.

14. REMOVE GEAR SHIFT FORK SHAFT NO.3

1. Using a magnetic finger, remove the straight pin from gear shift fork No. 3.



2. Using 2 screwdrivers and a hammer, remove the 2 snap rings from gear shift fork

shaft No. 3.

3. Cover gear shift fork shaft No.3 with a piece of cloth gear shift fork shaft No. 3 atthe upper edge with pliers as shown in the illustration, and pull gear shift fork

shaft No. 3 out of the transaxle case to remove gear shift fork No. 3, compression

spring and gear shift head No. 3.

15. REMOVE REVERSE IDLER GEAR SHAFT



1. Remove the reverse idler gear shaft from the transaxle case.

16. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

1. Remove the 2 bolts and reverse shift arm bracket from the transaxle case.

17. REMOVE GEAR SHIFT FORK SHAFT NO.2



1. Using a magnetic finger, remove the straight pin from the reverse shift fork.

2. Shift hub sleeve No. 2 into the 3rd gear, as shown.



3. Remove the set bolt from gear shift fork No. 2.

4. Pull out gear shift fork snap rings, gear shift fork and the reverse shift fork from

the transaxle case.


shaft No. 2.

6. Remove the reverse shift fork from gear shift fork shaft No. 2.




shaft No. 2.

8.

Remove gear shift fork No. 2 from gear shift fork shaft No. 2.

18. REMOVE INPUT SHAFT

1. Remove the input shaft assembly from the manual transaxle case.

19. REMOVE OUTPUT SHAFT

1. Remove the output shaft assembly from the manual transaxle case.



20. REMOVE FRONT DIFFERENTIAL CASE

1. Remove the differential case assembly from the front transaxle case.

21. REMOVE OIL RECEIVER PIPE NO. 2

1. Remove the oil receiver pipe No. 2 from the manual transmission case.

NOTICE:Do not damage oil receiver pipe No. 2.



22. REMOVE TRANSMISSION MAGNET

1. Remove the transmission magnet from the front transaxle case.

23. REMOVE FRONT TRANSAXLE CASE OIL SEAL

1. Using a screwdriver, remove the front transaxle case oil seal.



24. REMOVE OUTPUT SHAFT FRONT BEARING

1. Using SST, remove the output shaft front bearing (outer race) from the front

transaxle case.

SST

09308-00010

25. REMOVE OUTPUT SHAFT COVER

1. Remove the output shaft cover from the front transaxle case.



26. REMOVE TRANSMISSION CASE OIL SEAL

1. Using a screwdriver, remove the transmission case oil seal.

27. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

1. Using SST, remove the front differential case rear tapered roller bearing and the

shim.

SST



09950-60010 (09951-00560)

09950-70010 (09951-07200)

28. REMOVE TRANSAXLE CASE OIL SEAL

1. Using a screwdriver, remove the transaxle case oil seal from the front transaxle

case.

29. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING



1. Using a brass bar and hammer, remove the front differential case front tapered

roller bearing.

30. REMOVE INPUT SHAFT REAR BEARING SHIM

1. Remove the input shaft rear bearing shim.

31. REMOVE OUTPUT SHAFT REAR BEARING

1. Using SST, remove the output shaft rear bearing.



SST

09527-3001009612-65014 (09612-01030, 09612-01050)

32. REMOVE OUTPUT SHAFT REAR BEARING SHIM

1. Remove the output shaft rear bearing shim.



MULTI-MODE MANUAL

TRANSAXLE UNIT > INSPECTION

for Preparation

1. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

1.

Using a micrometer, measure the outer diameter of the reverse idler gear shaft.

Standard outer diameter:15.97 to 15.98 mm (0.6287 to 0.6291 in.)

Minimum outer diameter:

15.97 mm (0.6287 in.)

If the outer diameter is less than the minimum, replace the reverse idler gear shaft.



2. Using a caliper gauge, measure the inside diameter of the reverse idler gear.

Standard inside diameter:16.04 to 16.05 mm (0.6315 to 0.6319 in.)

Maximum inside diameter:

16.05 mm (0.6319 in.)

If the inside diameter exceeds the maximum, replace the reverse idler gear.

2. INSPECT REVERSE SHIFT FORK

1. Using a caliper gauge, measure the inside diameter of the reverse shift fork.

Standard inside diameter:

14.27 to 14.42 mm (0.5591 to 0.5677 in.) for A

14.01 to 14.03 mm (0.5516 to 0.5524 in.) for BMaximum inside diameter:

14.42 mm (0.5677 in.) for A14.03 mm (0.5524 in.) for B

If the inside diameter exceeds the maximum, replace the reverse shift fork.

3. INSPECT GEAR SHIFT FORK SHAFT NO.1



1. Using a micrometer, measure the outer diameter of gear shift fork shaft No. 1.

Standard outer diameter:13.97 to 13.98 mm (0.5500 to 0.5504 in.)

Minimum outer diameter:

13.97 mm (0.5500 in.)

If the outer diameter is less than the minimum, replace gear shift fork shaft No. 1.





Standard outer diameter:

13.97 to 13.98 mm (0.5500 to 0.5504 in.)Minimum outer diameter:

13.97 mm (0.5500 in.)




Standard outer diameter:

13.97 to 13.98 mm (0.5500 to 0.5504 in.)Minimum outer diameter:

13.97 mm (0.5500 in.)


6. INSPECT GEAR SHIFT FORK NO.1



1. Using vernier calipers, measure the inside diameter of gear shift fork No. 1.

Standard inside diameter and thickness:9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A

9.9 to 10.0 mm (0.3898 to 0.3937 in.) for B

14.00 to 14.02 mm (0.5512 to 0.5520 in.) for C

If the inside diameter and thickness are outside the specifications, replace gear

shift fork No. 1.



Standard inside diameter and thickness:



9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A

14.00 to 14.02 mm (0.5512 to 0.5520 in.) for B


shift fork No. 2.



Standard inside diameter and thickness:

9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A14.00 to 14.02 mm (0.5512 to 0.5520 in.) for B


shift fork No. 3.

9. INSPECT GEAR SHIFT HEAD NO.1



1. Using vernier calipers, measure the inside diameter of gear shift head No. 1.

Standard inside diameter:14.00 to 14.05 mm (0.5512 to 0.5531 in.)

Maximum inside diameter:14.05 mm (0.5531 in.)

If the inside diameter exceeds the maximum, replace gear shift head No. 1.

10. INSPECT GEAR SHIFT HEAD NO.3

1. Using vernier calipers, measure the inside diameter of gear shift head No. 3.

Standard inside diameter:14.00 to 14.05 mm (0.5512 to 0.5531 in.) for A

14.2 to 14.4 mm (0.5591 to 0.5669 in.) for B




14.05 mm (0.5531 in.) for A14.4 mm (0.5669 in.) for B

If the inside diameter exceeds the maximum, replace gear shift head No. 3.

