C551a Multi-Mode Manual Transaxle PDF

MULTI-MODE MANUAL
TRANSAXLE SYSTEM >

PRECAUTION
1.IGNITION SWITCH EXPRESSIONS
1. The type of ignition switch used on this model differs according to the
specifications of the vehicle. The expressions listed in the table below are used in
this section.
Expression
Ignition Switch
(position)
Engine Switch
(condition)
Ignition Switch off
LOCK
Off
Ignition Switch on (IG)
ON
On (IG)
Ignition Switch on (ACC)
ACC
On (ACC)
Engine Start
START
Start
2.PRECAUTION REGARDING ON-VEHICLE INSPECTION

1. When revving the engine, make sure that the gear is in neutral.
3.PRECAUTION REGARDING PARTS REMOVAL AND INSTALLATION

1. When removing or installing parts related to the multi-mode manual transmission
system, perform [Clamp Position Adjustment], [Initialization and Learning]
and/or [Synchronization Position Calibration]. In addition, the required operations
differ according to the parts to be removed and installed. Proceed with the
operation in the order shown in the table below.
Parts to be removed
Before removal
Operation order
See
procedure
Clutch actuator
Transmission
assembly
Transmission parts
(inside gear box)
Clutch disc and clutch
cover
Clutch release bearing
Clutch release fork
Clutch release lever
Flywheel
End plate (2SZ-FE
only)
Crankshaft
Shift and select
actuator (with clutch actuator)
CLAMP
POSITION
ADJUSTMENT
2.
Before installation
Parts to be installed
New clutch
actuator
Operation order
See
procedure
CLAMP POSITION
ADJUSTMENT
3. NOTICE:
4. Push rods of brand new clutch actuators (service supply parts) are not set in the
clutch clamp position. Therefore, adjust the clamp positions before installing new
clutch actuators.
5.
After installation
Parts installed
Transmission
assembly
Transmission parts
(inside gear box)
Shift and select
actuator (with clutch
actuator)
Operation order
1. INITIALIZATION OF MULTIMODE MANUAL
TRANSMISSION SYSTEM
[Initialization of ECU]
2. LEARNING OF MULTIMODE MANUAL
See
procedure
Transmission
control ECU
TRANSMISSION SYSTEM
3. SYNCHRONIZATION
POSITION CALIBRATION

TRANSMISSION SYSTEM
Shift stroke sensor [Initialization of transmission]
Select stroke sensor 2. LEARNING OF MULTIMODE MANUAL
TRANSMISSION SYSTEM
3. SYNCHRONIZATION
POSITION CALIBRATION
Clutch actuator
Clutch stroke
sensor

TRANSMISSION SYSTEM
[Initialization of clutch]
Clutch disc and

clutch cover
Clutch release
bearing
Clutch release fork
Clutch release lever 2. LEARNING OF MULTIMODE MANUAL
Flywheel
End plate (2SZ-FE TRANSMISSION SYSTEM
only)
Crankshaft
6. NOTICE:
Replace the clutch disc and clutch cover together. If only one is replaced,
the adjustment system of the clutch cover does not function properly. This
may cause clutch drag or clutch slippage, which may result in
deterioration of drivability or malfunctions of the system parts.
After replacing any system components, perform initialization and
learning of related components (refer to the operations listed above). If
initialization and learning are not performed, the transmission system will
not function properly.
Before proceeding with learning of the multi-mode manual transmission
system, clear (initialize) the previously stored learning values. Since the
multi-mode manual transmission system does not have an overwrite
function, clearing (initializing) stored data is necessary before the new
data can be stored.
4.TROUBLESHOOTING INITIALIZATION AND LEARNING (ENGINE DOES NOT
START)
HINT:
If any malfunctions are suspected in the transmission control system after
reassembling or repairing transmission system components, perform
troubleshooting in accordance with the following chart.
1.Check for DTC output

1. Using an intelligent tester, check for output DTCs.
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / DTC.
4. Read any DTCs.
Result:
Result
Proceed To
No DTC output
DTC output
Go to DTC Chart
2.Check clutch position learning condition

1. Check that the clutch position learning has been completed.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data
List.
4. Read the Learn-Clutch Stopper Point result.
Result:
Result
Proceed To
Exec (Executed)
Notexec (Not executed)
Fail (Failure)
Execute learning again ()
Check clutch system
3.Check T/M gear position learning condition

1. Check that the T/M gear position learning has been completed.
List.
4. Read the Learn-T/M results.
Result:
Result
Proceed To
Exec (Executed)
Fail (Failure)
Go to step 6
4.Check whether gear is in neutral
1. Referring to the shift slit position of the shift and select actuator, check whether
the actual transmission gear position is in neutral.
Result:
Result
Proceed To
Neutral
Other than Neutral
5.Check whether park/neutral position switch is ON
Check transmission assembly
1. Check whether the park/neutral position switch is ON ().

Result:
Result
Proceed To
ON
OFF
Check park/neutral position switch
A
Check starter system and brake system
6.Check whether T/M up-lock has occurred during gear position learning
1. Check whether T/M up-lock has occurred during gear position learning.
List.
4. Read the Possibility of T/M Uplock results.
HINT:
T/M up-lock: The transmission gear momentarily cannot be engaged due to
mechanical reasons during gear position learning.
Result:
Result
Proceed To
No (Not occurred)
Yes (Occurred)
A
Perform initialization and learning again (If g

learning fails twice or more, check transmissi
5.TROUBLESHOOTING INITIALIZATION AND LEARNING (VEHICLE DOES

NOT START OFF)
HINT:
If any malfunctions are suspected in the transmission control system after
reassembling or repairing transmission system components, perform
troubleshooting in accordance with the following chart.
1.Check for DTC output

1. Using an intelligent tester, check for output DTCs.
3. Select the following menu items: Powertrain / Multi-Mode M/T / DTC.
4. Read any DTCs.
Result:
Result
Proceed To
No DTC output
DTC output
Go to DTC Chart
2.Check clutch position learning condition

List.
4. Read the Learn-Clutch Stopper Point results.
Result:
Result
Proceed To
Exec (Executed)
Fail (Failure)
Check clutch system
3.Check T/M gear position learning condition

1. Check that the T/M gear position learning has been completed.
List.
4. Read the Learning-T/M results.
Result:
Result
Proceed To
Exec (Executed)
Fail (Failure)
Go to step 8
4.Check clutch standby point learning condition

List.
4. Read the Learn-Clutch Standby Point results.
Result:
Result
Proceed To
Exec (Executed)
Fail (Failure)
Execute learning again (Ignition switch off to

start engine)
Check clutch system
5.Confirm that gear position in [1st] or [R] when shift lever in [E], [M] or [R]
1. Start the engine.
2. Referring to the shift slit position of the shift and select actuator, check that the
actual transmission gear position is in the 1st or R position when the shift lever
position is changed from N to E, M or R.
NG
Go to step 9
OK
6.Inspect accelerator pedal position sensor signal

1. Check the accelerator pedal position sensor signal circuit.
List.
4. Check that value of the Accelerator Pedal Angle changes in accordance

with the accelerator pedal operation ().
2. Check the CAN communication circuit ().
Standard (1KR-FE):
Accelerator Pedal
Operation
Fully depressed
Fully released
Standard (2SZ-FE):
Accelerator Pedal
Operation
Tester
Display
60 to 100 %
0 to 25 %
Tester
Display
Fully depressed
52 to 100 %
Fully released
0 to 22 %
NG
Check engine control system and CAN comm

system
OK
7.Rev up engine with transmission in neutral

1. Check that the engine can be revved up when the transmission gear is in neutral.
Result:
Result
Proceed To
Possible
Impossible
A
Check clutch system and transmission control ECU
Check engine control system
8.Check whether T/M up-lock has occurred during gear position learning
1. Check whether T/M up-lock has occurred during gear position learning.
List.
4. Read the Possibility of T/M Uplock result.
HINT:
T/M up-lock: The transmission gear momentarily cannot be engaged due to
mechanical reasons during gear position learning.
Result:
Result
Proceed To
No (Not occurred)
Yes (Occurred)
Perform initialization and learning again (If g

learning fails twice or more, check transmissi
A
9.Check whether clutch disengaged when shift lever in [E], [M] or [R]
1. Check the actual clutch state when the shift lever is in the E, M or R position.
Result:
Result
Proceed To
Disengaged
Not disengaged
A
Check clutch system
6.PRECAUTIONS REGARDING USE OF SHIFT LOCK RELEASE BUTTON

1. When the vehicle is parked with the shift lever in any position other than N:
The engine cannot be started if the shift lever is moved to any position
other than N by operating the shift lock release button.
The shift lever should be moved back to the N position to start the engine.
The engine cannot be started if the shift lever is in the position it was in
when the vehicle was parked.
The shift lever should be moved back to the N position to start the engine.
When the shift lever is returned to the N position by operating the shift
lock release button, the gear is shifted to neutral when the ignition switch
is turned on (IG) so that the engine can be started.
2. When the vehicle is parked with the shift lever in the N position:
The engine can be started even if the shift lever is moved to any position
other than N by operating the shift lock release button. In this case, the
gear is shifted to the position in accordance with the shift lever position
after the engine starts.
Shift lever
position when
vehicle parked
Current shift
lever position
Engine
cranking
operation
Note
Other than N
Other than N*
Impossible
Other than N
Same position in
when vehicle
parked
Impossible
Other than N
N*
Possible
Gear shifted to neutral when

ignition switch on (IG)
Gear shifted to position in
accordance with shift lever
position after engine start
Other than N*
Possible
N
(Same position
in when vehicle
parked)
Possible
*: The shift lever was moved with the shift lock release button operation.
7.OTHER PRECAUTIONS REGARDING MULTI-MODE MANUAL

TRANSMISSION SYSTEM
Set the gear in neutral when revving the engine.
Set the gear to the neutral position before removing the shift and select actuator. If
the gear cannot be shifted to the neutral position due to malfunctions of the
actuator and/or transaxle gear, remove the plug from the shift and select actuator
and observe the position of the shift slit within. If the slit is in any position other
than neutral, use a screwdriver to set it to neutral.
8.PRECAUTION REGARDING ELECTRONIC THROTTLE CONTROL SYSTEM

(FOR 1KR-FE)
1. Perform the electronic throttle learning when the following operations are done ().
ECM replacement
Throttle body assembly replacement
9.PRECAUTION REGARDING USE OF INTELLIGENT TESTER

NOTICE:
Observe the following items for safety reasons:
Read its instruction books before using the tester.

Prevent the tester cable from being caught on the pedals, shift lever and steering
wheel when driving with the tester connected to the vehicle.
When driving the vehicle for testing purposes using the tester, two people are
required. One drives the vehicle, and the other operates the tester.
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > PARTS
LOCATION
for Preparation
1/5
2/5
3/5
4/5
5/5
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > SYSTEM
DIAGRAM
for Preparation
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > SYSTEM
DESCRIPTION
for Preparation
MULTI-MODE MANUAL TRANSMISSION SYSTEM OUTLINE

1. The multi-mode manual transmission has been developed from the conventional
manual transmission by adding actuators that are directly controlled by electric
motors. The transmission control system consists of an electronic throttle control
system, clutch actuator, shift and select actuator, sensors, a shift lever, and a
transmission control ECU. The system offers automatic clutch operation and two
driving modes: automatic shifting E mode and manual shifting M mode.
2. The stroke sensors, which are mounted on each actuator and detect the actuator
operating position, are double non-contact type.
3. The multi-mode manual transmission is equipped with a clutch actuator, which
has a motor for clutch engagement, and a shift and select actuator, which has two
motors for shifting and selecting gear shafts that have been used on the
conventional manual transmission. Each actuator operates in accordance with
signals from the transmission control ECU. The transmission control ECU
receives information from the ECM and sensors, and controls the engine and
multi-mode manual transmission.
4. The shift lever features a Shift-by-Wire System that electrically detects the shift
lever position chosen by the driver and sends a shift lever position signal to the
transmission control ECU to control the transmission.
5. The shift lever has an electrical shift lock mechanism. When the ignition switch is
turned off, or the shift lever is in the N position with the engine running and the
brake pedal released, the shift lever is locked in the current shift position.
6. The multi-mode manual transmission system has fail-safe functions. When the
transmission control ECU detects a malfunction in the system, the ECU
illuminates the Multi-mode Manual Transmission Warning Light (MMT Warning
Light) to inform the driver that a malfunction has occurred. If necessary, the ECU
illuminates the Malfunction Indicator Lamp (MIL) and MMT Warning Light
simultaneously. Under such conditions, the fail-safe function allows the vehicle to
be operated in order to avoid emergency situations.
FUNCTIONS OF MAIN COMPONENTS
Components
Outlines
Combination
Controls the operation of the indicator lights, warning light, and
meter (meter ECU) buzzer.
Multi-mode
manual
transmission
warning light
(built into
combination
meter)
Illuminates to alert the driver when a malfunction occurs in the

multi-mode manual transmission system.
Gear position
indicator
(built into
combination
meter)
Indicates the present gear position. The indicator flashes if the

actual gear position and the shift lever position do not match.
Mode indicator
Indicates E-mode or M-mode.
(built into
combination
meter)
Es indicator light
(built into
combination
meter)
Illuminates when the sporty [Es] pattern is selected during normal

