2n-conf.clan.su · MULTI-MODE MANUAL TRANSAXLE SYSTEM > PRECAUTION 1.IGNITION SWITCH EXPRESSIONS 1. The type of ignition switch used on this model differs according to the specifications

MULTI-MODE MANUAL TRANSAXLE SYSTEM > PRECAUTION 1.IGNITION SWITCH EXPRESSIONS

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

Expression Ignition 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 transmission system, 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 the operation in the order shown in the table below.

Before removal Parts to be removed Operation order See

procedure • Clutch actuator • Transmission

assembly • Transmission parts

(inside gear box) • Clutch disc and clutch

cover • Clutch release bearing • Clutch release fork • Clutch release lever • Flywheel • End plate (2SZ-FE

only) • Crankshaft • Shift and select

actuator (with clutch actuator)

• CLAMP POSITION ADJUSTMENT

2.

Before installation

Parts to be installed Operation order See procedure

• New clutch actuator

• CLAMP POSITION ADJUSTMENT

3. NOTICE: 4. Push rods of brand new clutch actuators (service supply parts) are not set in the

clutch clamp position. Therefore, adjust the clamp positions before installing new clutch actuators.

5.

After installation

Parts installed Operation order See procedure

1. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION SYSTEM [Initialization of ECU]

• Transmission assembly

• Transmission parts (inside gear box)

• Shift and select actuator (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. SYNCHRONIZATION POSITION CALIBRATION

1. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION SYSTEM [Initialization of clutch]

• Clutch actuator • Clutch stroke

sensor • Clutch disc and

clutch cover • Clutch release

bearing • Clutch release fork • Clutch release lever• Flywheel • End plate (2SZ-FE

only) • Crankshaft


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 in deterioration 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). If initialization and learning are not performed, the transmission system will not function properly.

• Before proceeding with learning of the multi-mode manual transmission system, 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 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. 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.


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. 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-T/M results.



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 ().


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. 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 Possibility of T/M Uplock results.

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 again (If glearning fails twice or more, check transmissi

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.


No DTC output A DTC output B

B. Go to DTC Chart A 2.Check clutch position learning condition


List. 4. Read the Learn-Clutch Stopper Point results.



Fail (Failure) C


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. 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 Learning-T/M results.



Fail (Failure) C


C. Go to step 8 A 4.Check clutch standby point learning condition


List. 4. Read the Learn-Clutch Standby Point results.



Fail (Failure) C

B. Execute learning again (Ignition switch off tostart engine)

C. Check clutch system 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. 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. 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 CAN commsystem

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.


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 / Data

List. 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 again (If glearning fails twice or more, check transmissi

A

Check transmission assembly 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.


Disengaged A Not disengaged B

B. Check clutch system A

Check transmission assembly

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 position

other 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, the gear is shifted to the position in accordance with the shift lever position after the engine starts.

Shift lever position when vehicle parked

Current shift lever position

Engine cranking operation

Note

Other than N Other than N* Impossible -

Other than N Same position in

when vehicle parked

Impossible -

Other than N N* Possible Gear shifted to neutral when ignition switch on (IG)

N Other than N* Possible Gear shifted to position in accordance with shift lever position after engine start

N

N (Same position in when vehicle

parked)

Possible -

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

7.OTHER PRECAUTIONS REGARDING MULTI-MODE MANUAL TRANSMISSION SYSTEM

• Set the gear in neutral when revving the engine.

• Set the gear to the neutral position before removing the shift and select actuator. If the 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 other than 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 are

required. One drives the vehicle, and the other operates the tester.

MULTI-MODE MANUAL TRANSAXLE SYSTEM > PARTS LOCATION for Preparation

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MULTI-MODE MANUAL TRANSAXLE SYSTEM > SYSTEM DIAGRAM for Preparation

MULTI-MODE MANUAL TRANSAXLE SYSTEM > SYSTEM DESCRIPTION for Preparation MULTI-MODE MANUAL TRANSMISSION SYSTEM OUTLINE

1. The multi-mode manual transmission has been developed from the conventional manual 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 a transmission 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 with signals 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 ECU illuminates the Multi-mode Manual Transmission Warning Light (MMT Warning Light) to inform the driver that a malfunction has occurred. If necessary, the ECU illuminates 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 position indicator (built into combination meter)

Indicates the present gear position. The indicator flashes if the actual 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 combination meter)

Illuminates when the sporty [Es] pattern is selected during normal [E] pattern driving in E-mode. Does not illuminate while the normal [E] pattern is selected.

Buzzer (built into combination meter)

Sounds if the following conditions met simultaneously: Engine is running Shift lever is in E, M or R position Driver's door is open

Shift lever position sensor (built into shift lever assembly)

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

Transmission shift main switch (built into shift lever 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 movement of the shift lever.

Shift motor (built into shift and select actuator)

Actuated by the transmission control ECU. Effects the shift operation 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 and select actuator)

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

Select stroke sensor (built into shift and select actuator)

Detects the shift and select actuator operation position (select direction).*

Clutch motor (built into clutch actuator)

Actuated by the transmission control ECU. Engages and disengages the clutch.

Clutch stroke sensor (built into clutch actuator)

Detects the push rod position of the clutch actuator from the rotational 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 light switch (built into transmission assembly)

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

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

Transmission control ECU

Controls the multi-mode manual transmission system and signals the ECM to effect engine control during upshifting or downshifting via CAN (Controller Area Network) communication. When the multi-mode manual transmission system malfunctions, the transmission control ECU diagnoses the malfunctioning areas and 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 the transmission control ECU. Affects engine control in accordance with signals from the transmission 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 is turned 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 turned to 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) or more, 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 the engine 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 fully depressed 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 fuel economy 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 excess shifting 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 is depressed, 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. This enables 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 pedal released 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). When the 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 AND INSTALLATION 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 the vehicle 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 fully retracted. 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 to the 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 is stopped (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 PARTS Refer to the respective pages for each part.

3. INITIALIZATION AND LEARNING

1. INITIALIZATION OF TRANSMISSION SYSTEM: • The transmission control ECU stores information from each

component, such as sensors and motors, to control the system. • Sensors and motors that comprise the multi-mode manual

transmission system have individual specification values. The transmission 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 is therefore 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 specification

values of components, such as sensors and actuators, in the transmission control ECU.

• 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 the gearshift accurately. Synchronization position calibration corrects and adjusts 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 TROUBLESHOOTING for 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 the CAN 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


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


NEXT

Go to step 13 12.PROBLEM SYMPTOMS TABLE


NEXT 13.CIRCUIT INSPECTION


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 performed individually.

• 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 stored information 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 control ECU 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.



See below

2. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM See below

• Transmission assembly • Transmission parts

(inside gear box) • Shift and select actuator

(with clutch actuator) • Transmission control 3. SYNCHRONIZATION POSITION

ECU CALIBRATION


See below





See below • Clutch actuator • Clutch stroke sensor • Clutch disc and clutch




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.

8. Read the information. 9. After checking the vehicle condition, press the Next key.



14. On the Multi-Mode M/T / Utility screen, select Step 3 Initial Learning. 15. Press the Next key.

16. Select the appropriate operation.

HINT:

• Initialization of clutch: when removing and installing the following parts related to the clutch system. Clutch actuator, clutch stroke sensor, clutch disc and clutch cover, clutch release 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.

17. Press the Next key.

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.

21. Read the information. 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 switch off.

• 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 transmission system 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 is disconnected. To clear all the stored information, initialize the transmission control 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 ignition switch 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.



See below




(with clutch actuator) • Transmission control

ECU 3. SYNCHRONIZATION POSITION CALIBRATION


See below





See below • Clutch actuator • Clutch stroke sensor • Clutch disc and clutch




1. Prepare the vehicle: • Stop the vehicle. • Shift the lever to the N position. • Turn the ignition switch off.

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

SST 09843-18040

3. Wait at least 10 seconds. 4. Turn the ignition switch on (IG).

5. Depress the brake pedal at least 7 times within 3 seconds.

1. The buzzer sounds twice with an interval of 0.25 seconds. 6. Depress the brake pedal.

7. Shift the shift lever in the following sequence with the brake pedal depressed. • When initializing the ECU: N → E → M → - → M → - → M → - → M

→ - → E → N. • When initializing the clutch: N → E → M → + → M → - → M → + →

M → - → E → N. • When initializing the transmission: N → E → M → - → M → - → M →

+ → M → + → E → N.

