MULTI-MODE MANUAL TRANSAXLE SYSTEM, Diagnostic DTC:P0810

DTC Code	DTC Name
P0810	Clutch Position Control Error

DESCRIPTION

In the multi-mode manual transaxle system, the clutch is engaged and disengaged by the TCM using a clutch actuator. The clutch actuator consists of an electric motor which moves the clutch master cylinder, a clutch stroke sensor which detects the clutch master cylinder position, and a worm gear which engages the push rod with the motor.

Clutch Actuator Control Malfunction
DTC No.	DTC Detection Condition	Trouble Area
P0810	The TCM detects the following conditions simultaneously for 2 seconds or more: (1-trip detection logic) Clutch motor current is 30 A or more, or less than -30 A. Difference between target clutch position and actual clutch position is 0.3 mm (0.0118 in.) or more. Clutch actuator movement is 122 mm/sec (4.8 in./sec) or less.	Clutch actuator assembly (clutch motor) Clutch mechanical system (clutch cover, clutch disc, clutch release with bearing cylinder assembly and hydraulic line) Clutch stroke sensor TCM

Tech Tips

The monitor runs when the vehicle is driven at a vehicle speed of 20 km/h (12.4 mph) or more.

Clutch System Malfunction
DTC No.	DTC Detection Condition	Trouble Area
P0810	All conditions below are detected for 0.5 seconds or more: (1-trip detection logic) Clutch system is normal. Starter is off. Engine speed is 2000 rpm or less. Current and target shift position is N. Vehicle is stopped. Input speed is 400 rpm or more.	Clutch actuator assembly (clutch motor) Clutch mechanical system (clutch cover, clutch disc, clutch release with bearing cylinder assembly and hydraulic line) Clutch stroke sensor TCM

WIRING DIAGRAM


*a	Sub
*b	Main
*c	Clutch Stroke Sensor
*d	Clutch Actuator Assembly (Clutch Motor)

MONITOR DESCRIPTION

Clutch Actuator Control Malfunction
This DTC is set in accordance with the stroke speed of the clutch actuator or the difference between the target clutch position and the actual clutch position. Therefore, if malfunctions occur in the clutch stroke sensor or the clutch motor circuit, the DTCs relating to the sensor or motor circuit open/short (DTC P0806, P0807, P0808, and/or P0900) are set before this DTC is set.

Clutch System Malfunction
With the vehicle stopped and the clutch disengaged, measure the input shaft rotation speed. If the input shaft rotation speed is higher than the standard, DTC P0810 is stored.

CAUTION / NOTICE / HINT

Note

In clutch stroke sensor or clutch actuator assembly replacement, perform Initialization and Learning of the multi-mode manual transaxle system after installing the sensor or actuator Click here. If the sensor or actuator is installed without the initialization and learning, it may cause driving performance degradation or system component breakage.

Tech Tips

If the symptom still occurs even after checking the following parts for dirt, wear, or any defects and replacing the defective parts, replace the TCM.

Clutch disc and clutch cover
Clutch release with bearing cylinder assembly
Hydraulic line

PROCEDURE

CHECK CLUTCH FLUID LEAK
1. Check the clutch fluid leaks in clutch hydraulic line.
NG
REPAIR OR REPLACE CLUTCH HYDRAULIC LINE

OK
PERFORM AIR BLEED
1. Perform the air bleed Click here.
NEXT

CONFIRM DTC OUTPUT

Confirm the DTCs output Click here.

Result
Result	Proceed to
P0810 is not output	A
P0810 is output	B

END

PERFORM ACTIVE TEST USING INTELLIGENT TESTER (TARGET CLUTCH CONTROL)
1. Remove the clutch actuator Click here.
2. Connect the clutch stroke sensor connector and the clutch actuator connector.
3. Connect the intelligent tester to the DLC3.
4. Turn the ignition switch to ON.
5. Turn the tester on.
6. Enter the following menus: Powertrain / Multi-Mode M/T / Active Test / Target Clutch Control.
7. Perform the Active Test.
  
  OK
  
  Clutch actuator moves smoothly in accordance with the tester operation.
NG
REPLACE CLUTCH ACTUATOR ASSEMBLY Click here

OK

OK
Clutch actuator moves smoothly in accordance with the tester operation.

INSPECT CLUTCH STROKE SENSOR

Remove the clutch stroke sensor.

Text In Illustration
*1	Sensor Arm
*a	Component without harness connected (Clutch Stroke Sensor)
*b	Main

Measure the voltage between the terminals of the clutch stroke sensor connector (Main).

Prepare 3 dry cell batteries (1.5 V) and 2 leads for connecting the batteries and the sensor.
Connect the batteries in series.
Connect the positive battery terminal to sensor terminal 3 (VCR1), and the negative battery terminal to sensor terminal 2 (E2R1).

Measure the voltage according to the value(s) in the table below.

Standard Voltage (combined dry cell battery voltage of 4.5 V)

Tester Connection

Condition

(Sensor Angle)

Specified Condition

1 (VSR1) - 2 (E2R1)

55°

Approximately 4.05 V

0°

Approximately 2.25 V

-55°

Approximately 0.45 V

Reference Voltage (combined dry cell battery voltage of 5.0 +/- 0.3 V)

Tester Connection

Condition

(Sensor Angle)

Specified Condition

1 (VSR1) - 2 (E2R1)

55°

Approximately 4.5 V

0°

Approximately 2.5 V

-55°

Approximately 0.5 V

Text In Illustration
*1	Sensor Arm
*a	Component without harness connected (Clutch Stroke Sensor)
*b	Sub

Measure the voltage between the terminals of the clutch stroke sensor connector (sub).