[E] pattern driving in E-mode. Does not illuminate while the
normal [E] pattern is selected.
Buzzer
(built into
combination
meter)
Sounds if the following conditions met simultaneously:

Engine is running
Shift lever is in E, M or R position
Driver's door is open
Shift lever position

Outputs the shift lever position and shift request (+ or -) through
sensor
the ON/OFF combination of 6-contact switch and 2-contact switch.
(built into shift
lever assembly)
Transmission shift
main switch
Outputs the shift mode signal (E-mode or M-mode).
(built into shift
lever assembly)
Shift lock solenoid
Actuated by the transmission control ECU. Restricts the movement
(built into shift
of the shift lever.
lever assembly)
Shift motor
Actuated by the transmission control ECU. Effects the shift
(built into shift and
operation of the shift and select lever shaft.*
select actuator)
Shift stroke sensor
Detects the shift and select actuator operation position (shift
direction).*
select actuator)
Select motor
Actuated by the transmission control ECU. Effects the select
operation of the shift and select lever shaft.*
select actuator)
Select stroke
Detects the shift and select actuator operation position (select
sensor
(built into shift and direction).*
select actuator)
Clutch motor
(built into clutch
actuator)
Actuated by the transmission control ECU. Engages and

disengages the clutch.
Clutch stroke
sensor
(built into clutch
actuator)
Detects the push rod position of the clutch actuator from the
rotational angle of the worm wheel in the clutch actuator, and sends
the signal to the transmission control ECU.
LCC (Load
The diaphragm spring height of the LCC is adjusted to a
Controlled Clutch predetermined position automatically, in order to apply a constant
cover)
load to the clutch motor.
Transmission
revolution sensor
Detects the input shaft speed of the transaxle and transmits it to the
transmission control ECU.
Park/neutral
position switch
(built into
transmission
assembly)
Detects whether the transmission gear is in neutral.
Back-up light
switch
(built into
transmission
assembly)
Detects whether the transmission gear is in reverse, and illuminates

the back-up lights.
Stop light switch
Detects whether the brake pedal is depressed or released.
Parking brake
switch
Detects whether the parking brake lever is applied.
Outputs the driving pattern (Normal [E] pattern or Sporty [Es]

Pattern select [Es]
pattern) in E-mode in accordance with the ON/OFF condition to the
switch
Transmission
control ECU
Controls the multi-mode manual transmission system and signals

the ECM to effect engine control during upshifting or downshifting
via CAN (Controller Area Network) communication.
When the multi-mode manual transmission system malfunctions,
the transmission control ECU diagnoses the malfunctioning areas
and stores the data. Furthermore, the multi-mode manual
transmission warning light and malfunction indicator lamp are
illuminated to inform the driver of malfunctions in the system.
Buzzer
(built into
transmission
control ECU)
Sounds during system warning.

When performing the initialization and learning or the clamp
position adjustment without using intelligent tester, the buzzer
sounds to inform that the ECU mode is changed.
ECM
Outputs sensor information via CAN communication to the

Affects engine control in accordance with signals from the
Accelerator pedal
position sensor
Detects the accelerator pedal position and transmits signals to the

ECM.
Crankshaft
position sensor
Detects the engine speed and transmits signals to the transmission

control ECU via the ECM.
HINT:
*: Shift and select directions are as shown in the illustration.
MULTI-MODE MANUAL TRANSMISSION SYSTEM CONTROL

1. System start:
The multi-mode manual transmission system starts when the ignition switch is
turned on (IG). The shift lever can be operated when the ignition switch is on and
the brake pedal is depressed. The engine starts when the ignition switch is turned
to the ST position (the engine switch is operated) with the brake pedal depressed
and the gear in neutral.
2. Take off/reverse assist control:
When the brake pedal is not depressed with the gear in 1st, 2nd or reverse, the
clutch is half-engaged, even if the accelerator pedal is not depressed. As a result,
the vehicle can creep slowly like an automatic transmission vehicle. This will
assist the vehicle in preparing to move. The take off assist control is cancelled
while the parking brake switch is ON.
HINT:
When attempting to shift to reverse at a vehicle speed of 6 km/h (3.7 mph) or
more, the reverse warning buzzer sounds, and the gear does not shift to reverse.
3. Shift control:
When upshifting with the accelerator pedal depressed, the ECM restrains the
engine rev up in accordance with the request signal from the transmission control
ECU.
[Automatic shift control (E and Es modes)]
When the shift lever is in the E position, the most appropriate gear is
automatically selected in accordance with the accelerator pedal opening angle and
the vehicle speed. In addition to this automatic shift control, LHD (Left Hand
Drive) vehicles have kick down control. When the accelerator pedal is fully
depressed until a click is felt, the ECM for LHD vehicles interprets this as the
kick down signal being received. Kick down signals affects the transmission shift
control.
Shift control can be switched between normal [E] mode and sporty [Es] mode by
pressing the pattern select switch.
Normal [E] mode: Economical automatic shift control with emphasis on fuel
economy
Sporty [Es] mode: Automatic shift control with emphasis on driving performance
[Sequential shift control (M-mode)]
Moving the shift lever to the M position enables the driver to select the gear. The
driver can select gears optionally by shifting the lever to the [+] or [-] position.
4. Ascent/descent shift control:
While driving in E-mode or Es-mode, the system operates to prevent excess
shifting and obtain the proper driving force and engine brake power by estimating
the road inclination based on the vehicle conditions.
[Ascent shift control]
On an ascent, upshifting to the 3rd, 4th or 5th gear is prohibited, depending on the
degree of road inclination.
[Descent shift control]
On a descent, the current gear position is maintained, depending on the degree of
road inclination, to obtain engine brake power. When the brake pedal is
depressed, the transmission control ECU automatically downshifts to improve the
vehicle (driving force) control performance.
5. AI (Artificial Intelligence) shift control:
The AI shift control enables the transmission control ECU to estimate the road
conditions and the driver's intention in order to automatically select the optimal
shift pattern. This improves the ride comfort.
[Accelerator pedal rapid open control]
When the accelerator pedal is rapidly depressed, the system interprets it as an
acceleration demand and advances the downshift timing.
[Accelerator pedal sudden close control]
When the accelerator pedal is suddenly released, the system interprets it as a
deceleration demand and ensures the engine brake power without changing gear.
This also ensures there is sufficient driving force for the next acceleration stage.
6. Control when the vehicle stops (stopping control):
The transmission control ECU automatically disengages the clutch when the input
speed of the transmission revolution sensor falls below a specified speed. This
enables the vehicle to stop without stalling. If the shift lever is in the E or M
positions, the transmission control ECU shifts the gear to the most appropriate
position when the vehicle speed decreases to less than a specified speed.
HINT:
If the shift lever is kept in the N position for 2 seconds with the brake pedal
released at a specified vehicle speed or less, the transmission control ECU locks
the shift lever to prevent improper shift lever operation. When depressing the
brake pedal, the shift lever is unlocked.
7. Control when the vehicle is parked (parking control):
When the ignition switch is turned off, the transmission control ECU locks the
shift lever in the current position, and 1 second later engages the clutch to park the
vehicle with the gear engaged.
HINT:
The multi-mode manual transmission system does not have a park position. The
vehicle can be parked with the shift lever in any position (N, E, M or R). When
the vehicle is parked with the shift lever in a position other than N, the vehicle is
parked with the gear engaged. The vehicle may not be parked with the gear
engaged if the ignition switch is turned off before the gearshift is complete.
MULTI-MODE MANUAL TRANSMISSION SYSTEM REMOVAL AND

INSTALLATION PROCEDURES
The multi-mode manual transmission differs from the conventional manual transmission.
The following operations are necessary when removing and installing the component
parts.
1. CLAMP POSITION ADJUSTMENT

Preload is applied to the clutch actuator push rod installed on the vehicle.
Clamp position adjustment is necessary to position the push rod when the
clutch actuator is reinstalled.
The push rod position of a new clutch actuator is not suitable for clutch
actuator installation. When installing a new clutch actuator, Clamp
Position Adjustment must be performed before the installation.
The push rod position of a clutch actuator that has been installed on the
vehicle is not suitable for clutch actuator reinstallation. Clamp Position
Adjustment must be performed when removing the clutch actuator.
For details of replacement, refer to CLAMP POSITION ADJUSTMENT
().
Push rod position A (Stopper position):

The stopper position is where the clutch actuator push rod is fully
retracted. Clearance exists between the release bearing and the diaphragm
spring.
Push rod position B (Clutch clamp position):
The clutch clamp position is where 0 N [newton] of preload is applied to
the diaphragm spring. Removal or installation of the clutch actuator is
possible at this point. No clearance exists between the release bearing and
the diaphragm spring.
Push rod position C (Complete engagement position):
During normal clutch operation, the push rod alternates between this
position and the standby position (between C and D). When the system is
stopped (while the ignition switch is off), the push rod maintains this
position.
Push rod position D (Standby position):
The standby position is where the clutch actuator push rod is protruded
and the clutch is not engaged.
2. REPLACEMENT OR REMOVAL/INSTALLATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM PARTS
Refer to the respective pages for each part.
3. INITIALIZATION AND LEARNING
1.
2.
INITIALIZATION OF TRANSMISSION SYSTEM:

The transmission control ECU stores information from each
component, such as sensors and motors, to control the system.
Sensors and motors that comprise the multi-mode manual
transmission system have individual specification values. The
transmission control ECU learns and stores these values, and
controls the multi-mode manual transmission system. Therefore,
the values stored in the transmission control ECU must be cleared
when the sensor or actuator is replaced.
Learning of the multi-mode manual transmission system can be
performed when there is no learning value in the ECU. It is
therefore necessary to perform initialization of the transmission
control ECU before performing learning of the multi-mode manual
transmission system.
For details of replacement, refer to INITIALIZATION AND
LEARNING ().
LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM:
This operation is performed to store the individual specification
values of components, such as sensors and actuators, in the
For details of replacement, refer to INITIALIZATION AND
LEARNING ().
NOTICE:
Perform this operation after initialization of the multi-mode manual transmission

system.
4. SYNCHRONIZATION POSITION CALIBRATION
The transmission components have individual specification values. The
transmission control ECU learns and stores those values, and controls the
gearshift accurately. Synchronization position calibration corrects and
adjusts the shift points appropriately in accordance with the individual
specification values of the components.
For details of replacement, refer to SYNCHRONIZATION POSITION
CALIBRATION ().
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > HOW TO

PROCEED WITH
TROUBLESHOOTING
for Preparation
1.VEHICLE BROUGHT TO WORKSHOP
NEXT
2.CUSTOMER PROBLEM ANALYSIS
NEXT
3.CONNECT INTELLIGENT TESTER TO DLC3

HINT:
If the display indicates a communication fault in the tool, inspect the DLC3.
NEXT
4.CHECK CAN COMMUNICATION SYSTEM

1. Check for output DTCs.
HINT:
The ECM of this system is connected to the CAN communication system.

Therefore, before starting troubleshooting, check that there is no trouble in the
CAN communication system ().
Result:
Display (DTC Output)
Proceed To
CAN communication system DTCs
No output
PROCEED TO CAN
COMMUNICATION SYSTEM
Go to step 5
5.CHECK DTC AND FREEZE FRAME DATA

NOTICE:
Record or print DTCs and freeze frame data, if necessary. Refer to the relevant
pages ().
NEXT
6.CLEAR DTC AND FREEZE FRAME DATA

HINT:
Refer to the relevant pages ().
NEXT
7.VISUAL INSPECTION
NEXT
8.PROBLEM SYMPTOM CONFIRMATION
Result:
Result
Proceed To
Symptom does not occur
Symptom occurs
Go to step 9
Go to step 10
9.SYMPTOM SIMULATION
HINT:
NEXT
10.DTC CHECK
HINT:
Result:
Display (DTC Output)
Proceed To
Output
No output
Go to step 11
Go to step 12
11.DTC CHART
HINT:
NEXT
Go to step 13
12.PROBLEM SYMPTOMS TABLE

