Automatic Transmission External Diagnosis

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Automatic

Transmission

External Diagnosis

Course Guide

Course Guide

Student Guide

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SAFETY FIRST

Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service. This module cannot possibly anticipate all such variations and provide advice or caution to each. Accordingly, anyone who departs from the instruction provided in this module must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts. The following list contains general warnings that should always be followed while working on a vehicle. • Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires underbody work.

• Be sure the ignition switch is always off unless otherwise specified by a procedure. • Set the parking brake when working on the vehicle.

• Operate the engine only in a well ventilated area. • Keep clear of moving parts when the engine is running.

• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on a vehicle.

Within this module you will find Notes, Cautionsand Warningswhich provide critical information and help you do your job safely and efficiently. Below are the definitions of these terms.

When you see a Note, Caution orWarning, be certain you understand the message before you attempt to perform any part of a service procedure.

NOTE

The purpose of a Note is to help you do your job more efficiently. A Note may provide additional information to help clarify a particular point or procedure.

CAUTION

A Caution alerts you to the possibility of damage to tools, equipment, or the vehicle. A Caution recommends that a procedure must be done in a certain way to avoid potential problems resulting from improper techniques or methods.

WARNING

A Warning alerts you to the highest level of risk. Warnings inform you that a procedure must be done in a particular way to minimize the chances of an accident that could result in personal injury or even loss of life.

!

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All rights reserved. No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. (“KMA”). KMA reserves the right to make changes in the descriptions, specifications, or procedures.

The content of this course is intended for informational and educational purposes only. Any reliance placed on such information is therefore strictly at your own risk. In no event will Kia Motors America, Inc. ("KMA") or Kia University be liable for any loss or damage including, without limitation, indirect or consequential loss or damage,

property loss, damage, personal injury or death caused to any persons arising out of or in connection with the use of this course.

While KMA makes all reasonable efforts to ensure that all course materials are correct, accuracy cannot be guaranteed and KMA does not assume any responsibility for the accuracy, completeness, or authenticity of any information contained in these course materials. Nothing in this course is intended as a guarantee of success.

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TT-ATED309-IL-CG01

6th Printing - January 2011

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Module Title

Automatic Transmission External Diagnosis

ATED Course Guide Module 01 1

Automatic Transmission External Diagnosis

Course Guide

COURSE OVERVIEW

COURSE GOAL

COURSE OBJECTIVES

EXPECTATIONS

The Automatic Transmission External Diagnosis (ATED) is performance-based course providing Kia service technicians the opportunity to continue their A/T diagnostic training begun in the A/T Internal Diagnosis (ATID) instructor-led course, and to understand causes determined not to be internal but external to the

transmission.

The goal of this course is to build upon the A/T

diagnostic skills Kia service technicians learned in ATID. These goals include:

x Diagnostic flow from internal diagnosis flowchart to external diagnosis

x DTC based A/T diagnostics using service information x Inspecting external A/T electrical circuit voltages x External sensor and actuator circuit inspection x Non-DTC based A/T external diagnostic strategy Upon completion of this course, the Kia Service Technician will be able to demonstrate the following skills with 80% or greater accuracy:

x Use DTC detecting conditions and strategy.

x Inspecting external A/T circuit voltages and signals. x Print ETM to identify circuits and interpret results. x Identify A/T sensors and actuators by type of signal. x Measure and interpret electrical circuits with DMM

and BOB Pro.

x Measure and interpret electrical circuits with GDS/VMI Scope

x Perform Signal Simulation Tests using GDS/VMI x Inspect and interpret current A/T data.

In the previous ATID ILT course you used the A/T diagnostic flowchart and A/T Tester Pro to determine if the transmission had an internal problem that required A/T unit replacement or external diagnosis.

In this course you will be expected to use the

diagnostic process required in diagnosing external A/T electrical circuits to fix the vehicle on the first visit.

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2 ATED Course Guide Module 01

Automatic Transmission External Diagnosis

TARGET AUDIENCES PREREQUISITES RECOMMENDED PREREQUISITES ABOUT TRAINING MODULES THEORY GUIDED PRACTICE PERFORMANCE ASSESSMENT

The target audience for ATED consists of Kia Service Technicians who have passed ATID.

The following Instructor-led courses must be completed prior to taking ATED.

x The Kia Automatic Transmission Internal Diagnosis (ATID) TEC-03-016-1

x Advance GDS Diagnosis (GDS5) TEC-03-029-01 The following courses are recommended prior to ATED. x Automotive Electrical Diagnosis (AED) TEC-03-017-1 Today's complex automotive technology demands that you, the professional Kia service technician, stay up to-date with the latest service information, special tools and complex repair procedures. We have adopted a modular training delivery system, designed to be part of a structured training plan consisting of lecture, interactive classroom discussion and hands-on shop activities under the direction of a trained Kia instructor. A Theory Module explains the subject allowing you to obtain a working knowledge of a component or system, and helping guide you to successful diagnosis and repair.

The Guided Practice Module allows you the

opportunity to practice through hands-on experience, the process of diagnosing external A/T concerns. The tasks are to be instructor supervised and verified. These diagnosis and testing exercises may include: the use of Kia service information system, accessing

Kdealer.net, live vehicle activities using GDS/VCI equipment and much more.

