1 BL AUTOMATIC TRANSMISSION (AISIN 30-40 LEi) CONTENTS SPECIFICATION SYSTEM CONSTRUCTION SYSTEM LAYOUT POWER FLOW COMPONENTS SHIFT LOCK DEVICE INSTALLATION ELECTRICAL CONTROL PARTS HYDARULIC CONTROL SYSTEM ELECTRONIC CONTROL 10 DIAGNOSIS 11 WIRING DIAGRAM 12 SHIFT PATTERN SPECIFICATION General Specifications ENGINE A-2.5 TCI A/T Model 30-40LEi (AISIN AW) General speed transmission (Full line pressure control) Maximum input torque (kg.m) Weight (kg) Torque converter Type Dia (mm) ATF oil ATF capacity (liter) Adapted vehicle Elements Stage Phases 254 Clutches, Brakes, OWCs Planetary gear Shift mode 35 79.8 Components Gear ratio 3.5 V6 Planetary gear sets (Simple type) 1,2,3,4/R 2.804, 1.531, 1.000, 0.705 / 2.393 P-R-N-D-2-L / SNOW(2WD only) CASTLE AUTO FLUID D - I I 9.2 TERRACAN(HMC), CROWN(TOYOTA), VOLVO 960 SYSTEM CONSTRUCTION Block Diagram Engine Shift lever Torque 토크 converter 컨버터 Oil pump Input shaft Sensors & switches SCSV A Valve body Clutch Inhibitor switch Control valves SCSV B OWC DCCSV Brake PCSV Accumulators Planetary gear Output shaft C U ECU Output sensor Input sensor Propeller shaft T Power flow Hydraulic flow Mechanical flow Electrical flow SYSTEM LAYOUT Output speed sensor To detect output shaft revolution Neutral switch To detect "N" range(A/T) or "Neutral" range(M/T) Elbow (cooler out) Way-out from a cooler hose to the A/T Elbow (cooler in) Way-in to the cooler hose from the torque converter Air Breather hose For air ventilation inside transmission Oil temp sensor To detect the oil temperature Input speed sensor To detect input shaft revolution Outer lever Connected to the control cable to change driving range T/M wire Solenoid valves and sensors connection POWER FLOW C2 C1 Components and function COMPONENTS FUNCTION C0 O/D direct clutch Connect O/D sun gear and O/D carrier C1 Forward clutch Connect O/D input shaft and input shaft C2 Direct clutch Connect input shaft and Fr/Rr planetary sun gear B0 O/D brake Hold O/D sun gear B1 2nd coast brake Hold Fr/Rr planetary sun gear B2 2nd brake Hold counterclockwise rotation of Fr/Rr planetary sun gear (Hold outer race of F1) B3 1st & reverse brake Hold Fr planetary carrier F0 O/D OWC Connect O/D sun gear and O/D carrier, when O/D sun gear rotates faster than O/D carrier F1 NO.1 OWC Hold counterclockwise rotation of Fr/Rr planetary sun gear, when B2 operates F2 NO.2 OWC Hold counterclockwise rotation of Fr planetary carrier POWER FLOW Components and operation B3 B2 B1 C2 C0 B0 C1 IN OWC 1(F1) OD OWC(F0) OD INPUT SHAFT OWC 2(F2) OUT INPUT SHAFT OUTPUT SHAFT POWER FLOW Components and operation POWER FLOW Components and operation P O S IT IO N S O L E N O ID CLUTCH S1 S2 SL P ON › OFF~ OFF~ R (V < ) ON › OFF~ R (V > = ) ON › N D L C0 BRAKE GEAR O W C R A T IO C1 C2 B0 B1 B2 B3 F0 F1 F2 ON › OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ OFF ~ OFF~ - OFF~ ON › OFF~ ON › OFF~ OFF~ OFF~ ON ON › OFF ~ OFF~ ON › OFF~ ON › OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ ON › OFF ~ OFF~ - | ON › OFF~ OFF~ ON › OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ OFF ~ OFF~ - | st