A/T Technical Training for SORENTO

Subject : OBD-II Fault handling

KIA MOTORS

Auto Transmission Engineering Team

4. TCU Block diagram & Terminal assignment

Auto Transmission Engineering Team

5. Fault handling 5-1. DTC List

DTC Description P0707 P0708 P0722 P0727 P0740 P0743 P0750 P0753 P0755 P0758 P0748 P1121 Transmission range sensor circuit low input Transmission range sensor circuit high input Output speed sensor circuit no signal Engine speed input sensor no signal 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 Σ3.5 NAS/EU Fault Type MIL B A A B B B B B B B B A O O O O O O O O O O O O Auto Transmission Engineering Team

P0710 P0717 P0716 P1795 P1630 P1631 ATF sensor circuit malfunction Input speed sensor circuit no signal Input speed sensor circuit range/performance Transfer high/low(L4) switch malfunction

※

1 CAN communication BUS OFF No ID from ECU Vehicle speed signal from Meter set Brake switch malfunction B B B B B B C C ※1 ; Only for 4WD vehicles, “-” ; not be supported Fault type ; A – DTC stored on the 1 st driving cycle B – DTC stored on the 2 nd driving cycle continuously C – Only Fail-safe (not DTC stored) MIL ; “

○

” -- supported(to be performed at the same time as DTC stored) O O O O O O Auto Transmission Engineering Team

5-5. DTC detection, decision condition & Fail safe

SYSTEM ITEM Transmission range sensor circuit low input NO signal DETECTION TCU detects no signal of range sensor more than 30 sec. with following condition.

1.

Output revolution is more than 1130 rpm.

2.

Engine revolution is more than 1500rpm DECISION Same timing of the above detection CONDITION FAILSAFE OPERATION TCU judges the position of range sensor is D range.

PASS CRITERIA To detect no failure more than 2 min.

DTC STORE 2 driving Fail safe cancel condition When TCU judges normal condition REMARKS If no signal is detected, the position of range sensor is judged to D range.

But, A/T is operated mechanically.

DG CODE P0707 MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM Transmission range sensor circuit high input Short DETECTION Detected 2 or more signals more than 10 sec. at same time.

DECISION Same timing of the above detection CONDITION FAILSAFE OPERATION TCU judges the position of range sensor with following priority.

D>2>L>R>N>P PASS CRITERIA To detect no failure more than 2min.

DTC STORE 2 driving Fail safe cancel condition When TCU judges normal condition REMARKS DG CODE P0708 MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM Output speed sensor circuit malfunction No pulse DG CODE DETECTION TCU detects NO pulse of output speed sensor while TCU detects 45 pulses of input speed signal .

P0722 DECISION The above detection 500 times continuously CONDITION

・

D,2,L range

・

25sec passed after N-D shifting

・

Output revolution calculated by C0 sensor

≧

190 rpm FAILSAFE OPERATION

・

TCU uses input speed sensor signal as a vehicle speed.

・

No L-up

・

No 4th gear

・

No throttle pressure reduction at shifting

・

No torque reduction at shifting

・

No Reverse control PASS CRITERIA To detect output speed more than 400rpm for 70 sec continuously.

DTC STORE 2 driving REMARKS Fail safe cancel condition When TCU judges normal, and 0 km/h is detected MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM Engine speed input sensor signal malfunction Malfunction DETECTION TCU detects F_N_ENG bit ON in EMS1 signal from ECU for 0.2sec.

DECISION The above detection is continued for 2.0 sec.

CONDITION DG CODE FAILSAFE OPERATION TCU detects that Engine rev. is 7000rpm. And the Line pressure to be maxium value.

PASS CRITERIA To detect F_N_ENG bit OFF for 2.0sec.

DTC STORE 2 driving REMARKS Fail safe cancel condition When TCU judges normal, and 0 km/h is detected P0727 MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM Shift solenoid A (S1)/ B(S2) ,Torque converter system (SL) Malfunction STUCK OFF / ON DG CODE S1 P0750 S2 P0755 SL P0740 DETECTION Refer to next Page.

DECISION Refer to next page CONDITION

・

D range

・

L4 sw off

・

ENG rev.

≧

600 rpm.

・

Engine water normal temperature

・

after 20 sec. after P,R,N,2,L

→

D

・

[only for SL stuck off]C0 cylinder is stopping.

・

During no failure of Output Speed sensor /Input Speed sensor/ Engine Rev./ WT sig./ Solenoid Electrical/Range sensor / Throttle sig./ L4 sw.