The Performance Assessment Module provides you the opportunity to demonstrate that you know the process in diagnosing A/T related concerns. Each

technician must successfully complete this module. It is designed to test your cognitive (knowledge) in

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Module Title

Automatic Transmission External Diagnosis

ATED Course Guide Module 01 3

COURSE MATERIAL

AGENDA

PERFORMANCE SCORECARD

COURSE ACHIEVEMENT

SCORECARD ROUTING

Module Number Module Title Theory Guided Practice Diagnosis Performance Assessment Guide

ATED 01 Course Guide X

ATED 02 A/T DTC

Diagnosis X

ATED 03 External A/T

Measurements X

ATED 04 A/T Controller

Circuits X

ATED 05 A/T Controller Circuits X ATED 06 Non-DTC Diagnosis X ATED 07 P. A. X

ATED.01 Course Introduction 8:00 – 8:30 am ATED.02 A/T DTC Diagnosis 8:30 – 10:00 am

Break 10:00 – 10:15 am

ATED.03 External A/T Measurements

10:15 – 11:30 am

Lunch 11:30 – 12:30 pm

ATED.04 A/T Controller Circuits 12:30 – 1:15 pm ATED 05 A/T Controller Circuits 1:15 – 3:15 pm

Break 3:15 – 3:30 pm

ATED 06 Non-DTC Diagnosis 3:30 – 4:00 pm ATED 07 P. A. 4:00 – 4:45 pm Wrap-up & conclusion 4:45 – 5:00 pm The Performance Scorecard is used to track your

performance.

A final score of 80% or greater is needed for completion credit.

One copy of the scorecard is yours, and one copy is used to update your Kia technical training records. Should you not complete the course, the third copy is forwarded to your Kia District Parts and Service Manager.

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4 ATED Course Guide Module 01

Automatic Transmission External Diagnosis

COURSE MANAGEMENT TAKE NOTES ASK QUESTIONS TEAMWORK LEARN AT EVERY OPPORTUNITY ICONS

!

The course and its materials are here for you to learn and keep. Use them and your time in a way that will benefit you when you return to your dealership. Make drawings, jot down notes, and highlight these materials to help you remember important details. Each module is designed with ample margins for your

important notes.

If you do not understand something in this course, ask your instructor for clarification. Asking questions is strongly encouraged to help you get the most out of this course.

During the hands-on activities, you will often be working as a team. By actively engaging in each activity, you will maximize your learning experience. While in the lab, feel free to ask the instructor questions at any time.

This course is an opportunity for you to learn in a controlled environment under the guidance of a trained Kia instructor. Through active participation you can build confidence in your abilities to diagnose customer concerns right the first time, every time!

The Reference Icon indicates you must refer to additional publications in order to complete the questions or activity.

The Activities Icon indicates an activity that supports a critical learning objective. These activities are offered to help you master the material.

The Feedback Icon indicates a progress check meant to provide you with feedback of your understanding of course material.

The Caution Icon indicates areas where special attention must be paid to avoid causing harm or damage.

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Automatic

Transmission

External Diagnosis

Theory Module

DTC Diagnosis

Student Guide

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SAFETY FIRST

NOTE

CAUTION

WARNING

!

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TT-ATED309-IL-TH02

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Automatic Transmission External Diagnosis

ATED Theory Module 02 1

A/T DTC Diagnosis

TARGET AUDIENCE MODULE GOAL MODULE OBJECTIVES MODULE INSTRUCTIONS TIME TO COMPLETE ACRONYMS

The target audience for this module consists of Kia Senior and Master Service Technicians who will diagnose and repair Kia automatic transmissions. The goal of this module is to train the Kia Service Technician with the skills required to confirm and diagnose an A/T concern, identified as external to the A/T by the diagnostic flowchart covered in ATID. Given this module and a written multiple-choice test, the technician will be able to answer questions about the following topics with 80% or greater accuracy: x DTC Detecting Conditions

x DTC Detecting Strategy x DTC Enable Conditions x Sections of a DTC x BOB Pro usage.

Carefully read the material, take notes based on the classroom discussion, demonstration and illustrations. There are Progress Check questions at the end of the module for you to take and an answer sheet to record your answers and turn in to your instructor.

Approximately 1 hour and 30 minutes

ATID: Automatic Transmission Internal Diagnosis BOB PRO: Break-Out-Box

DVOM Digital Volt Ohm Meter ECM: Engine Control Module ECU: Electronic Control Unit

ETM: Electrical Troubleshooting Manual GDS: Global Diagnostic System

PCM: Powertrain Control Module TCM: Transmission Control Module

VCI: Vehicle Communication Interface (GDS) VMI: Vehicle Measurement Interface (GDS)

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2 ATEDTheory Module 02

Automatic Transmission External Diagnosis

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Automatic Transmission External Diagnosis

PURPOSE

PREREQUISITES

In the previous Automatic Transmission Internal

Diagnosis (ATID) course, you learned how to follow the diagnostic flow chart, perform specific tests to verify the customer concern and determine if the cause is internal to the A/T.

