Service Bulletin

Section :

Chassis / Power Train Ref. No. : CP-5013

Service Bulletin

Date : Page :

May.,2005 1 of 8

Area Application : Europe Model Name : COROLLA, COROLLA VERSO Model Code : ZNR11#, NDE120# Subject : DTC P0810 Loss of Drive / Unable to Select Gears This Service Bulletin is issued to inform you of production improvement for TMMT produced Corolla Verso and TMMT/TMUK produced MMC Corolla models with Multi-Mode Manual Transmission. 1.

VEHICLE IDENTIFICATION NUMBER (VIN) NOTE This procedure is only applicable to vehicles made at Toyota Motor Manufacturing Turkey (TMMT) and Toyota Motor Manufacturing UK (TMUK). The distinguishing method is by checking the1st digit of the 17-digit VIN: N = Turkey S = UK

A

B

B083694E02

(a) The VIN is stamped on the cowl panel. It is also stamped on the manufacturer's plate as shown in the illustration. 2.

DESCRIPTION OF PHENOMENON Impossible shifting during driving, N light turns ON. Driver unable to select gears, transaxle remains in Neutral.

3.

PRODUCTION IMPROVEMENT Change in MMT ECU logic to suit better to high load conditions.

4.

FIELD FIX PROCEDURE (a) Symptom Confirmation: 1. Confirm problem symptom and conditions. 2. Check for DTC's "Present Codes" and "History Codes" (see procedure below). 3. If DTC P0810 is present, please repair according to the Repair procedure given at the next page. (b) Checking DTC's • If using Intelligent Tester I with software version 10.1 or higher, please check for all codes according to the procedure given in TSB CP-4008. OVERSEAS CUSTOMER SERVICE TECHNICAL DIV.

Service Bulletin

Ref. No. : CP-5013 Page :

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• If using Intelligent Tester II, please follow Repair Manual (RM1100E1) page 05-671, Multimode transaxle DTC Check / Clear. • Without using Intelligent Tester follow the procedure outlined in Repair Manual (RM1100E1) page 05-671, Multi-mode transaxle DTC Check / Clear, using service wire. SST 09843-18040 (c) Repair procedure: (1) Proceed step-by-step following the Field/fix repair procedure outlined below. 1. Confirm problem conditions. 2. Confirm Freeze-frame data. 3. Confirm clutch actuator rod pre-load. 4. Proceed with Field/fix.

Part No. Information : *

Prev.Part No

New Part No.

Part Name

COROLLA VERSO - TMMT I

89530-64010

Same as previous

Computer assembly, Transmission Control LHD

I

89530-64020

Same as previous

Computer assembly, Transmission Control RHD

I

89530-12210

Same as previous

Computer assembly, Transmission Control LHD w/ VSC

MMC COROLLA - TMMT, TMUK I

89530-12220

Same as previous

Computer assembly, Transmission Control LHD w/o VSC

I

89530-12230

Same as previous

Computer assembly, Transmission Control RHD w/ VSC

I

89530-12240

Same as previous

Computer assembly, Transmission Control RHD w/o VSC

* : INTERCHANGABILITY CODE Prev. Part

New Part

I

PP

NP

(I) Prev. Vehicle

New Vehicle

PP

NP

NI PV

NV

PP

NP

(NI) PV

NV

S PV

Interchangeable as a set

NV

In order to distinguish old and new parts a discrimination mark is placed on the ECU housing as outlined below.

OVERSEAS CUSTOMER SERVICE TECHNICAL DIV.

Service Bulletin 5.


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DISCRIMINATION MARK

ECU:

Label: Production Date, Lot No.

E110803E02

1. TMMT Corolla Verso If the production date shown on the label is October 13, 2004 or later, this indicates that the ECU was manufactured after the design was changed. Aplicable part No. Part No.

Label Color

89530-64010

Purple

89530-64020

Light Blue

2. MMC Corolla - TMUK & TMMT If the production date shown on the label is November 10, 2004 or later, this indicates that the ECU was manufactured after the design was changed. Aplicable part No. Part No.

Label Color

89530-12210

Navy

89530-12220

Gray

89530-12230

Black

89530-12240

Green

6.

Example:

HOW TO READ THE LABEL (a) Read the label. Year: 4

'04 year

5

'05 year

Month: Year

Month

Date E110804E02

A

January

G

July

B

February

H

August

C

March

J

September


Service Bulletin D

April


K

4 of 8

October

E

May

L

November

F

June

M

December

Production Effective : Model

VIN

Production Date

TMMT Corolla Verso

NMTER150-R030079 NMTE16R20R030068

October 22, 2004

TMMT MMC Corolla

NMTEC20E80R002904

November 26, 2004

TMUK MMC Corolla

SB1KC20E00E004709

November 25, 2004


Ref. No. : CP-5013

Service Bulletin

Page :

5 of 8

Chassis & Power Train MMT F/Fix method for DTC P0810 on MMT for Corolla and Corolla Verso 1.

Problem conditions (a) There are 4 possible cases. The repair method is different for each case as the cause is different. case

2.