FAILSAFE OPERATION [S1 STUCK ON] TCU prohibits to shift to 4 th gear, when detection counter is 1.

PASS CRITERIA Refer to next Page DTC STORE 2 driving REMARKS Fail safe cancel condition When TCU judges normal condition MIL 2 driving Auto Transmission Engineering Team

METHOD OF SOLENOID MALFUNCTION DETECTION

GEAR (Ex. 30-40LE) ENGINE T.C.C.

L-up off: free L-up on: 1.00

Gear Ratio 1 st : 2.826

2 nd : 1.493

3 rd : 1.00

4 th : 0.73

Gear Normal 1st 2nd 3rd 4th

○ ○

× × ×

○ ○

×

Engine Rev.: Ne Input Rev.: Ni

1 2 2 1 S1 STCUK ON

○ ○ ○ ○

×

○ ○

× S1 STCUK OFF 4 3 3 4 × × × × ×

○ ○

× S2 STCUK ON 2 2 3 3

○ ○

× ×

○ ○ ○ ○ Output Rev.: No

1 1 4 4 S2 STCUK OFF

○ ○

× × × × × × SL STCUK ON 1 2L (2) 3L (3) 4L SL STCUK OFF 1 2 3 4 (4L) ※Detection of Gear position … ※Ex) Detection of S1 STUCK ON failure : TCU detects 2nd gear ratio in case that TCU shifts to 3rd gear.

Auto Transmission Engineering Team

Condition of SHIFT SOLENOID Malfunction Gear position (Sol.

Output) Throttle Openings(%) Min Vehicle speed ( rpm ) Max Min Max S1 S2 Stuck on Failure Stuck on Normal Stuck off Failure *2 Stuck off Normal Stuck on Failure *2 Stuck on Normal Stuck off Failure *2 Stuck off Normal 3rd 3rd 1st 2nd 2nd 1st 4th 4th 2nd 3rd 3rd 8 8 100 100 175 175 65535 65535 Prhbt.

Time (sec) *1 2 2 Gear position of detection *1 2nd Detection Time (sec) *1 Decision counter 2 3rd 4th 3rd 2nd 2nd 3rd 4th 1st 4th 3rd 1 1 2 2 1 2 2 1 1 2 2 1

*1 ; The prohibition time is started when shift changes.

*2 ; It is necssary to get the failure detection in both gear position , due to failure decision. where, Vehicle speed(rpm) ; output shaft speed Auto Transmission Engineering Team

Condition of DCC SOLENOID Malfunction Gear position (Sol.

Output) Throttle Openings(%) Min Vehicle speed ( rpm ) Max Min Max S L Stuck on Failure *2 Stuck on Normal 2nd L/U off 3rd L/U off 2nd or 3rd L/U off 25 25 8 100 100 100 175 175 175 3200 1500 65535 Stuck off Failure *2 Stuck off Normal 3rd 3rd 8 25 100 100 175 175 65535 300 Prhbt.

Time (sec) *1 2 2 2 2 2 Relationship between Ne and Ni Detection Time (sec) Decision counter [Ne-Ni] ＜ 100rpm [Ne-Ni] ＜ 100rpm [Ne-Ni] ＞ 150rpm [Ne-Ni] ＞ 150rpm [Ne-Ni] ＜ 100rpm 1 2 1 2 1 2 1 1 1 1

*1 ; The prohibition time is started when shift changes or L/Up is full engaged.

*2 ; It is necssary to get the failure detection in both gear position , due to failure decision. where, Ne ; Engine speed Ni ; Turbine speed L/U ; Lock up Vehicle speed(rpm) ; Output shaft speed Auto Transmission Engineering Team

SYSTEM ITEM Torque converter clutch system (SL) electrical GND SHORT / OPEN /+B SHORT DG P0743 CODE DETECTION GND SHORT : To detects the “OFF “ signal of SL monitor during 300msec when SL driver outputs the “ON” signal.

OPEN / +B SHORT : To detects the “ON “ signal of SL monitor during 500msec when SL driver outputs the “OFF” signal.

DECISION OPEN/+B SHORT : The above detection 2 times at shifting continuously GND SHORT : The above detection 1 times at shifting continuously CONDITION FAILSAFE OPERATION * L-up sol off * 1st gear fixed under the 375 rpm in case of +B short / open.

PASS CRITERIA GND SHORT : To detects no fail for 1 sec. when L-up on.

OPEN / +B SHORT : To detects no fail for 1 sec. when L-up off.