This course is designed to help you continue diagnosing verified A/T related customer concerns that are typically electrical in nature and are external to the A/T after you have determined the A/T does not need replacement. External transmission diagnosis requires the use of these specific skills:

x DTC Enable conditions and diagnostic use

x Use BOB Pro with a GDS and VMI to measure scope readings of A/T inputs and outputs

x Use a BOB Pro with a DMM to measure voltage, and frequency.

Prior to taking the ATED course, you are required to have the following skills from these instructor-led training courses:

x Electrical diagnostic including DMM usage o Automotive Electrical Diagnosis

x ETM reading and interpretation of expected values o Automotive Electrical Diagnosis

x GDS with VCI and VMI usage for diagnosis o Diagnosing with GDS

x Search on-line for service and diagnostic information o Essential Kia Service Skills

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Automatic Transmission External Diagnosis

A/T RELATED DTC

In the ATID course, you followed the A/T diagnostic flowchart and performed the following:

x Verified the customer’s concern x Inspected and test drove

x Determined it’s an A/T Performance Concern x Searched for service repairs and information x Retrieved an A/T related DTC

When a DTC is retrieved, it’s usually a simple matter of going to the service information, following the DTC diagnostic information, and performing the repair. On the following pages, we will breakdown a DTC chart in the service information and discuss how to interpret this information to help you in your diagnosis.

Note: “No DTC found” diagnosis will be covered in module 6 of this course.

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Automatic Transmission External Diagnosis

DIAGNOSING A SPECIFIC DTC

GDS BASIC DIAGNOSTIC FLOW WITH A DTC

Continue with the diagnostic process using the GDS flowchart.

1. Using GDS, select Fault Code Search and the DTC. 2. Select DTC Analysis.

3. Select, review the items in the box above, including: a. General Description/Component Location

b. DTC Description

c. DTC Detecting Conditions

4. Continue following the diagnostic procedure. 5. Repair the vehicle.

6. Verify the repair.

Next we are going to examine detecting conditions, as they are the key issues used by the PCM to set DTC. x

NOTE: While you are following the diagnostic

procedure always ask yourself the following questions: x What am I checking in each step of the process? x What value would I expect to find if circuit is good? x Am I taking the correct measurements?

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE: ITEM

Item Detecting Condition Possible cause

DTC Strategy 1) Speed rationality check

1) Signal circuit is open or short. 2) Sensor power circuit is open 3) Sensor ground circuit is open 4) Faulty INPUT SPEED SENSOR 5) Faulty PCM/TCM

Enable Conditions

1) Vehicle speed is over 19 Mile/h(30 Km/h) 2) Ne > 1000 rpm (only at 1st or 2nd gear ) 3) 11V Battery Voltage 16V

4) TM oil temperature -23°C

Threshold value 1) No signal

Diagnostic Time 1) More than 1sec

Fail Safe

1) Locked into 3rd or 2nd gear

2) Manual shifting is possible(2 nd 3 rd, 3 rd 2 nd)

A/T DTC’s have a set of Detection Conditions, which are classified by item. These “Detection Conditions”

determine how the circuit or component is tested. The Detection Conditions are grouped by the following “item” classifications: x DTC Strategy x Enable Conditions x Threshold values x Diagnosis Times x Fail-safe

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE: ITEM - DTC STRATEGY

DTC Strategy 1) Speed rationality check

Enable Conditions

4) TM oil temperature -23°C Threshold value 1) No signal

Diagnostic Time 1) More than 1sec

Fail Safe

The item “DTC strategy” determines what the specific condition(s) the circuit or component is tested for. In the above example (P0717) only the speed rationality check is being performed.

Within any DTC Strategy the testing may include one or more of the following:

x No signal x Rationality x Voltage range x Gear ratio incorrect x Stuck OFF

x Stuck ON x A/T relay

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE: ITEM - ENABLE CONDITIONS

DTC Strategy 1) Speed rationality check

Enable Conditions

1) Vehicle speed is over 19 Mile/h(30 Km/h) 2) Ne > 1000 rpm (only at 1st or 2nd gear ) 3) 11V Battery Voltage 16V

4) TM oil temperature -23°C Threshold value 1) No signal

Fail Safe 1) Locked into 3rd or 2nd gear

The item “Enable Conditions” is the operating conditions of the engine and A/T when the circuit is tested.

These typically include several of the following: x Engine state ON/OFF

x Engine speed (RPM) * x Throttle position x Input speed x Output speed x Vehicle speed *

x ATF Oil temperature * x Battery voltage * x Range switch

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE: ITEM - THRESHOLD VALUE

Enable Conditions

4) TM oil temperature -23°C

Threshold value 1) No signal

Fail Safe

The item “Threshold value” is data parameter(s) stored in the computer that the measured or calculated value of the data is being compared to.

Examples of typical threshold values include: x No signal detected

x Multiple signal

x Feedback voltage less than or equal to ()X.XX volts x Feedback voltage greater than or equal to ()X.XX

volts

x Out of voltage range x Calculated vehicle speed

Next, let’s look at two examples of the same

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Automatic Transmission External Diagnosis

ITEM – THRESHOLD VALUE: - EXAMPLES

RANGE SWITCH LOW INPUT

Item Detecting Condition - P0707 Possible cause

DTC Strategy 1) Check for no signal

1) Open or short in circuit 2) Faulty TRANSAXLE

RANGE SWITCH 3) Faulty TCM(PCM) Enable Conditions 1) Engine state = "RUN"

2) 11V Battery Voltage 16V 3) TPS 3%

Threshold value 1) No signal detected

Diagnostic Time 1) More than 30seconds

Fail Safe

1) Recognition as previous signal.

