MULTI-MODE MANUAL TRANSAXLE SYSTEM, Diagnostic DTC:P0806,P0807 and P0808

DTC Code DTC Name
P0806 Clutch Position Sensor "A" Circuit Range / Performance
P0807 Clutch Position Sensor (Low)
P0808 Clutch Position Sensor (High)

DESCRIPTION

The clutch stroke sensor is mounted on the clutch actuator, and detects the clutch master cylinder position of the clutch actuator. The sensor consists of a sensor arm, a magnetic yoke and 2 Hall ICs. This sensor is a non-contact type, and uses Hall-effect elements (Hall ICs: main and sub), in order to yield accurate signals.

When the clutch actuator is operating, the magnetic yoke that is coaxially positioned on the sensor arm is rotated and the magnet position changes. The Hall ICs convert the magnet position change into the voltage signals and send them to the TCM. The TCM judges the clutch condition (whether the clutch is engaged, disengaged, or partially engaged) based on the signal from the clutch stroke sensor.

The main and sub circuits in the clutch stroke sensor have the same output characteristics.

C112730E14

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

Memory

P0806

Clutch Position Sensor "A" Circuit Range / Performance

Deviation between sensor signal 1 (main) and sensor signal 2 (sub) is 2.0 mm (0.078 in.) or more for 1.0 second or more

(1-trip detection logic)

  • Clutch stroke sensor

  • Open or short in clutch stroke sensor circuit

  • TCM

Does not come on

Comes on

DTC stored

P0807

Clutch Position Sensor (Low)

  • Clutch stroke sensor (main) signal voltage is 0.2 V or less for 0.5 seconds or more

    (1-trip detection logic)

  • Clutch stroke sensor (sub) signal voltage is 0.2 V or less for 0.5 seconds or more

    (1-trip detection logic)

  • Clutch stroke sensor

  • Open or short in clutch stroke sensor circuit

  • TCM

Comes on

Comes on

DTC stored

P0808

Clutch Position Sensor (High)

  • Clutch stroke sensor (main) signal voltage is 4.8 V or more for 0.5 seconds or more

    (1-trip detection logic)

  • Clutch stroke sensor (sub) signal voltage is 4.8 V or more for 0.5 seconds or more

    (1-trip detection logic)

  • Clutch stroke sensor

  • Open or short in clutch stroke sensor circuit

  • TCM

Comes on

Comes on

DTC stored

WIRING DIAGRAM

C279531E01

CAUTION / NOTICE / HINT

Note:

When installing parts related to the multi-mode manual transaxle system, perform the initialization and learning and synchronization position calibration procedures. In addition, the required operations differ according to the parts to be installed. Proceed with the operation in the order shown in the table below.

Table 1. After Installation

Part Installed

Part Installed

See Procedure

  • Transaxle assembly

  • Transaxle parts (inside gear box)

  • TCM

  • Clutch actuator assembly

  • Clutch disc and clutch cover

  • Clutch release with bearing cylinder assembly

  • Flywheel

  • Crankshaft

1. Initialization of multi-mode manual transaxle system

[Tester display: Initialization of ECU]

Click here

2. Learning of multi-mode manual transaxle system

3. Synchronization position calibration

  • Shift and select actuator

  • Shift stroke sensor

  • Select stroke sensor

1. Initialization of multi-mode manual transaxle system

[Tester display: Initialization of transmission]

2. Learning of multi-mode manual transaxle system

3. Synchronization position calibration

  • Clutch stroke sensor

1. Initialization of multi-mode manual transaxle system

[Tester display: Initialization of clutch]

2. Learning of multi-mode manual transaxle system

If the sensor or actuator is installed without the initialization and learning procedures, it may cause driving performance degradation or system component breakage.