HINT:
NEXT
13.CIRCUIT INSPECTION
HINT:
NEXT
14.IDENTIFICATION OF PROBLEM
NEXT
15.ADJUSTMENT, REPAIR
NEXT
16.CONFIRMATION TEST
NEXT
END
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
INITIALIZATION
for Preparation
INITIALIZATION AND LEARNING USING INTELLIGENT TESTER

HINT:
By using an intelligent tester, initialization and learning of the multi-mode manual

transmission system can be performed sequentially. Under manual operation (not
using intelligent tester), initialization and learning must be performed
individually.
The learning values and the DTC history of the multi-mode manual transmission
system are stored in the EEPROM in the transmission control ECU. The stored
information is not cleared even when the negative terminal of the battery is
disconnected. To clear all the stored information, initialize the transmission
control ECU.
Perform the procedure below to ensure that the initialized transmission control
ECU stores the adjusted clutch position (stopper position, clamp position, and
standby position) or gear position (shift position and select position).
If the initialization cannot be performed normally, there may be a malfunction in
the shift lever position sensor, NE signals, or CAN communication.
When replacing the following parts, proceed with the operation in the order listed
in the table below.
Parts installed
Transmission assembly
Transmission parts
(inside gear box)
Shift and select actuator
(with clutch actuator)
Transmission control
Operation order
See
procedure
1. INITIALIZATION OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM See below
2. LEARNING OF MULTI-MODE
MANUAL TRANSMISSION SYSTEM
3. SYNCHRONIZATION POSITION
See below
ECU
Shift stroke sensor

Select stroke sensor
CALIBRATION
[Initialization of transmission]
See below
CALIBRATION
Clutch actuator
Clutch stroke sensor
cover
Clutch release fork
Flywheel
End plate (2SZ-FE
only)
Crankshaft
1. Prepare the vehicle:

Stop the vehicle
Shift the shift lever to the N position.
Turn the ignition switch off.
See below
3. Turn the ignition switch on (IG).

4. Turn the intelligent tester ON.
5. Select the following menu items: Powertrain / Multi-Mode M/T / Utility / Parts
Exchange.
6. Read the information.

7. Press the Next key.

9. After checking the vehicle condition, press the Next key.


14. On the Multi-Mode M/T / Utility screen, select Step 3 Initial Learning.
16. Select the appropriate operation.

HINT:
Initialization of clutch: when removing and installing the following parts
related to the clutch system.
Clutch actuator, clutch stroke sensor, clutch disc and clutch cover, clutch
release bearing, clutch release fork or fork lever, flywheel, and end plate.
Initialization of transmission: when removing and installing the parts
related to the shift and select operation of the transmission assembly.
Initialization of ECU: This initializes learned values of both the clutch and
transmission.

19. Press the Next key after turning the ignition switch off.
20. Wait 10 seconds.

HINT:
Count down the seconds from 10 to 0.

22. Press the Next key after turning the ignition switch on (IG).
23. Wait 40 seconds.

HINT:
Count down the seconds from 40 to 0.
24. Press the Exit key.

25. Complete Initialization and Learning.
26. Turn the intelligent tester OFF and turn the ignition switch off.
27. Wait at least 20 seconds.
29. Depress the brake pedal with the shift lever position in the N position.
30. Start the engine and wait at least 10 seconds.
31. Shift the gear from neutral to any other position.
HINT:
When [Initialization of transmission] was selected at step (p), add the

following step between steps (w) and (x).
Additional step: (w') Wait at least 30 seconds.
If the Initialization and Learning operations fail, perform the operations
again from step (a) more than 15 seconds after turning the ignition switch
off.
Perform Synchronization Position Calibration after performing
Initialization of transmission or Initialization of ECU.
Shifting the gear from neutral to any other position at last, the
transmission control ECU learns the standby point. At this time, the value
of Learn-Clutch Standby Point in the Data List changes from [Notexec] to
[Exec].
INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION SYSTEM
WITHOUT USING INTELLIGENT TESTER

HINT:
The learning values and the DTC history of the multi-mode manual transmission
system are stored in the EEP ROM in the transmission control ECU. The stored
information is not cleared even when the negative terminal of the battery is
disconnected. To clear all the stored information, initialize the transmission
control ECU.
If the initialization of the multi-mode manual transmission system fails, perform
the operation again from step (a) more than 15 seconds after turning the ignition
switch off.
If the initialization cannot be performed normally, there may be a malfunction in
the shift lever position sensor, NE signals, or CAN communication.
When replacing the following parts, proceed with the operations in the order
listed in the table below.
Parts installed
Transmission parts
(inside gear box)
ECU
Shift stroke sensor

Operation order
See
procedure
See below
CALIBRATION
See below
CALIBRATION
Clutch actuator
cover
Clutch release fork
Flywheel
End plate (2SZ-FE
See below
only)
Crankshaft

Stop the vehicle.
Shift the lever to the N position.
2. Using SST, connect terminals TC (13) and CG (4) of the DLC3.

SST
09843-18040
5. Depress the brake pedal at least 7 times within 3 seconds.

1.
The buzzer sounds twice with an interval of 0.25 seconds.

6. Depress the brake pedal.
7. Shift the shift lever in the following sequence with the brake pedal depressed.
When initializing the ECU: N E M - M - M - M
- E N.
When initializing the clutch: N E M + M - M +
M - E N.
When initializing the transmission: N E M - M - M
+ M + E N.
8. Release the brake pedal
9. Depress the brake pedal once.

0. The buzzer sounds at intervals of 0.5 seconds as follows (an interval of 2.5
seconds exists between each cycle).
Twice when initializing the ECU (one cycle)
Three times when initializing the clutch (one cycle)
Four times when initializing the transmission (one cycle)
HINT:
If the buzzer does not sound as specified, wait at least 15 seconds
after turning the ignition switch off. Then, perform the procedure
from step (a) again.
If the buzzer sounds at intervals of 1 second (not at intervals of 0.5
seconds), wait at least 15 seconds after turning the ignition switch
off. Then, perform the procedure from step (a) again.
10. Depress the brake pedal 3 times or more within 2 seconds.
0. The buzzer sounds twice with an interval of 0.25 seconds.

11. Turn the ignition switch off and wait at least 10 seconds.
12. The initialization is complete.
13. Disconnect the SST from terminals TC and CG of the DLC3.
LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM WITHOUT

USING INTELLIGENT TESTER
HINT:
Perform the procedure below to ensure that the initialized transmission control
ECU stores the adjusted clutch position or gear position.
If the learning of the multi-mode manual transmission system fails, perform the
operation again from step (a) more than 15 seconds after turning the ignition
switch off.

Stop the vehicle.
Shift the shift lever to the N position.
4. Turn the ignition switch off.
7. Start the engine under the following conditions:
Shift lever is in the N position.
Brake pedal is depressed.
HINT:
The shift N position indicator blinks when the engine starts.
9. Check that the shift N position indicator turns on continuously (stops blinking).
10. The learning is complete.
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
CALIBRATION
for Preparation
SYNCHRONIZATION POSITION CALIBRATION

For smoother shifting, the transmission control ECU learns the synchronization position
of the transmission gears. Perform the synchronization position calibration of the multimode manual transmission while driving the vehicle after repairing system components.
HINT:
When replacing the following parts, proceed with the operation in the order listed
in the table below.
Parts installed
Transmission parts
(inside gear box)
ECU
Shift stroke sensor
Operation order
See
procedure
CALIBRATION
See below
CALIBRATION
Clutch actuator
cover
Clutch release fork
Flywheel
End plate (2SZ-FE
only)
Crankshaft
See below
1. While driving the vehicle in M-mode, shift up and down between 1st and 5th at
the vehicle speeds specified below.
2. Check that the gears shift smoothly.
Gear Change
Up shift
Recommended Gear Shifting Speeds

Gear Position
Vehicle Speed
1st2nd
25 to 40 km/h (15.5 to 24.8 mph)
2nd3rd
45 to 80 km/h (27.9 to 49.7 mph)
3rd4th
60 to 110 km/h (37.2 to 68.3 mph)
4th5th
75 to 140 km/h (46.6 to 86.9 mph)
Down shift
2nd1st
25 to 35 km/h (15.5 to 21.7 mph)
3. HINT:
Leave an interval of more than 2 seconds between gear changes.
If there is a shock when changing gears after the synchronization position
calibration, perform the synchronization position calibration again.
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > PROBLEM
SYMPTOMS TABLE
for Preparation
HINT:
When a malfunction cannot be confirmed by conducting a DTC check and the

cause of the problem cannot be identified through a basic inspection, troubleshoot
in accordance with the priority order indicated in the table below.
Inspect the fuse and relay before confirming the suspected areas as shown in the
chart below.
NOTICE:
When removing the following parts, perform the operations correctly by
following the precautions on the relevant pages.
Problem Symptoms for Multi-Mode Manual Transmission

Symptom
Suspected area
1. Transmission unit (Gears, bearings,
shift fork, synchronizer ring, shift key,
etc.)
2. Clutch disk (Clutch cover)
3. Clutch stroke sensor
4. Clutch actuator assembly
No up-shift, No down-shift
5. Shift stroke sensor

6. Select stroke sensor
7. Shift and select actuator
8. Shift lever position sensor
9. Shift lever assembly
10. Speed signal circuit
11. Transmission control ECU
Multi-mode manual transmission

warning light defective
1. Multi-mode manual transmission

warning light circuit
2. IG signal circuit
3. ECU power source circuit
Shift position indicator light defective

Buzzer does not sound when incorrect

operation occurs (built into transmission 1. Transmission control ECU
control ECU)
Buzzer does not sound when incorrect
operation occurs (built into combination
3. Front door courtesy switch
meter)
4. Combination meter
Shift impossible to any gear

See
page
etc.)
2. Shift stroke sensor
6. Clutch disk (clutch cover)
etc.)
2. Clutch disc (Clutch cover)
Too much time lag when changing gear 5. Shift stroke sensor
position
9. Shift lock solenoid circuit
11. Speed signal circuit
1. SFI system (1KR-FE)
Poor acceleration
2. SFI system (2SZ-FE)

3. Pattern select switch
1. Shift lock solenoid circuit
2. Stop light switch circuit
Change shift lever position impossible
Engine stalls when starting off or

stopping
1. Transmission revolution sensor
Gear not automatically shifted up or
1. CAN communication circuit
down during E mode driving
2. Transmission shift main switch

1. Transmission shift main switch
Mode switch impossible (E to M)

Setting to 1st or R positions impossible
Shift timing delays occur during M

mode driving

1. Accelerator pedal position sensor
(1KR-FE)
2. Accelerator pedal position sensor
(2SZ-FE)
Assist control does not operate when

engine started
1. Parking brake switch circuit

1. SFI system (1KR-FE)
2. SFI system (2SZ-FE)
3. Starter signal circuit
4. Stop light switch circuit
Engine does not crank

6. Starter (for 1KR-FE 0.9 kW)
7. Starter (for 1KR-FE 1.3 kW)
8. Starter (for 2SZ-FE)
1. Oil (level low)
Noise
2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
1. Oil (Level too high)
Oil leakage
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O-ring (Worn or damaged)
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
TERMINALS OF ECU
for Preparation
Transmission Control ECU:
Symbols
(Terminal
No.)
Wiring
Color
Terminal Description
Condition
Specified
Condition
+B - GND
(D79-1 D79-6)
B - W-B
Battery (ECU power

source)
Always
10 to 14 V
IG - GND
(D79-3 D79-6)
O - W-B
Ignition switch
PKB - GND
(D79-4 P - W-B
D79-6)
Parking brake switch
Ignition switch off Below 1 V

on (IG)
10 to 14 V
Ignition switch on
(IG),
Parking brake switch
OFF ON
(Parking brake lever
released pulled)
10 to 14 V
Below 1 V
Ignition switch on
10 to 14 V
(IG),
Brake pedal depressed Below 1 V
Released
SLS - GND
LG - W(D79-5 B
D79-6)
Shift lock solenoid
GND - Body
W-B ground
Body
(D79-6 ground
Body
ground)
Ground
Always
Below 1
10 to 14 V
Below 1 V
10 to 14 V
Below 1 V
MDSW GND
(D79-10 D79-6)
L - W-B
Transmission shift
main switch
Ignition switch on
(IG),
Shift lever position E
M
LS4C GND
B - W-B

sensor
Ignition switch on
(IG),
(D79-11 D79-6)
LS3C GND
(D79-12 D79-6)
LS2C GND
(D79-13 D79-6)
LSW5 GND
(D79-15 D79-6)
LSW4 GND
(D79-16 D79-6)
LSW3 GND
(D79-17 D79-6)
Shift lever position N

except N
W - W-B

sensor
Ignition switch on
(IG),
Shift lever position E
or M R or N
10 to 14 V
Below 1 V
LG - WB

sensor
Ignition switch on
(IG),
Shift lever position R
Except R
10 to 14 V
Below 1 V
R - W-B

sensor
Ignition switch on
(IG),
except [-] [-]
10 to 14 V
Below 1 V
G - W-B

sensor
Ignition switch on
(IG),
except N N
10 to 14 V
Below 1 V

sensor
Ignition switch on
(IG),
Shift lever position R
or N Except R and
N
10 to 14 V
Below 1 V
10 to 14 V
Below 1 V
B - W-B
LSW2 GND
(D79-18 D79-6)
W - W-B

sensor
Ignition switch on
(IG),
except R R
LSW1 GND
(D79-19 D79-6)
GR - WB

sensor
Ignition switch on
(IG),
except [+] [+]
10 to 14 V
Below 1 V
Pattern select switch
Ignition switch on
(IG),
Pattern select switch
OFF ON
10 to 14 V
Below 1 V
PWR - GND
GR - W(D79-23 B
D79-6)
DG - GND
(D79-25 D79-6)
INDC GND
(D79-29 D79-6)
Ignition switch on (IG)