MULTI-MODE MANUALTRANSAXLE UNIT >

REASSEMBLY

for Preparation



1. INSTALL TRANSAXLE CASE STRAIGHT PIN

1. Install the transaxle case straight pin.

Standard depth:10.5 to 11.5 mm (0.4134 to 0.4528 in.)

2. INSTALL OUTPUT SHAFT COVER

1. Install the output shaft cover as shown in the illustration.



3. INSTALL OUTPUT SHAFT FRONT BEARING

1. Using SST and a press, press in the output shaft front bearing (outer race).

SST09950-60010 (09951-00510)

09950-70010 (09951-07150)

4. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

1. Using SST and a press, press in the front differential case front tapered roller

bearing (outer race).



SST

09350-32014 (09351-32111, 09351-32130)

5. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

1. Install the shim onto the manual transmission case.

HINT:

When re-using the output shaft rear tapered roller bearing, first install a shim ofthe same thickness as before. If installing a new output shaft rear tapered roller

bearing, first select and install a shim which is thinner than the original.

2. Using SST and a press, press in the FR differential case rear tapered roller bearing

(outer race).

SST

09950-60010 (09951-00620)

09950-70010 (09951-07100)

6. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD



1. Coat the differential case assembly with gear oil, and install it onto the front

transaxle case.

2. Install the manual transmission case with the 13 bolts.

Torque:

29 N*m 300 kgf*cm , 22 ft.*lbf HINT:

Manual transmission case side: 8 bolts

Front transaxle case side: 5 bolts



3. Using SST and a torque wrench, turn the differential case assembly right and left

2 or 3 times to allow the bearings to settle.

SST

09564-32011

4. Using SST and a torque wrench, measure the preload.

SST

09564-32011

Preload (at starting): New bearing:

0.78 to 1.57 N*m (7.95 to 16.00 kgf*cm, 6.9 to 13.89 in.*lbf)

Used bearing:

0.49 to 0.98 N*m (5.00 to 9.99 kgf*cm, 4.3 to 8.67 in.*lbf)

5. Select another shim.

Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)

AA 2.10 (0.0827) HH 2.45 (0.0965) QQ 2.80 (0.1102)

BB 2.15 (0.0847) JJ 2.50 (0.0984) RR 2.85 (0.1122)

CC 2.20 (0.0866) KK 2.55 (0.1004) SS 2.90 (0.1142)

DD 2.25 (0.0886) LL 2.60 (0.1024) TT 2.95 (0.1161)EE 2.30 (0.0906) MM 2.65 (0.1043) UU 3.00 (0.1181)

FF 2.35 (0.0925) NN 2.70 (0.1063) - -

GG 2.40 (0.0945) PP 2.75 (0.1083) - -

6. Remove the 13 bolts and the manual transmission case from the front transaxle

case.




7. INSTALL OUTPUT SHAFT REAR BEARING

1. Install the output shaft rear bearing shim onto the manual transmission case.

HINT:

When re-using the output shaft rear tapered roller bearing, first install a shim of

the same thickness as before. If installing a new output shaft rear tapered roller bearing, first select and install a shim which is thinner than the original.

2. Using SST and a press, press in the output shaft rear bearing (outer race).

SST



09950-60010 (09951-00570)

09950-70010 (09951-07200)

8. ADJUST OUTPUT SHAFT BEARING PRELOAD

1. Install the output shaft assembly and the differential case assembly onto the front

transaxle case.

2. Install the manual transmission case onto the front transaxle case with the 13

bolts.

Torque:




3. Using SST and a torque wrench, turn the output shaft assembly and differential

case assembly right and left 2 or 3 times to allow the bearings to settle.

SST

09564-32011

4. Using SST and a torque wrench, measure the preload.

SST

09564-32011

Preload (at starting):

New bearing:

3.46 to 6.91 N*m (35.3 to 70.5 kgf*cm, 30.6 to 61.2 in.*lbf) for 1KR-FE3.18 to 6.35 N*m (32.4 to 64.7 kgf*cm, 28.1 to 56.2 in.*lbf) for 2SZ-FE

Used bearing:2.16 to 4.32 N*m (22.0 to 44.1 kgf*cm, 19.1 to 38.2 in.*lbf) for 1KR-FE

1.98 to 3.97 N*m (20.2 to 40.5 kgf*cm, 17.5 to 35.1 in.*lbf) for 2SZ-FE

5. Select another output shaft rear bearing shim.

MarkThickness

mm (in.)Mark

Thickness

mm (in.)

A 1.55(0.0610) J 1.95(0.0768)

B1.60

(0.0630)K

2.00

(0.0787)

C1.65

(0.0650)L

2.05(0.0807)

D 1.70 M 2.10



(0.0669) (0.0827)

E1.75

(0.0689) N

2.15

(0.0846)

F1.80

(0.0709)P

2.20(0.0866)

G1.85

(0.0728)Q

2.25

(0.0886)

H1.90

(0.0748)

6. Remove the 13 bolts and the manual transmission case from the front transaxle

case.

7. Remove the output shaft assembly from the front transaxle case.


9. INSTALL INPUT SHAFT REAR BEARING SHIM



1. Using vernier calipers, accurately measure dimensions A and B.

2.

Select an input shaft rear bearing shim that brings the value within thespecifications.

Shim thickness:

Shim thickness (B - A) should be more than 0 mm (0 in.) and less than 0.1 mm

(0.0039 in.)

MarkThickness

mm (in.)Mark

Thickness

mm (in.)

F1.80

(0.0709) N

2.15

(0.0846)

G 1.85(0.0728)

P 2.20(0.0866)

H1.90

(0.0748)Q

2.25

(0.0886)

J1.95

(0.0768)R

2.30(0.0906)

K 2.00 S 2.35



(0.0787) (0.0925)

L2.05

(0.0807)T

2.40

(0.0945)

M2.10

(0.0827)- -

3. Install the input shaft rear bearing shim.

10. INSTALL TRANSMISSION CASE OIL SEAL

1. Using SST and a hammer, install a new transmission case oil seal into the manual

transmission case.

SST

09950-60010 (09951-00370)09950-70010 (09951-07150)

Drive in depth:

2.1 to 3.1 mm (0.083 to 0.122 in.)

2.

Coat the tip of the transmission oil seal with MP grease.

11. INSTALL TRANSAXLE CASE OIL SEAL



1. Using SST and a hammer, install the transaxle case oil seal to the front transaxle

case.

SST

09316-60011 (09316-00011)

Drive in depth:1.7 to 2.7 mm (0.067 to 0.106 in.)