8. Release the brake pedal

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 procedure from 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 WITHOUT USING 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.

1. Prepare the vehicle: • 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. 6. Turn the ignition switch on (IG). 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 > CALIBRATION for 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.






(with clutch actuator) • Transmission control

ECU 3. SYNCHRONIZATION POSITION CALIBRATION See below

• Shift stroke sensor 1. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION SYSTEM

[Initialization of transmission] 2. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM • Select stroke sensor

3. SYNCHRONIZATION POSITION CALIBRATION See below


• Clutch actuator • Clutch stroke sensor • Clutch disc and clutch




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 > PROBLEM SYMPTOMS 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, troubleshoot in 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 area See 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 transmission warning light circuit

2. IG signal circuit 3. ECU power source circuit

Multi-mode manual transmission warning light defective

4. Transmission control ECU 1. Multi-mode manual transmission warning light circuit

2. IG signal circuit Shift position indicator light defective

3. Transmission control ECU Buzzer does not sound when incorrect operation occurs (built into transmission control ECU)

1. Transmission control 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 incorrect operation occurs (built into combination meter)

5. Transmission control ECU

Shift impossible to any gear 1. Transmission unit (Gears, bearings, shift fork, synchronizer ring, shift key,

etc.) 2. Shift stroke sensor 3. Select stroke sensor 4. Shift and select actuator 5. Shift lever position sensor 6. Clutch disk (clutch cover) 7. Clutch stroke sensor 8. Clutch actuator assembly 9. Transmission control ECU 1. Transmission unit (Gears, bearings, shift fork, synchronizer ring, shift key, etc.)

2. Clutch disc (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 lock solenoid circuit 10. Shift lever assembly 11. Speed signal circuit

Too much time lag when changing gear position

12. Transmission control ECU 1. SFI system (1KR-FE) 2. SFI system (2SZ-FE) 3. Pattern select switch

Poor acceleration

4. Transmission control ECU 1. Shift lock solenoid circuit 2. Stop light switch circuit 3. IG signal circuit 4. Shift lever assembly

Change shift lever position impossible

5. Transmission control ECU 1. Transmission revolution sensor Engine stalls when starting off or

stopping 2. Transmission control ECU Gear not automatically shifted up or 1. CAN communication circuit

2. Transmission shift main switch 3. Shift lever position sensor

down during E mode driving

4. Transmission control ECU 1. Transmission shift main switch 2. Shift lever assembly Mode switch impossible (E to M) 3. Transmission control ECU 1. Shift lever position sensor

Setting to 1st or R positions impossible 2. Transmission control ECU 1. Accelerator pedal position sensor (1KR-FE)

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

Shift timing delays occur during M mode driving

3. Transmission control ECU 1. Parking brake switch circuit Assist 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 5. Shift lever position sensor 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

10. Transmission control ECU 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 MANUAL TRANSAXLE SYSTEM > TERMINALS OF ECU for Preparation Transmission Control ECU:

Symbols (Terminal

No.)

Wiring Color Terminal Description Condition Specified

Condition

+B - GND (D79-1 - D79-6)

B - W-B Battery (ECU power source) Always 10 to 14 V

IG - GND (D79-3 - D79-6)

O - W-B Ignition switch Ignition 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 lever released → pulled)

10 to 14 V → Below 1 V

SLS - GND (D79-5 - D79-6)

LG - W-B Shift lock solenoid


Brake pedal depressed → Released


GND - Body ground

(D79-6 - Body

ground)

W-B - Body

ground Ground Always Below 1 Ω

MDSW - GND

(D79-10 - D79-6)

L - W-B Transmission shift main switch


Shift lever position E → M


LS4C - GND B - W-B Shift lever position

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-B Shift lever position sensor


Shift lever position E or M → R or N


LS2C - GND

(D79-13 - D79-6)

LG - W-B

Shift lever position sensor


Shift lever position R → Except R


LSW5 - GND

(D79-15 - D79-6)

R - W-B Shift lever position sensor


Shift lever position except [-] → [-]


LSW4 - GND

(D79-16 - D79-6)

G - W-B Shift lever position sensor


Shift lever position except N → N


LSW3 - GND

(D79-17 - D79-6)

B - W-B Shift lever position sensor


Shift lever position R or N → Except R and

N


LSW2 - GND

(D79-18 - D79-6)

W - W-B Shift lever position sensor


Shift lever position except R → R


LSW1 - GND

(D79-19 - D79-6)

GR - W-B

Shift lever position sensor


Shift lever position except [+] → [+]


PWR - GND (D79-23 -

D79-6)

GR - W-B Pattern select switch


Pattern select switch OFF → ON


DG - GND (D79-25 -

D79-6) P - W-B Terminal TC of DLC3

Ignition switch on (IG) → Connect terminals TC and CG of DLC3


INDC - GND

(D79-29 - D79-6)

R - W-B Communication line

with combination meter

Always Below 1.44 V

INDA - GND

(D79-31 - D79-6)

Y - W-B Communication line

with combination meter

Ignition switch on (IG)

Pulse generation

(See waveform 1)

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


Brake pedal released → depressed


CAN+ - CAN-

(A38-1 - A38-2)

W - B CAN communication Ignition switch on (IG)

Pulse generation

(See waveform 2)

MREL - GND

(A38-5 - D79-6)

LG - W-B

AMT relay (motor power source)

Ignition switch off → on (IG)


STA - GND (A38-6 - D79-6)

SB - W-B Starter relay operation

signal (input)

Ignition switch off, Brake pedal depressed, Shift lever position N → Starter operates


RSW - GND (A38-9 - D79-6)

R - W-B Back-up light switch


Shift lever position except R → R


NE - GND (A38-10 -

D79-6) L - W-B Engine speed signal

from ECM Idling

Pulse generation

(See waveform 3)

NIP- - NIP+ (A38-15 - A38-16)

V - P Transmission revolution sensor

Engine running, Clutch engaged (during driving)

Pulse generation

(See waveform 4)

E2S1 - GND (A38-17 -

D79-6) P - W-B

Shift stroke sensor ground (main)

Always Below 1Ω

VSS1 - GND

(A38-18 - D79-6)

B - W-B Shift stroke sensor

voltage monitor (main)

Ignition switch on (IG) 0.5 V to 4.5 V

VCS1 - GND

(A38-19 - D79-6)

W - W-B Shift 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) Ignition switch on (IG) 4.5 V to 5.5 V

VSL1 - GND

(A38-21 - D79-6)

V - W-B Select stroke sensor



E2L1 - GND

(A38-22 - D79-6)

Y - W-B Select stroke sensor ground (main) Always Below 1 Ω

SPD - GND (A38-23 -

D79-6) V - W-B Vehicle speed signal


during driving

Pulse generation

(See waveform 5)

E2L2 - GND

(A38-24 - D79-6)

GR - W-B

Select stroke sensor ground (sub) Always Below 1 Ω

E2R1 - GND

(A38-25 - D79-6)

LG - W-B

Clutch stroke sensor ground (main) Always Below 1 Ω

VSR1 - GND

(A38-26 - D79-6)

B - W-B Clutch stroke sensor



VCR1 - GND

(A38-27 - D79-6)

W - W-B Clutch 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 ground (sub) Always Below 1 Ω

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-B Shift 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) Ignition switch on (IG) 4.5 V to 5.5 V

VSL2 - GND

(A38-32 - D79-6)

LG - W-B

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

E2R2 - GND

(A38-33 - D79-6)

GR - W-B

Clutch stroke sensor ground (sub) Always Below 1 Ω

VSR2 - GND

(A38-34 - D79-6)

BR - W-B

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

VCR2 - GND

(A38-35 - D79-6)

G - W-B Clutch 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


motor not operating → operating

Pulse generation

()

+BM - GND (A37-2 - D79-6)

B - W-B Motor power source Ignition switch off → on (IG)


MSF- - GND

(A37-3 - D79-6)

W - W-B Shift motor



Below 1 V → Pulse

generation ()

MSL- - GND

(A37-4 - D79-6)

L - W-B Select motor



Below 1 V → Pulse

generation ()

MSL+ - GND

(A37-5 - D79-6)

B - W-B Select motor



Below 1 V → Pulse

generation ()

MCL- - GND

(A37-6 - D79-6)

GR - W-B Clutch motor



Below 1 V → Pulse

generation ()

MCL+ - GND

(A37-7 - D79-6)

G - W-B Clutch motor



Below 1 V → Pulse

generation ()

PGND - Body

ground (A37-8 -

Body ground)

W-B - Body

ground 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- Gauge set 1 V/DIV, 50 μs/DIV Condition Ignition switch on (IG)

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

Condition Vehicle speed of

approximately 30 km/h (19 mph)

8.