Problem occurs during clutch

pre-load on the clutch actuator rod is

1

disengagement

correct (no clearance)

2

disengagement

not correct (some clearance)

3

engagement

4

engagement

and

correct not correct

Problem Condition Confirmation Method: (a) Judge the problem condition by confirming problem condition (cases 1, 2, 3 or 4) using the following flow chart (refer to method described in next sheets to determine Clutch (dis)engagement - by "Freeze frame data" - and "Pre-load" condition):

1) Check DTC

NO

2) Are there freeze frame data of P0810? YES 3) During clutch disengagement?

NO

YES

4) Is the pre-load on the clutch rod correct?

NO

YES Case 1

4) Is the pre-load on the clutch rod correct?

NO

YES Case 2

Case 3

Case 4 E110748E02

1) Confirm DTC. Is there DTC P0810? 2) Are there freeze frame data of P0810? 3), 4) Which case is the problem vehicle? Note: • If Freeze Frame data cannot be checked, handle as cases 1 or 2 depending on Pre-load OVERSEAS CUSTOMER SERVICE TECHNICAL DIV.

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• If Pre-load cannot be judged clearly, handle as case 2. 3.

Confirmation Method of Freeze Frame Data P0810: Clutch Position Control Freeze Frame Data Item

Data

Unit

Item

Engine Coolant Temperature

86

Engine Revolution

Vehicle Speed

40

Accelerator Pedal Angle

Theoretical Engine Torque Shift Position (Current)

Data

Unit

2118.75 10.8

17

Nm

Clutch Position (Current)

37.404

mm

mm

Select Position (Current)

25.37209

mm

24

A

Shift Motor Current MMT

0

Select Motor Current MMT

0

A

Gear Position (Current)

3

Gear Position (Target) Cold Condition Judgement

3

Shift Lever Position Judge

E

69

Shift Lever Switch Signal 1

Open


Open


Gnd


Open


Open

Shift Lever Check Signal 1

Open


Gnd


Open

T/M Reverse Switch Signal

Open

Steering SW Signal Down

#NAME? Gnd

%

8.53414

Clutch Motor Current MMT

Ignition Signal

rpm

Steering Switch Signal Up

Gnd

Brake Switch Signal 1

Open OFF

Brake Switch Signal 2

Open

STP Switch Signal

STA Switch Signal

OFF

Mode Changes

Possibility of T/M Uplock

No

Learn-Clutch Standby Point

Exec

Learning-T/M

Exec

Learn-Clutch Stopper Point

Exec

A

38

Check "Clutch Motor Current MMT" whether "more than 22A" or "less than-22A". And also please check both "Shift Motor Current MMT" and "Select Motor Current MMT" are "0A". HINT: • When "Clutch Motor Current MMT" is "more than 22A", Problem condition is "during clutch engagement". • When "Clutch Motor Current MMT" is "less than -22A", Problem condition is "during clutch disengagement". • The example shown above is "during clutch engagement". 4.

Confirmation method of the pre-load on the clutch actuator rod (a) Checking method: (1) Turn the ignition switch to OFF and keep it there.


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(2) As shown in the illustrations below, put the finger lightly on the clutch actuator rod nut and apply small load in Up & Down direction. (Load applied by the finger is approx. 2N.) Check whether or not the rod moves in between the fork hook.

Fork

Rod nut

Fork hook

E110751E02

Judgement: • If the rod nut does not move in Up & Down direction with approx. 2N load → Pre-load adjustment on the clutch actuator rod is correct. • If the rod nut moves in Up & Down direction with approx. 2N load → Pre-load adjustment on the clutch actuator rod is incorrect. HINT: On the normal nominal condition, the load in the clutch actuator rod direction is 96N. 5.

Field /Fix repair Case

Problem Condition

Cause

F/Fix parts

1

1. During the clutch disengagement 2. The pre-load on the clutch actuator rod is correct.

1. Decreasing of clutch release efficiency

1. MMT-ECU 2. Grease

1. Replace the MMT-ECU by C/M one. 2. Clean the clutch release support and apply the grease. 3. MMT-ECU initialization

2

1. During the clutch disengagement 2. The pre-load on the clutch actuator rod is not correct.

1. Decreasing of clutch release efficiency 2. Too much LCC adjustment due to the low clutch release efficiency

1. 2. 3. 4.

1. Replace the MMT-ECU by C/M one. 2. Clean the clutch release support and apply the grease. 3. Replace the clutch disc and the clutch cover. 4. MMT-ECU initialization

MMT-ECU Grease LCC Clutch Disc

F/Fix procedure


Service Bulletin Cause


F/Fix parts

8 of 8

Case

Problem Condition

F/Fix procedure

3

1. During the clutch engagement 2. The pre-load on the clutch actuator rod is correct.

1. Clutch actuator internal lock

1. MMT-ECU

1. Replace the MMT-ECU by C/M one. 2. MMT-ECU initialization

4

1. During the clutch engagement 2. The pre-load on the clutch actuator rod is not correct.

1. Clutch actuator internal lock 2. Not correct installation of the clutch actuator at a vehicle factory

1. MMT-ECU

1. Replace the MMT-ECU by C/M one. 2. Reinstall the clutch actuator according to the repair manual. 3. MMT-ECU initialization