2. Coat the tip of the transmission case oil seal with MP grease.

12. INSTALL FRONT TRANSAXLE CASE OIL SEAL



1. Using SST and a hammer, install the front transaxle case oil seal into the front

transaxle case.

SST

09710-20011 (09710-06071)

09950-70010 (09951-07150)Drive in depth:14.4 to 15.4 mm (0.567 to 0.606 in.)

2. Coat the tip of the front transaxle case oil seal with MP grease.

13. INSTALL TRANSMISSION MAGNET

1. Clean the transmission magnet and then install it onto the front transaxle case.

14. INSTALL OIL RECEIVER PIPE NO. 2



1. Install oil receiver pipe No. 2 onto the manual transmission case.

NOTICE:Do not damage oil receiver pipe No. 2.

15. INSTALL FRONT DIFFERENTIAL CASE

1. Coat the differential case tapered roller bearings with gear oil, and install themonto the front transaxle case.

16. INSTALL OUTPUT SHAFT



1. Install the output shaft assembly onto the front transaxle case.

17. INSTALL INPUT SHAFT

1. Coat the sliding and rotating surfaces of the input and output shafts assembly with

gear oil, and install them onto the front transaxle case.

18. INSTALL GEAR SHIFT FORK SHAFT NO.2



1.

Install gear shift fork No. 2 onto gear shift fork shaft No. 2.

2. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft

No. 2.

3. Install the reverse shift fork onto gear shift fork shaft No. 2.

4.

Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft

No. 2.



5. Shift hub sleeve No. 2 into the 3rd gear, as shown.

6. Install gear shift fork shaft No. 2 with the 2 snap rings.

7. Install gear shift fork No.2 and reverse shift fork onto the transaxle case.

8. Set gear shift fork No. 2 onto hub sleeve No. 2.

9. Install the set bolt onto gear shift fork No. 2.

Torque:




10. Using a magnetic finger, install the straight pin into the reverse shift fork.

NOTICE:

Insert the straight pin along the groove on gear shift fork shaft No. 2, as shown inthe illustration.

19. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

1.

Install the reverse shift arm bracket onto the transaxle case with the 2 bolts.

Torque:


Fit the edge of the reverse shift fork into the hole in the reverse shift arm bracket.



20. INSTALL REVERSE IDLER GEAR SHAFT

1. Coat the reverse idler gear shaft with gear oil, and install it onto the transmission

case.

NOTICE:

Set the top of the reverse shift arm bracket into the groove on the reverse idler

gear, as shown in the illustration.

2. Align the mark on the reverse idler gear shaft with the bolt hole, as shown in the

illustration.




1. Install gear shift fork No. 3, the compression spring and gear shift head No. 3 onto

gear shift fork shaft No. 3.

2. Install gear shift fork shaft No. 3 onto the transaxle case together with gear shift

fork No. 3, the compression spring and shift head No. 3.

3. Set gear shift fork No. 3 onto hub sleeve No. 3.

4. Using a screwdriver and hammer, tap 2 new snap rings onto gear shift fork shaft

No. 3.



5. Using a magnetic finger, install the straight pin onto gear shift fork No. 3.


1. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft

No. 1.

2. Set gear shift fork No. 1 onto the reverse gear.

3. Set gear shift head No. 1 onto gear shift fork No. 1.

4. Install gear shift fork shaft No. 1 onto the transaxle case with the snap ring.



2. Coat the 13 bolts with sealant.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

3. Install the transmission case onto the transaxle case with the 13 bolts.

Torque:


26. INSTALL REVERSE IDLER GEAR SHAFT BOLT

1. Apply sealant to the reverse idler gear shaft lock bolt threads.

Sealant:




2. Install the reverse idler gear shaft lock bolt with a new gasket.


27. INSTALL TRANSMISSION REVOLUTION SENSOR

1. Install a new O-ring onto the transmission revolution sensor.

2. Install the transmission revolution sensor with the bolt.

Torque:


3. Install the transmission case protector with the bolt.


28. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY



1. Apply FIPG to the transmission case as shown.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

2. Apply sealant to the actuator set bolt threads.

Sealant:


3. Install the shift and select actuator with the 6 bolts and wire harness clamp.

Torque:


29. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY



1. Using SST, install the park/neutral position switch with a new gasket onto thetransaxle case.

Torque:

40 N*m 410 kgf*cm , 30 ft.*lbf SST

09817-16011

30. INSTALL LOCK BALL ASSEMBLY NO.1

1. Apply sealant to the lock ball assembly threads.

Sealant:




2. Using an 18 mm socket wrench, install the lock ball assembly onto the

transmission case.


31. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

1.

Using SST, install the back-up light switch with a new gasket onto the transaxlecase.

SST

09817-16011


32. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

33. INSTALL CLUTCH RELEASE FORK



34. INSTALL SHIFT STROKE SENSOR

INPUT SHAFT > COMPONENTS

for Preparation



1 / 2



2 / 2

INPUT SHAFT > DISASSEMBLY

for Preparation



1. INSPECT 3RD GEAR THRUST CLEARANCE

1.

Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance:

0.10 to 0.35 mm (0.0039 to 0.0138 in.)

Maximum clearance:0.35 mm (0.0138 in.)

If the clearance exceeds the maximum, replace the 3rd gear synchronizer ring.

2. INSPECT 5TH GEAR THRUST CLEARANCE

1. Using a dial indicator, measure the 5th gear thrust clearance.



Standard clearance:

0.10 to 0.50 mm (0.0039 to 0.0197 in.)Maximum clearance:

0.50 mm (0.0197 in.)

If the clearance exceeds the maximum, replace the 5th gear synchronizer ring.

3. INSPECT 3RD GEAR RADIAL CLEARANCE

1. Using a dial indicator, measure the 3rd gear radial clearance.

Standard clearance:


0.058 mm (0.0023 in.)

If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing

or the shaft.

4. INSPECT 4TH GEAR RADIAL CLEARANCE



0.015 to 0.058 mm (0.0006 to 0.0023 in.)


If the clearance exceeds the maximum, replace the 5th gear needle roller bearing

or the shaft.

6. REMOVE 5TH GEAR

1.

Using SST and a press, remove the input shaft rear radial ball bearing, hub sleeve

No. 3, 5th gear synchronizer ring and 5th gear from the input shaft.

SST

09950-00020

09612-24014 (09612-10061)HINT:

• Support the input shaft by hand to prevent it from dropping off.

• Set the claw of SST between the 4th gear and 5th gear, as shown in the

illustration.

NOTICE:

Do not excessively tighten SST.