DTC STORE 2 driving Fail safe cancel condition When TCU judges normal condition REMARKS MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM Shift solenoid S1 electrical GND SHORT / OPEN /+B SHORT DG CODE P0753 DETECTION GND SHORT : To detects the “OFF “ signal of S1 monitor during 300msec when S1 driver outputs the “ON” signal.

OPEN / +B SHORT : To detects the “ON “ signal of S1 monitor during 500msec when S1 driver outputs the “OFF” signal.

DECISION The above detection 2 times at shifting continuously CONDITION FAILSAFE OPERATION G E AR S 1 F AIL S 2 F AIL S 1 & S 2 F AIL After failure detection ; TCU operates shifting as right table.

SL OFF.

1 3 1 4 2 3 4 4 4 4 3 3 4 4 4 4 After failure decision : Emergency Mode PASS CRITERIA GND SHORT : To detect no fail for 1 sec. when Sol. on. (1st, 2nd) OPEN : To detect no fail for 1 sec. when Sol. off. (3rd, 4th) DTC STORE 1 driving REMARKS Fail safe cancel condition After I.G OFF -> ON Emergency mode ; fixed at 4th gear, Lock up off and Line pressure is max MIL 1 driving Auto Transmission Engineering Team

SYSTEM ITEM Shift solenoid S2 electrical GND SHORT / OPEN /+B SHORT DG CODE P0758 DETECTION GND SHORT : To detects the “OFF “ signal of S2 monitor during 300msec when S2 driver outputs the “ON” signal.

OPEN / +B SHORT : To detects the “ON “ signal of S2 monitor during 500msec when S2 driver outputs the “OFF” signal.

DECISION The above detection 2 times at shifting continuously CONDITION FAILSAFE OPERATION After failure detection ; TCU operates shifting as right table.

SL OFF.

G E AR 1 S 1 F AIL S 2 F AIL 3 1 S 1 & S 2 F AIL 4 2 3 4 4 3 4 4 4 4 4 3 After failure decision : Emergency Mode PASS CRITERIA GND SHORT : To detect no fail for 1 sec. when Sol. on. (2nd, 3rd) OPEN : To detect no fail for 1 sec. when Sol. off. (1st, 4th) DTC STORE 1 driving Fail safe cancel condition After I.G OFF -> ON REMARKS 4 MIL 1 driving Auto Transmission Engineering Team

SYSTEM ITEM Pressure solenoid (SLT) electrical GND SHORT / OPEN /+B SHORT DG CODE DETECTION GND SHORT / OPEN : To detect that the feed back A/D value is less than 15 for 70msec. continuously.

BATTERY SHORT : To detect that the feed back A/D value is more than 1000 for 500msec. continuously.

DECISION GND SHORT / OPEN : 12.5sec. continuously BATTERY SHORT : Same as detection CONDITION FAILSAFE OPERATION Emergency mode PASS CRITERIA To detect the no failure detection for 12.5 sec continuously.

DTC STORE 1 driving REMARKS Fail safe cancel condition After I.G OFF -> ON MIL P0748 1 driving Auto Transmission Engineering Team

SYSTEM ITEM Transmission Fluid Temperature Sensor Circuit Malfunction SHORT/OPEN DG CODE DETECTION SHORT : TCU detects out of sensor resistance from operating range for 5min. continuously.

OPEN : Fluctuation A/D value is less than 15 and minimum A/D value is more than 1000.

DECISION Same as detection CONDITION SHORT : No detection of normal condition (between 0

℃

and 150

℃

for 10sec) after IG ON OPEN : To detect E/G revolution more than 400 rpm for 15min at D,2,L,R range continuously FAILSAFE OPERATION * TCU judges the oil temp. is 200

℃

.

* No L-up control * No throttle pressure reduction control at shifting PASS CRITERIA To detect the oil temp. is between 0

℃

and 150

℃

for 15 min. continuously.

DTC STORE Fail safe cancel condition 2 driving REMARKS When TCU judges normal, and 0 km/h is detected MIL P0710 2 driving Auto Transmission Engineering Team

SYSTEM Input Speed Sensor Circuit No Signal ITEM No pulse DG CODE DETECTION TCU detects no pulse of input speed signal while TCU detects 12 pulses of output speed sensor.

P0717 DECISION The above detection 1000 times continuously.

CONDITION *output speed signal over 775 rpm *D,2, L range selected *1st, 2nd, 3rd gear (C0 rotation is stopped at 4th gear) *25 sec. later after changing the range *3.5 sec. later after changing the gear *E/G revolution more than 400 rpm *During No failure of shift solenoid electrical and malfunction *No pulse of 2nd gear for 1 sec. continuously FAILSAFE OPERATION * no Engine torque control at shifting.