1) When P-D or R-D or D-R SHIFT is detected, it is regarded as N-D or N-R though "N" signal is not detected

2) When sports mode S/W is ON without P, R, N, D-RANGE signals, it is regarded sports mode. (DTC is not set)

RANGE SWITCH MULTIPLE INPUT

Item Detecting Condition - P0708 Possible cause

DTC Strategy 1) Check for No signal

1) Open or short in TRANSAXLE RANGE SWITCH 2) Faulty TRANSAXLE RANGE SWITCH 3) Faulty PCM Enable Conditions

1) Engine state = "RUN" 2) 11V Battery Voltage 16V 3) TPS 3ୁ

Threshold value 1) Multiple signal

Fail Safe

1) Recognition as previous signal

1) When signal is input "D" and "N" at the same time, TCM regards it as "N" RANGE

2) After PCM/TCM Reset, If the if the PCM/TCM detects multiple signal or no signal, then it holds the 3rd gear position

Here is an example of the same component with two threshold values.

If no signal or multiple signals (fault) exist for longer than the listed diagnostic time, a DTC is set and the MIL may be illuminated.

When a DTC is set, the ECU will operate in the fail-safe mode described.

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE: ITEM - DIAGNOSTIC TIME

Enable Conditions

Diagnostic Time 1) More than 1sec

Fail Safe

Diagnostic time is the amount of time the condition must exist before the DTC will set.

Depending on the DTC requirements this can be: x Less than (<) 1 second

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE: ITEM - FAIL SAFE

Enable Conditions

Fail Safe 1) Locked into 3rd or 2nd gear

2) Manual shifting is possible(2 nd 3 rd, 3 rd 2 nd)

Fail-safe is the mode of the PCM/TCM command solenoid operation. In this example the A/T is: x Locked into 3rd_{or 2}nd_gear

x Manual shifting is possible (2nd_{to 3}rd_{and 3}rd_{to 2}nd_).

The chart indicates how the vehicle can be shifted while in the fail-safe mode with this specific DTC set.

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE SECTIONS – P0707

GENERAL DESCRIPTION

The Transaxle Range Switch sends the shift lever position information to the TCM (PCM) using a 12V (battery voltage) signal. When the shift lever is in the D (Drive) position the output signal of Transaxle Range Switch is 12V and in all other positions the voltage is 0V. The TCM (PCM) judges the shift lever position by reading all signals, for the Transaxle Range Switch, simultaneously.

DTC DESCRIPTION

The TCM (PCM) sets this code when the Transaxle Range Switch has no output signal for more than 30 seconds.

Next, let’s cover the procedures for all the troubleshooting sections of DTC P0707.

The first sections of the DTC chart will give you the: x Location

x General Description x And the DTC Description.

A photo or illustration indicating its basic location is provided.

Next, there is a description of how the circuit operates and a short description of how the code sets.

Range Switch, Connector and Shift Linkage LOCATION

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE SECTIONS – P0707 CONTINUED

DTC DETECTING CONDITION

Item Detecting Condition Possible cause DTC Strategy 1) Check for no signal

1) Open or short in circuit 2) Faulty TRANSAXLE

RANGE SWITCH 3) Faulty TCM(PCM) Enable Conditions

1) Engine state = "RUN" 2) 11V Battery Voltage 16V 3) TPS 3%

Threshold value 1) No signal detected Diagnostic Time 1) More than 30seconds

Fail Safe

1) Recognition as previous signal.

1) When P-D or R-D or D-R SHIFT is detected, it is regarded as N-D or N-R though "N" signal is not detected

2) When sports mode S/W is ON without P, R, N, D-RANGE signals, it is regarded sports mode. (DTC is not set)

As previously discussed, the DTC Detecting Conditions above list the conditions used by the ECU when testing the circuit for a P0707 fault.

This information is useful when you perform the test drive to verify the repair.

While it’s good to confirm the repair by test driving the vehicle under similar conditions reported by the

customer, it’s better to test drive following the

Detecting Conditions. This is how the ECU is going to check to determine if a fault exists.

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE SECTIONS – P0707 CONTINUED

The Schematic section shows the individual electrical schematic and its associated connectors and circuits that apply to the specific DTC P0707.

C21

C01-1 C21

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE SECTIONS – P0707 CONTINUED

TERMINAL & CONNECTOR INSPECTION

1. Many malfunctions in the electrical system are caused by poor harness and terminal condition. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.

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

3. Has a problem been found? YES

ඖGRepair as necessary and go to "Verification of vehicle repair" procedure. G

NO

ඖGGo to "Power circuit inspection" procedure.

G

The Terminal & Connector Inspection section has you perform:

x Electrical interference, mechanical or chemical damage

x A careful inspection of each terminal and connector for anything that may cause a poor connection. x The repair if a problem has been found, if not,

continue to Power Circuit Inspection (next page). Note: The connector schematic may only indicate specific pins; it is a good idea to check all the pins that are related to the A/T.