9. Waveform 5: Vehicle Speed Signal Terminal

Terminal SPD - GND Gauge set 5 V/DIV, 20 ms/DIV

Condition Vehicle speed of

approximately 20 km/h (12 mph)

ECM:

Symbols (Terminal No.) Wiring Color Terminal

Description Condition Specified Condition

CAN+ - CAN- (A32-34 - A32-

26) W - B CAN

Communication Ignition switch

on (IG)

Pulse generation

(See waveform 1)

NEO - E1 (C33-64 - A32-

1) L - W-B Engine speed

signal Engine idling

Pulse generation

(See waveform 2)

E1 - Body ground

(A32-1 - Body ground)

W-B - Body ground Ground Always Below 1 Ω

1. Waveform 1: CAN Communication Terminal

Terminal CAN+ - CAN- Gauge set 1 V/DIV, 50 μs/DIV Condition Ignition switch on (IG)

2.

3. Waveform 2: Engine speed signal

Terminal NEO - E1

Gauge set 5 V/DIV, 5 ms/DIV Condition Engine idling

MULTI-MODE MANUAL TRANSAXLE SYSTEM > DIAGNOSIS SYSTEM for 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 manual transmission 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 usual troubleshooting 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 from the 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 or intelligent 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 gear was 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 the DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format.

Symbol Terminal No. Name Reference

terminal Result Condition

SIL 7 Bus "+" line 5-Signal ground

Pulse generation

During transmission

CG 4 Chassis ground Body ground 1 Ω or less Always

SG 5 Signal ground Body 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 or higher

Ignition switch off *

CANH 6 CAN "High" line

4 - CG 1 kΩ or higher


Battery positive

1 MΩ or higher


CANL 14 CAN "Low" line

4 - CG 1 kΩ or higher


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 the ignition 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 to another 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

1. Turn the ignition switch on (IG). 2. Check that the warning light illuminates for 5 seconds. If the warning light does

not illuminate, proceed to troubleshooting the multi-mode manual transmission warning 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)

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. 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 display screen. [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 the fail-safe mode.

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

• P0806 • P0807 • P0808 • P0810 • P0900

• Clutch stroke sensor or its circuit

• Clutch actuator assembly or its circuit

• Gear does not change

• Vehicle does not start moving again after stopping

Either (a) or (b) met

10. (a) Aconditions m

•cond

•N po

•gear

•speedkm/h

11. (b) Pdetected andoff

• P0807 • P0808 • P0906 • P0907 • P0916

• Clutch stroke sensor or its circuit

• Select stroke sensor or its circuit

• Shift stroke

• Limit to 3rd gears or lower

Either of (a) or (b) m

22. (a) Afollowing co

•

• P0917 sensor or its circuit cond•

N po•

gear •

speedkm/h


• P0905 • P0906 • P0907 • P0909 • P0910 • P0915 • P0916 • P0917 • P0919 • P0920

• Shift stroke sensor or its circuit

• Shift actuator assembly or its circuit

• Select stroke sensor or its circuit

• Select actuator assembly or its circuit


• Vehicle does not start moving again after stopping



•cond

•N po

•speedkm/h


• P0725 • Engine speed input circuit

• Convert engine revolution signals into CAN communication signals

• No effect



•cond

•positneutr

•enga


• P0500 • P0715

• Vehicle speed sensor or its circuit

• Gear does not shift down while driving


54. (a) A

• Transmission revolution sensor or its circuit

• Only possible to drive in 1st or reverse gears after vehicle stops

conditions m•

cond•

speedkm/h

•peda

•depre


• P0603 • P0885

• Transmission control ECU

• Clutch actuator, shift actuator, select actuator power source circuit


• Engine cannot be started

• Transmission control ECU stops engine when vehicle stops

Pass condition detecignition switch off

• P0820

• Shift lever position sensor or its circuit

• Transmission shift main switch or its circuit

• Impossible to enter M-mode

• Gear does not shift to 1st or reverse (and forward or backward gears)

Pass condition detecignition switch off

• P0335 • P0339

• Crankshaft position sensor or its circuit

• Gear does not change Pass condition detec

ignition switch off

• U0100 • CAN

communication signal circuit


• Only possible to drive in 1st or reverse gears after vehicle stops



•cond

•stopp

•peda

•depre


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 reference only. 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]

Measurement Items: Display

Normal Conditions Diagnostic Notes

MIL Status [MIL Status]

MIL status: OFF or ON

ON: MIL comes on -

Calculated Engine Load [Calc E/G Load]

Load calculated by ECM: Min.: 0 %, Max.: 100 %

1KR-FE: 11 to 25 %: Idling 15 to 35 %: Running without load (2,500 rpm) 2SZ-FE: 12.8 to 19.2 %: Idling

-

10.3 to 17.9 %: Running without load (2,500 rpm)

Engine Coolant Temperature [Coolant Temp]

Coolant temperature: Min.: -40°C, Max.: 140°C

1KR-FE: 75 to 95°C (167 to 203°F): After engine warmed up 2SZ-FE: 80 to 100°C (176 to 212°F):After engine warmed up

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

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

Engine Run Time [Eng Run Time]

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: Idling 2SZ-FE: 600 to 700 rpm: Idling

If NE signal circuit has a short or open circuit, back-up engine speed data from CAN communication displayed

Vehicle Speed [Vehicle Spd]

Vehicle speed: Min.: 0 km/h, Max.: 255 km/h

0 km/h (0 mph): Vehicle stationary Approximately same value as combination meter display

When vehicle speed signal malfunctions, 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 after Malfunction [Driving Mileage]

Accumulated driving mileage since malfunction detection: Min.: 0 km/h, Max.: 65,535 km/h

0 km/h (0 mph): System normal

Distance driven since occurrence 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

Warmup Cycle Cleard DTC [Wu Cyc DTC clear]

Warm-up cycle since DTC cleared: Min.: 0 , Max.: 255

- Number of warm-up cycles since DTC cleared

Distance from DTC Cleared [Dist DTC Clear]

Distance since DTC cleared: Min.: 0 Km, Max.: 65535 Km

Equivalent to drive distance since DTCs erased

-

Time after DTC Cleared [Time DTC Clear]

Time since DTC cleared: Min.: 0 min, Max.: 65535 min

Equivalent to time since DTCs erased

-

Vehicle Speed Signal [Vehicle Spd Sig]

Vehicle speed signal: Min.: 0 km/h, Max.: 327.675 km/h

0 km/h (0 mph): Vehicle stationary

When vehicle speed signal malfunctions, 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 signal displayed

Backup Engine Speed [Bacup Engin Spd]

Back-up engine speed from CAN communication:Min.: 0 rpm, Max.: 8,160 rpm

Approximately same as tachometer reading: Engine running 0 rpm: Engine stopped

0 rpm displayed when CAN communication malfunctions

Accelerator Pedal Angle [Accel Pedl Angl]

Accelerator pedal angle: Min.: 0 %, Max.: 100 %

0 %: Accelerator pedal released

0 % displayed when CAN communication malfunctions

Theoretical Engine Torque [Theoretic Torq]

Theoretical engine 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.: 127.998 mm

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 (0.11 in.) to 29.0 mm (1.14 in.)

