Dtc P0919 Gear Shift Position Control Error. Corolla ZZE150

Трансмиссия. COROLLA, AURIS. ZZE150 ZRE151,152 NDE150
Механическая Трансмиссия 'Multimode' C53A. COROLLA, AURIS. ZZE150 ZRE151,152 NDE150

DESCRIPTION

WIRING DIAGRAM

INSPECTION PROCEDURE

CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0919)

INSPECT TCM

INSPECT TCM

INSPECT SHIFT STROKE SENSOR

PERFORM ACTIVE TEST USING INTELLIGENT TESTER

INSPECT TRANSAXLE ASSEMBLY (GEAR SHIFT MECHANICAL SYSTEM)

DTC P0919 Gear Shift Position Control Error


DESCRIPTION

In the multi-mode manual transaxle system, the transaxle gear is shifted up and down by the TCM using a shift and select actuator. The shift and select actuator assembly consists of two motors (shift motor and select motor), stroke sensors (shift stroke sensor and select stroke sensor) and gears to move the shift and select lever shaft. The shift motor moves the shift and select lever shaft in the shift direction according to the signal from the TCM.
This DTC is set in accordance with the stroke speed of the shift and select actuator or the difference between the target shift position and the actual shift position. Therefore, if malfunctions occur in the shift stroke sensor or the shift motor circuit, the DTCs relating to the sensor or motor circuit open/short (DTC P0915, P0916, P0917 and/or P0920) are set before this DTC is set.

DTC No.
DTC Detection Condition
Trouble Area
P0919
The TCM detects the following conditions simultaneously:
(1-trip detection logic)
  1. Shift motor current is 32A or more, -32A or less for 2.0 seconds
  2. Difference between target shift position and actual shift position is 0.3 mm (0.0118 in.) or more
  3. Shift and select actuator movement is 122 mm/sec (4.8 in./sec) or less
  1. Shift stroke sensor
  2. Shift and select actuator assembly (shift motor)
  3. TCM
  4. Transaxle assembly

WIRING DIAGRAM


COROLLA, AURIS. ZZE150 ZRE151,152 NDE150.Механическая Трансмиссия 'Multimode' C53A.Система Механической Трансмиссии


INSPECTION PROCEDURE

ПРИМЕЧАНИЕ:
In shift stroke sensor or shift and select actuator assembly replacement, perform the [Initialization and Learning] procedure (See page Нажмите здесь) and [Synchronization Position Calibration] procedure (See page Нажмите здесь) after installing the sensor or actuator assembly. If the sensor or actuator is installed without performing [Initialization and Learning] and [Synchronization Position Calibration], it may cause driving performance degradation or system component breakage.
УКАЗАНИЕ:
If the symptom still occurs even after checking the following parts for dirt, wear, and defects and replacing the defective parts, replace the TCM.
  1. Synchronizer Rings
  2. Shift Forks
  3. Hub Sleeves
1.CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0919)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch on (IG) and turn the tester ON.

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

  1. Read DTCs.

    Result:

    Result
    		Proceed to
    P0919
    		A
    P0919 and other DTCs
    		B
    If DTC P0919 is detected together with DTC P0915, P0916, P0917 and/or P0920 (DTCs related to the shift stroke sensor or shift motor circuit open/short), troubleshoot those DTCs first.


B
GO TO DTC CHART (Нажмите здесь)
A


2.INSPECT TCM


    COROLLA, AURIS. ZZE150 ZRE151,152 NDE150

  1. Check the shift and select actuator motor terminal output using an oscilloscope.

    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch on (IG) and turn the tester ON.

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

    4. Turn the ignition switch off within 2 seconds of clearing the DTC.



      5. COROLLA, AURIS. ZZE150 ZRE151,152 NDE150.Механическая Трансмиссия 'Multimode' C53A.Система Механической Трансмиссии

    5. Connect the oscilloscope probes to the TCM terminals.

    6. Check the waveform when the ignition switch is turned on (IG), and the shift lever position is changed from the N position to any other position.