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE SECTIONS – P0707 CONTINUED

POWER SUPPLY CIRCUIT INSPECTION

1. CHECK POWER TO RANGE SWITCH

(1) Disconnect "TRANSAXLE RANGE SWITCH" connector. (2) Ignition "ON" & Engine "OFF".

(3) Measure voltage between terminal "8" of the sensor harness connector and chassis ground.

Specification : approx. B+

(4) Is voltage within specifications? YESG

ඖGGo to "Signal circuit inspection" procedure. NOG

ඖGCheck that Fuse 7.5 A is installed or not blown.

ඖGCheck for open in harness. Repair as necessary and go to "Verification of vehicle repair" procedure.

The Power Supply Circuit Inspection:

x Describes where to measure voltage in the circuit. x Provides specification and explains.

x Calls for repair if a problem is found, if not, continue to Signal Circuit Inspection (next page).

Note: When performing measurements, use the correct size T-Connectors whenever possible. Be extremely careful not to damage the terminal.

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE SECTIONS – P0707 CONTINUED

SIGNAL CIRCUIT INSPECTION

1. Ignition "OFF".

2. Disconnect "TRANSAXLE RANGE SWITCH" and "TCM (PCM)" connector.

3. Measure resistance between each terminal of the sensor harness connector and TCM(PCM) harness connector as below.

Specification : #1 #2 #3 #4

Pin No of "TRANSAXLE RANGE

SWITCH" C21 No.1 C21 No.3 C21 No.4 C21 No.7

Pin No of "PCM" harness C01-1 No.6 C01-1 No.3 C01-1 No.5 C01-1 No.4

Specification 0 0 0 0

4. Is resistance within specifications? YES

ඖGGo to "Component inspection" procedure. NO

ඖGCheck for Open in harness. Repair as necessary and Go to "Verification of Vehicle Repair" procedure.

The chart shows the pin numbers and specifications for all four circuits.

If the resistance of the four circuits is within the specifications, then component inspection is next. C21:

C01-1:

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE SECTIONS – P0707 CONTINUED

COMPONENT INSPECTION

1. Ignition "OFF."

2. Remove "TRANSAXLE RANGE SWITCH."

3. Measure the resistance between each terminal of the sensor. Specification : approx. 0 ȳG

G

4. Is resistance within specifications? YES

ඖGSubstitute with a known-good PCM/TCM and check for proper operation. If the problem is corrected, replace PCM/TCM as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

ඖGReplace "TRANSAXLE RANGE SWITCH" as necessary and Go to "Verification of Vehicle Repair" procedure.

In this example of Component Inspection you are only shown two terminals 1 & 8 to measure.

To validate the switch you must measure all of the pins as they relate to the chart.

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Automatic Transmission External Diagnosis

FAULT CODE DIAGNOSIS PROCEDURE SECTIONS – P0707 CONTINUED

VERIFICATION OF VEHICLE REPAIR

After a repair, it is essential to verify that the fault has been corrected. 1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.

2. Using a scan tool, Clear DTC.

3. Operate the vehicle within DTC Enable Conditions in General Information. 4. Are any DTCs present?

YES

ඖGGo to the applicable troubleshooting procedure. NO

ඖGSystem performing to specification at this time.

After you have completed the repairs, always verify that the fault has been corrected by operating the vehicle under the conditions detailed in the DTC Detecting Condition.

Note: If multiple A/T related DTCs are stored, look for common power and ground circuits (wire, pins and connectors) related to the DTCs. The DTCs are probably not caused by an internal A/T failure.

SUMMARY Based upon the A/T related DTC stored, the fault code

diagnosis procedure is used to diagnose the concern and includes:

x Location

x General Description of how the circuit works x DTC Description on how the DTC sets

x Detecting Conditions to set the DTC x Schematic of the circuit

x Terminal and connector inspection x Power supply circuit inspection x Signal circuit inspection

x Component inspection x Verification of vehicle repair

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Automatic Transmission External Diagnosis

BREAK OUT BOX (BOB) PRO

INTRODUCTION When diagnosing a DTC you need to test electrical

circuits. The Break Out Box (BOB) Pro allows you to connect to an Electronic Control Unit (ECU) and its associated wiring.

BOB Pro is a digital break out box that can be

connected to most 2003 and later Kia PCM, ECM and TCM equipped vehicles.

The BOB Pro provides access to multiple ECU terminals that require measurements such as voltage, resistance, and frequency. In addition, it also provides access points for external test equipment such as an oscilloscope.

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Automatic Transmission External Diagnosis

BOB PRO APPLICATION TABLE AND OVERLAY

The Application Table for BOB Pro is on-line at KGIS and provides the correct program number/overlay sheet number and “red” interface cable box number for the vehicle application.

The front cover of the overlay sheet will also provide the same information, but only for one vehicle

application. The overlay sheet is a flipchart with the following information:

x ETM and ECU terminal pin number x Name of the signal

x Test condition, such as idle, park or A/C ON/OFF x Type of input/output signal value for meter setup:

o Type such as pulse, DC or analog o Level such as 1.0 V

o

Note: Older Kia vehicles may be tested with BOB, which uses manual pin selections and has similar overlay sheets with holes to overlay the pin-out box.