ON › OFF~ OFF~ ON › ON › OFF~ OFF~ OFF~ OFF~ OFF~ ON › OFF ~ ON OFF › ~ 2nd ON › ON › OFF~ ON › ON › OFF~ OFF~ OFF~ ON › OFF~ ON › ON OFF › ~ OFF~ 3 rd OFF~ ON › ON › ON › ON › ON › OFF~ OFF~ ON › OFF~ ON › OFF~ OFF~ 0 th OFF~ OFF~ ON › OFF~ ON › ON › ON › OFF~ ON › OFF~ OFF~ OFF~ OFF~ st ON › OFF~ OFF ~ ON › ON › OFF ~ OFF~ OFF~ OFF~ OFF~ ON › OFF~ ON OFF › ~ 2nd ON › ON › OFF ~ ON › ON › OFF ~ OFF~ ON › ON › OFF~ ON › ON › OFF~ 3 rd OFF~ ON › OFF ~ ON › ON › ON › OFF~ OFF~ ON › OFF~ ON › OFF~ OFF~ 0 st ON › OFF~ OFF ~ ON › ON › OFF ~ OFF~ OFF~ OFF~ ON › ON › OFF~ ON 2nd ON › ON › OFF ~ ON › ON › OFF ~ OFF~ ON › ON › OFF~ ON › ON › OFF~ › › | 8 POWER FLOW 10 Principle of each range 3rd gear 1st /2nd gear C1 O/D C1 Fr / Rr Direct Speed coupling reduction Power flow OD input shaft ÆOD gear set(coupling by C0) ÆFr/Rr (speed reduction by F2(1st gear), by B2&F1(2nd gear)) Engine brake - D range 1st,2nd gear: non(F2,F1 free to clockwise) - range: 1st gear(non), 2nd gear(operated by B1) - L range 1st,2nd gear: operated by B1, B3 4th gear O/D Direct Direct coupling coupling Power flow OD input shaft Æ OD gear set(coupling by C0) ÆFr/Rr (coupling by C1 & C2) Engine brake - D & range: operates Reverse gear C1 O/D Fr / Rr C1 Fr / Rr Speed Direct increase coupling Power flow OD input shaft Æ OD gear set (speed increase by B0) Æ Fr/Rr (coupling by C1&C2) Engine brake - D range: operates O/D Fr / Rr Direct Reversed coupling rotation Power flow OD input shaft Æ OD gear set (coupling by C0) Æ Fr/Rr (reverse rotation by B3) Reverse inhibition control: C2 DIAGNOSIS 98 How to count the O/D OFF lamp flashing For example : P1783 / P0604 A B D A C A C A C A C A C A C A B A C A C A C A C A C A A : 0.5sec B A C A C A C A C A C A C A C A B B : 1.5sec D B C : 0.3sec A C A C A C A D : 1.5sec B A C A C A DIAGNOSIS 99 MIL Request ■ MIL: On-board warning lamp for OBD-II, EOBD Emission regulation ■ MIL ON condition - When DTC is memorized in TCM, ; TCU CAN Message, TCU_OBD Bit sets Æ Bit MIL blinking Bit MIL on Bit freeze frame Bit readiness ■ MIL OFF condition - After no failure detected, the D/C condition below should be satisfied ÆUS/EUR: consecutive D/C - When DTC is erased by a Hi-Scan (Pro) or by means of DGC DIAGNOSIS 100 DTC detected condition and failsafe CODE DESCRIPTION P0707 Output speed >= 1130, Engine rpm>= 1500 P0708 or more signals are dectected for more than 10 sec st P0722 P0743 P0748 P0753 P0758 P1121 P0710 P1115 P0717 P0716 P1630 P1631 - rd (1 -3 gear) No output while 45 input pulses detected th (4 gear) 1500 output rpm drop and rpm detected (Short to GND) 'OFF' detected for 300 msec after 'ON' (Open/short to B+) 'ON' detected for 50 msec after 'OFF' (Open/short to GND) AD value =< 15 for 70 msec (Short to B+) AD value >= 1000 for 500 msec (Short to GND) 'OFF' detected for 300 msec after 'ON' (Open/short to B+) 'ON' detected for 50 msec after 'OFF' (Short to GND) 'OFF' detected for 300 msec after 'ON' (Open/short to B+) 'ON' detected for 50 msec after 'OFF' TPS message FF H is received for 0.2 sec (Short) Abnormal sensor resistance detected for (Open) AD