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A/T Technical Training for SORENTO. Subject : OBD-II Fault handling. KIA MOTORS. 4. TCU Block diagram & Terminal assignment. 5. Fault handling. 5-1. DTC List. ※1 ; Only for 4WD vehicles, “-” ; not be supported Fault type ; A – DTC stored on the 1 st driving cycle - PowerPoint PPT Presentation
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Auto Transmission Engineering Team
A/T Technical Training for SORENTO
KIA MOTORS
Subject : OBD-II Fault handling
Auto Transmission Engineering Team
4. TCU Block diagram & Terminal assignment
Auto Transmission Engineering Team
5. Fault handling
5-1. DTC List
Fault Type MIL
P0707 Transmission range sensor circuit low input B O
P0708 Transmission range sensor circuit high input B O
P0722 Output speed sensor circuit no signal B O
P0727 Engine speed input sensor no signal B O
P0740 Torque converter clutch circuit(SL) malfunction B O
P0743 Torque converter clutch circuit(SL) electrical B O
P0750 Shift solenoid A(S1) malfunction B O
P0753 Shift solenoid A(S1) electrical A O
P0755 Shift solenoid B(S2) malfunction B O
P0758 Shift solenoid B(S2) electrical A O
P0748 Pressure solenoid(SLT) electrical A O
P1121 Throttle sensor signal invalid B O
Σ3.5 NAS/EUDTC Description
Auto Transmission Engineering Team
※1 ; Only for 4WD vehicles, “-” ; not be supported
Fault type ; A – DTC stored on the 1st driving cycle
B – DTC stored on the 2nd driving cycle continuously
C – Only Fail-safe (not DTC stored)
MIL ; “○” -- supported(to be performed at the same time as DTC stored)
P0710 ATF sensor circuit malfunction B O
P0717 Input speed sensor circuit no signal B O
P0716 Input speed sensor circuit range/performance B O
P1795 Transfer high/low(L4) switch malfunction ※1 B O
P1630 CAN communication BUS OFF B O
P1631 No ID from ECU B O
- Vehicle speed signal from Meter set C -
- Brake switch malfunction C -
Auto Transmission Engineering Team
5-5. DTC detection, decision condition & Fail safe SYSTEM
DG
CODE
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.
To detect no failure more than 2 min.
DTC STORE
2 driving
MIL
2 driving
CONDITION
FAILSAFE OPERATION
TCU judges the position of range sensor is D range.
PASS CRITERIA
DECISION
Same timing of the above detection
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
Transmission range sensor circuit low inputITEM NO signal P0707
Auto Transmission Engineering Team
SYSTEMDG
CODE
Fail safe cancel condition
When TCU judges normal condition 2 driving
Transmission range sensor circuit high inputITEM Short P0708
Same timing of the above detection
DETECTION
Detected 2 or more signals more than 10 sec. at same time.
DECISION
CONDITION
FAILSAFE OPERATION
TCU judges the position of range sensor with following priority.
D>2>L>R>N>P
REMARKS
PASS CRITERIA
DTC STORE MIL
To detect no failure more than 2min.
2 driving
Auto Transmission Engineering Team
SYSTEMDG
CODE
Fail safe cancel conditionWhen TCU judges normal, and 0 km/h is detected
REMARKS
PASS CRITERIATo detect output speed more than 400rpm for 70 sec continuously.DTC STORE 2 driving
MIL2 driving
・TCU uses input speed sensor signal as a vehicle speed.
・No Reverse control
・No L-up ・No 4th gear
・No throttle pressure reduction at shifting
・No torque reduction at shifting
DECISION
・ Output revolution calculated by C0 sensor ≧ 190 rpm
FAILSAFE OPERATION
・ D,2,L range ・ 25sec passed after N-D shifting
Output speed sensor circuit malfunctionITEM No pulse P0722
The above detection 500 times continuously
CONDITION
DETECTION
TCU detects NO pulse of output speed sensor while TCU detects 45 pulses of input speed signal .