10 to 14 V
P - W-B Terminal TC of DLC3 Connect terminals
Below 1 V
TC and CG of DLC3
R - W-B
Communication line
with combination
meter
Always
Below 1.44 V
INDA GND
(D79-31 D79-6)
Y - W-B
STP - GND
(D79-34 - G - W-B
D79-6)
ST1- - GND
(D79-35 - Y - W-B
D79-6)
CAN+ CAN(A38-1 A38-2)
W-B
MREL GND
(A38-5 D79-6)
LG - WB
Pulse
Communication line
generation
with combination Ignition switch on (IG)
(See waveform
meter
1)
Stop light switch
Stop light switch
Brake pedal depressed 10 to 14 V

Released
Below 1 V
Ignition switch on
(IG),
Brake pedal released
depressed
10 to 14 V
Below 1 V
Pulse
generation
CAN communication Ignition switch on (IG)
(See waveform
2)
AMT relay (motor
power source)

on (IG)
10 to 14 V
Ignition switch off,

STA - GND
Starter relay operation
Brake pedal depressed, Below 1 V
(A38-6 - SB - W-B
signal
10 to 14 V
Shift lever position N
D79-6)
(input)
Starter operates
Ignition switch on
(IG),
except R R
Below 1 V
10 to 14 V
L - W-B
Engine speed signal

from ECM
Idling
Pulse
generation
(See waveform
3)
V-P
Transmission
revolution sensor
Engine running,
Clutch engaged
(during driving)
Pulse
generation
(See waveform
4)
Shift stroke sensor

ground
(main)
Always
Below 1
RSW - GND
(A38-9 R - W-B
D79-6)
NE - GND
(A38-10 D79-6)
NIP- - NIP+
(A38-15 A38-16)
E2S1 - GND
(A38-17 - P - W-B
D79-6)
VSS1 GND
(A38-18 D79-6)
B - W-B
Back-up light switch
Shift stroke sensor

voltage monitor
(main)
Ignition switch on (IG) 0.5 V to 4.5 V
VCS1 GND
(A38-19 D79-6)
W - W-B
Shift stroke sensor

power source (main)
VCL1 GND
(A38-20 D79-6)
O - W-B

power source (main)
VSL1 GND
(A38-21 D79-6)
V - W-B

voltage monitor
(main)
E2L1 GND
(A38-22 D79-6)
Y - W-B

ground (main)
Always
Below 1
Vehicle speed signal
Ignition switch on
(IG),
during driving
Pulse
generation
(See waveform
5)
SPD - GND
(A38-23 - V - W-B
D79-6)
E2L2 GND
(A38-24 D79-6)
GR - WB

ground (sub)
Always
Below 1
E2R1 GND
(A38-25 D79-6)
LG - WB

ground (main)
Always
Below 1
VSR1 GND
(A38-26 D79-6)
B - W-B

voltage monitor
(main)
VCR1 GND
(A38-27 D79-6)
W - W-B

power source (main)
E2S2 - GND
GR - W(A38-28 B
D79-6)
VSS2 GND
(A38-29 D79-6)
Shift stroke sensor

ground (sub)
Always
Below 1
BR - W- Shift stroke sensor

B
voltage monitor (sub)
VCS2 GND
(A38-30 D79-6)
R - W-B
Shift stroke sensor

power source (sub)
VCL2 GND
(A38-31 D79-6)
L - W-B

power source (sub)
VSL2 GND
(A38-32 D79-6)
LG - W- Select stroke sensor

B
E2R2 GND
(A38-33 D79-6)
GR - WB
VSR2 GND
(A38-34 D79-6)
BR - W- Clutch stroke sensor

B
VCR2 GND
(A38-35 D79-6)
G - W-B
MSF+ GND
(A37-1 D79-6)
B - W-B
+BM - GND
B - W-B
(A37-2 D79-6)
MSF- GND
(A37-3 D79-6)
MSL- GND
(A37-4 D79-6)
MSL+ GND
(A37-5 D79-6)
W - W-B
L - W-B
B - W-B

ground (sub)
Always
Below 1

power source (sub)
Shift motor
Ignition switch on
(IG),
motor not operating
operating
Pulse
generation
()
Motor power source

on (IG)
10 to 14 V
Shift motor
Ignition switch on
Below 1 V
(IG),
Pulse
motor not operating generation
operating
()
Select motor
Ignition switch on
Below 1 V
(IG),
Pulse
operating
()
Select motor
Ignition switch on
Below 1 V
(IG),
Pulse
operating
()
MCL- GND
(A37-6 D79-6)
GR - WB
Clutch motor
Ignition switch on
Below 1 V
(IG),
Pulse
operating
()
Ignition switch on
Below 1 V
(IG),
Pulse
operating
()
MCL+ GND
(A37-7 D79-6)
G - W-B
Clutch motor
PGND Body
ground
(A37-8 Body
ground)
W-B Body
ground
Ground
1. Waveform 1:
Communication with Combination Meter
2.
Terminal
INDA - GND
Gauge set
2 V/DIV, 500 s/DIV
Condition
Always
Below 1
3. Waveform 2:
CAN Communication Terminal
Terminal
CAN+ - CAN-
Gauge set
1 V/DIV, 50 s/DIV
Condition
4.
5. Waveform 3:
Engine speed signal from ECM
Terminal
NE - GND
Gauge set
5 V/DIV, 5 ms/DIV
Condition
Engine idling
6.
7. Waveform 4:
Transmission Revolution Sensor Terminal
Terminal
NIP- - NIP+
Gauge set 500 mV/DIV, 500 s/DIV

Vehicle speed of
Condition approximately 30 km/h (19
mph)
8.
9. Waveform 5:
Vehicle Speed Signal Terminal
Terminal
SPD - GND
Gauge set
5 V/DIV, 20 ms/DIV
Vehicle speed of
Condition approximately 20 km/h (12
mph)
ECM:
Symbols
(Terminal No.)
Wiring Color
Terminal
Description
W-B
CAN
Communication
NEO - E1
(C33-64 - A321)
L - W-B
Engine speed
signal
Engine idling
Pulse
generation
(See waveform
2)
E1 - Body
ground
(A32-1 - Body
ground)
W-B - Body
ground
Ground
Always
Below 1
CAN+ - CAN(A32-34 - A3226)
Condition
Specified
Condition
Pulse
Ignition switch
generation
on (IG)
(See waveform
1)
1. Waveform 1:
CAN Communication Terminal
Terminal
CAN+ - CAN-
Gauge set
1 V/DIV, 50 s/DIV
Condition
2.
3. Waveform 2:
Engine speed signal
Terminal
NEO - E1
Gauge set
5 V/DIV, 5 ms/DIV
Condition
Engine idling
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
DIAGNOSIS SYSTEM
for Preparation
DESCRIPTION
The transmission control ECU has a self-diagnosis system. If the ECU, the multimode manual transmission system or any components fail to operate correctly, the
ECU detects the malfunction, and illuminates the multi-mode manual
transmission warning light on the combination meter.
The multi-mode manual transmission warning light is illuminated when the multimode manual transmission system malfunctions.
When troubleshooting Euro-OBD vehicles, the only difference from the usual
troubleshooting procedure is that an OBD scan tool (complying with ISO 157654) or an intelligent tester is connected to the vehicle, and various data output from
the vehicle ECU is read.
Euro-OBD regulations require that the vehicle's on board computer illuminates
the MIL (Malfunction Indicator Lamp) on the combination meter when the ECM
(Engine Control Module) detects a malfunction in: 1) the emission control
systems and components, or 2) the powertrain control components (which affect
vehicle emissions), or 3) the ECM. Therefore, the transmission control ECU
illuminates the MIL and multi-mode manual transmission warning light together
if malfunctions related to these systems or components are detected.
If the malfunction does not recur on 3 consecutive trips, the MIL goes out
automatically. However, the DTCs remain recorded in the transmission control
ECU memory.
To check DTCs, connect the OBD scan tool or intelligent tester to the DLC3
(Data Link Connector 3) on the vehicle. The OBD scan tool or intelligent tester
also enables the DTCs to be erased and the freeze frame data and various forms of
engine data to be checked. See the instruction manual of the OBD scan tool or
intelligent tester for details.
The DTCs include ISO controlled codes and manufacturer controlled codes. ISO
controlled codes must be set as prescribed by the ISO, while manufacturer
controlled codes can be set by the manufacturer within prescribed limits ().
FREEZE FRAME DATA
Freeze frame data record the vehicle conditions (engine speed, vehicle speed,
transmission gear position, shift position, etc.) when malfunctions are detected.
When troubleshooting, the freeze frame data can help determine if the vehicle was
moving or stationary, if the engine was warmed up or not, the transmission gear
was in neutral or not, and other data, from the time the malfunction occurred.
DLC3 (Data Link Connector 3)
1. The ECU uses ISO 15765-4 for communication. The terminal arrangement of the
DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format.
Symbol
Terminal
No.
Name
Reference
terminal
Result
Condition
SIL
Bus "+" line
5-Signal
ground
Pulse
generation
During
transmission
CG
Chassis
ground
Body ground
1 or less
Always
SG
Signal
ground
Body ground
1 or less
Always
BAT
16
Battery
positive
Body ground
9 to 14 V
Always
14 - CANL
54 to 69
Ignition switch
off *
1 M or
higher
Ignition switch
off *
1 k or
higher
Ignition switch
off *
1 M or
higher
Ignition switch
off *
1 k or
higher
Ignition switch
off *
CANH 6
CAN "High" Battery

line
positive
4 - CG
CANL 14
Battery
CAN "Low" positive
line
4 - CG
2. NOTICE:
3. *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and
do not operate the ignition switch, any other switches or the doors.
4. HINT:
5. The DLC3 is the interface prepared for reading various data from the vehicle's
ECU. After connecting the cable of an intelligent tester or OBD scan tool, turn the
ignition switch on (IG) and turn the tester or scan tool ON.
6. If a communication failure message is displayed on the tester or scan tool screen
(on the tester: no information available), a problem exists in either the vehicle or
tester. In order to identify the location of the problem, connect the tester to
another vehicle.
If communication is normal: Inspect the DLC3 on the original vehicle.
If communication is impossible: The problem is probably with the tester itself.
Consult the service department listed in the instruction manual.
CHECK MULTI-MODE MANUAL TRANSMISSION WARNING LIGHT

2. Check that the warning light illuminates for 5 seconds. If the warning light does
not illuminate, proceed to troubleshooting the multi-mode manual transmission
warning light circuit ().
BATTERY VOLTAGE
1. Measure the voltage of the battery.
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge the battery before proceeding.
2. Inspect the battery, fuses, fusible links, wiring harness, connectors and ground.
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > DTC
CHECK / CLEAR
for Preparation
HINT:
DTCs which are stored in the transmission control ECU can be displayed on the
intelligent tester.
CHECK DTC (Using intelligent tester)
1.
2.
3.
4.
5.
Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG) and turn the intelligent tester ON.
Select the following menu items: Powertrain / Multi-Mode M/T.
Check DTCs and freeze frame data, and write them down.
See DTC chart to confirm the details of the DTCs ().
HINT:
Intelligent testers can display current DTC data, pending DTC data and historical
DTC data. Touch the [Current], [Pending] or [History] button on the DTC display
screen.
[Current]: Displays the current DTC data.
[Pending]: Displays the pending DTC data
[History]: Displays the historical DTC data (past codes).
FREEZE FRAME DATA