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Automatic Transmission External Diagnosis

BOB PRO OVERLAY

ETM VS OVERLAY

2008 MG 2.7L shown

The BOB Pro overlay terminal number (PCM) matches the ETM connector and pin numbers as shown.

The overlay provides the type of signal to measure and its results based upon the test condition.

The terminal number (BOB) is used when “Test 198 Mode” is selected on the BOB Pro unit. The preferred mode is to select the vehicle, year, engine and ECU is the mode to use. This is shown on the following pages. Note: The PCM terminal numbers on the BOB Pro overlay sheet maybe different than the ETM pin number.

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Automatic Transmission External Diagnosis

BOB PRO OPERATION: FRONT PANEL OF BODY UNIT

BOB Body

The tester panel uses the following configuration: 1. Display window

2. Vehicle Up/Down selection button 3. Voltage/Frequency selection button 4. Select (Sel.) button

a. Vehicle

b. Channel 1 through 4 5. Pin selection Up/Down button

6. Voltage/Waveform check point (CH 1-4) 7. Main cable port

8. Power cable port

Note: The numbers above correspond with the numbers on the panel illustration above.

> C201-1-03 12.6V C201-1-04 0.0V C201-1-05 0.0V C201-1-06 0.0V

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Automatic Transmission External Diagnosis

BOB PRO SETUP CONNECTIONS

1. Check the vehicle year, model, and choose the correct interface cable/red interface cable box and overlay/application chart.

2. Connect the interface cable to the BOB SUB Plus (black box).

3. Connect the Main Cable to the BOB body and BOB SUB Plus.

4. Connect the Power Cable to the BOB body and to the vehicle cigarette lighter or to the battery with the appropriate adapter.

5. Connect the vehicle harness ECU connector(s) to the red interface cable box, and connect the interface cable(s) to the ECU.

6. Verify that all cables are correctly connected 7. Turn IGN ON to power up BOB Pro.

Caution: BOB Pro must be connected prior to

connecting to the vehicle’s ECU. Be sure the key is OFF before disconnecting any vehicle cables and the

interface cables do not contact the battery B+ terminal.

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Automatic Transmission External Diagnosis

BOB PRO OPERATION

(8) Welcome Screen (9-10) Vehicle Selection

(11-12) Pin Selection (14) Check Points

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Automatic Transmission External Diagnosis

After connecting BOB to the vehicle and turning the IGN ON:

8. Verify that the “Welcome to” is displayed on the screen, then display changes to voltage or frequency (Welcome Screen).

Note: If the voltage value or frequency is not displayed, recheck all cables and connections.

9. Press the vehicle up or down button for more than 1 second and the tester will enter in to the vehicle selection mode (Vehicle Selection). 10. Use the button to scroll through and select the

vehicle you are working on. After selecting the correct vehicle press the “selection” button to confirm the selection and exit the mode. Caution: The Tester may be damaged and will not function properly if it is placed in the wrong Vehicle Selection Mode.

11. Press the selection button to select the desired channel.

12. After selecting the “Channel,” Press the “Pin Selection Up/Down” to check the desired signal as indicated on the overlay sheet (Pin Selection). 13. If you want to switch from Voltage to Frequency

press the V/F button.

14. Use a DMM or oscilloscope in the appropriate channel test points to measure voltage or frequency (Check Points).

Caution: Do not allow the test probes to make contact with each other. This accidental contact could damage the BOB Pro and the ECU.

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Automatic Transmission External Diagnosis

EXAMPLE OF LIVE DATA WITH BOB

You can use the BOB Pro; GDS with VMI scope function and VCI for current data and compare that data with the signal, to determine what may be causing an A/T related drivability concern.

The GDS can display both the current data and scope pattern at the same time.

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Automatic Transmission External Diagnosis

BOB PRO CPU UPDATE

BOB Pro has a replaceable E-Prom chip for updating the unit due to:

x New vehicles

x New PCM in current vehicles x Programming updates

The chip is easily installed after taking off the front panel, as shown above. The chip is usually shipped out with the new essential tools (SST) to your parts

department. It comes with a new overlay/application chart(s) for the new vehicle/PCM systems.

Note: When changing the CPU chip, note the location of the direction indicator on the right side of the chip above.

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Automatic Transmission External Diagnosis

SUMMARY

In this module you learned about:

x DTC Detection Conditions, which determine how the circuit or component is tested.

x DTC Detecting Strategy which determines what the circuit or component is tested for.

x DTC Enable Conditions which are the operating condition of the engine and A/T when the circuit is tested.

x Fault code diagnosis procedure.

x The setup required to use BOB Pro to measure voltage and frequency.

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Automatic Transmission External Diagnosis

PROGRESS CHECK QUESTIONS

SELECT THE BEST ANSWER HERE AND ON THE ANSWER SHEET

1. Technician A says that BOB Pro can be used on most 2003 and later PCM, ECM and TCM equipped Kia vehicles. Technician B says that BOB Pro can be used on all PCM, ECM and TCM equipped Kia

vehicles. Who is right? a. Technician A only b. Technician B only

c. Both Technician A and Technician B d. Neither Technician A nor Technician B

2. Technician A says that an A/T related circuit DTC strategy describes what the circuit or component is being tested for. Technician B says that A/T related circuit Enable Condition is the operating condition of the engine and A/T when the circuit is tested. Who is right?

a. Technician A only b. Technician B only

c. Both Technician A and Technician B d. Neither Technician A nor Technician B 3. Technician A says that A/T DTC’s have a set of

Detection Conditions, which describe how the circuit or component is tested. Technician B says that only emission related DTC’s have a set of Detection Conditions, which determine how the circuit or component is tested. Who is right?

