Automated Manual Transaxle: _5D-1 Automated Manual Transaxle Precautions Precautions for Diagnosing Trouble ‘AENDL7086400001 + Before using scan tool, read its Operator's Manual to know how to use it + When replacing TCM with used one, all learned gear change conditions which are stored in TCM memory should be cleared after the replacement referring to “TCM and Clutch Initialization” (Page 5D-81). + Be sure to read “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3) before inspection and observe what is written there. + Communication of ECM, TCM incorporated in automated manual transaxle actuator unit and BCM is established by means of CAN. Therefore, handle CAN communication line with care referring to “Precautions for CAN Communication System’ in Section 00 (Page 00-9) General Description Automated Manual Transaxle Description AENDLTOAS«O001 ‘Automated manual transaxle consists of an automated manual transaxle actuator unit (1), gear shift and select shaft assembly (2) and manual transaxle (3) The automated manual transaxle is a transaxle developed in conjunction with automated manual transaxle actuator Unit added to a conventional manual transaxle. TCM controls clutch engagement / disengagement and gear changes electrically,5D-2_Automated Manual Transaxle: Automated Manual Transaxle Actuator Unit Construction ‘The automated manual transaxle actuator unit consists of a clutch actuator (1), clutch position sensor (2), valve body (3), electric motor (4), oil pump (5), accumulator (6), reservoir tank (7), and TCM (8). The valve body includes a shift position sensor, select position senor, pressure sensor, shift solenoid valve 1, shift solenoid valve 2, clutch solenoid valve and select solenoid valve. However, disassembling the automated manual transaxle actuator unit is not permitted. Manual Transaxle Construction ‘The manual transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts: input shaft, countershaff and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.Automated Manual Transaxle: _5D-3 2 Wpat sats gear [8 cuen a 75. Low speed syratvonza’ leave and aD 3. Input shat th goar 0. tpt shat 7. Courershat st gar 5 lpul hat Sa gear 72. Countrsatl a 8. Direrish ase 6 Let ase 78. Counternat 7. igh esse 14 Counershat anor Gear Shift and Clutch Operating Mechanism When the shift selector is operated, the TCM incorporated in automated manual transaxle actuator unit controls the automated manual transaxle actuator unit based on the information inputted init. The clutch solenoid valve causes the clutch to engage / disengage by moving the release shaft, and shift solenoid valve 1, shift solenoid valve 2 and select solenoid valve cause the gears to change by moving the shif fork System of the automated manual transaxle actuator unit to control clutch engagement / disengagement and gear change of the transaxle consists of the shift selector, clutch solenoid valve, shift solenoid valve 1, shift solenoid valve 2, select solenoid valve, VSS, clutch speed sensor, clutch position sensor, shift position sensor, select position sensor, brake light switch, driver's door switch and TCM and the automated manual transaxle actuator unit has the following functions. (Page 50-11) + Automated manual transaxle can be driven in D (drive) mode and M (manual) mode. + Operation of shift selector from D to R or R to D is not effective when driver's door is open and the gear stays in neutral at this moment. + If shift up operation by shift selector fails to engage gear to target position, shifting to higher gear is attempted. And, if shit down operation by shift selector fails to engage gear, the gear remains in a position before the shift down + The engine can be started only when the brake is applied and the shift selector isin N to prevent sudden movement of vehicle + Gear change is controlled by TCM according to the accelerator