      Oscilloscope settings
      Items
      		Contents
      Terminals
      		A29-3 (MSF-) - E33-6 (GND)
      A29-1 (MSF+) - E33-6 (GND)
      Gauge set
      		5 V/DIV., 50 μs/DIV.
      Condition
      		Ignition switch on (IG)
      Standard:
      Correct waveform shown in the illustration.
      УКАЗАНИЕ:
      The waveform is displayed for several seconds until the DTC is set.


NG
REPLACE TCM (Нажмите здесь)
OK


3.INSPECT TCM


    COROLLA, AURIS. ZZE150 ZRE151,152 NDE150.Механическая Трансмиссия 'Multimode' C53A.Система Механической Трансмиссии

  1. Remove the shift stroke sensor from the shift and select actuator assembly.

  1. Connect the shift stroke sensor connector.

  1. Turn the ignition switch on (IG).

  1. Check the voltage change between the terminals of the TCM connector when moving the sensor arm of the shift stroke sensor.

    Standard voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A34-18 (VSS1) - A34-17 (E2S1)
    		Ignition switch on (IG)
    		Voltage changes in accordance with sensor arm position
    A34-29 (VSS2) - A34-28 (E2S2)
    		↑
    		Voltage changes in accordance with sensor arm position

  1. Reinstall the shift stroke sensor (See page Нажмите здесь).

  1. Perform [Initialization and Learning] (See page Нажмите здесь) and [Synchronization Position Calibration] (See page Нажмите здесь).

    Result:
    Result
    		Proceed to
    NG
    		A
    OK
    		B


B
Перейдите к шагу 5
A


4.INSPECT SHIFT STROKE SENSOR


    COROLLA, AURIS. ZZE150 ZRE151,152 NDE150.Механическая Трансмиссия 'Multimode' C53A.Система Механической Трансмиссии

  1. Remove the shift stroke sensor.

  1. Measure the voltage between the terminals of the shift 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, and the negative battery terminal to 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


    COROLLA, AURIS. ZZE150 ZRE151,152 NDE150.Механическая Трансмиссия 'Multimode' C53A.Система Механической Трансмиссии

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

    1. Connect the positive battery terminal to sensor terminal 6, and the negative battery terminal to 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
      ПРИМЕЧАНИЕ:
      1. Do not apply more than 6 V
      2. Do not use a sensor which has been dropped.

  1. Reinstall the shift stroke sensor (See page Нажмите здесь).

  1. Perform [Initialization and Learning] (See page Нажмите здесь) and [Synchronization Position Calibration] (See page Нажмите здесь).



NG
REPLACE SHIFT STROKE SENSOR (Нажмите здесь)
OK

REPLACE TCM (Нажмите здесь)

5.PERFORM ACTIVE TEST USING INTELLIGENT TESTER

  1. Remove the shift and select actuator.

  1. Connect the connectors to the shift and select actuator.

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch on (IG) and the tester ON.

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

  1. Turn the ignition switch off within 2 seconds of clearing the DTC.

  1. Turn the ignition switch on (IG).

  1. Select the following menu items: Powertrain / Multi-Mode M/T / Active Test / Target Gear Position Control.

  1. Perform the Active Test.

    OK:
    Shift and select actuator moves smoothly in accordance with the tester operation.

  1. Reinstall the shift and select actuator.

  1. Perform [Initialization and Learning] (See page Нажмите здесь) and [Synchronization Position Calibration] (See page Нажмите здесь).



NG
REPLACE SHIFT AND SELECT ACTUATOR ASSEMBLY (Нажмите здесь)
OK


6.INSPECT TRANSAXLE ASSEMBLY (GEAR SHIFT MECHANICAL SYSTEM)

  1. Remove the transaxle assembly (See page Нажмите здесь).

  1. Check for dirt, wear and defects in the gear shift mechanical system (synchronizer rings, shift forks, hub sleeves, etc.).

    OK:
    No defective parts in the transaxle assembly.


NG
REPAIR OR REPLACE DEFECTIVE PART IN TRANSAXLE ASSEMBLY (Нажмите здесь)
OK

REPLACE SHIFT AND SELECT ACTUATOR ASSEMBLY (Нажмите здесь)