value is under 15 or over 1000 detected WT message FF H is received for 0.2 sec No input while 12 pulses of output signal are detected Input speed >= 7000 rpm detected BUS OFF is detected 0.2 sec after IG on No message received from ECM Output rpm >= 2260, TPS>=5%, Brake on >= 10sec FAILSAFE Judge 'D' range (system mechanically operates) D>2>L>R>N>P (operation priority) Gear shift by using input speed sensor signals th No lock-up/4 gear/ETR/LPC/Rverse/Squat control DCCSV OFF st gear hold if output rpm < 375 (Open/B+ short) 4th gear hold Lock-up inhibited Gear hold: D range-4th,2 range-3rd,L range-1st Lock-up inhibited Gear hold: D range-4th,2 range-3rd,L range-1st Judge TPS 0%, Max line pressure, No ETR/LPC Judge ATF temp 200℃, No lock-up, ETR/LPC inhibited while shifting Judge the Temperature normal No lock-up, ETR/LPC inhibited while shifting No lock-up, maximum line pressure, No ETR/LPC No lock-up, maximum line pressure, No ETR/LPC Ignore the brake signal, Lock-up available DIAGNOSIS DTC P0707 P0708 P0722 P0726 P0727 P0740 P0743 P0750 P0753 P0755 P0758 P0748 P1121 P0710 P1115 P0717 P0716 P1795 P1630 P1631 - 101 DESCRIPTION Transmission Range Sensor Circuit Low Input Transmission Range Sensor Circuit High Input Output Speed Sensor Circuit No Signal Engine Speed Input Sensor Range/Performance Engine Speed signal invalid Torque Converter Clutch Circuit (SL) Malfunction Torque Converter Clutch Circuit (SL) Electrical Shift Solenoid A(S1) Malfunction Shift Solenoid A (S1 ) Electrical Shift Solenoid B (S2) Malfunction Shift Solenoid B (S2) Electrical Pressure Solenoid (SLT) Electrical Throttle Sensor Signal invalid ATF Temp Sensor Circuit Malfunction Water Temp Signal Malfunction from ECU to TCU Input Speed Sensor Circuit No Signal Input Speed Sensor Circuit Range / Performance Transfer High/Low(L4) Switch Malfunction CAN communication BUS OFF No ID from ECU Vehicle Speed Signal From Meter Set Brake SW malfunction 3.5 V6(EUR/US) Fault type MIL B O B O B O B O B O B O B O B O A O B O A O A O B O B O B O B O B O B O B O B O C C - 3.5 V6(DOM/GEN), A-2.5 Fault type W/L B B B O B B B B B A B A A B O B B B O B B O B O C - * Fault type - Type A: DTC stored on the 1st driving, Type B: DTC stored on the 2nd driving, Type C: only failsafe (Not DTC stored) * Warning lamp: O/D OFF lamp DIAGNOSIS 102 Troubleshooting P0753 P0758 P0743 Solenoid No.1 (S1) Open, Ground short Solenoid No.2 (S2) Open, Ground short L-up solenoid (SL) Open, Ground short DTC detected condition Cause of failure Ground short: A failure will be displayed in case any trouble is detected at any other gears times after a trouble is detected at one gear for 0.3 sec Harness or connector between each shift solenoid and TCM Open: A failure will be displayed in case any trouble is detected at any other gears times after a trouble is detected at one gear for 0.5 sec Each shift solenoid TCM DIAGNOSIS 103 Troubleshooting P0748 Pressure control solenoid Open, Ground short DTC detected condition Open/short to GND: 20 mA or less current has been detected for 12.5 seconds or more, DTC is memorized