7. REMOVE TRANSMISSION CLUTCH HUB NO.3



1. Remove the 2 shifting key springs No. 1 from the transmission clutch hub No. 3.

2. Remove the transmission hub sleeve No. 3 from the transmission clutch hub No.

3.

3. Remove the 3 shifting keys No. 3 from the transmission clutch hub No. 3.

8. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

1. Remove the 5th gear needle roller bearing from the input shaft.



9. REMOVE 5TH GEAR BEARING SPACER

1. Remove the 5th gear bearing spacer from the input shaft.



Standard clearance:0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:



0.55 mm (0.0217 in.)


11. REMOVE 5TH GEAR SHAFT SNAP RING

1. Using a snap ring expander, remove the 5th gear shaft snap ring from the input

shaft.

HINT:Do not damage the journal surface of the input shaft.

12. REMOVE 5TH GEAR THRUST WASHER



1. Remove the 4th gear from the input shaft.

15. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

1. Remove the 4th gear needle roller bearing from the input shaft.

16. REMOVE 4TH GEAR BEARING SPACER



1. Remove the 4th gear bearing spacer from the input shaft.

17. REMOVE 4TH GEAR SYNCHRONIZER RING

1. Remove the 4th gear synchronizer ring from the clutch hub No. 2.

18. REMOVE CLUTCH HUB NO.2 SETTING SHAFT SNAP RING



1. Using a snap ring expander, remove the clutch hub No. 2 setting shaft snap ringfrom the input shaft.

HINT:

Do not damage the journal surface of the input shaft.

19. REMOVE 3RD GEAR

1. Using SST and a press, remove the hub sleeve No. 2, 3rd gear synchronizer ring

and 3rd gear from the input shaft.

SST

09950-00020

NOTICE:

• Do not excessively tighten SST.

• Support the input shaft by hand to prevent it from dropping off




1. Remove the 2 shifting key springs No. 1 from the transmission clutch hub No. 2.

2.

Remove the transmission hub sleeve No. 2 from the transmission clutch hub No.

2.

3. Remove the 3 shifting keys No. 2 from the transmission clutch hub No. 2.

21. REMOVE 3RD GEAR NEEDLE ROLLER BEARING



1. Remove the 3rd gear needle roller bearing from the input shaft.

22. REMOVE INPUT SHAFT FRONT BEARING

1. Using a press, remove the input shaft front bearing from the input shaft.

SST

09950-00020

HINT:Support the input shaft by hand to prevent it from dropping off.



INPUT SHAFT > INSPECTION

for Preparation

1. INSPECT INPUT SHAFT

1. Check the input shaft for wear and damage.

2. Using a dial indicator, check the input shaft runout.

Maximum runout:

0.03 mm (0.0012 in.)



If the runout exceeds the maximum, replace the input shaft.

3. Using a micrometer, measure the outer diameter of the input shaft journal surface.

Standard:

Measured

Part

Outer Diameter mm

(in.)

A25.502 to 25.515

(1.0040 to 1.00453)

B30.985 to 31.000(1.2199 to 1.2205)

C, D33.985 to 34.000(1.3380 to 1.3386)

E23.002 to 23.015

(0.9056 to 0.9091)

F22.967 to 23.000

(0.9042 to 0.9055)

If the outer diameters are below the minimum, replace the input shaft.

2. INSPECT 3RD GEAR



1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.


39.015 to 39.031 mm (1.5360 to 1.5367 in.)


If the inside diameter exceeds the maximum, replace the 3rd gear.

3. INSPECT 4TH GEAR

1. Using a cylinder gauge, measure the inside diameter of the 4th gear.


39.015 to 39.031 mm (1.5360 to 1.5367 in.)




39.031 mm (1.5367 in.)

If the inside diameter exceeds the maximum, replace the 4th gear.

4. INSPECT 5TH GEAR

1. Using a cylinder gauge, measure the inside diameter of the 5th gear.


36.015 to 36.031 mm (1.4179 to 1.4185 in.)Maximum inside diameter:

36.031 mm (1.4185 in.)

If the inside diameter exceeds the maximum, replace the 5th gear.

5. INSPECT 3RD GEAR SYNCHRONIZER RING



1. Check for wear and damage.

2. Coat the 3rd gear cone with gear oil.

3.

Turn the 3rd gear synchronizer ring in one direction while pushing it against the3rd gear cone.

4. Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 3rd

gear.

5.

Using a feeler gauge, measure the clearance between the synchronizer ring back

and the gear spline end.

Standard clearance:

0.75 to 1.65 mm (0.0295 to 0.0650 in.)Minimum clearance:

0.75 mm (0.0295 in.)



If the clearance is less than the minimum, replace the synchronizer ring or the 3rd

gear.

6. INSPECT 4TH GEAR SYNCHRONIZER RING


2. Coat the 4th gear cone with gear oil.

3.

Turn the synchronizer ring in one direction while pushing it against the 4th gear

cone.

4. Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 4th

gear.



2. Coat the 5th gear cone with gear oil.

3. Turn the synchronizer ring in one direction while pushing it against the 5th gear

cone.

4.

Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 5th

gear.

5. Using a feeler gauge, measure the clearance between the synchronizer ring backand the gear spline end.


Minimum clearance:

0.75 mm (0.0295 in.)

If the clearance is less than the minimum, replace the synchronizer ring or the 5th

gear.

8. INSPECT TRANSMISSION HUB SLEEVE NO.2



0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is outside the specifications, replace the transmission hub sleeve

No. 3 and gear shift fork No. 3.

INPUT SHAFT > REASSEMBLY

for Preparation



1. INSTALL INPUT SHAFT FRONT BEARING

1.

Using SST and a press, install a new input shaft front bearing onto the input shaft.

SST

09515-10010

2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

1. Coat the 3rd gear needle roller bearing with gear oil, and install it onto the inputshaft.



3. INSTALL 3RD GEAR

1.

Coat the 3rd gear with gear oil, and install it onto the input shaft.

4. INSTALL 3RD GEAR SYNCHRONIZER RING

1.

Coat the 3rd gear synchronizer ring with gear oil, and install it onto the 3rd gear.

5. INSTALL TRANSMISSION CLUTCH HUB NO.2



1. Install the 3 shifting keys No. 2, 2 shifting key springs and transmission hub

sleeve No. 2 onto the clutch hub No. 2.

NOTICE:

Assemble the transmission hub sleeve No. 2 and transmission clutch hub No. 2 in

the correct orientations, as shown in the illustration.

2. Using SST and a press, install the transmission clutch hub sleeve No. 2 onto the

input shaft.

SST

09506-35010

6. INSTALL CLUTCH HUB NO.2 SETTING SHAFT SNAP RING



1. Select a snap ring that allows the minimum axial play.

Standard clearance:0.1 mm (0.0039 in.) or less.