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Automatic Transmission External Diagnosis

PROGRESS CHECK QUESTIONS

SELECT THE BEST ANSWER HERE AND ON THE ANSWER SHEET

4. Technician A says refer to the BOB Pro Application Table for the correct vehicle application, green colored overlay sheet number, and interface cable number. Technician B says always refer to the BOB Pro on-screen instructions for the correct vehicle application, green colored overlay sheet number, and interface cable number. Who is right? a. Technician A only

b. Technician B only

5. Technician A says that BOB Pro can measure voltage and frequency. Technician B says that an oscilloscope can be connected to BOB Pro. Who is right?

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Automatic

Transmission

External Diagnosis

Guided Practice

Beginning A/T External

Measurements

Student Guide

ATED.03

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SAFETY FIRST

NOTE

CAUTION

WARNING

!

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TT-ATED309-IL-GP03

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Automatic Transmission External Diagnosis

ATED Guided Practice 03 1

EXTERNAL A/T MEASUREMENTS

TARGET AUDIENCE

MODULE GOAL

MODULE OBJECTIVES

MODULE INSTRUCTIONS

TIME TO COMPLETE

The target audience for this module consists of Kia Senior and Master Service Technicians who will diagnose and repair Kia automatic transmissions. The goal of this module is to provide the Kia Service Technician with the opportunity to practice skills required to diagnose an external A/T concern. Given this module, and the required materials listed, the technician will be able to perform the following skills with 80% or greater accuracy:

x Retrieve, print and review A/T ETM schematics for interpretation & voltage expectations.

x Highlight the power, ground, relays and relay circuits on previously printed A/T ETM.

x Match and record selected A/T related PCM/TCM pin numbers from Bob PRO and ETM.

x Determine the application and install Bob PRO on assigned vehicle.

x Locate, inspect and test A/T related power, ground, internal and external relays.

x Using ETM and DMM to locate inspect and test on A/T using an internal TCM.

Carefully read and follow the instructions for each task. Answer the questions and fill in the blanks with the requested information as you perform the task. Check off each item as it’s completed.

When you have finished, have your training instructor evaluate your work and sign off that it has been properly completed.

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2 ATED Guided Practice 03

Automatic Transmission External Diagnosis

REQUIRED MATERIALS TASK STATIONS STATION 1: STATION 2: STATION 3: STATION 4: STATION 5: STATION 6:

In order to complete this module, you will need: x GDS with VCI, VMI and printer

x DVOM

x BOB PRO with overlay sheets and vehicle cables x Highlighters (red and green).

x A vehicle per team

x Optima 2.7L, Borrego 3.8L & 4.6L, Soul 2.0L

Retrieve, print and review related A/T ETM schematics. Use highlighters to identify power, ground, related relays and fuses on A/T ETM schematics.

List the pin numbers on the schematic and BOB PRO overlay.

Determine the correct cable and overlay application and install BOB PRO on an assigned vehicle.

Set up BOB PRO for the correct vehicle and ECU. Locate, inspect and test A/T related power, ground, relays and fuses on an assigned vehicle using a DMM and BOB PRO.

x 5A: 2.7 L Optima x 5B: 3.8 L Borrego

4.6 L Borrego - Locate, inspect and measure voltage to the TCM using an ETM and DMM.

As you complete each item in the following guided practice, place a check in the box to indicate that the step has been completed and review with your

instructor.

When Station is completed, review with your instructor and clean up the station.

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Automatic Transmission External Diagnosis

STATION 1:

RETRIEVE, PRINT AND REVIEW RELATED ETM SCHEMATICS

Each technician will be assigned to a team to complete the guided practices in this module on the one vehicle assigned by your instructor.

Using the GDS with a printer, print A/T ETM schematics for the assigned vehicles as directed by your instructor. Year:_________ Model:_________ Engine:_________ Year:_________ Model:_________ Engine:_________ Year:_________ Model:_________ Engine:_________ Year:_________ Model:_________ Engine:_________

Also, using the GDS with a printer, print the A/T ETM schematics and component CTG-ZF location photo for the Borrego 4.6L. This will be used later in this module.

Using markers, highlight the following circuits on each ETM:

x The A/T power source (red) x A/T relay (red)

x Fuse circuits (red) x Ground (green).

Discuss the operation of the highlighted sections with your instructor.

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Automatic Transmission External Diagnosis

STATION 2:

LIST PCM/TCM PIN NUMBERS

After reviewing the ETM with your instructor, your team will be assigned one vehicle to complete the following: Year_________ Model_________ Engine__________ BOB Pro Overlay Sheet Program No.: ____________

Using the related ETM schematic from Station 1 and the BOB PRO Overlay Sheet for the vehicle that has been assigned to you, record the PCM/TCM

connector and pin numbers and type of signal. BOB PRO A/T ETM Type of

Signal Input Speed OD Solenoid Battery Voltage Relay Control P Input Ground

Discuss the differences between BOB Pro and ETM numbers with your instructor.