Current select position value displayed (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 Oil Temperature [AT Oil Temp]

Transmission fluid temperature calculated by ECU: Min.: -128°C, Max.: 127°C

Equivalent to actual transmission fluid temperature

-

Shift Lever Switch Signal1 [Shift SW Sig1]

Shift lever switch signal (+): OFF or ON

ON: Shift lever position in (+) OFF: Other than above

LSW1(LSW+) terminal signal of transmission control ECU


Shift lever switch signal (R): OFF or ON

ON: Shift lever position in (R) OFF: Other than above

LSW2 (LSWR) terminal signal of transmission control ECU


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 of transmission control ECU

Shift Lever Switch Signal4 [Shift SW

Shift lever switch signal (N): OFF or ON

ON: Shift lever position in (N) OFF: Other than above

LSW4 (LSWN) terminal signal of transmission control ECU

Sig4] Shift Lever Switch Signal5 [Shift SW Sig5]

Shift lever switch signal (-):OFF or ON

ON: Shift lever position in (-) OFF: Other than above

LSW5 (LSW-) terminal signal of transmission control ECU

Shift Lever Check Signal1 [Shift Chek Sig1]

Check signal of shift lever switch signal 2: OFF or ON

OFF: Shift lever position in (R) ON: Other than above

LS2C (LSRC) terminal signal of transmission ECU Reversal signal of LSW2 (LSWR) (ON and OFF reversed)



OFF: Shift lever position in (E), (M), (+) or (-) ON: Shift lever position in (R) or (N)

LS3C (LSSC) terminal signal of transmission control ECU Reversal signal of LSW3 (LSWS) (ON and OFF reversed)



OFF: Shift lever position in (N) ON: Other than above

LS4C (LSNC) terminal signal of transmission ECU Reversal signal of LSW4 (LSWN) (ON and OFF reversed)

T/M Reverse Switch Signal [T/M R SW Sig]

Transmission reverse switch signal: OFF or ON

ON: Transmission gear in reverse OFF: Other than above

During malfunctions, indicator shows 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 SW Sig]

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 (Automatic shift control)

-

Parking Brake Signal [Pkb Sig]

Parking brake switch signal: OFF or ON

ON: Parking brake applied OFF: Parking brake released

-

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

Signal2 [Brake SW Sig2]

signal (ST1-): OFF or ON

pedal depressedON: Brake pedal released

transmission control ECU

Brake Switch Signal1 [Brake SW Sig1]

Brake switch signal (STP): OFF or ON

ON: Brake pedal depressedOFF: Brake pedal released

STP terminal signal of transmission control ECU

STA Switch Signal [STA SW Sig]

STA signal: OFF or ON

ON: During cranking -

Gear Position (Current) [Gear Pos-Cur]

Current gear position: Min.: 0, Max.: 255

Actual gear position displayed

0 = Non 1 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 not operated: Target gear position equals current gear position

0 = Non 1 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 gear change control operation (varies with vehicle condition)

-

Shift Position (Target) [Shift Pos-Tar]

Target shift position: Min.: 0 mm, Max.: 127.998 mm

Difference between actual and target shift positions: Maximum of 15 mm during gear change control operation (varies with vehicle 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 mm during gear change control operation (varies with vehicle condition)

-

Clutch Motor Current Req [Clutch Motor Req]

Requested clutch motor current from CPU: Min.: -50 A, Max.: 50 A

-20 to 20 A Instruction (calculated) current value from CPU

Clutch Motor Current MMT [Clutch Motor]

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

-20 to 20 A 0 A: When clutch motor not in operation

Shift Motor Current Req [Shift Motor Req]

Requested shift motor current from CPU: Min.: -50 A, Max.: 50 A

-40 to 40A Instruction (calculated) current value from CPU

Shift Motor Current MMT [Shift Motor]

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

-40 to 40A 0 A: When shift motor not in operation

Select Motor Current Req [Select Motor Req]

Requested select motor current from CPU: Min.: -50 A, Max.: 50 A

-25 to 25 A Instruction (calculated) current value from CPU

Select Motor Current MMT [Select Motor]

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

-25 to 25 A 0 A: When select motor not in operation

Base Clutch Load [Base Clutch Load]

Base clutch load:Min.: -1000 N, Max.: 1000 N

Learning value shown

Base clutch load: Calculated from average clutch motor current when ECU performing initialization and learning of clutch system

Current Clutch Load [Current Clutch Load]

Current clutch load (calculated value): Min.: -1000 N, Max.: 1000 N

Reference value (varies with vehicle condition) 39.33 to 45.29: Stopper position 37.07 to 43.03: Complete engagement position 24.5 to 35.25: Standby position

Current clutch load: Calculated from average clutch motor current Difference between Base Clutch Load and Current Clutch Load increases as clutch disks wear away After performing LCC adjustment, difference decreases (Almost same as Base Clutch Load value)

Clutch Adjust Count [Clutch Adj Cnt]

Number of LCC (Load Controlled Clutch cover) adjustment performed: Min.: 0 , Max.: 255

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

Clutch Adjust Fail Count [Clutch Adj Fail]

Number of LCC (Load Controlled Clutch cover) adjustment judged unnecessary: Min.: 0 , Max.: 255

-

When difference between Base Clutch Load and Current Clutch 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 Current Clutch Load exceeds threshold, the count increases by 1

Mode Changes [Mode Changes]

System control mode: Min.: 0, Max.: 255

-

11: System wake-up control mode 12: Vehicle driving control mode 13: System end control mode 14: System initialization mode17: Engine starting control mode 20: Fixed gear shift control

mode 21: Gear shift control mode 22: Shift lever lock control mode 25: Shut-down control mode 26: Vehicle stationary control mode 27: Vehicle start off control mode

Gear Mode Changes [Gear Mode]

Gear change mode 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 Uplock Sig]

3rd gear up-lock signal: OFF or ON

4th Uplock Signal [4th Uplock Sig]

4th gear up-lock signal: OFF or ON

5th Uplock Signal [5th Uplock Sig]

5th gear up-lock signal: 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 not Up-lock: Transmission gear momentarily cannot be engaged due to mechanical reasons (not malfunction)

Vehicle Speed Signal Open [Vehicle Spd Open]

Vehicle speed signal circuit open judgement:OFF or ON

OFF: During vehicle running

ON: When momentarily interruption 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 for long time

Clutch partially engaged when following conditions met:

• Engine running • Transmission

gear in 1st, 2nd or Reverse

• Brake pedal not depressed

• Parking brake released

• Accelerator pedal released

Low Voltage Signal [Low Volt]

+B terminal low voltage judgement: OFF or ON

OFF: +B terminal voltage 8 V or more

-

Run Off Signal [Run Off Sig]

Vehicle run-off judgement OFF or ON

OFF: While vehicle running

ON: High differential spin occurred sharply at differential gear When following conditions met, transmission control ECU detects run-off in vehicle and restricts gear shift:

• Accelerator pedal angle exceeds threshold

• SPD signal change rate above threshold

• Shift position in 1st, 2nd or 3rd

Clutch Heat [Clt Heat]

Clutch heat judgement: OFF or ON

OFF: Engine idling, gear in neutral

ON: Calculated clutch temperature 280°C (536°F) or more Clutch temperature calculated from relative revolution speed between engine and transmission 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: Engine idling, gear in neutral

ON: Calculated clutch temperature 330°C (626°F) or more

Clutch Motor Current Enable [Clt Curr Ena]

Clutch motor current enabled OFF or ON

OFF: Target clutch motor current less than 1 A ON: OFF condition not met

-

Motor Relay Signal [Mot Relay Sig]

AMT relay drive signal: OFF or ON

ON: Ignition switch on (IG) OFF: Ignition switch off and after system shut-down

-

Shift Lever Lock Solenoid [SLS]

Shift lever lock solenoid operation: OFF or ON

OFF: Shift lever locked -

Clutch Touch Position [Clt Touch Pos]

Clutch touch position: Min.: 0 mm, Max.: 127.998 mm


Difference between Clutch Touch position and Clutch Clamp Position within 4.0 mm (0.16 in.) to 16.0 mm (0.63 in.)

Clutch Clamp Position [Clt Clamp Pos]

Clutch clamp position: Min.: 0 mm, Max.: 127.998 mm


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.: 127.998 mm


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

Neutral Position (Select)

Neutral position (select position):Min.: 0 mm,


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 (shift position): Min.: 0 mm, Max.: 127.998 mm


• 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


Difference between [1st Pos (Sel)] and [3rd Pos (Sel)] within 5.5 mm (0.22 in.) to 8.5 mm (0.33 in.)