2. Turn the ignition switch on (IG) and turn the intelligent tester ON.
3. Read DTCs by selecting the following menu items: Powertrain / Multi-Mode M/T
/ DTC.
4. Select the parameter(s) to check the freeze frame data.
5. Note down the DTC(s) and freeze frame data.
HINT:
A "!" displayed to the left of DTC data shown in red indicates that freeze
frame data has been recorded for that parameter.
For further information about using the intelligent tester, refer to the
instruction manual.
CLEAR DTCs AND FREEZE FRAME DATA (Using intelligent tester)

1.
2.
3.
4.
Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG) and turn the intelligent tester ON.
Select the following menu items: Powertrain / Multi-Mode M/T / DTC / Clear.
Erase DTCs and freeze frame data by pressing the YES button on the tester.
HINT:
For further information about using the intelligent tester, refer to the instruction
manual.
MULTI-MODE MANUAL
TRANSAXLE SYSTEM > FAILSAFE CHART
for Preparation
FAIL-SAFE CHART
1. If any of the following codes is recorded, the transmission control ECU enters the
fail-safe mode.
DTC No.
Malfunction Areas
Fail-safe Functions
Fail-safe Deactivat
Either (a) or (b) met
10.
(a) A
conditions m
P0806
P0807
P0808
P0810
P0900
Clutch stroke
sensor or its circuit
Clutch
actuator assembly or
its circuit
cond
Gear does
not change
Vehicle does
not start moving
again after stopping
N po
gear
speed
km/h
11.
(b) P
detected and
off
P0807
P0808
P0906
P0907
P0916
Clutch stroke
Select stroke
Shift stroke
Either of (a) or (b) m
Limit to 3rd
gears or lower
22.
(a) A
following co
P0917
cond
N po
gear
speed
km/h
23.
(b) P
detected and
off
P0905
P0906
P0907
P0909
P0910
P0915
P0916
P0917
P0919
P0920
Shift stroke
Shift
its circuit
Select stroke
Select
its circuit
40.
Gear does
not change
Vehicle does
not start moving
again after stopping
(a) A
conditions m
cond
N po
speed
km/h
41.
(b) P
detected and
off

46.
P0725
Engine speed
input circuit
Convert
engine revolution
signals into CAN
communication
signals
No effect
(a) A
conditions m
cond
posit
neutr
enga
47.
(b) P
detected and
off
P0500
P0715
Vehicle
speed sensor or its
circuit

Gear does
not shift down while
driving
54.
(a) A
Transmission
revolution sensor or
its circuit
Only
possible to drive in
1st or reverse gears
after vehicle stops
conditions m
cond
speed
km/h
peda
depre
55.
(b) P
detected and
off
P0603
P0885
P0820
P0335
P0339
Transmission
control ECU
Clutch
actuator, shift
actuator, select
actuator power
source circuit
Shift lever
position sensor or its
circuit
Transmission
shift main switch or
its circuit
Crankshaft
position sensor or its
circuit
Gear does
not change
Engine
cannot be started
Pass condition detec
Transmission
ignition switch off
control ECU stops
engine when vehicle
stops
Impossible
to enter M-mode
Gear does
not shift to 1st or
ignition switch off
reverse (and forward
or backward gears)
Gear does
not change

ignition switch off
U0100
CAN
communication
signal circuit
Gear does
not change
Only
possible to drive in
1st or reverse gears
after vehicle stops
76.
(a) A
conditions m
cond
stopp
peda
depre
77.
HINT:
: Transmission gear: Actual transmission gear position

The transmission control ECU identifies the actual transmission gear
position through the signals from the shift stroke sensor and select stroke
sensor.
The transmission control ECU identifies the shift lever position through
the signal from the shift lever position sensor.
MULTI-MODE MANUAL
(b) P
detected and
off
TRANSAXLE SYSTEM > DATA

LIST / ACTIVE TEST
for Preparation
DATA LIST
HINT:
By reading the Data List displayed on an intelligent tester, you can check values,
including those of the switches, sensors, and actuators, without removing any
parts. Reading the Data List as the first step of troubleshooting is one method of
shortening diagnostic time.
NOTICE:
In the table below, the values listed under Normal Conditions are for reference
only. Do not depend solely on these values when determining whether or not a
part is faulty.
1.
2.
3.
4.
5.
6.
Warm up the engine.

Connect an intelligent tester to the DLC3.
Turn the ignition switch on (IG) and turn the tester ON.
Select the following menu items: Powertrain / Multi-Mode M/T / Data List.
Check the values by referring to the table below.
Items
Measurement
[Abbreviation] Items: Display
Normal
Conditions
MIL Status
[MIL Status]
MIL status:
OFF or ON
ON: MIL
comes on
Calculated
Engine Load
[Calc E/G
Load]
1KR-FE:
11 to 25 %:
Idling
Load calculated 15 to 35 %:
by ECM:
Running
Min.: 0 %, Max.: without load
100 %
(2,500 rpm)
2SZ-FE:
12.8 to 19.2 %:
Idling
Diagnostic Notes
-
10.3 to 17.9 %:
Running
without load
(2,500 rpm)
1KR-FE:
75 to 95C (167
to 203F):
After engine
warmed up
2SZ-FE:
80 to 100C
(176 to 212F):
After engine
warmed up
Engine
Coolant
Temperature
[Coolant
Temp]
Coolant
temperature:
Min.: -40C,
Max.: 140C
Engine Run
Time
[Eng Run
Time]
Engine run time:

Time since
Min.: 0 s, Max.:
engine start
65535 s
Engine
Revolution
[Engine Rev]
Engine
revolutions per
minute:
Min.: 0 rpm,
Max.: 16,383.75
rpm
1KR-FE:
730 to 830 rpm:
Idling
2SZ-FE:
600 to 700 rpm:
Idling
0 km/h (0 mph):
Vehicle
Vehicle speed: stationary
Vehicle Speed
Min.: 0 km/h,
Approximately
[Vehicle Spd]
Max.: 255 km/h same value as
combination
meter display
Battery
Voltage
[Batt]
Battery voltage:
10 to 15 V:
Min.: 0 V, Max.:
Idling
65.535 V
Drive Mile
after
Malfunction
[Driving
Mileage]
Accumulated
driving mileage
since
malfunction
detection:
Min.: 0 km/h,
Max.: 65,535
km/h
Running Time Running time

from MIL ON from MIL ON:
If value -40 C
(-40 F): sensor circuit
open
If value 140 C
(284 F): sensor circuit
shorted
If NE signal circuit has a short

or open circuit, back-up engine
speed data from CAN
communication displayed
When vehicle speed signal

malfunctions, speed value
calculated from input
revolution signal displayed
Distance driven since

0 km/h (0 mph):
occurrence of diagnosis
System normal
malfunction displayed
Equivalent to
running time
[MIL On Run Min.: 0 min,

since MIL ON
Time]
Max.: 65535 min
Warmup
Cycle Cleard
DTC
[Wu Cyc DTC
clear]
Warm-up cycle
since DTC
cleared:
Min.: 0 , Max.:
255
Distance from
DTC Cleared
[Dist DTC
Clear]
Distance since
DTC cleared:
Min.: 0 Km,
Max.: 65535 Km
Equivalent to
drive distance
since DTCs
erased
Time after
DTC Cleared
[Time DTC
Clear]
Time since DTC

Equivalent to
cleared:
time since
Min.: 0 min,
DTCs erased
Max.: 65535 min
Vehicle speed
Vehicle Speed
signal:
Signal
Min.: 0 km/h,
[Vehicle Spd
Max.: 327.675
Sig]
km/h
Input
Revolution
[Input Rev.]
When vehicle speed signal

0 km/h (0 mph):
malfunctions, speed value
Vehicle
calculated from input
stationary
revolution signal displayed
Transmission
input revolution:
0 rpm: Vehicle
Min.: 0 rpm,
stationary
Max.: 12,800
rpm
Back-up engine
Backup
speed from CAN
Engine Speed
communication:
[Bacup Engin
Min.: 0 rpm,
Spd]
Max.: 8,160 rpm
Number of warm-up cycles

since DTC cleared
When input revolution signal

malfunctions, value calculated
from vehicle speed signal
displayed
Approximately
same as
tachometer
0 rpm displayed when CAN
reading: Engine
communication malfunctions
running
0 rpm: Engine
stopped
Accelerator
Pedal Angle
[Accel Pedl
Angl]
Accelerator
0 %:
pedal angle:
Accelerator
Min.: 0 %, Max.:
pedal released
100 %
Theoretical
Engine Torque
[Theoretic
Torq]
Theoretical
engine torque:
0 N*m: Idling
Min.: 0 N*m,
Max.: 255 N*m
Clutch
Position
(Current)
Current clutch
position:
Min.: 0 mm,
0 % displayed when CAN

communication malfunctions
19.0 mm (0.74
Current clutch position
in.) to 44.0 mm
displayed
(1.73 in.)
[Clutch PosCur]
Max.: 127.998
mm
Current shift
Shift Position
position:
(Current)
Min.: 0 mm,
[Shift PosMax.: 127.998
Cur]
mm
5.0 mm (0.20
Current shift position value
in.) to 31.9 mm displayed (1st, 3rd, 5th, or
(1.25 in.)
Neutral, or 2nd, 4th, Reverse)
Current select
Select Position
position:
(Current)
Min.: 0 mm,
[Select PosMax.: 127.998
Cur]
mm
3.0 mm (0.11
Current select position value
in.) to 29.0 mm displayed (gear shift fork shaft
(1.14 in.)
No. 1, No. 2 or No. 3)
Shift lever
Shift Lever
position:
Position Judge
INVALID
[Shift Pos
POSITION, P,
Judge]
R, N, E, M
Actual shift
lever position
displayed
Calculated AT
Oil
Temperature
[AT Oil
Temp]
Transmission
fluid temperature
calculated by
ECU:
Min.: -128C,
Max.: 127C
Equivalent to
actual
transmission
fluid
temperature
Shift Lever
Switch
Signal1
[Shift SW
Sig1]
Shift lever
switch signal
(+):
OFF or ON
ON: Shift lever

position in (+) LSW1(LSW+) terminal signal
OFF: Other
of transmission control ECU
than above
Shift Lever
Switch
Signal2
[Shift SW
Sig2]
Shift lever
switch signal
(R):
OFF or ON
ON: Shift lever

position in (R) LSW2 (LSWR) terminal signal
OFF: Other
than above
Shift Lever
Switch
Signal3
[Shift SW
Sig3]
Shift lever
switch signal
(M) or (E):
OFF or ON
ON: Shift lever

position in (E),
(M), (+) or (-) LSW3 (LSWS) terminal signal
OFF: Shift lever of transmission control ECU
position in (R)
or (N)
Shift Lever
Switch
Signal4
[Shift SW
Shift lever
switch signal
(N):
OFF or ON
ON: Shift lever

position in (N) LSW4 (LSWN) terminal signal
OFF: Other
than above
Sig4]
Shift Lever
Switch
Signal5
[Shift SW
Sig5]
ON: Shift lever

Shift lever
position in (-) LSW5 (LSW-) terminal signal
switch signal (-):
OFF: Other
OFF or ON
than above
Shift Lever
Check Signal1
[Shift Chek
Sig1]
Check signal of
shift lever switch
signal 2:
OFF or ON
LS2C (LSRC) terminal signal

OFF: Shift lever
of transmission ECU
position in (R)
Reversal signal of LSW2
ON: Other than
(LSWR) (ON and OFF
above
reversed)
OFF: Shift lever

Shift Lever
Check signal of position in (E),
Check Signal2 shift lever switch (M), (+) or (-)
[Shift Chek
signal 3:
ON: Shift lever
Sig2]
OFF or ON
position in (R)
or (N)
LS3C (LSSC) terminal signal

(LSWS) (ON and OFF
reversed)
Shift Lever
Check Signal3
[Shift Chek
Sig3]
Check signal of
shift lever switch
signal 4:
OFF or ON
LS4C (LSNC) terminal signal

OFF: Shift lever
of transmission ECU
position in (N)
ON: Other than
(LSWN) (ON and OFF
above
reversed)
T/M Reverse
Switch Signal
[T/M R SW
Sig]
Transmission
reverse switch
signal:
OFF or ON
ON:
Transmission
gear in reverse
OFF: Other
than above
During malfunctions, indicator

shows either OFF or ON
continuously, regardless of
gear position
Ignition switch
Ignition Signal
signal:
[Ignition Sig]
OFF or ON
ON: Ignition
switch on (IG)
Mode Switch
Signal
[Mode SW
Sig]
ON: Sequential
shift control
(M-mode)
selected
Transmission
shift main switch
signal:
OFF or ON
ON: Sporty [Es]