Short to B+: 1.36 A or more output current is detected for 0.5 seconds or more, DTC is memorized Cause of failure Harness or connector between PCSV and TCM PCSV TCM DIAGNOSIS 104 Troubleshooting P0716, P0717 P0722 Input speed sensor No signal Output speed sensor No signal DTC detected condition No C0 signal: No pulse from C0 is detected while 12 pulses of SP signal detected, failure is time More than 1000 times continuously detected, it is judged a temporary failure When it is detected again after IG OFF to ON, total failure become times DTC is displayed No SP signal : No pulses from SP is detected while 45 pulses of C0 signal detected, failure is time More than 500 times continuously detected, a temporary failure is memorized When it is detected again after IG OFF to ON, total failure become times DTC is displayed Cause of failure Harness or connector between each speed sensor and TCM Each speed sensor TCM DIAGNOSIS 105 Troubleshooting P0707 TR switch No signal, Open DTC detected condition No signal: DTC decides a temporary failure in case no signal is transmitted more than 30 seconds at 1130 rpm When any trouble is detected again after IG OFF to ON, the number of problems total and DTC decides a failure Open: DTC decides a temporary failure in case detected or more signals for more than 10 sec When any trouble is detected again after IG OFF to ON, the number of problems total and DTC decides a failure Cause of failure Harness or connector between TR switch and TCM TR switch TCM DIAGNOSIS 106 Troubleshooting P0710 ATF temp sensor open or short to Ground DTC detected condition Cause of failure Open: When detected detection condition that the abnormal condition of oil temperature after 15 minutes has passed since IG ON, a temporary failure is decided When it is detected again after IG OFF => ON, the total of failures become times and DTC is decided Harness or connector between ATF temp sensor and TCM Ground short: When detected detection condition that the abnormal condition for minutes since IG ON, a temporary failure is decided When it is detected again after IG is OFF => ON, the total of failures become times and DTC is decided ATF temp sensor TCM DIAGNOSIS 107 TCM input and output terminal voltage table No PIN NAME SCSV 13 (1st, 2nd speed operation) SCSV 14 (2nd,3rd speed operation) SNOW SW (2WD VEHICLE) C0 CYLINDER REV SNSR (Over drive clutch drum) VEHICLE SPEED SENSOR 31 O/D OFF SW 48 INHIBITOR SW(P) 12 INHIBITOR SW(R) 34 BATT CONDITION DRIVING (P,N/1st/2nd 3rd/4th speed) DRIVING (P,N/1st/2nd 3rd/4th speed) SW OFF SW ON INPUT&OUTPUT SIGNAL TYPE Frequency Level Vbatt - 0V Io : 1.9A MAX Vbatt - 0V Frequency Frequency DC IDLE Pusle DRIVING Pulse OFF SW OFF OFF SW ON P R/N/D/2/L R P/N/D/2/L IGN OFF IGN ON DC DC DC DC DC DC DC DC LOCK-UP SOLENOID DRIVING (over 45km/h) Frequency PCSV IDLE Io : 1.9A MAX V GND -0.3 - 2V V(IG.1) V Hi - V Low 16 Pulse/Co cylinder rev V Hi - V Low 12Pulse/TM rev V(IG.1) V GND -0.3 - 2V Vbatt BELOW 0.8V Vbatt BELOW 0.8V Vbatt Vbatt REMARK SCSV1: Shift Control Solenoid Valve no.1 SCSV2: Shift Control Solenoid Valve no.2