2nd Gear Position (Shift) [2nd Pos (Shift)]

2nd gear position (shift position): Min.: 0 mm, Max.: 127.998 mm


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


Difference between [2nd Pos (Sel)] and [4th Pos (Sel)] within 5.5 mm (0.22 in.) to 8.5 mm (0.33 in.)

3rd Gear Position (Shift) [3rd Pos (Shift)]

3rd gear position (shift position): Min.: 0 mm, Max.: 127.998 mm


• Difference between [3rd Pos (Shift)] and [4th Pos (Shift)] within 15.0 mm (0.59 in.) to 19.5 mm (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,


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 (shift position): Min.: 0 mm, Max.: 127.998 mm


• Difference between [3rd Pos (Shift)] and [4th Pos (Shift)] within 15.0 mm (0.59 in.) to 19.5 mm (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


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

5th Gear Position (Shift) [5th Pos (Shift)]

5th gear position (shift position): Min.: 0 mm, Max.: 127.998 mm


• 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.: 127.998 mm


Difference between [5th Pos (Sel)] and [3rd Pos (Sel)] within 5.5 mm (0.22 in.) to 8.5 mm (0.33 in.)

Reverse Gear Pos (Shift) [R Pos (Shift)]

Reverse gear position (shift position): Min.: 0 mm, Max.: 127.998 mm


• 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 [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.: 127.998 mm


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 of transmission up-lock: No or Yes

No: Initialization and learning complete

Yes: Transmission gear temporarily could not be engaged due to mechanical reasons during gear position learning

Learn-Clutch Standby Point [Lern-Stby_Pnt]

Clutch actuator standby position learning: Notexec, Fail or Exec

Exec: Initialization and learning complete

-

Learning-T/M [Lern-T/M]

Learning T/M system: Notexec, Fail or Exec


-

Learn-Clutch Stopper Point [Lern-Stppr_Pnt]

Clutch actuator stopper position learning: Notexec, Fail or Exec


-

# Codes [# Codes]

Number of codes: Min.: 0, Max.: 255

- Number of detected DTCs

Check Mode [Check Mode]

Check mode: OFF or ON

ON: Check mode 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.

Items Test Details/Vehicle conditions Diagnosis Notes

Target Gear Position Control

[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 Select stroke sensor Shift and select actuator assembly AMT relay Transmission assembly Transmission control ECU

Target Clutch Control

[Test Details] Target clutch control Standby 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 to the position indicated, there could be some malfunctions in the following parts: Clutch stroke sensor Clutch actuator assembly AMT relay Clutch 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.

1. Prepare the vehicle: • Stop the vehicle. • Shift the lever into the N position. • Turn the ignition switch off. • Apply the parking brake.

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.



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).




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 manual transmission 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 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.

1. Prepare the vehicle. • Stop the vehicle. • Shift the lever into the N position. • Turn the ignition switch off. • 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.


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.


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 Signal Circuit

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 is not 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.

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

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.


Measurement Items: Display Normal Conditions Diagnostic

Notes STA Switch

Signal [STA SW Sig]

STA signal: ON or OFF

ON: During cranking -

5. OK: 6. [ON] displays in the STA Switch Signal during cranking.

OK

PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS 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 Connections Specified Conditions

1KR-FE: STA (A32-27) -

STA (A38-6) 2SZ-FE:

STA (A21-48) - STA (A38-6)

Below 1 Ω

STA (A38-6) - Body ground 10 kΩor 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 Select Switch 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 and vehicle 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.

Standard resistance: Tester

Connections Switch

ConditionsSpecified

Conditions1 - 4 ON Below 1 Ω

1 - 4 OFF 10 kΩ or higher

3. Reinstall the pattern select switch.

NG

REPLACE PATTERN SELECT SWITCH ASSEMBLY

OK

2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - BODY GROUND)




Connections Switch

ConditionsSpecified

ConditionsPWR (D79-23) - Body

ground OFF 10 kΩ or

higher

PWR (D79-23) - Body

ground ON Below 1 Ω


NG


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 select switch OFF

10 to 14 V

PWR (D79-23) - Body ground

Pattern select switch ON

Below 1 V

NG

REPLACE TRANSMISSION CONTROL ECU ASSEMBLY

OK


MULTI-MODE MANUAL TRANSAXLE SYSTEM > IG Signal Circuit

for Preparation

DESCRIPTION When the ignition switch is turned on (IG), the battery voltage is applied to terminal IG of the transmission control ECU. Power is supplied to the transmission control ECU via terminal +B and IG. The transmission control ECU interprets the ignition switch condition according to the potential at IG terminal.

WIRING DIAGRAM


1.READ VALUE USING INTELLIGENT TESTER

1. Connect the 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 / Data List / Ignition Signal.

4. Read the value.


Measurement Items: Display Normal Conditions Diagnostic

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).

OK


NG

2.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY (IG TERMINAL VOLTAGE)



3. Measure the voltage between the terminal of the transmission control ECU connector and the body ground.

Standard voltage:

Tester Connections

Ignition Switch

Conditions

Specified Conditions

IG (D79-3) - Body ground

Ignition switch 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:


Integration relay (1C-1) - Body ground 10 to 14 V

3. Reinstall the integration relay.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (INTEGRATION RELAY - 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.


Connections Specified

Conditions 1C-1 - 1B-4 10 kΩ or higher

1C-1 - 1B-4

Below 1 Ω (When battery

voltage applied to terminals 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.

Standard resistance: Below 1 Ω

3. Reinstall the IGN fuse.

NG

CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE

OK

6.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - INTEGRATION RELAY)

1. Remove the integration relay.



Standard resistance (Check for open):


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

Standard resistance (Check for short):


IG (D79-3) - Body ground 10 kΩ or higher


5. Reconnect the ECU connector

Result:

Result Proceed 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 BODY ECU)


2. Remove the main body ECU.




Integration relay (1B-2) - IG2D (D65-5) Below 1 Ω

Integration relay (1B-3) - Body ground Below 1 Ω



IG2D (D65-5) - Body ground 10 kΩ or higher


5. Reinstall the main body ECU.

NG


OK

CHECK ENTRY AND START SYSTEM 8.CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - IGNITION SWITCH)


2. Disconnect the ignition switch connector.




Integration relay (1B-2) - Ignition switch

IG2 (D8-6) Below 1 Ω

Integration relay (1B-3) - Body ground Below 1 Ω



Ignition switch IG2 (D8-6) - Body ground

10 kΩ or higher


5. Reconnect the ignition switch connector.

NG


OK

9.INSPECT IGNITION SWITCH

1. Remove the ignition switch.

2. Measure the resistance between the terminals of the ignition switch.

Standard resistance: Switch

Positions Tester


Conditions

LOCK - 10 kΩ or higher

ACC 2 - 4 Below 1 Ω1 - 2 - 4 Below 1 Ω

ON 5 - 6 Below 1 Ω

1 - 3 - 4 Below 1 ΩSTART

5 - 6 - 7 Below 1 Ω

3. Reinstall the ignition switch.

NG

REPLACE IGNITION SWITCH

OK

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

MULTI-MODE MANUAL TRANSAXLE SYSTEM > Shift Lock Solenoid Circuit

for Preparation

DESCRIPTION The shift lock solenoid is built into the shift lever assembly. When the ignition switch is turned off, or when the shift lever is in the N position without depressing the brake pedal although 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 lock solenoid 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.



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 -

TRANSMISSION CONTROL ECU, BODY GROUND)

1. Disconnect the shift lever assembly connector.





SLS (D79-5) - IG (D81-2) Below 1 Ω

E (D81-6) - Body ground Below 1 Ω

SLS (D79-5) - Body ground 10 kΩ or higher


5. Reconnect the shift lever assembly connector.

NG


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

ConnectionsSpecified

ConditionsBrake pedal

depressed

SLS (D79-5) - Body ground

10 to 14 V

Brake pedal

released

SLS (D79-5) Body ground Below 1 V

NG


OK


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

for Preparation

DESCRIPTION The combination meter interprets the multi-mode manual transmission system condition through 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 to send the multi-mode manual transmission warning light signal to the combination meter when the ignition switch is off.

• INDA Terminal Circuit: Power is supplied to the INDA circuit when the ignition switch is on. While the ignition switch is on (IG), the combination meter controls the multi-mode manual transmission warning light ON/OFF condition in accordance with the signal from the INDA circuit. The INDA circuit is used to send the signals for the multi-mode manual transmission warning light and shift position indicator to the combination meter.