* No Lock up control * No throttle pressure reduction control at shifting PASS CRITERIA To detect input speed signal more than 400rpm for 70 sec. continuously.

DTC STORE 2 driving Fail safe cancel condition When TCU judges normal, and 0 km/h is detected REMARKS MIL 2 driving Auto Transmission Engineering Team

SYSTEM Input speed sensor circuit range / performance ITEM High range DETECTION TCU detects Input revolution ≥ 7000 rpm.

DECISION The above detection is continued for 10.0 sec.

CONDITION FAILSAFE OPERATION PASS CRITERIA 0

＜

Input rev.

＜

7000 rpm for 20 sec. continuously.

DTC STORE Fail safe cancel condition 2 driving REMARKS When TCU judges normal, and 0 km/h is detected DG CODE P0716 MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM Transfer High/Low(L4) Switch Malfunction OPEN/SHORT DETECTION OPEN (transfer low, L4 switch off ) : N1/N2 ≥ X SHORT (transfer High, L4 switch on ) : N1/N2

＜

X N1 : Output revolution calculated by output speed sensor N2 : Output revolution calculated by speed meter sensor X : ( T/F gear ratio – 1.0 ) / 2 +1.0 = ( 2.48

– 1) / 2 + 1.0 = 1.74

DECISION The above detection is continued for 20.0 sec.

CONDITION *TH' OPENING ≥ *Vehicle speed ≥ 2 % 1500 rpm *D range *No Output speed and SPM failure FAILSAFE OPERATION PASS CRITERIA To detect no failure for 10 sec. continuously DTC STORE 2 driving Fail safe cancel condition REMARKS DG CODE P1795 MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM TPS signal malfunction from ECU to TCU Malfunction DETECTION TCU detects TPS data is FFh for 0.2sec via ECU message.

DECISION The above detection is continued for 2.0 sec.

CONDITION FAILSAFE OPERATION *TCU judges throttle opening is 0% for shifting.

*No throttle pressure reduction control at shifting and N-D,N-R.

*No engine torque control at shifting and N-D,N-R *Line pressure is almost max.

PASS CRITERIA To detect no failure for 10 sec. continuously DTC STORE 2 driving Fail safe cancel condition When TCU judges normal, and 0 km/h is detected REMARKS DG CODE P1121 MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM CAN communication BUS OFF Malfunction DETECTION To detect the BUS OFF signal in CPU.

DECISION The above detection is continued for 0.2sec.

CONDITION After 0.2sec. passed from IG ON.

FAILSAFE OPERATION *Throttle pressure is full.

*No torque control PASS CRITERIA To detect the BUS normal signal for 2.0sec continuously DTC STORE 2 driving Fail safe cancel condition When TCU judges normal, and 0 km/h is detected REMARKS DG CODE P1630 MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM ECU No ID Malfunction DETECTION To detect the nothing of EMS1 or EMS2 signal on CAN BUS for 0.2 sec.

DECISION The above detection is continued for 2.0 sec.

CONDITION After 0.2sec. passed from IG ON.

FAILSAFE OPERATION *Throttle pressure is full.

*No torque control PASS CRITERIA To detect ID of both EMS1 and EMS2 on CAN BUS for 2.0sec continuously DTC STORE 2 driving REMARKS Fail safe cancel condition When TCU judges normal, and 0 km/h is detected DG CODE P1631 MIL 2 driving Auto Transmission Engineering Team

SYSTEM ITEM Vehicle speed signal from meter set Malfunction DETECTION TCU detects VS signal is FFh for 0.2sec.

DECISION The above detection 2.0sec continuously CONDITION FAILSAFE OPERATION PASS CRITERIA TCU detects VS signal is between 00h and FEh for 2.0sec continuously.

DTC STORE

－

REMARKS Fail safe cancel condition

－

DG CODE

－

MIL

－

Auto Transmission Engineering Team

SYSTEM ITEM Brake Switch Malfunction DETECTION TCU detects following conditions at the same time.

1. Vehicle speed is more than 2260rpm.

2. Throttle angle is more than 5%.

3. Brake Switch on time is more than 10 second.

DECISION Same as detection CONDITION FAILSAFE OPERATION Cancel the judgment of Brake Switch “ON”, and allow the L-up control.

PASS CRITERIA To detect Brake Switch off signal.

DTC STORE REMARKS

－

Fail safe cancel condition

－

DG CODE CODE

－

MIL

－

Auto Transmission Engineering Team

6. TCU Circuit diagram

Auto Transmission Engineering Team