Auto Transmission Engineering Team
SYSTEM
Fail safe cancel condition
When TCU judges normal, and 0 km/h is detected
MIL
2 driving
Malfunction DG
CODE
REMARKS
PASS CRITERIA
DTC STORE
To detect F_N_ENG bit OFF for 2.0sec.
2 driving
DECISION
CONDITION
FAILSAFE OPERATION
TCU detects that Engine rev. is 7000rpm. And the Line pressure to be maxium value.
Engine speed input sensor signal malfunctionITEM P0727
The above detection is continued for 2.0 sec.
DETECTION
TCU detects F_N_ENG bit ON in EMS1 signal from ECU for 0.2sec.
Auto Transmission Engineering Team
SYSTEMDG S1 P0750
CODE S2 P0755
SL P0740
Fail safe cancel conditionWhen TCU judges normal condition
REMARKS
Refer to next PageDTC STORE
2 drivingMIL
2 driving
FAILSAFE OPERATION
[S1 STUCK ON] TCU prohibits to shift to 4th gear, when detection counter is 1.PASS CRITERIA
CONDITION
WT sig./ Solenoid Electrical/Range sensor / Throttle sig./ L4 sw.
Shift solenoid A (S1)/ B(S2) ,Torque converter system (SL) Malfunction
DECISION
DETECTION
ITEM STUCK OFF / ON
・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./
Refer to next Page.
・D range ・L4 sw off ・ENG rev. ≧ 600 rpm.
・Engine water normal temperature
Refer to next page
Auto Transmission Engineering Team
METHOD OF SOLENOID MALFUNCTION DETECTION
Gear Ratio
1st: 2.826
2nd
: 1.493
3rd
: 1.00
4th
: 0.73
L-up off: freeL-up on: 1.00
GEAR(Ex. 30-40LE)
T.C.C.ENGINE
Input Rev.: NiEngine Rev.: Ne Output Rev.: No
GearSL
STCUK ONSL
STCUK OFF
1st ○ × 1 ○ × 4 × × 2 ○ ○ 1 ○ × 1 1
2nd ○ ○ 2 ○ ○ 3 × ○ 2 ○ ○ 1 ○ × 2L (2) 2
3rd × ○ 2 ○ ○ 3 × ○ 3 × ○ 4 × × 3L (3) 3
4th × × 1 ○ × 4 × × 3 × ○ 4 × × 4L 4 (4L)
NormalS1
STCUK ONS1
STCUK OFFS2
STCUK ONS2
STCUK OFF
※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
*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
Condition of SHIFT SOLENOID Malfunction
Min Max Min MaxStuck onFailure
3rd 2nd 2
Stuck onNormal
3rd 3rd 1
1st 4th 22nd 3rd 2
Stuck offNormal
2nd 2nd 1
1st 2nd 24th 3rd 2
Stuck onNormal
4th 4th 1
2nd 1st 23rd 4th 2
Stuck offNormal
3rd 3rd 1
DetectionTime(sec)*1
Decisioncounter
8 100 175 65535 12
Stuck offFailure *2
Gearposition
(Sol.Output)
Prhbt.Time(sec)*1
Gearposition
ofdetection *1
8 100 175 65535 2S2
Stuck onFailure *2
1
S1Stuck off
Failure *2
ThrottleOpenings(%)
Vehiclespeed( rpm )
Auto Transmission Engineering Team
*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
Condition of DCC SOLENOID Malfunction
Min Max Min Max2nd
L/U off25 100 175 3200 2
[Ne-Ni]< 100rpm
1 2
3rdL/U off
25 100 175 1500 2[Ne-Ni]
< 100rpm2 1
Stuck onNormal
2nd or3rd
L/U off8 100 175 65535 2
[Ne-Ni]>150rpm
1 1
Stuck offNormal
3rd 25 100 175 300 2[Ne-Ni]
< 100rpm1 1
13rd 8 100
SL
Stuck onFailure *2
175 65535 2[Ne-Ni]
>150rpm2
Stuck offFailure *2
Gearposition
(Sol.Output)
Prhbt.Time(sec)*1
Relationshipbetween
Ne and Ni
ThrottleOpenings(%)
DetectionTime(sec)
Decisioncounter
Vehiclespeed( rpm )
Auto Transmission Engineering Team
SYSTEMDG
CODE
OPEN / +B SHORT : To detects the “ON “ signal of SL monitor during 500msec when SL driver outputs
the “OFF” signal.
