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Automatic Transaxle Control System - Hev: Diagnosis Kia Optima III

Automatic Trans 27 illustrations ~2178 words

Fault Diagnosis

Features a fail-safe mechanism that prevents dangerous situations from developing in the event of a transaxle failure. The limp home mode engages if the transaxle malfunctions. In this mode, the transaxle operates at a minimal functionality level, making it possible for the vehicle to reach a service center.

Fail-Safe: Prevents dangerous situations from developing in the event of a malfunction.

Limp Home: Maintains minimal functionality (*) in the event of a malfunction, making it possible for the vehicle to reach a service center.

(*) Minimal Functionality: Drive (fixed gear setting), Reverse, and Neutral

Self-diagnosis

TCM is in constant communication with the control system's components (sensors and solenoids). If an abnormal signal is received for longer than the predefined duration, TCM recognizes a fault, stores the fault code in memory, and then sends out a fault signal through the self-diagnosis terminal. Such fault codes are the ignition switch is turned off, the battery is disconnected, or the TCM connector is disconnected.

Note. Disconnecting a sensor or an actuator connector while the ignition switch is in the "On" position generates a diagnostic trouble code (DTC) and commits the code to memory. In such event, disconnecting the battery will not clear the fault diagnosis memory. The diagnosis tool must be used to clear the fault diagnosis memory. Before removing or installing any part, read the diagnostic trouble codes and then disconnect the battery negative (-) terminal. Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. Removal or connection of the battery cable during engine operation or while the ignition switch is ON could cause damage to the TCM When checking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the ECM from damage due to the voltage. When charging the battery with the external charger, disconnect the vehicle side battery terminals to prevent damage to the TCM.

Checking Procedure (Self-diagnosis)

  1. When battery voltage is excessively low, diagnostic trouble codes can not be read. Be sure to check the battery for voltage and the charging system before starting the test.
  2. Diagnosis memory is erased if the battery or the TCM connector is disconnected. Do not disconnect the battery before the diagnostic trouble codes (DTC) are completely read and recorded.

Inspection Procedure (Using the GDS)

  1. Turn OFF the ignition switch.
  2. Connect the GDS to the data link connector on the lower crash pad.
  3. Turn ON the ignition switch.
  4. Use the GDS to check the diagnostic trouble code.
  5. Repair the faulty part from the diagnosis chart.
  6. Erase the diagnostic trouble code.
  7. Disconnect the GDS.

Note. Perform TCM learning after replacing the automatic transaxle to prevent slow automatic transaxle response, jerky acceleration and jerky startup. (Refer to " REPAIR PROCEDURES " in this group) Adding automatic transaxle fluid. (Refer to "Hydraulic system(Fluid)" in this group.) After servicing the automatic transaxle or TCM, clear the diagnostic trouble code (DTC) using the GDS tool. Diagnostic trouble codes (DTC) cannot be cleared by disconnecting the battery.

TCM Problem Inspection Procedure

  1. TEST TCM GROUND CIRCUIT: Measure resistance between TCM and chassis ground using the backside of TCM harness connector as TCM side check point. If the problem is found, repair it. Specification: Below 1ohms
  2. TEST TCM CONNECTOR: Disconnect the TCM connector and visually check the ground terminals on TCM side and harness side for bent pins or poor contact pressure. If the problem is found, repair it.
  3. If problem is not found in Step 1 and 2, the TCM could be faulty. If so, make sure there were no DTC's before swapping the TCM with a new one, and then check the vehicle again. If DTC's were found, examine this first before swapping TCM.
  4. RE-TEST THE ORIGINAL TCM: Install the original TCM (may be broken) into a known-good vehicle and check the vehicle. If the problem occurs again, replace the original TCM with a new one. If problem does not occur, this is intermittent problem (Refer to "Intermittent Problem Inspection Procedure" in Basic Inspection Procedure).

Inspection

  1. Turn ignition switch OFF.
  2. Disconnect the oil temperature sensor connector.
  3. Measure resistance between sensor signal terminal and sensor ground terminal.
  4. Check that the resistance is within the specification.

Scheme 697

Scheme 697: Removal
Scheme 697: Removal

Scheme 698

Scheme 698
Scheme 698

Scheme 699

Scheme 699
Scheme 699

Scheme 700

Scheme 700
Scheme 700
  1. Air cleaner assembly and air duct. (Refer to "Intake and Exhaust system" in EM group)
  2. Remove the Hybrid Power Control Unit (HPCU) assembly. (Refer to " «HYBRID CONTROL SYSTEM»(ref-535721-S23921223772013031200000) " in HC group)
  3. Remove the under cover (A). Tightening torque: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
  4. Remove the ATF warmer. (Refer to " «ATF WARMER»(ref-535749-S01542930182013031200000) " in this group)
  5. Remove the AT tube (A) after removing eye bolt (B). Tightening torque: 42 ~ 48 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 31.4 lb-ft)
  6. Replace new gasket and the plug after draining the automatic transaxle fluid by removing the drain plug.(Refer to " «AUTOMATIC TRANSAXLE»(ref-535716-S07341099932013031200000) " in this group.)
  7. Remove the valve body cover (A) and breather hose clip (B). Tightening torque: 13.8 ~ 15.7 N.m (1.4 ~ 1.6 kgf.m, 10.1 ~ 11.6 lb-ft)
  8. Disconnect the oil temperature sensor connector (A).
  9. Remove the oil temperature sensor (A) after removing a bolt. Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) CAUTION: Be careful not to damage the harness lock connector.