The contents of signals from the INDC and INDA circuits, and the status of the multi-mode manual transmission warning light and indicator are shown in the table below.

When Ignition Switch ON: INDA

circuit state (at

combination meter)

Normal Inconsistent signal input (3 seconds or

more)

Interrupted signal input (3 seconds or

more)

INDC circuit (at

combination meter)

Normal +B short or open Normal +B short or

open Normal +B short or open

Shift position indicator

*1

ON depends on

communication signal

ON depends on


OFF OFF OFF OFF

Multi-mode manual

transmission warning

light

ON depends on


ON depends on


ON ON ON ON

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

When Ignition Switch OFF: INDA

circuit state (at

combination meter)

Normal Inconsistent signal input (3 seconds or

more)

Interrupted signal input (3 seconds or

more)

INDC circuit state

(at combination

Normal +B short or open Normal +B short or

open Normal +B short or open

meter) Shift

position indicator

*1

ON depends on


ON depends on


OFF OFF OFF OFF

Multi-mode manual

transmission warning

light

ON depends on


ON depends on


ON ON OFF ON

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

WIRING DIAGRAM

INSPECTION PROCEDURE 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 5 seconds 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 be malfunctioning. 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 following conditions 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.

1.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - COMBINATION METER ASSEMBLY)


2. Disconnect the combination meter connector




INDC (D79-29) - BRQ (D1-13) Below 1 Ω

INDA (D79-31) - TX+ (D1-8) Below 1 Ω

INDC (D79-29) - Body ground

10 kΩ or higher

INDA (D79-31) - Body ground

10 kΩ or higher


5. Reconnect the combination meter connector.

NG


OK

2.INSPECT COMBINATION METER

1. Measure the voltage between the terminal of the combination meter and the body ground.

Standard voltage: Tester

Connection Conditions Specified Conditions

TX+ (D1-8) - Body ground

Ignition switch off

3.64 V or more

TX+ (D1-8) - Body ground

Ignition switch on

(IG)

1.44 V or less

BRQ (D1-13) - Body

ground Always 1.44 V or

less

NG

INSPECT METER / GAUGE SYSTEM

OK


MULTI-MODE MANUAL TRANSAXLE SYSTEM > Parking Brake Switch Circuit

for Preparation

DESCRIPTION The transmission control ECU detects the ON/OFF status of the parking brake switch. When the parking brake is applied, the parking brake switch turns ON. When the parking brake is released, the switch turns OFF. HINT:

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 assists the vehicle in preparing to move. The take off assist control is cancelled while the parking brake switch is ON.

WIRING DIAGRAM


1.INSPECT PARKING BRAKE SWITCH ASSEMBLY

1. Remove the parking brake switch assembly.

2. Check the parking brake switch resistance.


Connections Switch

Position Specified

Conditions

1 - Switch body

OFF (shaft

pressed)

10 kΩ or higher

1 - Switch body

ON (shaft

released) Below 1 Ω

3. Reinstall the parking brake switch assembly.

NG

REPLACE PARKING BRAKE SWITCH ASSEMBLY

OK

2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - BODY GROUND)




Connections Switch

ConditionsSpecified

ConditionsPKB (D79-4) - Body ground

OFF 10 kΩ or higher

PKB (D79-4) - Body ground

ON Below 1 Ω


NG


OK

3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY


2. Measure the voltage between the terminal of the transmission control ECU connector and the body ground when the parking brake switch is ON and OFF.

Standard voltage: Tester

Connections Switch

ConditionsSpecified

Conditions


Parking brake switch OFF

10 to 14 V


Parking brake switch

ON

Below 1 V

NG


OK


MULTI-MODE MANUAL TRANSAXLE SYSTEM > TC and CG Terminal Circuit

for Preparation

DESCRIPTION Terminal TC and CG are located in the DLC3. When performing [Clamp Position Adjustment] and [Initialization and Learning] without using an intelligent tester, connecting terminals TC and CG is necessary. If the TC terminal circuit is open, these calibration procedures cannot be performed without using an intelligent tester.

WIRING DIAGRAM


1.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - DLC3)





DG (D79-25) - TC (D15-13) Below 1 Ω

DG (D79-25) - Body ground 10 kΩor higher


NG


OK

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




CG (D15-4) - Body ground Below 1 Ω

NG


OK


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 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.

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

DIFFERENTIAL OIL SEAL > COMPONENTS for Preparation

1 / 2

2 / 2

DIFFERENTIAL OIL SEAL > REMOVAL for Preparation

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.


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:

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

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

13. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT:

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

SST 09520-01010 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.

NOTICE:


18. REMOVE TRANSAXLE CASE OIL SEAL

1. Using SST, remove the oil seal.

SST 09308-00010

19. REMOVE TRANSMISSION CASE OIL SEAL

1. Using SST, remove the oil seal.

SST 09308-00010

DIFFERENTIAL OIL SEAL > INSTALLATION for 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 09636-20010 Drive 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.

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. • Do not damage the oil seal. • Do not damage the inboard joint boot.

HINT: Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH HINT:

The installation procedure for the RH side is the same as that for the LH side. 5. 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 push the front axle further out of the vehicle than is necessary. • 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.

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: 74 N*m 755 kgf*cm , 55 ft.*lbf 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:

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

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

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

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




NOTICE:





21. INSPECT ABS SPEED SENSOR SIGNAL () 22. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT () 23. CHECK FOR TRANSAXLE OIL LEAKAGE

SHIFT LEVER > COMPONENTS for Preparation

1 / 2

2 / 2

SHIFT LEVER > ON-VEHICLE INSPECTION for Preparation

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.

3. Check the solenoid operating sound when applying battery voltage across terminals 2 and 6. If the solenoid does not operate, replace the shift lever assembly.

4. Connect the indicator light wire connector.

2. INSPECT TRANSMISSION SHIFT MAIN SWITCH

1. Disconnect the indicator light wire connector.

2. Move the shift lever to the M position.

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

Standard Resistance: Shift

position Terminals Specified condition

M 4 - 8 Below 1 Ω

4. Move the shift lever to the E position.

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



E 4 - 8 10 kΩ 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

1. Disconnect the shift lever position sensor connector.

2. Using an ohmmeter, measure the resistance according to the values in the table below.



R 4 - 9 - 10 - 13 Below 1 Ω

N 4 - 2 - 10 - 6 Below 1 Ω

E, M 4 - 2 - 3 - 13 Below 1 Ω

+ 11 - 5 Below 1 Ω

M 11 - 5 - 12 10 kΩ or higher

- 11 - 12 Below 1 Ω

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

3. Connect the shift lever position sensor connector.

SHIFT LEVER > REMOVAL for Preparation 1. REMOVE REAR CONSOLE BOX COVER

1. Disengage the 8 claws and remove the console box rear cover.

2. REMOVE REAR CONSOLE BOX ASSEMBLY

1. Remove bolt <F>.

2. Disengage the 2 clips and remove the console box rear.

3. REMOVE SHIFT LEVER ASSEMBLY

1. Disconnect the 2 connectors.

2. Remove the 4 bolts and shift lever assembly.

SHIFT LEVER > DISASSEMBLY for Preparation 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY 2. REMOVE POSITION INDICATOR LIGHT GUIDE

1. Disconnect the indicator light wire from the shift lever assembly

2. Disengage the 4 claws and remove the position indicator light guide from the shift lever 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

5. REMOVE SHIFT LOCK RELEASE BUTTON

1. Remove the shift lock release button and compression spring from the shift lever assembly.

6. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY

1. Disconnect the indicator light wire connector from the shift lever assembly.

2. Remove the bulb and cap from the indicator light wire.

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

4. Put marks on wire harnesses 2 and 4.

5. Release the locking lugs of terminals 2, 4, 6 and 8, and pull the wire harness out of the terminals.

SHIFT LEVER > REASSEMBLY for Preparation

1. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY

1. Connect marked wire harnesses 2 and 4 to the indicator light wire connector as shown 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

1. Engage the 4 claws to install the position indicator housing.

2. Engage the 4 claws to install the 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

1. Engage the 2 clips and install the console box rear.

2. Install bolt <F>.

3. INSTALL REAR CONSOLE BOX COVER

1. Engage the 8 claws and install the console box rear cover.

MULTI-MODE MANUAL TRANSAXLE ASSEMBLY > COMPONENTS for Preparation

1 / 10

2 / 10

3 / 10

4 / 10

5 / 10

6 / 10

7 / 10

8 / 10

9 / 10

10 / 10

MULTI-MODE MANUAL TRANSAXLE ASSEMBLY > REMOVAL for Preparation

1. CLUTCH POSITION ADJUSTMENT () 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 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

7. REMOVE ENGINE UNDER COVER RH 8. 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.


9. REMOVE HOOD SUB-ASSEMBLY 10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

1. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

2. Remove the nut and front wiper arm.

11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH HINT:

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 the clutch 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.