operation similarly to automatic transmission and creeping is also available with accelerator and brake pedal released. + Similarly to conventional manual transaxle, itis possible to park the vehicle while the gear is engaged in reverse or ‘st positon with ignition “OFF” + The gear is shifted from reverse, D or M to neutral automatically to prevent risk of danger when any one of the following conditions is met with engine running Driver's door is open without depressing brake pedal and accelerator pedal Driver does no operation for 10 minutes. — 5 seconds have passed after releasing brake pedal Specific malfunction is detected TCM Learning The TCM monitors and leans conditions of the clutch and manual transax‘e for optimum gear change. However, if clutch, gear shift and select shaft assembly, automated manual transaxle actuator unit or manual transaxle is removed or replaced, the learned values are deviated, Therefore, itis necessary to clear the learned value in the past using the SUZUKI scan too! when removing or replacing these parts and make the TCM initialize and leam necessary values again for optimum control of the clutch and transaxle, For initialization, refer to “TCM and Clutch Initialization” (Page 50-81). Gear Shift Mechanism Electric motor (1) operated oil pump in the automated manual transaxle actuator unit accumulates oll pressure in the accumulator (2) and the pressurized oil operates both engage piston (3) and select piston (4). Receiving shift selector operation signal, the TCM causes the gears to change by moving engage piston and select piston in the automated manual transaxle actuator unit via gear shift and select shaft assembly (5).5D-4_Automated Manual Transaxle: TAY Auorated manoal vansaxl acuatorunt-| 7. Rah epesd pear shah 3. Ravers pear shit Tever ‘ene rom btm ‘Low sp00d persis 3. Shaver shisha Gear shirk bok Clutch Operating Mechanism Electric motor operated oil pump in the automated manual transaxle actuator unit accumulates oil pressure in the accumulator and the pressurized oil operates clutch mechanism. Receiving shift selector operation signal, the TCM ‘causes the clutch actuator (1) and release arm (2) in the automated manual transaxle actuator unit to advance the release bearing and pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the pressure plate away from flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to transaxle input shaft.Automated Manual Transaxle: _5D-5 Warning Buzzer Operation The BCM sounds the warning buzzer in two patterns as follows. ‘Buzzer operation Condition On(sec) | Off (sec,) Time When gear is disengaged and shifted to neutral automatically for [safety reasons. 0.08 0.08 2 |When shifting to reverse gear is inhibited due to vehicle condition. [When cranking without depressing brake pedal. [When clutch is overheating. 0.18 0.32 1 [When shift selector lover positon and aclual oar postion disagree. Function of Automated Manual Transaxle Control System Component AENOLTOASAO:000 Part name Function (Clutch speed sensor [Detects clutch speed, [Clutch position sensor Detects clutch position. [Shift position sensor Detects position of engage piston. [Select position sensor [Detects position of select piston. [Pressure sensor Detects oil pressure in automated manual transaxle actuator unit [Clutch solenoid valve [Opens / closes oil circuit for moving clutch actuator. [Shift solenoid valve 1 [Opens / closes oil circuit for moving engage piston. [Shift solenoid valve 2 [Select solenoid valve [Opens / closes oll circuit for moving select piston. [Clutch actuator [Operated by clutch solenoid valve for clutch engagement disengagement [Engage piston [Moves gear shift and select shafl assembly according to shift solenoid valves 1 and 2. [Select piston [Moves gear shift and select shafl assembly according to select solencid valve. [Electric motor (Operates oll