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Automatic Transmission External Diagnosis

STATION 3:

DETERMINE APPLICATION AND INSTALL BOB

Continue with your team’s previously assigned vehicle; choose the correct BOB Pro overlay sheet and red interface cable box. Install BOB Pro on assigned vehicle.

Cable Box No. _______________________________ Check condition of all BOB PRO components to

ensure that they are not damaged.

Use the appropriate A/T ETM schematics printed at Station One.

Inspect that the Ignition is OFF.

Locate and disconnect the ECU harness connector. Connect the vehicle harness ECU connector(s) to

the red interface cable box, and connect the interface cable(s) to the ECU.

Connect the four interface cable to the BOB SUB Plus (black box).

Connect the Main Cable to the BOB body and BOB SUB Plus.

Connect the Power Cable to the BOB body and to the appropriate vehicle battery adapter.

Do not connect and power up BOB Pro at this time.

Verify that all cables are correctly connected to the BOB PRO.

Have your instructor check your connections. Continue on to Station 4.

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Automatic Transmission External Diagnosis

STATION 4:

SET UP BOB PRO FOR THE CORRECT VEHICLE & ECU

Plug the BOB Pro power cable into the vehicle’s cigarette lighter or to the battery post with an adapter.

Turn ignition to the ON position.

Verify that the “Welcome to” is displayed, and then changes to voltage or frequency display.

NOTE: If the voltage value or frequency is not displayed, recheck all cables and connections.

Press the vehicle up or down button for more than 1 second and the tester will switch to the vehicle selection mode/Program number.

Use the button to scroll through and select the system for the vehicle you are working on. After selecting the correct vehicle press the “selection” button to confirm the selection.

Have your instructor check your selections. Continue on to Station 5. Use the specific vehicle guided practice sheet for your instructor assigned vehicle.

Caution: The Tester and or the ECU may be damaged and will not function properly if the incorrect vehicle is selected.

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Automatic Transmission External Diagnosis

STATION 5A – OPTIMA 2.7L:

MEASURE A/T POWER, GROUND, AND A/T RELAY CONTROL OPTIMA 2.7L

Using the ETM printed at Station One, a DMM & BOB PRO connected to your assigned vehicle’s PCM, measure and record the following:

x Battery voltage x Relay control voltage x Sensor ground

x ON/START input

Use the ETM (Station 1) and Overlay Sheet to identify the terminals below.

Set channel 1 for “Battery voltage” from ATM Relay to PCM.

Set channel 2 for “Relay control” from PCM. Set channel 3 for “Sensor ground” from Oil temp

Sensor.

Set channel 4 for “P input (Park)” from PCM. Start the vehicle.

Connect the DMM to each test point and record the DMM voltage for each channel.

Channel 1 Pin # _____________ DMM Volts _________ Channel 2 Pin # _____________ DMM Volts _________ Channel 3 Pin # _____________ DMM Volts _________ Channel 4 Pin # _____________ DMM Volts _________

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Automatic Transmission External Diagnosis

STATION 5B – BORREGO 3.8L:

MEASURE A/T POWER AND GROUND

Using the A/T ETM printed at Station One, a DMM & BOB PRO connected to your assigned vehicle’s TCM, measure and record the following:

x Battery voltage/Memory Power x TCM ground

x Sensor ground x ON/START input

Use the ETM (Station 1) and Overlay Sheet to identify the terminals below.

Set channel 1 for “Memory Power”. Set channel 2 for “Ground” of TCM.

Set channel 3 for “GND” from ATM control unit or auto module to TCM.

Set channel 4 for “ON/START input”. Start the vehicle.

Connect the DMM to each test point and record the DMM voltage for each channel.

Channel 1 Pin # _____________ DMM Volts _________ Channel 2 Pin # _____________ DMM Volts _________ Channel 3 Pin # _____________ DMM Volts _________ Channel 4 Pin # _____________ DMM Volts _________

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Automatic Transmission External Diagnosis

STATION 6: BORREGO 4.6L

MEASURE VOLTAGE TO THE TCM BORREGO 4.6L

Year_________ Model Borrego Engine 4.6 L

Use the A/T ETM schematic and component CTG-ZF location photo for the Borrego 4.6L printed at station one.

Based on the schematic:

Where is the TCM located? ___________________ Does the TCM receive power from a relay?

YES NO

Can the source voltage and ground be measured with BOB PRO

YES NO Raise the vehicle

Disconnect the TCM connector CTG-ZF.

With the key ON engine OFF, and using the brown test lead adaptor, measure the following pins on the wiring harness CTG-ZF connector (power and

ground voltage) and record your results below. ON/START Input: _________________

Memory Power: ___________________ Ground: _________________________ Review the results with your instructor.

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Automatic Transmission External Diagnosis

NOTE PAGE

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Automatic Transmission External Diagnosis

NOTE PAGE

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Automatic Transmission External Diagnosis

NOTE PAGE

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A/T Controller Circuits

Automatic

Transmission

External Diagnosis

Theory Module Student Guide

ATED.04

IG_ATED04_TM_Cover:Layout 1 12/28/2010 9:29 AM Page 1

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SAFETY FIRST

NOTE

CAUTION

WARNING

!

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