MarkThickness

mm (in.)Mark

Thickness

mm (in.)

A2.28(0.0898)

D2.46(0.0969)

B2.34

(0.0921)E

2.52

(0.0992)

C2.40(0.0945) F

2.58(0.1016)

2. Using a snap ring expander, install the new snap ring onto the input shaft.



HINT:

Do not damage the journal surface of the input shaft.

7. INSPECT 3RD GEAR THRUST CLEARANCE

1. Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance:

0.10 to 0.35 mm (0.0039 to 0.0138 in.)

Maximum clearance:

0.35 mm (0.0138 in.)

If the clearance exceeds the maximum, replace the 3rd gear synchronizer ring.

8. INSPECT 3RD GEAR RADIAL CLEARANCE



1. Using a dial indicator, measure the 3rd gear radial clearance.

Standard clearance:

0.015 to 0.058 mm (0.0006 to 0.0023 in.)


If the clearance exceeds the maximum, replace the 3rd gear needle roller bearingor the shaft.

9. INSTALL 4TH GEAR SYNCHRONIZER RING

1. Coat the 4th gear synchronizer ring with gear oil, and install it onto transmission

clutch hub No. 2.



12. INSTALL 4TH GEAR

1. Coat the 4th gear with gear oil, and install it onto the input shaft.

13. INSTALL 5TH GEAR THRUST WASHER BALL

1. Install the 5th gear thrust washer ball onto the input shaft.



14. INSTALL 5TH GEAR THRUST WASHER

1.

Coat the 5th gear thrust washer with gear oil, and install it onto the input shaft.

15. INSTALL 5TH GEAR SHAFT SNAP RING

1.

Select a snap ring, using the table below, that makes the thrust clearance of the5th gear thrust washer less than 0.1 mm (0.0039 in.).

MarkThickness

mm (in.)Mark

Thickness

mm (in.)

12.28

(0.0898)4

2.46

(0.0969)



22.34

(0.0921)5

2.52

(0.0992)

32.40(0.0945)

62.58(0.1016)

2. Using a snap ring expander, install a new snap ring onto the input shaft.

HINT:Do not damage the journal surface of the input shaft.





Standard clearance:

0.1 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance :

0.55 mm (0.0217 in.)



1. Using a dial indicator, measure the 4th gear radial clearance.

Standard clearance:


0.058 mm (0.0023 in.)


or the shaft.

18. INSTALL 5TH GEAR BEARING SPACER



1. Coat the 5th gear bearing spacer with gear oil, and install it onto the input shaft.

19. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

1. Coat the 5th gear needle roller bearing with gear oil, and install it onto the input

shaft.

20. INSTALL 5TH GEAR



1. Coat the 5th gear with gear oil, and install it onto the input shaft.

21. INSTALL 5TH GEAR SYNCHRONIZER RING

1. Coat the 5th gear synchronizer ring with gear oil, and install it onto the 5th gear.




1. Install the 3 shifting keys No. 3, 2 shifting key springs No. 1 and transmission hubsleeve No. 3 onto the transmission clutch hub No. 3.

NOTICE:

Assemble the transmission hub sleeve No. 3 and the transmission clutch hub No.3 in the correct orientations, as shown in the illustration.

2. Place the 5th gear synchronizer ring on the 5th gear, and align the synchronizerring slots with the shifting keys No. 3.

3.

Using SST and a press, press the No. 3 hub sleeve into the input shaft.

SST

09515-10010

NOTICE:Install the transmission hub sleeve No. 3 in the correct orientation, as shown in

the illustration.



23. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

1. Using SST and a press, install a new input shaft rear radial ball bearing onto the

input shaft.

SST

09515-10010





Standard clearance:


0.50 mm (0.0197 in.)



1. Using a dial indicator, measure the 5th gear radial clearance.

Standard clearance:


0.058 mm (0.0023 in.)


or the shaft.



OUTPUT SHAFT > COMPONENTS

for Preparation



1 / 2



2 / 2

OUTPUT SHAFT > DISASSEMBLY

for Preparation



1. REMOVE OUTPUT SHAFT REAR BEARING

1.

Using SST and a press, remove the output shaft rear bearing.

SST

09950-60010 (09951-00220)

09950-70010 (09951-07100)

2. INSPECT 1ST GEAR THRUST CLEARANCE

1. Using a feeler gauge, measure the 1st gear thrust clearance.


Maximum clearance:



0.45 mm (0.0177 in.)

If the clearance exceeds the maximum, replace the 1st gear synchronizer ring.

3. INSPECT 2ND GEAR THRUST CLEARANCE

1. Using a feeler gauge, measure the 2nd gear thrust clearance.

Standard clearance:


0.55 mm (0.0217 in.)

If the clearance exceeds the maximum, replace the 2nd gear synchronizer ring.

4. INSPECT 1ST GEAR RADIAL CLEARANCE



1. Using a dial indicator, measure the 1st gear radial clearance.

Standard clearance:

0.015 to 0.056 mm (0.0006 to 0.0022 in.)


If the clearance exceeds the maximum, replace the 1st gear needle roller bearingor the shaft.

5. INSPECT 2ND GEAR RADIAL CLEARANCE

1. Using a dial indicator, measure the 2nd gear radial clearance.

Standard clearance:



0.015 to 0.056 mm (0.0006 to 0.0022 in.)


If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing

or the shaft.

6. REMOVE COUNTER 5TH GEAR SHAFT SNAP RING

1.

Using 2 screwdrivers and a hammer, remove the counter 5th gear shaft snap ringfrom the output shaft.

7. REMOVE 4TH DRIVEN GEAR



1. Using SST and a press, remove the 3rd driven gear and 2nd gear from the output

shaft.

SST

09950-00020

10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

1. Remove the 2nd gear needle roller bearing from the output shaft.

11. REMOVE 2ND GEAR BEARING SPACER



1. Remove the 2nd gear bearing spacer from the output shaft.

12. REMOVE 2ND GEAR SYNCHRONIZER RING

1. Remove the 2nd gear synchronizer ring from the reverse gear.

13. REMOVE CLUTCH HUB NO.1 SHAFT SNAP RING



1. Using 2 screwdrivers, remove the clutch hub No. 1 shaft snap ring from the outputshaft.

HINT:

Do not damage the journal surface of the output shaft.

14. REMOVE 1ST GEAR

1. Using a press, remove the transmission clutch hub No. 1 and 1st gear from the

output shaft.

15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING



1. Remove the 1st gear needle roller bearing from the output shaft.

16. REMOVE OUTPUT SHAFT FRONT BEARING

1. Using SST and a press, remove the output shaft front bearing from the output

shaft.