Es Mode
Es Mode Switch
mode selected
Switch Signal Signal:
(Automatic
[Es SW Sig] OFF or ON
shift control)
Parking Brake Parking brake
Signal
switch signal:
[Pkb Sig]
OFF or ON
ON: Parking
brake applied
OFF: Parking
brake released
Brake Switch
OFF: Brake
Brake switch
ST1- terminal signal of
Signal2
[Brake SW
Sig2]
Brake Switch
Signal1
[Brake SW
Sig1]
signal (ST1-):
OFF or ON
Brake switch
signal (STP):
OFF or ON
pedal depressed transmission control ECU

ON: Brake
pedal released
ON: Brake
pedal depressed STP terminal signal of
transmission control ECU
OFF: Brake
pedal released
STA Switch
STA signal:
Signal
OFF or ON
[STA SW Sig]
ON: During
cranking
Gear Position
(Current)
[Gear PosCur]
Actual gear
position
displayed
0 = Non
1 to 6 = 1st to 6th
254 = Neutral
255 = Reverse
Target gear
Gear Position
position:
(Target)
Min.: 0, Max.:
[Gear Pos-Tar]
255
When shift
lever not
operated:
Target gear
position equals
current gear
position
0 = Non
1 to 6 = 1st to 6th
254 = Neutral
255 = Reverse
Clutch
Position
(Target)
[Clutch PosTar]
Target clutch
position:
Min.: 0 mm,
Max.: 127.998
mm
Difference
between actual
and target
clutch
positions:
Maximum of 15
mm during gear
change control
operation
(varies with
vehicle
condition)
Target shift
Shift Position position:
(Target)
Min.: 0 mm,
[Shift Pos-Tar] Max.: 127.998
mm
Difference
between actual
and target shift
positions:
Maximum of 15
mm during gear
change control
operation
(varies with
vehicle
condition)
Current gear
position:
Min.: 0, Max.:
255
Target select
Select Position
position:
(Target)
Min.: 0 mm,
[Select PosMax.: 127.998
Tar]
mm
Difference
between actual
and target select
positions:
Maximum of 15
mm during gear
change control
operation
(varies with
vehicle
condition)
Requested clutch
Clutch Motor
motor current
Current Req
-20 to 20 A
from CPU:
[Clutch Motor
Min.: -50 A,
Req]
Max.: 50 A
Instruction (calculated) current

value from CPU
Clutch Motor
Current MMT
[Clutch
Motor]
Actual clutch
motor current:
Min.: -50 A,
Max.: 50 A
-20 to 20 A
0 A: When clutch motor not in

operation
Shift Motor
Current Req
[Shift Motor
Req]
Requested shift
motor current
from CPU:
Min.: -50 A,
Max.: 50 A
-40 to 40A

value from CPU
-40 to 40A
0 A: When shift motor not in

operation
Actual shift
Shift Motor
motor current:
Current MMT
Min.: -50 A,
[Shift Motor]
Max.: 50 A
Requested select
Select Motor
motor current
Current Req
-25 to 25 A
from CPU:
[Select Motor
Min.: -50 A,
Req]
Max.: 50 A

value from CPU
Actual select
Select Motor
motor current:
Current MMT
Min.: -50 A,
[Select Motor]
Max.: 50 A
0 A: When select motor not in

operation
Base Clutch
Load
[Base Clutch
Load]
-25 to 25 A
Base clutch load:

Base clutch load:
Calculated from average clutch
Learning value
Min.: -1000 N,
motor current when ECU
shown
Max.: 1000 N
performing initialization and
learning of clutch system
Reference value
(varies with
vehicle
condition)
39.33 to 45.29:
Current clutch
Current Clutch
Stopper
load (calculated
Load
position
value):
[Current
37.07 to 43.03:
Min.: -1000 N,
Clutch Load]
Complete
Max.: 1000 N
engagement
position
24.5 to 35.25:
Standby
position
Current clutch load:

Calculated from average clutch
motor current
Difference between Base
Clutch Load and Current
Clutch Load increases as clutch
disks wear away
After performing LCC
adjustment, difference
decreases (Almost same as
Base Clutch Load value)
Number of LCC
(Load Controlled
Clutch Adjust
Clutch cover)
Count
adjustment
[Clutch Adj
performed:
Cnt]
Min.: 0 , Max.:
255
When clutch motor stroke

amount reaches certain value,
the count increases by 1
When difference between Base

Clutch Load exceeds threshold,
When difference between Base

Clutch Load exceeds threshold,
11: System wake-up control

mode
12: Vehicle driving control
mode
13: System end control mode
14: System initialization mode
17: Engine starting control
mode
20: Fixed gear shift control
Number of LCC
(Load Controlled
Clutch Adjust Clutch cover)
Fail Count
adjustment
[Clutch Adj
judged
Fail]
unnecessary:
Min.: 0 , Max.:
255
Number of LCC
(Load Controlled
Clutch Adjust
Clutch cover)
Detection
adjustment
[Clutch Adj
required:
Detect]
Min.: 0 , Max.:
255
System control
Mode Changes
mode:
[Mode
Min.: 0, Max.:
Changes]
255
mode
21: Gear shift control mode
22: Shift lever lock control
mode
25: Shut-down control mode
26: Vehicle stationary control
mode
27: Vehicle start off control
mode
Gear Mode
Changes
[Gear Mode]
Gear change
mode indication:
Min.: 0, Max.:
255
1st Uplock
Signal
[1st Uplock
Sig]
1st gear up-lock

signal:
OFF or ON
2nd Uplock
Signal
[2nd Uplock
Sig]
2nd gear up-lock

signal:
OFF or ON
3rd Uplock
Signal
[3rd Uplock
Sig]
3rd gear up-lock

signal:
OFF or ON
4th Uplock
Signal
[4th Uplock
Sig]
4th gear up-lock

signal:
OFF or ON
5th Uplock
Signal
[5th Uplock
Sig]
5th gear up-lock

signal:
OFF or ON
Rev Uplock
Signal
[Rev Uplock
Sig]
Reverse gear uplock signal:

OFF or ON
Vehicle Speed
Signal Open
[Vehicle Spd
Open]
Vehicle speed
ON: When momentarily
OFF: During
signal circuit
interruption in vehicle speed
open judgement: vehicle running
signal
OFF or ON
Input Rev
Signal Open
Input revolution OFF: During

ON: When abnormal pulse
signal circuit
engine running interval detected
If gear shift fails, uplock signal

indicates whether transmission
up-lock has occurred or not
Up-lock:
Transmission gear momentarily
cannot be engaged due to
mechanical reasons (not
malfunction)
[In Rev Open] open judgement:

OFF or ON
Clutch partially engaged when
following conditions met:
Vehicle creep
Creep Control
control mode:
[Creep Ctrl]
OFF or ON
ON: Clutch
partial
engagement
continues for
long time
Low Voltage
Signal
[Low Volt]
+B terminal low
OFF: +B
voltage
terminal voltage
judgement:
8 V or more
OFF or ON
Engine running
Transmission
gear in 1st, 2nd or
Reverse
Brake pedal not
depressed
Parking brake
released
Accelerator
pedal released
ON: High differential spin

occurred sharply at differential
gear
When following conditions
met, transmission control ECU
detects run-off in vehicle and
restricts gear shift:
Run Off
Vehicle run-off
Signal
judgement
[Run Off Sig] OFF or ON
OFF: While
vehicle running
Clutch Heat
[Clt Heat]
Clutch heat
judgement:
OFF or ON
OFF: Engine
idling, gear in
neutral
Accelerator
pedal angle exceeds
threshold
SPD signal
change rate above
threshold
Shift position in
1st, 2nd or 3rd
ON: Calculated clutch

temperature 280C (536F) or
more
Clutch temperature calculated
from relative revolution speed
between engine and
transmission input shaft, clutch
torque, heat radiation, heat
conduction, sum of current

clutch temperature and
variation in clutch temperature,
etc.
Clutch Heat
and Overuse
[Clt Heat
Overuse]
Clutch heat and

overuse
judgement:
OFF or ON
Clutch Motor
Clutch motor
Current
current enabled
Enable
OFF or ON
[Clt Curr Ena]
Motor Relay
Signal
[Mot Relay
Sig]
OFF: Engine
idling, gear in
neutral
OFF: Target
clutch motor
current less than
1A
ON: OFF
condition not
met
ON: Ignition
switch on (IG)
AMT relay drive
OFF: Ignition
signal:
switch off and
OFF or ON
after system
shut-down
ON: Calculated clutch

temperature 330C (626F) or
more
Shift lever lock

Shift Lever
solenoid
Lock Solenoid
operation:
[SLS]
OFF or ON
OFF: Shift lever

locked
Clutch touch
Clutch Touch
position:
Position
Min.: 0 mm,
[Clt Touch
Max.: 127.998
Pos]
mm
Difference between Clutch

Learning value Touch position and Clutch
shown
Clamp Position within 4.0 mm
(0.16 in.) to 16.0 mm (0.63 in.)
Clutch clamp
Clutch Clamp
position:
Position
Min.: 0 mm,
[Clt Clamp
Max.: 127.998
Pos]
mm
Difference between Clutch

Learning value Touch position and Clutch
shown
Clamp Position within 4.0 mm
(0.16 in.) to 16.0 mm (0.63 in.)
Neutral position
Neutral
Median value between [3rd Pos
(shift position):
Position
Learning value
(Shift)] and [4th Pos (Shift)]
Min.: 0 mm,
(Shift)
shown
displayed
Max.: 127.998
[N Pos (Shift)]
mm
Neutral
Position
(Select)
Neutral position
Median value between [1st Pos
Learning value
(select position):
(Sel)] and [5th Pos (Sel)]
shown
Min.: 0 mm,
displayed
[N Pos (Sel)]
Max.: 127.998
mm
1st Gear
Position
(Shift)
[1st Pos
(Shift)]
1st gear position

(shift position):
Learning value
Min.: 0 mm,
shown
Max.: 127.998
mm
Difference
between [1st Pos
(Shift)] and [2nd Pos
(Shift)] within 15.0 mm
(0.59 in.) to 19.5 mm
(0.77 in.)
Difference
between [1st Pos
(Shift)] and [3rd Pos
(0.06 in.)
1st gear position

1st Gear
(select position):
Position
Learning value
Min.: 0 mm,
(Select)
shown
Max.: 127.998
[1st Pos (Sel)]
mm
Difference between [1st Pos

(Sel)] and [3rd Pos (Sel)]
within 5.5 mm (0.22 in.) to 8.5
mm (0.33 in.)
2nd Gear
Position
(Shift)
[2nd Pos
(Shift)]
Difference between [1st Pos

(Shift)] and [2nd Pos (Shift)]
within 15.0 mm (0.59 in.) to
19.5 mm (0.77 in.)
2nd gear position

(shift position):
Learning value
Min.: 0 mm,
shown
Max.: 127.998
mm
2nd gear position

2nd Gear
(select position):
Position
Learning value
Min.: 0 mm,
(Select)
shown
Max.: 127.998
[2nd Pos (Sel)]
mm
Difference between [2nd Pos

within 5.5 mm (0.22 in.) to 8.5
mm (0.33 in.)
Difference
between [3rd Pos
(Shift)] and [4th Pos
(0.59 in.) to 19.5 mm
(0.77 in.)
Difference
between [5th Pos
(Shift)] and [3rd Pos
(0.06 in.)
3rd Gear
Position
(Shift)
[3rd Pos
(Shift)]
3rd gear position

(shift position):
Learning value
Min.: 0 mm,
shown
Max.: 127.998
mm
3rd Gear
Position
(Select)
3rd gear position

Difference between [3rd Pos
Learning value
(select position):
shown
Min.: 0 mm,
within 5.5 mm (0.22 in.) to 8.5
[3rd Pos (Sel)] Max.: 127.998

mm
mm (0.33 in.)
4th Gear
Position
(Shift)
[4th Pos
(Shift)]
4th gear position

(shift position):
Learning value
Min.: 0 mm,
shown
Max.: 127.998
mm
4th gear position

4th Gear
(select position):
Position
Learning value
Min.: 0 mm,
(Select)
shown
Max.: 127.998
[4th Pos (Sel)]
mm
Difference between [R Pos

within 5.5 mm (0.22 in.) to 8.5
mm (0.33 in.)
5th Gear
Position
(Shift)
[5th Pos
(Shift)]
5th gear position

(shift position):
Learning value
Min.: 0 mm,
shown
Max.: 127.998
mm
5th gear position

