MULTI-MODE MANUAL TRANSAXLE SYSTEM, Diagnostic DTC:P0810

DTC Code DTC Name
P0810 Clutch Position Control Error

DESCRIPTION

In the multi-mode manual transmission system, the clutch is engaged and disengaged by the transmission control ECU using a clutch actuator. The clutch actuator consists of an electric motor which moves the push rod to push the release lever, a clutch stroke sensor which detects the push rod position, and a worm gear which geared the motor to the push rod.

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.

DTC No. DTC Detection Conditions Trouble Areas
P0810

The transmission control ECU detects the following conditions simultaneously:

(1 trip detection logic)


  1. Clutch motor current is 22A or more, or less than -22A for 2 seconds or more

  2. Difference between target clutch position and actual clutch position is 0.3 mm (0.0118 in.) or more

  3. 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, release lever, release fork, release bearing)

  • Clutch stroke sensor

  • Transmission control ECU

Tech Tips

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

WIRING DIAGRAM

A0138J4E01

INSPECTION PROCEDURE

Note


  • In new clutch actuator assembly installation, perform Clamp Position Adjustment before installing the actuator. The push rods of new clutch actuator assemblies (service supply parts) are not set to the clutch clamp position.

  • In clutch stroke sensor or clutch actuator assembly replacement, perform Initialization and Learning of the multi-mode manual transmission 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 transmission control ECU.


  • Clutch Disc and Clutch Cover

  • Release Bearing

  • Clutch Release Fork

PROCEDURE


  1. CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0810)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON and turn the tester ON.

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

    4. Read DTCs.

      Result
      Display (DTC Output) Proceed To
      P0810 A
      P0810 and other DTCs B

      If DTC P0810 is detected together with DTC P0806, P0807, P0808 and/or P0900 (DTCs related to the clutch position sensor or clutch actuator motor circuit open/short), troubleshoot those DTCs first.


    B

    GO TO DTC CHART

    A

  2. INSPECT TRANSMISSION CONTROL ECU ASSEMBLY


    1. A01380A

      Check the clutch actuator motor terminal output using an oscilloscope.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON and turn the tester ON.

      3. Clear the DTC after saving the recorded freeze frame data.

      4. Turn the ignition switch to OFF within 2 seconds after clearing the DTC.

      5. Connect the oscilloscope probes to the transmission control ECU terminals.

      6. Check the waveform when the ignition switch is turned to ON.

        Tester Settings
        Items Contents
        Terminals

        MCL- (A29-6) - GND (A27-6)

        MCL+ (A29-7) - GND (A27-6)
        Gauge set 5 V/DIV, 50 μs/DIV
        Condition Ignition switch ON
        Standard
        Correct waveform shown in the illustration.

        Tech Tips

        The waveform is displayed for several seconds until the DTC is set.


    NG

    REPLACE TRANSMISSION CONTROL ECU ASSEMBLY

    OK

  3. INSPECT TRANSMISSION CONTROL ECU ASSEMBLY

    A0135VXE05

    1. Remove the clutch stroke sensor from the clutch actuator assembly.

    2. Connect the clutch stroke sensor connector.

    3. Turn the ignition switch to ON.

    4. Check the voltage change between the terminals of the transmission control ECU connector when moving the sensor arm of the clutch stroke sensor.

      Standard Voltage
      Tester Connections Specified Conditions
      VSR1 (A28-26) - E2R1 (A28-25) Voltage changes in accordance with sensor arm position
      VSR2 (A28-34) - E2R2 (A28-33) Voltage changes in accordance with sensor arm position

    5. Reinstall the clutch stroke sensor Click here.

    6. Perform initialization and learning Click here.


    OK

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER Click here

    NG

  4. INSPECT CLUTCH STROKE SENSOR

    A0138U2E03

    1. Remove the clutch stroke sensor.

    2. A0138U2E04

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


      1. Prepare 3 dry cell batteries (1.5 V) and 2 leads for connecting the batteries and the sensor.

      2. Connect the batteries in series.

      3. Connect the positive battery terminal and sensor terminal 3, and the negative battery terminal and sensor terminal 2.

      4. Check the voltage between terminals 1 and 2.

        Standard Voltage (combined dry cell battery voltage of 4.5 V)
        Sensor Angle Terminal (1-2) Output Voltage
        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)
        Sensor Angle Terminal (1-2) Output Voltage
        55° Approximately 4.5 V
        0° Approximately 2.5 V
        -55° Approximately 0.5 V

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


      1. Connect the positive battery terminal and sensor terminal 6, and the negative battery terminal and sensor terminal 5.

      2. Check the voltage between terminals 4 and 5.

        Standard Voltage (combined dry cell battery voltage of 4.5 V)
        Sensor Angle Terminal (4-5) Output Voltage
        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)
        Sensor Angle Terminal (4-5) Output Voltage
        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.

    4. Reinstall the clutch stroke sensor Click here.

    5. Perform initialization and learning Click here.


    NG

    REPLACE CLUTCH STROKE SENSOR

    OK

    REPLACE TRANSMISSION CONTROL ECU ASSEMBLY

  5. PERFORM ACTIVE TEST USING INTELLIGENT TESTER


    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 and the tester ON.

    5. Clear the DTC after saving the recorded freeze frame data.

    6. Turn the ignition switch to OFF within 2 seconds after clearing the DTC.

    7. Turn the ignition switch to ON.

    8. Select the following menu items: Powertrain / Multi-Mode M/T / Active Test / Target Clutch Control.

    9. Perform the Active Test.

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

    10. Reinstall the clutch actuator.

    11. Perform initialization and learning Click here.


    NG

    REPLACE CLUTCH ACTUATOR ASSEMBLY

    OK

  6. 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, release lever, release bearing and release fork).

      OK
      No defective parts in the clutch mechanical system.

    NG

    REPAIR OR REPLACE DEFECTIVE PART IN CLUTCH SYSTEM

    OK

    REPLACE CLUTCH ACTUATOR ASSEMBLY