Scheme 701

Scheme 701
Scheme 701
  1. Check signal waveform of Input&output speed sensor using the GDS.

Specification: Refer to "Signal Wave Form" section.

Scheme 702

Scheme 702: Removal
Scheme 702: Removal

Scheme 703

Scheme 703
Scheme 703

Scheme 704

Scheme 704
Scheme 704

Scheme 705

Scheme 705
Scheme 705

Scheme 706

Scheme 706
Scheme 706
  1. Air cleaner assembly and air duct. (Refer to "Intake and Exhaust system" in EM group)
  2. Remove the Hybrid Power Control Unit (HPCU) assembly. (Refer to " «HYBRID CONTROL SYSTEM»(ref-535721-S23921223772013031200000) " in HC group)
  3. Remove the under cover (A). Tightening torque: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
  4. Replace new gasket and the plug after draining the automatic transaxle fluid by removing the drain plug. (Refer to " «AUTOMATIC TRANSAXLE»(ref-535716-S07341099932013031200000) " in this group)
  5. Remove the ATF warmer. (Refer to " «ATF WARMER»(ref-535749-S01542930182013031200000) " in this group)
  6. Remove the AT tube (A) after removing eye bolt (B). Tightening torque: 42 ~ 48 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 31.4 lb-ft)
  7. Remove the valve body cover (A) and breather hose clip (B). Tightening torque: 13.8 ~ 15.7 N.m (1.4 ~ 1.6 kgf.m, 10.1 ~ 11.6 lb-ft) NOTE: Remove installation bolts in the engine room first and then remove others under the vehicle.
  8. Remove the bolt (3ea) after disconnecting the solenoid valve connector (B) and the oil temperature sensor connector (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  9. Remove the valve body assembly (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  10. Disconnect the input&output speed sensor connector (A).
  11. Remove the input&output speed sensor (B) after removing the bolts (2ea). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Scheme 707

Scheme 707
Scheme 707
  1. Check signal waveform of Input&output speed sensor using the GDS.

Specification: Refer to " SIGNAL WAVEFORM " section.

Scheme 708

Scheme 708: Removal
Scheme 708: Removal

Scheme 709

Scheme 709
Scheme 709

Scheme 710

Scheme 710
Scheme 710

Scheme 711

Scheme 711
Scheme 711

Scheme 712

Scheme 712
Scheme 712
  1. Air cleaner assembly and air duct. (Refer to "Intake and Exhaust system" in EM group)
  2. Remove the Hybrid Power Control Unit (HPCU) assembly. (Refer to " «HYBRID CONTROL SYSTEM»(ref-535721-S23921223772013031200000) " in HC group)
  3. Remove the under cover (A). Tightening torque: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
  4. Replace new gasket and the plug after draining the automatic transaxle fluid by removing the drain plug. (Refer to " «AUTOMATIC TRANSAXLE»(ref-535716-S07341099932013031200000) " in this group.)
  5. Remove the ATF warmer. (Refer to " «ATF WARMER»(ref-535749-S01542930182013031200000) " in this group)
  6. Remove the AT tube (A) after removing eye bolt (B). Tightening torque: 42 ~ 48 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 31.4 lb-ft)
  7. Remove the valve body cover (A) and breather hose clip (B). Tightening torque: 13.8 ~ 15.7 N.m (1.4 ~ 1.6 kgf.m, 10.1 ~ 11.6 lb-ft) NOTE: Remove installation bolts in the engin room first and then remove others under the vehicle.
  8. Remove the bolt (3ea) after disconnecting the solenoid valve connector (B) and the oil temperature sensor connector (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  9. Remove the valve body assembly (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  10. Disconnect the input&output speed sensor connector (A).
  11. Remove the input&output speed sensor (B) after removing the bolts (2ea). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Scheme 713