pump by demand trom TCM.5D-6 Automated Manual Transaxle: Part name Function Oi punp ‘Generates oll pressure in automated manual transaxle actuator unit ‘Accumulator ‘Accumulates oil pressure generated by oil pump. TCM + Controls gear shift and clutch operation. [tL Diagnoses automated manual transaxle control system components, ‘Gear shift and select shaft assembly | Transmits movement of engage piston and select piston in automated manual transaxle actuator unit to gear shift shat Automatic Gear Shift Table ‘Automatic gear shift schedule is shown in the following table. Road test the vehicle on a flat road in D range. Throttle Vehicle speed kmih shift Remark opening (%) (ile/h) Fat nd 25 (16) 2nd—> 3rd 64 (40) 8010100 | 3rd = ath 98 (61) ath Gth| 30 t 139 (Bt to 86) Yat 2nd | 17023 (11 to 14) up em ovw7 [anid | arta a5 to 37" no sudden change in acclerator ath Sth | 68 to 120 (42 to 75) ‘9 pp ‘ist > 2nd 14(7) 2nd — 3rd | 24 Yo 26 (15 to 76) 10%030 | 3rd ath | 3210 37 (2010 23) 4th > Sth 45 to 48 (28 to 30) Sth ath | 96 to 126 (60 to 78) ain 3rd_| 7010 87 (43 to 54) 8010100 | “3rd and | 32%0 67 (20 to 38) 2nd» ist 73 (6) Sth = ath | 60 to 80 (37 1050) There is no sudden change in accelerator DOWN shit} 40t070 [| Sh 3rd [AROSE PSI) poping, rd and = Hard brake isnot being applied 2nd ist = 19 app 3th ath = ath = 3rd = 101030 | ard 2nd = ‘2nd ist = NOTE ‘The gear change is done at the shift point different from the above if any of the following conditions is met. Bear this in mind when performing inspection. Shift hold control when accelerator (throttle) is quickly closed When the accelerator is closed during acceleration, up-shift usually takes place in many cases because the gear change point for accelerator 0% opening is used as reference. With this control function, however, needless up-shift is avoided in accordance with the speed at which the accelerator is closed. As a result, the gear is held in the position used at that time. In this way, the engine brake can be used effectively and acceleration after that will be done ‘smoothly, Shift hold control using estimated gradient of slope ‘The gradient of the road surface is constantly estimated while the vehicle is running using the engine torque data and vehicle speed data. When itis judged as exceeding the specified value, needless up-shift is avoided. This maintains, engine brake effective on a down-hill slope and suitable gear in used on a up-hill slope. ‘Coast down control when brake is applied With this control, the gear change point is changed to the one for coast-down based on the brake signal and vehicle deceleration (calculated from the vehicle speed signal). Consequently, at hard braking, down-shift takes place at a higher vehicle speed than the normal down-shift vehicle speed and is over during deceleration. In this way, time lag at the time of re-acceleration (without this control, down-shift takes place after the accelerator pedal is depressed) is eliminated for smooth acceleration.Automated Manual Transaxle: _5D-7 ‘Automated Manual Transaxle Diagnosis, General Description ‘AEN 7oA5401004 TCM has an On-Board Diagnosis System which detects a malfunction in this system. ‘When diagnosing a trouble in transaxle control including this system, be sure to have full understanding of "On- Board Diagnostic System Description” (Page 5D-7) and each item in "Precautions for Diagnosing Trouble” (Page 5D-1) and execute diagnosis according to “Automated Manual Transaxle System Check’ (Page 5D-12) to ‘obtain correct result smoothly, On-Board Diagnostic System Description ARNDLToASA01005 TCM has the following functions, + When TCM detects a malfunction in automated manual transaxle control system, TCM tums on malfunction indicator lamp (MIL) (1) and/or automated manual transaxle warning light (2) and stores malfunction DTC in TCM memory. + Itis possible to communicate