Fail safe cancel conditionWhen TCU judges normal condition
REMARKS
DTC STORE 2 driving
MIL2 driving
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.
CONDITION
* L-up sol off * 1st gear fixed under the 375 rpm in case of +B short / open.PASS CRITERIA
FAILSAFE OPERATION
GND SHORT : The above detection 1 times at shifting continuously
DECISION
OPEN/+B SHORT : The above detection 2 times at shifting continuously
DETECTION
GND SHORT : To detects the “OFF “ signal of SL monitor during 300msec when SL driver outputs
the “ON” signal.
Torque converter clutch system (SL) electricalITEM GND SHORT / OPEN /+B SHORT P0743
Auto Transmission Engineering Team
S Y S T E MD GC O D E
O P E N / + B S H O R T : T o d e t e c t s t h e “ O N “ s i g n a l o f S 1 m o n i t o r d u r i n g 5 0 0 m s e c w h e n S 1 d r i v e r o u t p u t s t h e “ O F F ” s i g n a l .
F a i l s a f e c a n c e l c o n d i t i o nA f t e r I . G O F F - > O N
1 d r i v i n gM I L
1 d r i v i n gR E M A R K S
O P E N : T o d e t e c t n o f a i l f o r 1 s e c . w h e n S o l . o f f . ( 3 r d , 4 t h )D T C S T O R E
A f t e r f a i l u r e d e c i s i o n : E m e r g e n c y M o d eP A S S C R I T E R I AG N D S H O R T : T o d e t e c t n o f a i l f o r 1 s e c . w h e n S o l . o n . ( 1 s t , 2 n d )
S h i f t s o l e n o i d S 1 e l e c t r i c a lI T E M G N D S H O R T / O P E N / + B S H O R T P 0 7 5 3
D E C I S I O NT h e a b o v e d e t e c t i o n 2 t i m e s a t s h i f t i n g c o n t i n u o u s l y
D E T E C T I O NG N D S H O R T : T o d e t e c t s t h e “ O F F “ s i g n a l o f S 1 m o n i t o r d u r i n g 3 0 0 m s e c w h e n S 1 d r i v e r o u t p u t s t h e “ O N ” s i g n a l .
C O N D I T I O N
A f t e r f a i l u r e d e t e c t i o n ; T C U o p e r a t e s s h i f t i n g a s r i g h t t a b l e . S L O F F .
F A I L S A F E O P E R A T I O N
GEAR S1 FAIL S2 FAIL S1 &S2 FAIL1 3 1 42 3 4 43 3 4 44 4 4 4
Emergency mode ; fixed at 4th gear, Lock up off and Line pressure is max
Auto Transmission Engineering Team
S Y S T E MD GC O D E
O P E N / + B S H O R T : T o d e t e c t s t h e “ O N “ s i g n a l o f S 2 m o n i t o r d u r i n g 5 0 0 m s e c w h e n S 2 d r i v e r o u t p u t s t h e “ O F F ” s i g n a l .
F a i l s a f e c a n c e l c o n d i t i o nA f t e r I . G O F F - > O N
C O N D I T I O N
A f t e r f a i l u r e d e t e c t i o n ; T C U o p e r a t e s s h i f t i n g a s r i g h t t a b l e . S L O F F .