SST

09950-00020




1. Remove the 2 shifting key springs No. 1, 3 shifting keys No. 1 and reverse gear

from the transmission clutch hub No. 1.



OUTPUT SHAFT > INSPECTIONfor Preparation

1. INSPECT OUTPUT SHAFT

1. Using a dial indicator, check the shaft runout.

Maximum runout:

0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the output shaft.



2. Using a micrometer, measure the outer diameter of the output shaft journal

surface.

Standard:

Measured

Part

Outer Diameter mm

(in.)

A23.002 to 23.015

(0.9056 to 0.9061)

B, C 28.3 (1.1142)

D, E33.985 to 34.000

(1.3380 to 1.3386)

F25.002 to 25.015

(0.9843 to 0.9847)

If the outer diameters are below the minimum, replace the input shaft.

2. INSPECT 1ST GEAR



1. Using a cylinder gauge, measure the inside diameter of the 1st gear.


39.015 to 39.031 mm (1.5360 to 1.5367 in.)


If the inside diameter exceeds the maximum, replace the 1st gear.

3. INSPECT 2ND GEAR

1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.


39.015 to 39.031 mm (1.5360 to 1.5367 in.)




39.031 mm (1.5367 in.)

If the inside diameter exceeds the maximum, replace the 2nd gear.

4. INSPECT 1ST GEAR SYNCHRONIZER RING


2. Coat the 1st gear cone with gear oil.

3.

Turn the synchronizer ring in one direction while pushing it against the 1st gear

cone.

4. Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 1st

gear.




Standard clearance:

0.8 to 1.6 mm (0.031 to 0.063 in.)Minimum clearance:0.80 mm (0.031 in.)

If the clearance is less than the minimum, replace the synchronizer ring or the 1st

gear.

5. INSPECT 2ND GEAR SYNCHRONIZER RING




2. Coat the 2nd gear cone with gear oil.

3. Turn the synchronizer ring in one direction while pushing it against the 2nd gear

cone.

4.

Check that the ring locks.If the synchronizer ring does not lock, replace the synchronizer ring or the 2nd

gear.



Minimum clearance:

0.80 mm (0.031 in.)

If the clearance is less than the minimum, replace the synchronizer ring or the 2nd

gear.

6. INSPECT REVERSE GEAR



1. Using vernier calipers, measure the clearance between the reverse gear and the

reveres gear fork.

Standard clearance (A-B):

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is outside the specifications, replace the reverse gear fork and

reverse gear.



OUTPUT SHAFT > REASSEMBLY

for Preparation

1. INSTALL OUTPUT SHAFT FRONT BEARING

1. Using SST and a press, install the output shaft front bearing onto the output shaft.

SST

09710-22021 (09710-01051)

2. INSTALL 1ST GEAR NEEDLE ROLLER BEARING



1. Coat the 1st gear needle roller bearing with gear oil, and install it onto the outputshaft.

3. INSTALL 1ST GEAR

1. Coat the 1st gear with gear oil, and install it onto the output shaft.

4. INSTALL 1ST GEAR SYNCHRONIZER RING



1. Coat the 1st gear synchronizer ring with gear oil, and install it onto the 1st gear.


1. Install 2 shifting key springs No. 1, 3 shifting keys No. 1 and the reverse gear

onto the transmission clutch hub No. 1.



2. Using SST and a press, install the transmission clutch hub No. 1 onto the output

shaft.

SST

09316-60011 (09316-00011, 09316-00071) NOTICE:Install the reverse gear assembly in the correct orientation, as shown in the

illustration.

6. INSTALL CLUTCH HUB NO.1 SHAFT SNAP RING

1. Select a snap ring that allows the minimum axial play.

Standard clearance:0 to 0.1 mm (0 to 0.0039 in.)

Mark Thickness Mark Thickness



mm (in.) mm (in.)

A2.28

(0.0898)D

2.46

(0.0969)

B2.34

(0.0921)E

2.52(0.0992)

C2.40

(0.0945)F

2.58

(0.1016)

2. Using a snap ring expander, install the new snap ring onto the output shaft.

7. INSPECT 1ST GEAR THRUST CLEARANCE



1. Using a feeler gauge, measure the 1st gear thrust clearance.


Maximum clearance:

0.45 mm (0.0177 in.)

If the clearance exceeds the maximum, replace the 1st gear synchronizer ring.

8. INSPECT 1ST GEAR RADIAL CLEARANCE

1. Using a dial indicator, measure the 1st gear radial clearance.


Maximum clearance:

0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the 1st gear needle roller bearing

or the shaft.

9. INSTALL 2ND GEAR BEARING SPACER



1. Coat the 2nd gear bearing spacer with gear oil and install it onto the output shaft.

10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

1. Coat the 2nd gear needle roller bearing with gear oil, and install it onto the output

shaft.

11. INSTALL 2ND GEAR SYNCHRONIZER RING



1. Coat the 2nd synchronizer ring with gear oil, and install it onto the reverse gear.

12. INSTALL 2ND GEAR

1. Coat the 2nd gear with gear oil, and install it onto the output shaft.

13. INSTALL 3RD DRIVEN GEAR



1. Using SST and a press, install the 3rd driven gear onto the output shaft.

SST09316-60011 (09316-00041)

14. INSPECT 2ND GEAR THRUST CLEARANCE

1. Using a feeler gauge, measure the 2nd gear thrust clearance.

Standard clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance :

0.55 mm (0.0217 in.)



If the clearance exceeds the maximum, replace the 2nd gear synchronizer ring.

15. INSPECT 2ND GEAR RADIAL CLEARANCE

1.

Using a dial indicator, measure the 2nd gear radial clearance between the gear and

shaft.

Standard clearance:


0.056 mm (0.0023 in.)

If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing

or the shaft.

16. INSTALL OUTPUT SHAFT SPACER



1. Install the output shaft spacer onto the output shaft.

17. INSTALL 4TH DRIVEN GEAR

1. Using SST and a press, install the 4th driven gear onto the output shaft.

SST09223-00010

09316-60011 (09316-00021)

18. INSTALL 5TH DRIVEN GEAR



1. Using SST and a press, install the 5th driven gear onto the output shaft.

SST09223-00010

09316-60011 (09316-00021)

19. INSTALL COUNTER 5TH GEAR SHAFT SNAP RING

1. Select a snap ring, using the table below, that makes the thrust clearance of the

5th driven gear less than 0.1 mm (0.0039 in.).

MarkThicknessmm (in.)

Mark Thicknessmm (in.)