with TCM through data link connector (DLC) (3) by using SUZUKI scan tool (4). (Diagnostic information can be checked and cleared by using SUZUKI scan tool.) CAN Communication System Description Warm-Up Cycle ‘Awarm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22 °C (40 °F) from engine starting and reaches a minimum temperature of 70 °C (160 °F). Driving Cycle ‘A"Driving Cycle” consists of engine startup, driving ‘mode where a malfunction would be detected if present, and engine shutoff [AENDL70AS401006, Refer to “CAN Communication System Description” in Section 10H (Page 10H1) for CAN communication system description.5D-8 Automated Manual Transaxle: Schematic and Routing TCM Circuit Diagram rowfsoi, srw fc16-20 aw foresee i suure.oisse- Eby, ~ wo vwnxfors.e FL rs ww auxforss—y - Dep Tecisab iran wpe evens. a = cerned fors13—FL,” ow erso ces imam a ony feis17 Foray ew } a 7 + $ cre caver s 3 eo fois], a wirfors-104 crea} veL 7] ‘ ze] ws 2 ss 2 | Bag 1825] uranw ae} @ ——— Lecrs2nh wr: x 42Automated Manual Transaxle: _5D-9 1 Shi elodtor "2 Rulomatd marvalWarsonle acusior | 23. Diverside ont doorawich | 34 “Ti Wise 2 fal eens 7a Tow 2 BoM 3 _1GW fe ‘To contol maduesconrecedby CAN | 14. CAN diver 25. Backup ighraay 36. "ST se Valve body 18. Eleerie motor auionsiod manual | 26. Back up nt 37. IGT SIG" ace teaneand actatr un, "5 Shilpzalon sensor TE_Cltch speed sensor anion sch 3a STIS he Select poston sensor "7 Ga psten eat aonied | 28 Sing coaiahy | 5. Man isobar 7 Pressre seraor aves Sarina mote Baty ‘4 Shitsoloned vaNe 19, Temainreby 30.72 he 41. Engine ond ‘3. Shit solonod vale 2 70 ECw 31. "STOF" tne 22. Body rune 7a. Clach soli valve 21. Brake Tight sich 32. "BAOE tse 7 Selet solenoid vave 22 Baie oft 33, “TM POMP fs5D-10_Automated Manual Transaxle: Electronic Shift Control Input / Output Diagram INPUT ouTPUT ‘Automated manual transaxle actuator unit Pressure sensor |] TOM Valve body [Shit solenoid valve t ‘Shift positon sensor _ (Gear shit control Select positon sensor [Shit solenoid valve 2 Shifting conta! Clutch postion sensor Reverse control | +|[Cluteh solenoid valve VSS, Clutch control t—+[Eecrcmoor Gluich speed sensor Brake ight switch signal Searing meter eon E | Brake switch signal accu ight sonal ] Ignition “START signal Shit selector power supply Shi eelector| Laver postion swith Mt sia Lever pstonawien M2 sal Hal sensor Laver postin seh Ht signal Protective funeion ‘Ot pur high temp, conta Driver side front door swt signal Faiveate function 'BcM Divers font door sth gna Ambient temperature sensor ina Self diagnosis Eom ‘Acselratr pada postion Engin coalant tmperature Warning function ‘Combination meter ‘Aulomaled manval anes Shit slaior positon > - Signal on can ‘communincaton lineAutomated Manual Transaxle: _5D-11 Component Location Electronic Shift Control System Component Location Brake igh swith 7. TEM incorporated naviomaled manual | 13. Backup ligtroby srenssle actor unt ver ie Fn door awh Automated manus! wansane seat unt | Ta. Staring mor coneaeaay 3 Avomtd manual waneaxle wamina Toh? ._Cuenspees sensor 78. Salecslono vals om 10. Vat body (automated manvalianeade | 16. Clieh solnoi ake ‘ction. = Saeancor Ti Eleaie malt laralod mani vancane | 17 Shitaaanoi vale Yana dif eabnow valve = ‘cuatarunt) 5. Atomod manual earsaxe vss 58, Proseie sensor5D-12_Automated Manual Transaxle: Diagnostic Information and Procedures Automated Manual Transaxle System Check (Step 1 ‘Action ‘Customer complaint analysis 1) Perform customer complaint analysis, “(Page 5D-12) Was customer complaint analysis performed? Yes (Goto Step 2 No Perform customer Jcomplaint analysis. 2 |DTC/ freeze frame data check, record and clearance [Print DTC and freeze [Go to Step 4. 1) Check for DTC. «(Page 5D-13) frame data or write them down and clear them by Is there any DTC(s)? referring to “DTC Clearance” (Page §D- 22). Then go to Step 3. 