F A I L S A F E O P E R A T I O N
D E C I S I O NT h e a b o v e d e t e c t i o n 2 t i m e s a t s h i f t i n g c o n t i n u o u s l y
D E T E C T I O NG N D S H O R T : T o d e t e c t s t h e “ O F F “ s i g n a l o f S 2 m o n i t o r d u r i n g 3 0 0 m s e c w h e n S 2 d r i v e r o u t p u t s t h e “ O N ” s i g n a l .
S h i f t s o l e n o i d S 2 e l e c t r i c a lI T E M G N D S H O R T / O P E N / + B S H O R T P 0 7 5 8
O P E N : T o d e t e c t n o f a i l f o r 1 s e c . w h e n S o l . o f f . ( 1 s t , 4 t h )D T C S T O R E
A f t e r f a i l u r e d e c i s i o n : E m e r g e n c y M o d eP A S S C R I T E R I AG N D S H O R T : T o d e t e c t n o f a i l f o r 1 s e c . w h e n S o l . o n . ( 2 n d , 3 r d )
1 d r i v i n gM I L
1 d r i v i n gR E M A R K S
GEAR S1 FAIL S2 FAIL S1 &S2 FAIL1 3 1 42 3 4 43 3 4 44 4 4 4
Auto Transmission Engineering Team
SYSTEMDGCODE
Fail safe cancel conditionAfter I.G OFF -> ON
CONDITION
To detect the no failure detection for 12.5 sec continuously.
1 driving 1 drivingREMARKS
DTC STORE MIL
PASS CRITERIA
FAILSAFE OPERATION Emergency mode
Pressure solenoid (SLT) electricalITEM GND SHORT / OPEN /+B SHORT P0748
DECISION
DETECTIONGND 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.
GND SHORT / OPEN :
BATTERY SHORT : Same as detection
12.5sec. continuously
Auto Transmission Engineering Team
DGCODE
Fail safe cancel conditionWhen TCU judges normal, and 0 km/h is detected
2 drivingMIL
2 drivingREMARKS
PASS CRITERIATo detect the oil temp. is between 0℃ and 150℃ for 15 min. continuously.
DTC STORE
CONDITIONSHORT :
FAILSAFE OPERATION * TCU judges the oil temp. is 200℃.
SYSTEMCircuit Malfunction
ITEM SHORT/OPEN P0710
OPEN :
Same as detectionDECISION
OPEN :
Transmission Fluid Temperature Sensor
Fluctuation A/D value is less than 15 and minimum A/D value is more than 1000.
DETECTIONSHORT : TCU detects out of sensor resistance from operating range for 5min. continuously.
* No throttle pressure reduction control at shifting * No L-up control
To detect E/G revolution more than 400 rpm for 15min at D,2,L,R range continuously
No detection of normal condition (between 0℃ and 150℃ for 10sec) after IG ON
Auto Transmission Engineering Team
DGCODE
*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
Fail safe cancel conditionWhen TCU judges normal, and 0 km/h is detected
DETECTION TCU detects no pulse of input speed signal while TCU detects 12 pulses of output speed sensor.
* No throttle pressure reduction control at shifting * No Lock up control
The above detection 1000 times continuously.DECISION
SYSTEM
ITEM No pulse P0717
Input Speed Sensor Circuit No Signal
PASS CRITERIATo detect input speed signal more than 400rpm for 70 sec. continuously.
DTC STORE
CONDITION
FAILSAFE OPERATION * no Engine torque control at shifting.
2 drivingMIL
2 drivingREMARKS
Auto Transmission Engineering Team
DGCODE
Fail safe cancel conditionWhen TCU judges normal, and 0 km/h is detected
2 drivingMIL
2 drivingREMARKS
PASS CRITERIA
0< Input rev. < 7000 rpm for 20 sec. continuously.DTC STORE
CONDITION
FAILSAFE OPERATION
SYSTEM
ITEM High range P0716
Input speed sensor circuit range / performance
DETECTION
TCU detects Input revolution ≥ 7000 rpm.