5th Gear
(select position):
Position
Learning value
Min.: 0 mm,
(Select)
shown
Max.: 127.998
[5th Pos (Sel)]
mm
Difference
between [R Pos (Shift)]
and [5th Pos (Shift)]
within 15.0 mm (0.59
in.) to 19.5 mm (0.77
in.)
Difference
between [3rd Pos
(0.06 in.)
Difference between [5th Pos

(Sel)] and [3rd Pos (Sel)]
within 5.5 mm (0.22 in.) to 8.5
mm (0.33 in.)
Reverse gear
position (shift
Reverse Gear
position):
Pos (Shift)
Min.: 0 mm,
[R Pos (Shift)]
Max.: 127.998
mm
Difference
between [3rd Pos
(0.59 in.) to 19.5 mm
(0.77 in.)
Difference
within 1.5 mm (0.06
in.)
Learning value
shown
Difference
within 15.0 mm (0.59
in.) to 19.5 mm (0.77
in.)
Difference

within 1.5 mm (0.06
in.)
Reverse Gear
Pos (Select)
[R Pos (Sel)]
Reverse gear
position (select
position):
Min.: 0 mm,
Max.: 127.998
mm
Difference between [R Pos

Learning value (Sel)] and [4th Pos (Sel)]
shown
within 5.5 mm (0.22 in.) to 8.5
mm (0.33 in.)
Yes: Transmission gear
temporarily could not be
engaged due to mechanical
reasons during gear position
learning
Possibility of
Possibility of
transmission upT/M Uplock
lock:
[T/M Uplock]
No or Yes
No:
Initialization
and learning
complete
Clutch actuator
Learn-Clutch
standby position
Standby Point
learning:
[LernNotexec, Fail or
Stby_Pnt]
Exec
Exec:
Initialization
and learning
complete
Learning T/M
Learning-T/M system:
[Lern-T/M]
Notexec, Fail or
Exec
Exec:
Initialization
and learning
complete
Clutch actuator
Learn-Clutch
stopper position
Stopper Point
learning:
[LernNotexec, Fail or
Stppr_Pnt]
Exec
Exec:
Initialization
and learning
complete
# Codes
[# Codes]
Number of
codes:
Min.: 0, Max.:
255
Check Mode Check mode:

[Check Mode] OFF or ON
ON: Check
mode ON
Number of detected DTCs
ACTIVE TEST
HINT:
Performing an Active Test enables components including the relays, VSV
(Vacuum Switching Valve), and actuators, to be operated without removing any
parts. The Active Test can be performed with an intelligent tester. Performing an
Active Test as the first step of troubleshooting is one method of shortening

diagnostic time.
Data List can be displayed during Active Tests.
1.
2.
3.
4.
Connect an intelligent tester to the DLC3.

Turn the ignition switch on (IG) and turn the tester ON.
Select the following menu items: Powertrain / Multi-Mode M/T / Active Test.
Perform the Active Test by referring to the table below.
Items
Test Details/Vehicle
conditions
[Test Details]
Target gear position control
(Gear position)
Target Gear N, 1st, 2nd, 3rd, 4th, 5th, R
Position
[Vehicle Conditions]
Control
Ignition switch on (IG),
Engine stopped, Vehicle
stationary, Shift lever N
position
Target
Clutch
Control
[Test Details]
Target clutch control
Standby position: Standby
Clamp position: Clamp
[Vehicle Conditions]
Ignition switch on (IG),
Engine stopped, Vehicle
stationary, Shift lever N
position
Diagnosis Notes
If shift and select actuator does not
shift to the gear indicated, there
could be some malfunctions in the
following parts:
Shift stroke sensor
Shift and select actuator assembly
AMT relay
Transmission control ECU
If clutch actuator does not operate to
the position indicated, there could be
some malfunctions in the following
parts:
Clutch actuator assembly
AMT relay
Clutch release fork
Transmission control ECU
MULTI-MODE MANUAL
TRANSAXLE SYSTEM >
ADJUSTMENT
for Preparation
1. USING INTELLIGENT TESTER: CLAMP POSITION ADJUSTMENT (CLUTCH

POSITION ADJUSTMENT)
HINT:
The multi-mode manual transmission system has a load controlled clutch cover
(adjustment system). The pressure plate moves depending on the wear condition
of the clutch disc lining.
When removing or installing any parts related to the multi-mode manual
transmission system, move the clutch actuator to the clutch clamp position. This is
for normal operation of the load controlled clutch cover (adjustment system).
If the clutch position adjustment operation input fails, perform the operation again
from step (a) more than 15 seconds after turning the ignition switch off.
NOTICE:
Do not depress the brake pedal while performing the clamp position adjustment
using an intelligent tester.
Stop the vehicle.
Shift the lever into the N position.
Apply the parking brake.

4. Turn the intelligent tester ON.
5. Select the following menu items: Powertrain / Multi-Mode M/T / Utility / Parts
Exchange.


9. After checking the vehicle condition, press the Next key.


14. On the Multi-Mode M/T / Utility screen, select Step 1 Clutch Position Adjustment
(Clamp Position Adjustment).

18. Complete Clutch Position Adjustment.
19. Turn the intelligent tester OFF.
20. Turn the ignition switch off.
21. Replace the malfunctioning parts.
HINT:
Perform [Initialization and Learning] after repairing the multi-mode manual
transmission control system ().
2. WITHOUT USING INTELLIGENT TESTER: CLAMP POSITION ADJUSTMENT

(CLUTCH POSITION ADJUSTMENT)
HINT:
The multi-mode manual transmission system has a load controlled clutch cover
(adjustment system). The pressure plate moves depending on the wear condition
of the clutch disc lining.
When removing or installing any parts related to the multi-mode manual
transmission system, move the clutch actuator to the clutch clamp position. This is
for normal operation of the load controlled clutch cover (adjustment system).
If the clutch position adjustment operation input fails, perform the operation again
from step (a) more than 15 seconds after turning the ignition switch off.
1. Prepare the vehicle.

Stop the vehicle.
Shift the lever into the N position.
Apply the parking brake.
2. Using SST, connect terminals TC (13) and CG (4) of the DLC3

SST
09843-18040
3. Turn the ignition switch on (IG) with the brake pedal released.

6. Shift the shift lever in the following sequence with the brake pedal depressed:
NEM+M+M+M+MEN.
7. Release the brake pedal.
8. Depress the brake pedal again.

1. The buzzer sounds once at intervals of 2.5 seconds.
HINT:
If the buzzer does not sound at this time, wait at least 15 seconds after turning the
ignition switch off. Then, perform the procedure from step (a) again.
11. Shift the shift lever to the [-] position with the brake pedal depressed.
12. Release the brake pedal.
13. Complete clutch position adjustment.
14. Turn the ignition switch OFF and wait at least 10 seconds.
15. Disconnect the SST from terminals TC and CG of the DLC3.
16. Repair the malfunctioning parts.
HINT:
Perform [Initialization and Learning] after repairing the multi-mode manual
transmission control system ().
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Starter Signal

Circuit
for Preparation
DESCRIPTION
In this vehicle, since the starter motor control depends on the ECM due to cranking
holding function, the ST relay that supplies power to the starter motor is operated by the
ECM. When the appropriate vehicle conditions are satisfied (the brake pedal is depressed
and the transmission gear is in neutral) the engine can be cranked. If the brake pedal is
not depressed or the transmission gear is not in neutral, the engine cannot be cranked.
During cranking, the ST relay operation signal (STA signal) is input into the STA
terminal of the transmission control ECU, and is used to control the multi-mode manual
transmission system.
WIRING DIAGRAM
INSPECTION PROCEDURE
1.READ VALUE USING INTELLIGENT TESTER
1. Connect an intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and turn the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data List / STA
Switch Signal.
4. Check the value displayed on the tester when the ignition switch is turned on (IG)
and the engine starts.
Items
[Abbreviation]
Measurement Items:
Display
Normal Conditions
STA Switch
STA signal:
ON: During
Signal
ON or OFF
cranking
[STA SW Sig]
5. OK:
6. [ON] displays in the STA Switch Signal during cranking.
Diagnostic
Notes
-
OK
PROCEED TO NEXT CIRCUIT

INSPECTION SHOWN IN PROBLEM
SYMPTOMS TABLE
NG
2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU ECM)
1. Disconnect the transmission control ECU connector.

2. Disconnect the ECM connector.
3. Remove the ST relay from the engine room relay block.
4. Check the resistance.
Standard resistance:
Tester Connections
Specified
Conditions
1KR-FE:
STA (A32-27) STA (A38-6)
2SZ-FE:
STA (A21-48) STA (A38-6)
Below 1
STA (A38-6) - Body

10 kor higher
ground
5. Reconnect the transmission control ECU connector.
6. Reconnect the ECM connector.
7. Reinstall the ST relay.
NG
REPAIR OR REPLACE HARNESS OR

CONNECTOR
OK
GO TO STARTER SIGNAL CIRCUIT (ENGINE CONTROL SYSTEM)
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Pattern Select

Switch Circuit
for Preparation
DESCRIPTION
While the vehicle is driven with the shift lever in the E position, the most appropriate
gear is automatically selected in accordance with the accelerator pedal opening angle and
vehicle speed. In this time, shift control can be switched between normal mode (E) and
sports mode (Es) by pressing the pattern select switch.
WIRING DIAGRAM
1.INSPECT PATTERN SELECT SWITCH ASSEMBLY
1. Remove the pattern select switch.

2. Check the resistance of the pattern select switch terminals.
Tester
Switch
Specified
Connections Conditions Conditions
1-4
ON
Below 1
1-4
OFF
10 k or
higher
3. Reinstall the pattern select switch.
NG
REPLACE PATTERN SELECT

SWITCH ASSEMBLY
OK
2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU BODY GROUND)

Tester
Switch
Specified
PWR (D7923) - Body
ground
OFF
10 k or
higher
PWR (D7923) - Body

ground
ON
Below 1
NG

CONNECTOR
OK
3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY (PWR TERMINAL

VOLTAGE)

2. Measure the voltage between the terminal of the transmission control ECU
connector and the body ground when the pattern select switch is ON and OFF.
Standard voltage:
Tester
Switch
Specified
Pattern
PWR (D79select
23) - Body
switch
ground
OFF
10 to 14 V
PWR (D79- Pattern

Below 1 V
23) - Body select
ground
switch ON
NG
REPLACE TRANSMISSION
CONTROL ECU ASSEMBLY
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS
TABLE
MULTI-MODE MANUAL TRANSAXLE SYSTEM > IG Signal Circuit
for Preparation
DESCRIPTION
When the ignition switch is turned on (IG), the battery voltage is applied to terminal IG
of the transmission control ECU. Power is supplied to the transmission control ECU via
terminal +B and IG. The transmission control ECU interprets the ignition switch
condition according to the potential at IG terminal.
WIRING DIAGRAM
1.READ VALUE USING INTELLIGENT TESTER
1. Connect the intelligent tester to the DLC3
2. Turn the ignition switch on (IG) and turn the tester ON.
3. Select the following menu items: Powertrain / Multi-Mode M/T / Data List /
Ignition Signal.
4. Read the value.
Items
[Abbreviation]
Measurement Items:
Display
Normal Conditions
Diagnostic
Notes
Ignition
Ignition switch signal: ON: Ignition switch on
Signal
OFF or ON
(IG)
[Ignition Sig]
5. OK:
6. [ON] displays in the item [Ignition Signal] when the ignition switch is turned on
(IG).
OK
PROCEED TO NEXT CIRCUIT

INSPECTION SHOWN IN PROBLEM
SYMPTOMS TABLE
NG
2.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY (IG TERMINAL

VOLTAGE)

connector and the body ground.
Standard voltage:
Ignition
Tester
Specified
Switch
Connections
Conditions
Conditions
IG (D79-3) - Ignition
Below 1 V
Body ground switch off
Ignition
IG (D79-3) switch on 10 to 14 V
Body ground
(IG)
OK
NG
3.INSPECT INTEGRATION RELAY
1. Remove the integration relay from the engine room relay block.
2. Measure the voltage between the terminal of the integration relay and the body
ground.
Standard voltage:
Tester Connections
Specified
Conditions
Integration relay (1C1) - Body ground
10 to 14 V
3. Reinstall the integration relay.
NG

CONNECTOR (INTEGRATION
RELAY - BATTERY)
OK
4.INSPECT INTEGRATION RELAY (AM2 FUSE AND IG2 RELAY)
1. Inspect the AM2 fuse.