3 |Visual inspection Repair orreplace |Goto Step. 1) Perform visual inspection. + (Page 5D-13) malfunction part. Then 90 to Step 11 Is there any faulty condition? 4 |Visual inspection Repair orreplace__|Goto Step 6. 1) Perform visual inspection. «(Page SD-13) matfunction part. Then goto Step 11 Is there any faulty condition? 5 |Trouble symptom confirmation Goto Siep 6. [Go to Step 7. 1) Confirm trouble symptom. # (Page 5D-14) Is trouble symptom identified? © |Rechecking and record of DTC /freeze frame data___|Goto Step 9. Goto Step 8. 1), Recheck for and freeze frame data. (Page 50-14) Is there any DTC(s)? 7 JRechecking and record of DTG [freeze frame data [Goto Siep. [Goto Step 10. 1) Recheck for DTC and freeze frame data. (Page 5D- 14) Is there any DTC(s)? 3 [Automated manual transaxle symptom diagnosis (Goto Siep Tt Check and repair 1) Check automated manual transaxle symptom diagnosis matfunction part(s). (Page 50-14) [Then go to Step 11. |Are check and repair complete? Troubleshooting for DTC (Goto Siep 17 (Check and repair 1), Perform troubleshooting for applicable OTC. (Page malfunction part(s). 5-14) [Then go to Step 11 \Are check and repair complete? 70 [Check for intermittent problems Repair orreplace _|Goto Step 17. 1) Check for intermittent problems. «(Page SD-14) malfunction part(s). Then go to Step 11 Is there any faulty condition? 77 [Final confirmation test Goto Siep 6. End 1) Clear DTC if any. 12) Perform final confirmation test. “(Page 5D-14) Is there any problem symptom, DTC or abnormal condition?| ‘Step 1. Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred by the customer. For this purpose, use of such a questionnaire from shown below will facilitate collecting information for proper analysis and diagnosis,Automated Manual Transaxle: _D-13 NOTE The form is a standard sample. It should be modified according to characteristic of each market. Customer questionnaire form (Example) (User name: Model: VIN: Date of issue: Date of Reg.: Date of problem: Mileage: PROBLEM SYMPTOMS. Vehicle does not move (R, D, M) No upshift (Ci tstto 2nd C1 2nd to 8rd. 8rd to 4th [2 4th to Sth) No downshift (C) 3rd to 2nd (2nd to 1st [4th to 3rd C1 Sth to 4th) Shift lever cannot be operated (JN > D OD >N ON>R OR>NOD>MOMD) Noise (Ci Motor 11 Gear (1 Clutch 1 Other ) © Automatic shift point too high or too low Excessive gear change shook (1st/2nd/3rd/4th/ 5th/Reverse) No kickdown Clutch stipping © Others VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather Fair Ci Cloudy 0 Rain Ci Always (1) Other Temperature (°F °C) COHot C Warm (3 Coot CI Cold Ci Always Frequency (Always Ci Sometimes ( times/ day, month) [i Only once C1 Under certain condition Read (Urban Ci Suburb Cl Highway C Mountainous Cl Uphill C] Downhill Cj Tarmacadam OGravel 1 Other Vehicle Condition Engine & (Cold Ci Warming up phase? C1 Warmed up transmission Engine speed ( r/min.) condition Throttle opening (CI Idle/ C1 About _% ful) Vehicle condition | TJ At stop/ Ci During driving (Ci Constant speed [i Accelerating C1 Decelerating Ci Brak- ing) (Right hand comer CI Left hand corner 1 Vehicle speed ( — km/h_—_mile/h) DOther MTA warning Ti Aways ON L] Sometimes ON 1 Always OFF lamp }00d condition Malfunction ToBlink Cl Always ON Zi Sometimes ON Cl Always OFF indicator lamp Good cancion Diagnostic trouble | First check: C} No code Ci Malfunction code ( ) code ‘Second check: (1 No code L Malfunction code ( ) Step 2. DTC / Freeze Frame Data Check, Record and | Step 3 and 4, Visual Inspection Clearance As a preliminary step, perform visual check of the items First, check DTC (current DTC). (Page 50-21) that support proper function of the engine and IfDTC is indicated, print DTC and freeze frame data or | automated manual transaxle referring to “Visual ‘write them down and then clear them. =-(Page 5D-22) | Inspection" (Page 5D-14),