The above detection is continued for 10.0 sec.DECISION
Auto Transmission Engineering Team
SYSTEMDGCODE
Fail safe cancel condition-
REMARKS
PASS CRITERIA To detect no failure for 10 sec. continuously
DTC STORE 2 driving
MIL2 driving
DETECTION OPEN (transfer low, L4 switch off ) : N1/N2 ≥ X
Transfer High/Low(L4) Switch MalfunctionITEM OPEN/SHORT P1795
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
N1 : Output revolution calculated by output speed sensor
SHORT (transfer High, L4 switch on ) : N1/N2 < X
*TH' OPENING ≥ 2 %
DECISION The above detection is continued for 20.0 sec.CONDITION
FAILSAFE OPERATION
*Vehicle speed ≥ 1500 rpm *D range *No Output speed and SPM failure
Auto Transmission Engineering Team
SYSTEM
Fail safe cancel conditionWhen TCU judges normal, and 0 km/h is detected
*Line pressure is almost max.
*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
FAILSAFE OPERATION
DECISION The above detection is continued for 2.0 sec.CONDITION
DETECTION TCU detects TPS data is FFh for 0.2sec via ECU message.
TPS signal malfunction from ECU to TCUITEM P1121Malfunction DG
CODE
REMARKS
PASS CRITERIA To detect no failure for 10 sec. continuously
DTC STORE 2 driving
MIL2 driving
Auto Transmission Engineering Team
SYSTEM
Fail safe cancel conditionWhen TCU judges normal, and 0 km/h is detected
PASS CRITERIA
DTC STORE MIL2 driving
To detect the BUS normal signal for 2.0sec continuously
2 drivingREMARKS
DETECTION
CAN communication BUS OFFITEM P1630Malfunction DG
CODE
After 0.2sec. passed from IG ON.
To detect the BUS OFF signal in CPU.
DECISION The above detection is continued for 0.2sec.
CONDITION
FAILSAFE OPERATION *Throttle pressure is full. *No torque control
Auto Transmission Engineering Team
SYSTEMDGCODE
Fail safe cancel conditionWhen TCU judges normal, and 0 km/h is detected
REMARKS
To detect ID of both EMS1 and EMS2 on CAN BUS for 2.0sec continuously
DTC STORE 2 driving
MIL2 driving
Malfunction
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.
FAILSAFE OPERATION
CONDITION After 0.2sec. passed from IG ON.
DETECTION
ECU No IDITEM P1631
*Throttle pressure is full. *No torque control
PASS CRITERIA
Auto Transmission Engineering Team
SYSTEM
Fail safe cancel condition
-
CONDITION
FAILSAFE OPERATION
DTC STORE
-MIL
-
TCU detects VS signal is FFh for 0.2sec.
Vehicle speed signal from meter setITEM -
DETECTION
DG CODEMalfunction
DECISION
REMARKS
The above detection 2.0sec continuously
TCU detects VS signal is between 00h and FEh for 2.0sec continuously.PASS CRITERIA
Auto Transmission Engineering Team
SYSTEM
DG CODE -CODE
Fail safe cancel condition
-REMARKS
2. Throttle angle is more than 5%.
Same as detection
PASS CRITERIA
3. Brake Switch on time is more than 10 second.
DECISION
Cancel the judgment of Brake Switch “ON”, and allow the L-up control.FAILSAFE OPERATION
To detect Brake Switch off signal.
- -
1. Vehicle speed is more than 2260rpm.
Brake SwitchITEM
TCU detects following conditions at the same time.
Malfunction
DETECTION
CONDITION
DTC STORE MIL
Auto Transmission Engineering Team
6. TCU Circuit diagram