PROCEDURE

  1. INSPECT TCM (VCR1 AND VCR2 VOLTAGE)

    1. Disconnect the clutch stroke sensor connector.

    2. C195874C05

      *a

      Front view of wire harness connector

      (to Clutch Stroke Sensor)

      Turn the ignition switch to ON.

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

      Standard Voltage

      Tester Connection

      Condition

      Specified Condition

      A106-2 (E2R1) - A106-3 (VCR1)

      Ignition switch ON

      4.7 to 5.3 V

      A106-5 (E2R2) - A106-6 (VCR2)

      Ignition switch ON

      4.7 to 5.3 V

    Result

    Proceed to

    OK

    NG
    NG

    CHECK HARNESS AND CONNECTOR (CLUTCH STROKE SENSOR - TCM)Click here

    OK

  2. INSPECT CLUTCH STROKE SENSOR

    1. Remove the clutch stroke sensor.

    2. C234947C05

      *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°

        3.6 to 4.5 V

        0°

        1.8 to 2.7 V

        -55°

        0.27 to 0.63 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°

        4.0 to 5.0 V

        0°

        2.0 to 3.0 V

        -55°

        0.3 to 0.7 V
    3. C234947C06

      *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°

        3.6 to 4.5 V

        0°

        1.8 to 2.7 V

        -55°

        0.27 to 0.63 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°

        4.0 to 5.0 V

        0°

        2.0 to 3.0 V

        -55°

        0.3 to 0.7 V
        Note:

        • Do not apply more than 6 V.

        • Do not use a sensor which has been dropped.

    Result

    Proceed to

    OK

    NG
    NG

    REPLACE CLUTCH STROKE SENSORClick here

    OK

  3. CHECK HARNESS AND CONNECTOR (CLUTCH STROKE SENSOR - TCM)

    1. Disconnect the TCM connector.

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

      Standard Resistance

      Tester Connection

      Condition

      Specified Condition

      A106-1 (VSR1) - A108-26 (VSR1)

      Always

      Below 1 Ω

      A106-4 (VSR2) - A108-34 (VSR2)

      Always

      Below 1 Ω

      A108-26 (VSR1) - Body ground

      Always

      10 kΩ or higher

      A108-34 (VSR2) - Body ground

      Always

      10 kΩ or higher

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  4. REPLACE TCM

    1. Replace the TCM.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  5. PERFORM INITIALIZATION

    1. Perform the initialization and learning procedure.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    END

  6. REPLACE CLUTCH STROKE SENSOR

    1. Replace the clutch stroke sensor.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

  7. PERFORM INITIALIZATION

    1. Perform the initialization and learning procedure.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    END

  8. CHECK HARNESS AND CONNECTOR (CLUTCH STROKE SENSOR - TCM)

    1. Disconnect the TCM connector.

    2. Disconnect the clutch stroke sensor connector.

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

      Standard Resistance

      Tester Connection

      Condition

      Specified Condition

      A106-2 (E2R1) - A108-25 (E2R1)

      Always

      Below 1 Ω

      A106-3 (VCR1) - A108-27 (VCR1)

      Always

      Below 1 Ω

      A106-5 (E2R2) - A108-33 (E2R2)

      Always

      Below 1 Ω

      A106-6 (VCR2) - A108-35 (VCR2)

      Always

      Below 1 Ω

      A108-25 (E2R1) - Body ground

      Always

      10 kΩ or higher

      A108-27 (VCR1) - Body ground

      Always

      10 kΩ or higher

      A108-33 (E2R2) - Body ground

      Always

      10 kΩ or higher

      A108-35 (VCR2) - Body ground

      Always

      10 kΩ or higher

    Result

    Proceed to

    OK

    NG
    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  9. REPLACE TCM

    1. Replace the TCM.

      Click hereClick here

    Result

    Proceed to

    NEXT
    NEXT

  10. PERFORM INITIALIZATION

    1. Perform the initialization and learning procedure.

      Click here

    Result

    Proceed to

    NEXT
    NEXT

    END