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.

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:

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

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

43. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT:

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

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.

SST 09520-01010 09520-24010 (09520-32040) NOTICE:


47. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

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

NOTICE:


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: 28 N*m 286 kgf*cm , 21 ft.*lbf

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: 35 N*m 357 kgf*cm , 26 ft.*lbf

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 (for 1KR-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 MANUAL TRANSAXLE 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 A 39 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.


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



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)





6. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET

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

Torque:

39 N*m 398 kgf*cm , 29 ft.*lbf 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 RH and LH alternately, tighten bolts A, B and C on both sides to the specified torque, in several steps.

SST 09670-00011 Torque: 70 N*m 714 kgf*cm , 52 ft.*lbf for Bolt A 160 N*m 1,631 kgf*cm , 118 ft.*lbf for Bolt B 95 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.

• Do not damage the oil seal. • Do not damage the inboard joint boot.

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:

The installation procedure for the RH side is the same as that for the LH side. 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 push the front axle further out of the vehicle than is necessary. • 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:

The installation procedure for the RH side is the same as that for the LH side. 12. INSTALL FRONT STABILIZER LINK ASSEMBLY LH

1. Install the stabilizer link with the nut.

Torque: 74 N*m 755 kgf*cm , 55 ft.*lbf 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:

The installation procedure for the RH side is the same as that for the LH side. 14. 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.

15. INSTALL TIE ROD END SUB-ASSEMBLY RH HINT:

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

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.

17. 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. 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 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.

19. INSTALL SPEED SENSOR FRONT RH HINT:

The installation procedure for the RH side is the same as that for the LH side. 20. INSTALL FRONT AXLE SHAFT LH NUT

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


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 4 compression springs and 4 bolts.


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.


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.



3. Connect terminal 30 with the nut.


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.


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.


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. Install the cowl top panel outer with the 9 bolts.


2. Engage the clamp and install the wiper motor connector wire harness.

36. INSTALL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2

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.


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.


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.


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.


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.


45. INSTALL HOOD SUB-ASSEMBLY 46. INSPECT HOOD SUB-ASSEMBLY

1. Check that the clearance measurements are within the standard ranges.

Standard:

Area Measurement Area Measurement

A 1.7 to 5.7 mm (0.067 to 0.224 in.) G -1.55 to 2.45 mm

(-0.061 to 0.096 in.)

B -2 to 2 mm (-0.079 to 0.079 in.) H 1.75 to 5.75 mm

(0.067 to 0.226 in.)

C 4.45 to 10.45 mm (0.175 to 0.411 in.) I -1.25 to 2.75 mm

(-0.049 to 0.108 in.)

D -0.95 to 5.05 mm (-0.037 to 0.199 in.) J -1.5 to 1.5 mm

(-0.059 to 0.059 in.) E 7.55 to 13.55 mm K 2.0 to 5.0 mm

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

F 1.65 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.


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.


48. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

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


2. Tighten bolt A.


49. INSTALL COLUMN HOLE COVER SILENCER SHEET

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

2. Install the floor carpet.

50. ADD TRANSAXLE OIL 51. INSPECT AND ADJUST TRANSAXLE OIL




NOTICE:





52. INSTALL ENGINE UNDER COVER RH 53. INSTALL ENGINE UNDER COVER LH 54. INSTALL FRONT WHEELS


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


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

1. Remove the reverse idler gear shaft lock bolt with the gasket from the transmission case.

11. REMOVE MANUAL TRANSMISSION CASE


2. Using a brass bar and hammer, tap the projection of the transmission case and remove the case.

3. Remove the shim from the transmission case.

12. REMOVE SHIFT HEAD SET SLOTTED SPRING PIN

1. Using a pin punch and hammer, drive out the 2 slotted spring pins out of gear shift heads No. 1 and No. 3.

13. REMOVE GEAR SHIFT FORK SHAFT NO.1

1. Remove the set bolt from gear shift fork No. 1.

2. Pull out gear shift fork shaft No.1 and the snap ring from the transaxle case.

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.


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 at the 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.


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.


6. Remove the reverse shift fork from gear shift fork 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 09527-30010 09612-65014 (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 B Maximum inside diameter: 14.42 mm (0.5677 in.) for A 14.03 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.


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









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




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


9. INSPECT GEAR SHIFT HEAD NO.1

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


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

Maximum inside diameter: 14.05 mm (0.5531 in.) for A 14.4 mm (0.5669 in.) for B

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

MULTI-MODE MANUAL TRANSAXLE 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).

SST 09950-60010 (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 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 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.


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-FE 3.18 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.

Mark Thickness mm (in.) Mark Thickness

mm (in.)

A 1.55 (0.0610) J 1.95

(0.0768)

B 1.60 (0.0630) K 2.00

(0.0787)

C 1.65 (0.0650) L 2.05

(0.0807) D 1.70 M 2.10

(0.0669) (0.0827)

E 1.75 (0.0689) N 2.15

(0.0846)

F 1.80 (0.0709) P 2.20

(0.0866)

G 1.85 (0.0728) Q 2.25

(0.0886)

H 1.90 (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 the specifications.

Shim thickness: Shim thickness (B - A) should be more than 0 mm (0 in.) and less than 0.1 mm (0.0039 in.)


mm (in.)

F 1.80 (0.0709) N 2.15

(0.0846)

G 1.85 (0.0728) P 2.20

(0.0866)

H 1.90 (0.0748) Q 2.25

(0.0886)

J 1.95 (0.0768) R 2.30

(0.0906) K 2.00 S 2.35

(0.0787) (0.0925)

L 2.05 (0.0807) T 2.40

(0.0945)

M 2.10 (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 them onto 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.


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.


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 in the illustration.

19. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

1. Install the reverse shift arm bracket onto the transaxle case with the 2 bolts.

Torque: 17 N*m 175 kgf*cm , 13 ft.*lbf NOTICE: 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.



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.

NOTICE: Insert the straight pin along the groove on gear shift fork shaft No. 1, as shown in the illustration.

5. Install the set bolt onto gear shift fork No. 1.


23. INSTALL SHIFT HEAD SET SLOTTED SPRING PIN

1. Using a pin punch and hammer, tap the 2 slotted spring pins into the No. 1 and No. 3 gear shift heads.

Drive in depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.)

24. INSTALL INPUT SHAFT REAR BEARING SHIM

1. Install the input shaft rear bearing shim onto the transmission case.

HINT: Install the previously selected shim.

25. INSTALL MANUAL TRANSMISSION CASE

1. Apply FIPG to the transmission case, as shown in the illustration.

FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: Assemble the parts within 10 minutes of application.

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.


26. INSTALL REVERSE IDLER GEAR SHAFT BOLT

1. Apply sealant to the reverse idler gear shaft lock bolt threads.


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.


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.


3. Install the shift and select actuator with the 6 bolts and wire harness clamp.


29. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

1. Using SST, install the park/neutral position switch with a new gasket onto the transaxle 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:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

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 transaxle case.

SST 09817-16011 Torque: 40 N*m 410 kgf*cm , 30 ft.*lbf

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.


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.


If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing or the shaft.

4. INSPECT 4TH GEAR RADIAL CLEARANCE

1. Using a dial indicator, measure the 4th gear radial clearance.


If the clearance exceeds the maximum, replace the 4th gear needle roller bearing or the shaft.



Standard clearance:

0.015 to 0.058 mm (0.0006 to 0.0023 in.) Maximum clearance: 0.058 mm (0.0023 in.)


