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 transmission control ECU 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 pull rod with the motor.

DTC No. DTC Detection Condition Trouble Area
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

A01360JE01

MONITOR DESCRIPTION

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.

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 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 transmission control ECU.


  • Clutch disc and clutch cover

  • Release bearing

  • Clutch release fork

PROCEDURE


  1. 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

  2. INSPECT CLUTCH STROKE SENSOR


    1. Remove the clutch stroke sensor.

    2. A01376TE01
      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).


      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 to sensor terminal 3 (VCR1), and the negative battery terminal to sensor terminal 2 (E2R1).

      4. 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
    3. A01376TE02
      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).


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

      2. 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.


    NG

    Click here

    OK

  3. INSPECT TRANSMISSION CONTROL ECU (MCL TERMINAL VOLTAGE)


    1. Turn the ignition switch to ON.

    2. A0137QSE13
      Text in Illustration
      *a

      Component with harness connected

      (Transmission Control ECU)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A49-6 (MCL+) - Body ground Ignition switch ON 4.0 to 7.0 V
      A49-5 (MCL-) - Body ground Ignition switch ON 4.0 to 7.0 V

    3. Turn the ignition switch off.


    NG

    CHECK TERMINAL CONDITION (TRANSMISSION CONTROL ECU) Click here

    OK

  4. 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).

      OK
      No defective parts in the clutch mechanical system.

    NG

    REPAIR OR REPLACE DEFECTIVE PART IN CLUTCH SYSTEM

    OK

  5. REPLACE TRANSMISSION CONTROL ECU


    1. Replace the transmission control ECU Click here.


    NEXT

  6. PERFORM INITIALIZATION


    1. Perform the initialization and learning for multi-mode manual transaxle system Click here.


    NEXT

    END

  7. CHECK TERMINAL CONDITION (TRANSMISSION CONTROL ECU)


    1. Disconnect the A49 transmission control ECU connector.

    2. Check the connections of the transmission control ECU connector.

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

    NG

    CONNECT CORRECTLY

    OK

  8. INSPECT CLUTCH ACTUATOR CIRCUIT


    1. A0137TQE11
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Transmission Control ECU)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A49-6 (MCL+) - A49-5 (MCL-) Always 0.1 to 100 Ω
      A49-6 (MCL+) - Body ground Always 10 kΩ or higher
      A49-5 (MCL-) - Body ground Always 10 kΩ or higher

    NG

    CHECK TERMINAL CONDITION (CLUTCH ACTUATOR) Click here

    OK

  9. REPLACE TRANSMISSION CONTROL ECU


    1. Replace the transmission control ECU Click here.


    NEXT

  10. PERFORM INITIALIZATION


    1. Perform the initialization and learning for multi-mode manual transaxle system Click here.


    NEXT

    END

  11. CHECK TERMINAL CONDITION (CLUTCH ACTUATOR)


    1. Disconnect the B27 clutch actuator assembly connector.

    2. 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.

    NG

    CONNECT CORRECTLY

    OK

  12. CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - CLUTCH ACTUATOR)


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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A49-6 (MCL+) - B27-2 Always Below 1 Ω
      A49-5 (MCL-) - B27-1 Always Below 1 Ω
      A49-6 (MCL+) or B27-2 - Body ground Always 10 kΩ or higher
      A49-5 (MCL-) or B27-1 - Body ground Always 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  13. INSPECT CLUTCH ACTUATOR ASSEMBLY


    1. Disconnect the B27 clutch motor connector.

    2. A0135Z0E02
      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 0.1 to 100 Ω
      1 - Body ground Always 10 kΩ or higher
      2 - Body ground Always 10 kΩ or higher

    NG

    REPLACE CLUTCH ACTUATOR ASSEMBLY Click here

    OK

    CHECK INTERMITTENT PROBLEMS Click here

  14. REPLACE CLUTCH ACTUATOR ASSEMBLY


    1. Replace the clutch actuator assembly Click here.


    NEXT

  15. PERFORM INITIALIZATION


    1. Perform the initialization and learning for multi-mode manual transaxle system Click here.


    NEXT

    END

  16. REPLACE CLUTCH STROKE SENSOR


    1. Replace the clutch stroke sensor Click here.


    NEXT

  17. PERFORM INITIALIZATION


    1. Perform the initialization and learning for multi-mode manual transaxle system Click here.


    NEXT

    END