Scheme 713
Scheme 713
  1. Turn ignition switch OFF.
  2. Disconnect the solenoid valve connector.
  3. Measure a resistance between Engine Clutch(E/C) solenoid valve terminal and power at solenoid valve connector.
  4. Check that the resistance is within the specification.
  1. Turn ignition switch OFF.
  2. Disconnect the solenoid valve connector.
  3. Measure a resistance between 26 Brake(26/B) solenoid valve terminal and power at solenoid valve connector.
  4. Check that the resistance is within the specification.
  1. Turn ignition switch OFF.
  2. Disconnect the solenoid valve connector.
  3. Measure a resistance between Line Pressure(L/P) solenoid valve terminal and power at solenoid valve connector.
  4. Check that the resistance is within the specification.
  1. Turn ignition switch OFF.
  2. Disconnect the solenoid valve connector.
  3. Measure a resistance between 35R Clutch(35R/C) solenoid valve terminal and power at solenoid valve connector.
  4. Check that the resistance is within the specification.
  1. Turn ignition switch OFF.
  2. Disconnect the solenoid valve connector.
  3. Measure a resistance between Underdrive Brake(UD/B) solenoid valve terminal and power at solenoid valve connector.
  4. Check that the resistance is within the specification.
  1. Turn ignition switch OFF.
  2. Disconnect the solenoid valve connector.
  3. Measure a resistance between Overdrive Clutch(OD/C) solenoid valve terminal and power at solenoid valve connector.
  4. Check that the resistance is within the specification.
  1. Turn ignition switch OFF.
  2. Disconnect the solenoid valve connector.
  3. Measure a resistance between solenoid valve(SS-A) terminal and power at solenoid valve connector.
  4. Check that the resistance is within the specification.

Scheme 714

Scheme 714: Removal
Scheme 714: Removal

Scheme 715

Scheme 715
Scheme 715

Scheme 716

Scheme 716
Scheme 716

Scheme 717

Scheme 717
Scheme 717
  1. Air cleaner assembly and air duct. (Refer to "Intake and Exhaust system" in EM group)
  2. Remove the Hybrid Power Control Unit (HPCU) assembly. (Refer to " «HYBRID CONTROL SYSTEM»(ref-535721-S23921223772013031200000) " in HC group)
  3. Remove the under cover (A). Tightening torque: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
  4. Replace new gasket and the plug after draining the automatic transaxle fluid by removing the drain plug. (Refer to " «AUTOMATIC TRANSAXLE»(ref-535716-S07341099932013031200000) " in this group.)
  5. Remove the ATF warmer. (Refer to " «ATF WARMER»(ref-535749-S01542930182013031200000) " in this group)
  6. Remove the AT tube (A) after removing eye bolt (B). Tightening torque: 42 ~ 48 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 31.4 lb-ft)
  7. Remove the valve body cover (A) and breather hose clip (B). Tightening torque: 13.8 ~ 15.7 N.m (1.4 ~ 1.6 kgf.m, 10.1 ~ 11.6 lb-ft) NOTE: Remove installation bolts in the engin room first and then remove others under the vehicle.
  8. Remove the bolt (3ea) after disconnecting the solenoid valve connector (B) and the oil temperature sensor connector (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  9. Remove the solenoid valve (B) after removing the solenoid support (A).

Scheme 718

Scheme 718
Scheme 718
  1. Turn ignition switch OFF.
  2. Disconnect the solenoid valve connector.
  3. Measure a resistance between solenoid valve(SS-B) terminal and power at solenoid valve connector.
  4. Check that the resistance is within the specification.

Scheme 719

Scheme 719: Removal
Scheme 719: Removal

Scheme 720

Scheme 720
Scheme 720

Scheme 721

Scheme 721
Scheme 721

Scheme 722

Scheme 722
Scheme 722
  1. Air cleaner assembly and air duct. (Refer to "Intake and Exhaust system" in EM group)
  2. Remove the Hybrid Power Control Unit (HPCU) assembly. (Refer to " «HYBRID CONTROL SYSTEM»(ref-535721-S23921223772013031200000) " in HC group)
  3. Remove the under cover (A). Tightening torque: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
  4. Replace new gasket and the plug after draining the automatic transaxle fluid by removing the drain plug. (Refer to " «AUTOMATIC TRANSAXLE»(ref-535716-S07341099932013031200000) " in this group.)
  5. Remove the ATF warmer. (Refer to " «ATF WARMER»(ref-535749-S01542930182013031200000) " in this group)
  6. Remove the AT tube (A) after removing eye bolt (B). Tightening torque: 42 ~ 48 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 31.4 lb-ft)
  7. Remove the valve body cover (A) and breather hose clip (B). Tightening torque: 13.8 ~ 15.7 N.m (1.4 ~ 1.6 kgf.m, 10.1 ~ 11.6 lb-ft) NOTE: Remove installation bolts in the engin room first and then remove others under the vehicle.
  8. Remove the bolt (3ea) after disconnecting the solenoid valve connector (B) and the oil temperature sensor connector (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  9. Remove the solenoid valve (B) after removing the solenoid support (A).

Scheme 723

Scheme 723
Scheme 723

Note. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.

Power Circuit Inspection

  1. Disconnect the Inhibitor swtich connector (A).
  2. Ignition KEY "ON"&Engine "OFF".
  3. Measure voltge between supplied power and ground at inhibitor circuit.

Specification: Approx. 12V

Signal Circuit Inspection

  1. Connect the Inhibitor switch connector (A).
  2. Ignition KEY "ON"&Engine "OFF".
  3. Measure voltages between each terminal and chassis ground during shift lever changed "P, R, N, D".

Specification: See below " SIGNAL CODE TABLE "

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