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 5th gear thrust washer from the input shaft.

13. REMOVE 5TH GEAR THRUST WASHER BALL

1. Using a magnetic finger, remove the ball from the input shaft.

14. REMOVE 4TH GEAR

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 ring from 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.)

A 25.502 to 25.515 (1.0040 to 1.00453)

B 30.985 to 31.000 (1.2199 to 1.2205)

C, D 33.985 to 34.000 (1.3380 to 1.3386)

E 23.002 to 23.015 (0.9056 to 0.9091)

F 22.967 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.


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.

Standard inside diameter: 39.015 to 39.031 mm (1.5360 to 1.5367 in.) Maximum inside diameter:

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.


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 the 3rd 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.



If the clearance is less than the minimum, replace the synchronizer ring or the 4th gear.

7. INSPECT 5TH GEAR SYNCHRONIZER RING


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.



If the clearance is less than the minimum, replace the synchronizer ring or the 5th gear.

8. INSPECT TRANSMISSION HUB SLEEVE NO.2

1. Using vernier calipers, measure the clearance between the transmission hub sleeve No. 2 and the shift fork No. 2.

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 transmission hub sleeve No. 2 and gear shift fork No. 2.

9. INSPECT TRANSMISSION HUB SLEEVE NO.3

1. Using vernier calipers, measure the clearance between the transmission hub sleeve No. 3 and the shift fork No. 3.

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 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 input shaft.

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.


mm (in.)

A 2.28 (0.0898) D 2.46

(0.0969)

B 2.34 (0.0921) E 2.52

(0.0992)

C 2.40 (0.0945) F 2.58

(0.1016)

2. Using a snap ring expander, install the new snap ring onto the input shaft.


7. INSPECT 3RD GEAR THRUST CLEARANCE

1. Using a feeler gauge, measure the 3rd gear thrust clearance.


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.


If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing or 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.

10. INSTALL 4TH GEAR BEARING SPACER

1. Coat the 4th gear bearing spacer with gear oil, and install it onto the input shaft.

11. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

1. Coat the 4th gear needle roller bearing with gear oil, and install it onto the input shaft.

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 the 5th gear thrust washer less than 0.1 mm (0.0039 in.).


mm (in.)

1 2.28 (0.0898) 4 2.46

(0.0969)

2 2.34 (0.0921) 5 2.52

(0.0992)

3 2.40 (0.0945) 6 2.58

(0.1016)

2. Using a snap ring expander, install a new snap ring onto 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.)






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 hub sleeve 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 synchronizer ring 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









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.

Standard clearance: 0.10 to 0.45 mm (0.0039 to 0.0177 in.) 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.


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.


If the clearance exceeds the maximum, replace the 1st gear needle roller bearing or 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.) Maximum clearance: 0.056 mm (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 ring from the output shaft.

7. REMOVE 4TH DRIVEN GEAR

1. Using a press, remove the 5th driven gear and 4th driven gear from the output shaft.

8. REMOVE OUTPUT SHAFT SPACER

1. Remove the output shaft spacer from the output shaft.

9. REMOVE 2ND 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 output shaft.

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 > INSPECTION for 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.)

A 23.002 to 23.015 (0.9056 to 0.9061)

B, C 28.3 (1.1142)

D, E 33.985 to 34.000 (1.3380 to 1.3386)

F 25.002 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.


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.

Standard inside diameter: 39.015 to 39.031 mm (1.5360 to 1.5367 in.) Maximum inside diameter:

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.



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.



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 output shaft.

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.)

A 2.28 (0.0898) D 2.46

(0.0969)

B 2.34 (0.0921) E 2.52

(0.0992)

C 2.40 (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.


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.


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.

SST 09316-60011 (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.


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.

SST 09223-00010 09316-60011 (09316-00021)

18. INSTALL 5TH DRIVEN GEAR

1. Using SST and a press, install the 5th driven gear onto the output shaft.

SST 09223-00010 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.).


mm (in.)

A 2.22 (0.0874) F 2.52

(0.0992) B 2.28 G 2.58

(0.0898) (0.1016)

C 2.34 (0.0921) H 2.64

(0.1039)

D 2.40 (0.0945) J 2.70

(0.1063)

E 2.46 (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.

SST 09612-22011

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.

SST 09950-00020 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.

SST 09950-00020 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 from the 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 > REASSEMBLY for Preparation 1. INSTALL FRONT DIFFERENTIAL CASE

1. Install the appropriate thrust washers and side gears. Refer to the table below and select 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 pin through 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 the front 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

SHIFT STROKE SENSOR > REMOVAL for Preparation

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE AIR CLEANER INLET NO.1 (for 2SZ-FE)


3. REMOVE BATTERY HOLD DOWN CLAMP 4. REMOVE BATTERY 5. REMOVE BATTERY TRAY 6. REMOVE BATTERY CARRIER (for 1KR-FE)




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.

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 voltage

55° 4.05 V 0° 2.25 V

-55° 0.45 V Voltage (Power source voltage at 4.7 to 5.3 V):

Sensor angle


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.

SHIFT 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.


5. Connect the shift stroke sensor connector.

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








4. INSTALL BATTERY TRAY 5. INSTALL BATTERY 6. INSTALL BATTERY HOLD DOWN CLAMP 7. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)



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

SELECT STROKE SENSOR > REMOVAL for Preparation







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.

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


55 ° 4.05 V 0° 2.25 V

-55° 0.45 V Voltage (Power source voltage at 4.7 to 5.3V):

Sensor angle


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.

SELECT 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.


5. Connect the select stroke sensor connector.

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








4. INSTALL BATTERY TRAY 5. INSTALL BATTERY 6. INSTALL BATTERY HOLD DOWN CLAMP 7. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)



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 ()

TRANSMISSION REVOLUTION SENSOR > COMPONENTS for Preparation

1 / 1

TRANSMISSION REVOLUTION 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.

TRANSMISSION REVOLUTION 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.

TRANSMISSION REVOLUTION 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.


3. Install the transmission case protector with the bolt.


4. Connect the revolution sensor connector.

2. ADD TRANSAXLE OIL 3. INSPECT AND ADJUST TRANSAXLE OIL




NOTICE:





BACK-UP LIGHT SWITCH > COMPONENTS for Preparation

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2 / 4

3 / 4

4 / 4

BACK-UP LIGHT SWITCH > REMOVAL for Preparation







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

BACK-UP LIGHT SWITCH > INSPECTION for Preparation 1. INSPECT BACK-UP LIGHT SWITCH ASSEMBLY


Standard Resistance: Condition Specified condition Released Below 1 Ω Pushed 10 kΩ or higher

If the result is not as specified, replace the back-up light switch.

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.

SST 09817-16011 Torque: 40 N*m 410 kgf*cm , 30 ft.*lbf

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)



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



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


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

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











8. INSTALL BATTERY TRAY

9. INSTALL BATTERY 10. INSTALL BATTERY HOLD DOWN CLAMP 11. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)



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

PARK / NEUTRAL POSITION SWITCH > COMPONENTS for Preparation

1 / 1

PARK / NEUTRAL POSITION 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 the transaxle case.

SST 09817-16011

PARK / NEUTRAL POSITION SWITCH > INSPECTION for Preparation 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY


Standard Resistance: Condition Specified condition Released Below 1 Ω Pushed 10 kΩ or higher

If the result is not as specified, replace the park/neutral position switch.

PARK / NEUTRAL POSITION SWITCH > INSTALLATION for Preparation 1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

SST 09817-16011

1. Using SST, install the park/neutral position switch with a new gasket onto the transaxle case.


2. Connect the park/neutral position switch connector.

SHIFT AND SELECT ACTUATOR > COMPONENTS for Preparation

1 / 1

SHIFT AND SELECT ACTUATOR > 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.

Standard Resistance: 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.

Standard Resistance: Tester

connection Specified condition

1 - 2 0.1 to 100 Ω

If the resistance is not as specified, replace the shift and select actuator.

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.


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 release the 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)


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 release the 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)


2. Remove the bolt and screw, then remove the transmission control ECU.

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2n-conf.clan.su · MULTI-MODE MANUAL TRANSAXLE SYSTEM > PRECAUTION 1.IGNITION SWITCH EXPRESSIONS 1. The type of ignition switch used on this model differs according to the specifications