A2.22

(0.0874)F

2.52(0.0992)

B 2.28 G 2.58



(0.0898) (0.1016)

C2.34

(0.0921)H

2.64

(0.1039)

D2.40

(0.0945)J

2.70(0.1063)

E2.46

(0.0969)- -

2. Using a brass bar and hammer, tap the new snap ring onto the output shaft.

20. INSTALL OUTPUT SHAFT REAR BEARING



1. Using SST and a press, install the output shaft rear bearing onto the output shaft.

SST09612-22011

DIFFERENTIAL CASE >

COMPONENTS

for Preparation



1 / 1

DIFFERENTIAL CASE >

DISASSEMBLY

for Preparation



1. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

1. Using SST, remove the front differential case front tapered roller bearing.

SST09950-00020

09950-00030

HINT:

Set the claw of SST to the bearing inner race at the indented part of the

differential case.

2. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING



1. Using SST, remove the front differential case rear tapered roller bearing.

SST09950-00020

09950-00030

3. REMOVE FRONT DIFFERENTIAL RING GEAR

1. Place matchmarks on the front differential ring gear and the front differential

case.



2. Remove the 6 bolts. Using a hammer, remove the front differential ring gear fromthe front differential case.

4. REMOVE FRONT DIFFERENTIAL CASE

1. Using a pin punch and hammer, remove the pinion shaft slotted spring pin.



2. Remove the pinion shaft from the differential case.

3. Remove the 2 pinion gears, 2 side gears and the 4 thrust washers from each gear.



DIFFERENTIAL CASE >

REASSEMBLYfor Preparation

1. INSTALL FRONT DIFFERENTIAL CASE

1. Install the appropriate thrust washers and side gears. Refer to the table below andselect thrust washers that bring the backlash to within the specifications. Select

washers of the same size for both sides.

Standard backlash:0.05 to 0.20 mm (0.0020 to 0.0079 in.)

Thickness mm (in.) Thickness mm (in.)

0.50 (0.0197) 0.75 (0.0295)

0.55 (0.0217) 0.80 (0.0315)0.60 (0.0236) 0.85 (0.0335)

0.65 (0.0256) 0.90 (0.0354)

0.70 (0.0276) 0.95 (0.0374)



2. Install the thrust washers and the side gears into the differential case.

3. Install the pinion shaft.



4. Using a dial indicator, check the side gear backlash. Measure the side gear

backlash while holding one pinion gear toward the differential case.

Standard backlash:

0.05 to 0.20 mm (0.0020 to 0.0079 in.)

If the backlash is not within the specification, install a thrust washer of a different

thickness.

5. Using a pin punch and a hammer, install the pinion shaft slotted spring pinthrough the front differential case and the hole in the pinion shaft.

6. Using a chisel and hammer, caulk the pin holes around the circumference of thefront differential case.



2. INSTALL FRONT DIFFERENTIAL RING GEAR

1. Using a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).

2. Clean the contact surface of the front differential case.

3. Aligning the matchmarks, quickly install the front differential ring gear onto the

front differential case with the 6 bolts.




3. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

1. Using SST and a press, install the front differential case rear tapered roller

bearing.

SST

09350-32014 (09351-32120, 09351-32140)

4. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

1.

Using SST and a press, install the front differential case front tapered roller

bearing.



SST

09350-32014 (09351-32120, 09351-32140)

SHIFT STROKE SENSOR >

COMPONENTS

for Preparation



1 / 2



2 / 2


REMOVAL

for Preparation







4. REMOVE BATTERY








8. REMOVE SHIFT STROKE SENSOR




2. Disconnect the shift stroke sensor connector.

3. Remove the 2 screws and the shift stroke sensor from the shift and select actuator.

4. Remove the O-ring from the shift stroke sensor.




INSPECTION

for Preparation

1. INSPECT SHIFT STROKE SENSOR



1. Connect the 3 dry batteries of 1.5 V in series.

2. Connect the battery positive (+) lead to terminal A and the negative (-) lead to

terminal B.

3. Turn the sensor arm and check the voltage between terminals B and C.

Reference: Voltage (Power source voltage at 4.5 V):

Sensor

angle

Terminal (B - C) output

voltage55° 4.05 V

0° 2.25 V

-55° 0.45 V

Voltage (Power source voltage at 4.7 to 5.3 V):

Sensor

angle


voltage



55° 4.5 V

0° 2.5 V

-55° 0.5 V

NOTICE:

• Do not apply more than 6 V.

• Do not drop the clutch stroke sensor. If dropped, replace it with a new one.

If the voltage is not as specified, replace the stroke sensor.




INSTALLATION

for Preparation

1. INSTALL SHIFT STROKE SENSOR

1. Apply MP grease to a new O-ring.

2.

Install the new O-ring onto the stroke sensor.

3. Set the stroke senor so that the sensor side and the actuator side sensor arms are in

the positions shown in the illustration.



4. Turn the stroke sensor clockwise and fix it with the 2 screws.

Torque:


5. Connect the shift stroke sensor connector.

6. Install the wire harness bracket onto the transaxle with the bolt.






5. INSTALL BATTERY





Torque:5.4 N*m 55 kgf*cm , 48 in.*lbf

9. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION ECU

()



10. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM

()

11. SYNCHRONIZATION POSITION CALIBRATION()

SELECT STROKE SENSOR >

COMPONENTS

for Preparation



1 / 2



2 / 2


REMOVAL

for Preparation







4. REMOVE BATTERY








8. REMOVE SELECT STROKE SENSOR




2. Disconnect the select stroke sensor connector.

3. Remove the 2 screws and select stroke sensor from the shift and select actuator.

4. Remove the O-ring from the select stroke sensor.




INSPECTION

for Preparation

1. INSPECT SELECT STROKE SENSOR



1. Connect the 3 dry batteries of 1.5 V in series.

2. Connect the battery positive (+) lead to terminal A and the negative (-) lead to

terminal B.

3. Turn the sensor arm and check the voltage between terminals B and C.

Reference: Voltage (Power source voltage at 4.5 V):

Sensor

angle


voltage55 ° 4.05 V

0° 2.25 V

-55° 0.45 V

Voltage (Power source voltage at 4.7 to 5.3V):

Sensor

angle


voltage



55 ° 4.5 V

0° 2.5 V

-55° 0.5 V

NOTICE:

• Do not apply more than 6 V.

• Do not drop the clutch stroke sensor. If dropped, replace it with a new one.

If the voltage is not as specified, replace the stroke sensor.




INSTALLATION

for Preparation

1. INSTALL SELECT STROKE SENSOR


2.

Install the new O-ring onto the stroke sensor.

3. Set the stroke sensor so that the sensor side and the actuator side sensor arms are

in the positions shown in the illustration.