Connect the positive battery terminal to sensor terminal 6 (VCR2), and the negative battery terminal to sensor terminal 5 (E2R2).

Measure the voltage according to the value(s) in the table below.

Standard Voltage (combined dry cell battery voltage of 4.5 V)

Tester Connection

Condition

(Sensor Angle)

Specified Condition

4 (VSR2) - 5 (E2R2)

55°

Approximately 4.05 V

0°

Approximately 2.25 V

-55°

Approximately 0.45 V

Reference Voltage (combined dry cell battery voltage of 5.0 +/- 0.3 V)

Tester Connection

Condition

(Sensor Angle)

Specified Condition

4 (VSR2) - 5 (E2R2)

55°

Approximately 4.5 V

0°

Approximately 2.5 V

-55°

Approximately 0.5 V

Note

Do not apply more than 6 V
Do not use a sensor which has been dropped.

REPLACE CLUTCH STROKE SENSOR Click here

INSPECT TCM (MCL TERMINAL VOLTAGE)

Turn the ignition switch to ON.

Text in Illustration
*a	Component with harness connected (TCM)

Measure the voltage according to the value(s) in the table below.

Standard Voltage

Tester Connection	Switch Condition	Specified Condition
A46-6 (MCL+) - Body ground	Ignition switch ON	4.0 to 7.0 V
A46-5 (MCL-) - Body ground	Ignition switch ON	4.0 to 7.0 V

Turn the ignition switch off.

CHECK TERMINAL CONDITION (TCM) Click here

CHECK CLUTCH SYSTEM (CLUTCH MECHANICAL OPERATION)
1. Remove the transaxle assembly Click here.
2. Check for dirt, wear and defects in the clutch system parts (clutch disc, clutch cover, clutch release with bearing cylinder assembly and hydraulic line).
  
  OK
  
  No defective parts in the clutch mechanical system.
NG
REPAIR OR REPLACE DEFECTIVE PART IN CLUTCH SYSTEM

OK
REPLACE TCM
1. Replace the TCM Click here.
NEXT
PERFORM INITIALIZATION
1. Perform the initialization and learning for multi-mode manual transaxle system Click here.
NEXT
END

OK
No defective parts in the clutch mechanical system.

CHECK TERMINAL CONDITION (TCM)

Disconnect the TCM connector.

Check the connections of the TCM connector.

OK
The TCM and wire harness connectors and connector terminals are connected securely and are not bent, rusted, or damaged.

CONNECT CORRECTLY

INSPECT CLUTCH ACTUATOR CIRCUIT

Text in Illustration
*a	Front view of wire harness connector (to TCM)

Measure the resistance according to the value(s) in the table below.

Standard Resistance

Tester Connection	Switch Condition	Specified Condition
A46-6 (MCL+) - A46-5 (MCL-)	Always	Below 10 Ω
A46-6 (MCL+) - Body ground	Always	10 kΩ or higher
A46-5 (MCL-) - Body ground	Always	10 kΩ or higher

CHECK TERMINAL CONDITION (CLUTCH ACTUATOR) Click here

REPLACE TCM
1. Replace the TCM Click here.
NEXT
PERFORM INITIALIZATION
1. Perform the initialization and learning for multi-mode manual transaxle system Click here.
NEXT
END

CHECK TERMINAL CONDITION (CLUTCH ACTUATOR)

Disconnect the clutch actuator assembly connector.

Check the connections of the clutch actuator connector.

OK
The clutch actuator and wire harness connectors and connector terminals are connected securely and are not bent, rusted, or damaged.

CONNECT CORRECTLY

CHECK HARNESS AND CONNECTOR (TCM - CLUTCH ACTUATOR)

Measure the resistance according to the value(s) in the table below.

Standard Resistance

Tester Connection	Switch Condition	Specified Condition
A46-6 (MCL+) - B60-2	Always	Below 1 Ω
A46-5 (MCL-) - B60-1	Always	Below 1 Ω
A46-6 (MCL+) or B60-2 - Body ground	Always	10 kΩ or higher
A46-5 (MCL-) or B60-1 - Body ground	Always	10 kΩ or higher

REPAIR OR REPLACE HARNESS OR CONNECTOR

INSPECT CLUTCH ACTUATOR ASSEMBLY

Text In Illustration
*a	Component without harness connected (Clutch Actuator Assembly)

Measure the resistance according to the value(s) in the table below.

Standard Resistance

Tester Connection	Switch Condition	Specified Condition
1 - 2	Always	Below 10 Ω
1 - Body ground	Always	10 kΩ or higher
2 - Body ground	Always	10 kΩ or higher

CHECK INTERMITTENT PROBLEMS Click here

REPLACE CLUTCH ACTUATOR ASSEMBLY
1. Replace the clutch actuator assembly Click here.
NEXT
PERFORM INITIALIZATION
1. Perform the initialization and learning for multi-mode manual transaxle system Click here.
NEXT
END
REPLACE CLUTCH STROKE SENSOR
1. Replace the clutch stroke sensor Click here.
NEXT
PERFORM INITIALIZATION
1. Perform the initialization and learning for multi-mode manual transaxle system Click here.
NEXT
END