4. Turn the stroke sensor clockwise and fix it with the 2 screws.

Torque:


5. Connect the select stroke sensor connector.

6. Install the wire harness bracket onto the transaxle with the bolt






5. INSTALL BATTERY






9. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION ECU

()



10. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM

()

11. SYNCHRONIZATION POSITION CALIBRATION()

TRANSMISSION REVOLUTION

SENSOR > COMPONENTS

for Preparation



1 / 1


SENSOR > REMOVAL

for Preparation



1. DRAIN TRANSAXLE OIL

1.

Remove the filler plug and the gasket.

2. Remove the drain plug and gasket and drain the transaxle oil.

3. Install a new gasket and the drain plug.


2. REMOVE TRANSMISSION REVOLUTION SENSOR

1. Disconnect the revolution sensor connector.



2. Remove the bolt and transmission case protector.

3. Remove the bolt and transmission revolution sensor.

4. Using a screwdriver, remove the O-ring from the transmission revolution sensor.




SENSOR > INSPECTION

for Preparation

1. INSPECT TRANSMISSION REVOLUTION SENSOR



1. Using an ohmmeter, measure the resistance between the terminals.

Standard Resistance:560 to 680 Ω at 20 °C(68°F)

If the resistance is not as specified, replace the revolution sensor.


SENSOR > INSTALLATION

for Preparation



1. INSTALL TRANSMISSION REVOLUTION SENSOR

1. Install a new O-ring onto the transmission revolution sensor.

2. Install the transmission revolution sensor with the bolt.

Torque:


3. Install the transmission case protector with the bolt.

Torque:




4. Connect the revolution sensor connector.







3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the

filler plug opening.

NOTICE:

•

An excessively large or small amount of oil may cause problems.• After replacing the oil, drive the vehicle and check the oil level again.



Torque:




BACK-UP LIGHT SWITCH >

COMPONENTS

for Preparation



1 / 4



2 / 4



3 / 4







4. REMOVE BATTERY








8. SUPPORT MULTI-MODE MANUAL TRANSAXLE ASSEMBLY

9. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KR-

FE)





10. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZ-

FE)





11. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-

FE)


12. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-

FE)




13. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

1. Disconnect the back-up light switch connector.

2. Separate the back-up light switch wire harness from the 2 clamps.

3. Using SST, remove the back-up light switch and gasket from the transaxle case.

SST

09817-16011




INSPECTION

for Preparation

1. INSPECT BACK-UP LIGHT SWITCH ASSEMBLY





Condition Specified conditionReleased Below 1 Ω

Pushed 10 k Ω or higher

If the result is not as specified, replace the back-up light switch.




INSTALLATION

for Preparation

1. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

1. Using SST, install the back-up light switch with a new gasket onto the transaxle

case.

SST09817-16011

Torque:




2. Install the back-up light switch wire harness into the 2 clamps.

3. Connect the back-up light switch connector.

2. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-

FE)

1.

Install the engine mounting bracket LH with the 4 bolts.


3. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-FE)




Torque:


4. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KR-

FE)


Torque:52 N*m 530 kgf*cm , 38 ft.*lbf for bolt A

64 N*m 653 kgf*cm , 47 ft.*lbf for bolt B




the bolt and nut.

Torque:

52 N*m 530 kgf*cm , 38 ft.*lbf for nut C

5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZ-FE)



2. Install the engine mounting bracket LH and engine mounting insulator LH withthe bolt and nut.





9. INSTALL BATTERY








PARK / NEUTRAL POSITION

SWITCH > COMPONENTS

for Preparation



1 / 1


SWITCH > REMOVAL

for Preparation



1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

1. Disconnect the park/neutral position switch connector.

2.

Using SST, remove the park/neutral position switch with the gasket from thetransaxle case.

SST

09817-16011




SWITCH > INSPECTION

for Preparation

1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY





Condition Specified conditionReleased Below 1 Ω

Pushed 10 k Ω or higher

If the result is not as specified, replace the park/neutral position switch.




SWITCH > INSTALLATION

for Preparation

1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

SST09817-16011

1.

Using SST, install the park/neutral position switch with a new gasket onto the

transaxle case.

Torque:




2. Connect the park/neutral position switch connector.



SHIFT AND SELECT ACTUATOR >

COMPONENTS

for Preparation

1 / 1




DISASSEMBLY

for Preparation

1. REMOVE SELECT STROKE SENSOR



1. Remove the 2 screws and select stroke sensor.

2. Remove the O-ring from the select stroke sensor.



SHIFT AND SELECT ACTUATOR >INSPECTION

for Preparation

1. INSPECT SHIFT AND SELECT ACTUATOR ASSEMBLY

1. Check the resistance between the terminals of the shift motor.




Tester

connection

Specified

condition

1 - 2 0.1 to 100 Ω

If the resistance is not as specified, replace the shift and select actuator.

2. Check the resistance between the terminals of the select motor.


Tester

connection

Specified

condition

1 - 2 0.1 to 100 Ω

If the resistance is not as specified, replace the shift and select actuator.




REASSEMBLY

for Preparation

1. INSTALL SELECT STROKE SENSOR




2. Install the new O-ring onto the select stroke sensor.

3. Set the stroke sensor so that the sensor side and the actuator side sensor arms are

in the positions shown in the illustration.

4.

Turn the select stroke sensor clockwise and fix it with the 2 screws.

Torque:




MULTI-MODE MANUAL

TRANSAXLE ECU >

COMPONENTS

for Preparation



1 / 2



2 / 2

MULTI-MODE MANUAL

TRANSAXLE ECU > REMOVAL

for Preparation



1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER

()

2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (for RHD)

1. Slightly deform the upper part of the glove compartment door assembly to releasethe 2 stoppers and open the glove compartment door assembly until it becomes

horizontal.



2. Pull the glove compartment door assembly out horizontally to disengage the hinge

portion and remove the glove compartment door assembly.

NOTICE:

Pull the glove compartment door out horizontally, otherwise, installation failure

caused by excessive play around the hinge portion will result.

3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for LHD)



1. Disconnect the 3 connectors.


3. Disengage the clip and remove the transmission control ECU.

4. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for RHD)




2. Remove the bolt and screw, then remove the transmission control ECU.



MULTI-MODE MANUAL

TRANSAXLE ECU > REMOVAL

for Preparation

1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER

()



2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (for RHD)

1. Slightly deform the upper part of the glove compartment door assembly to releasethe 2 stoppers and open the glove compartment door assembly until it becomes

horizontal.



2. Pull the glove compartment door assembly out horizontally to disengage the hinge

portion and remove the glove compartment door assembly.

NOTICE:

Pull the glove compartment door out horizontally, otherwise, installation failure

caused by excessive play around the hinge portion will result.

3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for LHD)





3. Disengage the clip and remove the transmission control ECU.

4. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for RHD)

C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf

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Transcript of C551A MULTI-MODE MANUAL TRANSAXLE (1).pdf