1. Remove the AM2 fuse.
2. Check the fuse resistance.
Below 1
3. Reinstall the fuse.
2. Inspect the relay.
1. Check the relay resistance.
Tester
Specified
Connections
Conditions
1C-1 - 1B-4
10 k or higher
1C-1 - 1B-4
Below 1
(When battery
voltage applied to
terminals 1B-2 and
1B-3)
NG
OK
5.INSPECT FUSE (IGN FUSE)
REPLACE INTEGRATION RELAY
1. Remove the IGN fuse from the main body ECU.

2. Check the fuse resistance.
Below 1
3. Reinstall the IGN fuse.
NG
CHECK FOR SHORT IN ALL

HARNESSES AND CONNECTORS
CONNECTED TO FUSE AND
REPLACE FUSE
OK
6.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU INTEGRATION RELAY)
1. Remove the integration relay.

Standard resistance (Check for open):
Tester Connections
Specified
Conditions
Integration relay (1BBelow 1

4) - IG (D79-3)
Standard resistance (Check for short):
Specified
Tester Connections
Conditions
IG (D79-3) - Body
10 k or higher
ground
5. Reconnect the ECU connector
Result:
Result
Proceed
To
Outside normal range
Within normal range (with

Entry and Start System)
Within normal range

(without Entry and Start
System)
Go to step 7
Go to step 8
A
REPAIR OR REPLACE HARNESS OR CONNECTOR
7.CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - MAIN BODY
ECU)

2. Remove the main body ECU.
Tester Connections
Specified
Conditions
Integration relay (1B2) - IG2D (D65-5)
Below 1

3) - Body ground
Specified
Tester Connections
Conditions
IG2D (D65-5) Body ground
10 k or higher

5. Reinstall the main body ECU.
NG

CONNECTOR
OK
CHECK ENTRY AND START SYSTEM
8.CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - IGNITION
SWITCH)

2. Disconnect the ignition switch connector.
Tester Connections
Specified
Conditions
Integration relay (1B2) - Ignition switch

IG2 (D8-6)
Below 1

3) - Body ground
Specified
Tester Connections
Conditions
Ignition switch IG2
(D8-6) - Body ground
10 k or
higher

5. Reconnect the ignition switch connector.
NG
OK
9.INSPECT IGNITION SWITCH

CONNECTOR
1. Remove the ignition switch.

2. Measure the resistance between the terminals of the ignition switch.
Switch
Tester
Specified
Positions Connections Conditions
LOCK
10 k or
higher
ACC
2-4
Below 1
1-2-4
Below 1
5-6
Below 1
1-3-4
Below 1
5-6-7
Below 1
ON
START
3. Reinstall the ignition switch.
NG
REPLACE IGNITION SWITCH
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION SWITCH BATTERY)
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Shift Lock

Solenoid Circuit
for Preparation
DESCRIPTION
The shift lock solenoid is built into the shift lever assembly. When the ignition switch is
turned off, or when the shift lever is in the N position without depressing the brake pedal
although the ignition switch is turned on (IG), the shift lock solenoid restricts the shift
lever movement.
The transmission control ECU sends the shift lock cancellation signal to the shift lock
solenoid to cancel the shift lock when the multi-mode manual transmission system
conditions are satisfied.
WIRING DIAGRAM
1.INSPECT SHIFT LOCK SOLENOID
1. Disconnect the shift lever assembly connector.

2. Measure the shift lock solenoid resistance.
Tester
Connections
IG (D81-2) - E
(D81-6)
Specified
Conditions
30 to 35 at 20C
(68F)
NG
REPLACE SHIFT LOCK SOLENOID
OK
2.CHECK HARNESS AND CONNECTOR (SHIFT LOCK SOLENOID -
TRANSMISSION CONTROL ECU, BODY GROUND)
1. Disconnect the shift lever assembly connector.

Tester Connections
Specified
Conditions
SLS (D79-5) - IG
(D81-2)
Below 1
E (D81-6) - Body
ground
Below 1
SLS (D79-5) - Body

10 k or higher
ground
5. Reconnect the shift lever assembly connector.
NG

CONNECTOR
OK
3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY

2. Measure the voltage between the terminal of the transmission control ECU and
the body ground when the brake pedal is operated.
Standard voltage:
Pedal
Tester
Specified
Conditions Connections Conditions
Brake
SLS (D79-5)
10 to 14 V
pedal
- Body
depressed
ground
Brake
pedal
released
SLS (D79-5)
Below 1 V
Body ground
NG
OK
TABLE
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Multi-Mode

Manual Transmission Warning Light Circuit
for Preparation
DESCRIPTION
The combination meter interprets the multi-mode manual transmission system condition
through information from the INDC and INDA circuits, and if necessary, illuminates
(blinks) the multi-mode manual transmission warning light and sounds the buzzer.
INDC Terminal Circuit:

The battery voltage is constantly supplied to the INDC circuit. If the INDC circuit
is open, the combination meter detects a malfunction in the circuit and illuminates
the multi-mode manual transmission warning light. The INDC circuit is used to
send the multi-mode manual transmission warning light signal to the combination
meter when the ignition switch is off.
INDA Terminal Circuit:

Power is supplied to the INDA circuit when the ignition switch is on. While the
ignition switch is on (IG), the combination meter controls the multi-mode manual
transmission warning light ON/OFF condition in accordance with the signal from
the INDA circuit. The INDA circuit is used to send the signals for the multi-mode
manual transmission warning light and shift position indicator to the combination
meter.
The contents of signals from the INDC and INDA circuits, and the status of the multimode manual transmission warning light and indicator are shown in the table below.
When Ignition Switch ON:

INDA
circuit state
(at
combination
meter)
INDC
circuit (at
combination
meter)
Shift
position
indicator
*
1
Normal
Normal
+B short or
open
Inconsistent signal Interrupted signal

input (3 seconds or input (3 seconds or
more)
more)
Normal
+B short or
+B short or
Normal
open
open
ON
ON
depends on
depends on
OFF
communication communication
signal
signal
OFF
OFF
OFF
Multi-mode
ON
ON
manual
depends on
depends on
ON
ON
ON
ON
transmission
warning
signal
signal
light
*
1: when shift position indicator ON, the number or letter segments are illuminated.
When Ignition Switch OFF:

INDA
circuit state
(at
combination
meter)
INDC
circuit state
(at
combination
Normal
Normal
+B short or
open
Inconsistent signal Interrupted signal

input (3 seconds or input (3 seconds or
more)
more)
Normal
+B short or
+B short or
Normal
open
open
meter)
Shift
position
indicator
*
1
ON
ON
depends on
depends on
OFF
signal
signal
OFF
OFF
OFF
Multi-mode
ON
ON
manual
depends on
depends on
ON
ON
OFF
ON
transmission
warning
signal
signal
light
*
1: when shift position indicator ON, the number or letter segments are illuminated.
WIRING DIAGRAM
HINT:
Check that the multi-mode manual transmission warning light and shift position
indicator light come on.
Under normal conditions, the shift position indicator indicates the current gear
position while the ignition switch is turned on (IG), and the multi-mode manual
transmission warning light comes on for a bulb check for approximately 5
seconds when the ignition switch is turned from off to on (IG).
If the shift position indicator light does not come on, the INDA circuit may be
malfunctioning. If the multi-mode manual transmission warning light does not
come on, the INDA and/or INDC circuits may be malfunctioning.
The buzzer built into the combination meter sounds when the following
conditions are met:
The shift lever is in any position except N.
The driver's door is open.
Vehicle speed is 10 km/h (6.21 mph) or less.
Engine speed is 400 rpm or more.
1.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU COMBINATION METER ASSEMBLY)

2. Disconnect the combination meter connector
Tester Connections
Specified
Conditions
INDC (D79-29) BRQ (D1-13)
Below 1
INDA (D79-31) TX+ (D1-8)
Below 1
INDC (D79-29) Body ground
10 k or
higher
INDA (D79-31) Body ground
10 k or
higher

5. Reconnect the combination meter connector.
NG

CONNECTOR
OK
2.INSPECT COMBINATION METER
1. Measure the voltage between the terminal of the combination meter and the body
ground.
Standard voltage:
Tester
Specified
Conditions
Connection
Conditions
TX+ (D1-8)
Ignition
- Body
switch off
ground
3.64 V or
more
TX+ (D1-8) Ignition

- Body
switch on
ground
(IG)
1.44 V or
less
BRQ (D113) - Body

ground
1.44 V or
less
Always
NG
INSPECT METER / GAUGE SYSTEM
OK
TABLE
MULTI-MODE MANUAL TRANSAXLE SYSTEM > Parking Brake

Switch Circuit
for Preparation
DESCRIPTION
The transmission control ECU detects the ON/OFF status of the parking brake switch.
When the parking brake is applied, the parking brake switch turns ON. When the parking
brake is released, the switch turns OFF.
HINT:
When the brake pedal is not depressed with the gear in 1st, 2nd or reverse, the
clutch is half-engaged, even if the accelerator pedal is not depressed. As a result,
the vehicle can creep slowly like an automatic transmission vehicle. This assists
the vehicle in preparing to move. The take off assist control is cancelled while the
parking brake switch is ON.
WIRING DIAGRAM
1.INSPECT PARKING BRAKE SWITCH ASSEMBLY
1. Remove the parking brake switch assembly.

2. Check the parking brake switch resistance.
Tester
Switch
Connections Position
Specified
Conditions
1 - Switch
body
OFF
(shaft
pressed)
1 - Switch
body
ON
Below 1
(shaft
released)
10 k or
higher
3. Reinstall the parking brake switch assembly.
NG
REPLACE PARKING BRAKE

SWITCH ASSEMBLY
OK
2.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU BODY GROUND)

Tester
Switch
Specified
PKB (D794) - Body
ground
OFF
10 k or
higher
PKB (D794) - Body

ground
ON
Below 1
NG

CONNECTOR
OK
3.INSPECT TRANSMISSION CONTROL ECU ASSEMBLY

connector and the body ground when the parking brake switch is ON and OFF.
Standard voltage:
Tester
Switch
Specified
PKB (D794) - Body
ground
Parking
brake
switch
OFF
10 to 14 V
PKB (D794) - Body

ground
Parking
brake
switch
ON
Below 1 V
NG
OK
TABLE
MULTI-MODE MANUAL TRANSAXLE SYSTEM > TC and CG

Terminal Circuit
for Preparation
DESCRIPTION
Terminal TC and CG are located in the DLC3. When performing [Clamp Position
Adjustment] and [Initialization and Learning] without using an intelligent tester,
connecting terminals TC and CG is necessary. If the TC terminal circuit is open, these
calibration procedures cannot be performed without using an intelligent tester.
WIRING DIAGRAM
1.CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU DLC3)

Tester Connections
Specified
Conditions
DG (D79-25) - TC
(D15-13)
Below 1
DG (D79-25) Body ground
10 kor higher
NG

CONNECTOR
OK
2.CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND)

Tester Connections
Specified
Conditions
CG (D15-4) - Body
ground
Below 1
NG

CONNECTOR
OK
REPLACE TRANSMISSION CONTROL ECU ASSEMBLY
MULTI-MODE MANUAL
TRANSAXLE OIL > ON-VEHICLE
INSPECTION
for Preparation
1. INSPECT TRANSAXLE OIL
1. Stop the vehicle on a level place.

2. Remove the filler plug and gasket.
3. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the
filler plug opening.
NOTICE:
An excessively large or small amount of oil may cause problems.

After replacing the oil, drive the vehicle and check the oil level again.
4. When the oil level is low, check for oil leakage.

5. Install the filler plug and a new gasket.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
DIFFERENTIAL OIL SEAL >

COMPONENTS
for Preparation
1/2
2/2

REMOVAL
for Preparation
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN TRANSAXLE OIL

2. Remove the drain plug and gasket, and drain the oil.
3. Install the drain plug with a new gasket.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
3. REMOVE FRONT WHEELS
4. REMOVE FRONT AXLE SHAFT LH NUT
1. Using SST and a hammer, release the staked part of the axle hub nut.
SST
09930-00010
NOTICE:
Insert SST into the groove with the flat surface facing up.
Do not damage the tip of SST using grinders.
Completely unstake the staked part before removing the axle hub nut.
Do not damage the threads of the drive shaft.
2. Using a 30 mm socket wrench, remove the axle hub nut.
5. REMOVE FRONT AXLE SHAFT RH NUT

HINT:
The removal procedure for the RH side is the same as that for the LH side.
6. SEPARATE SPEED SENSOR FRONT LH
1. Remove the bolt and separate the speed sensor and flexible hose.
2. Remove the bolt and separate the speed sensor from the steering knuckle.
NOTICE:
Keep the speed sensor tip and installation portion free of foreign matter.
Remove the speed sensor without turning it from its original installation
angle.
7. SEPARATE SPEED SENSOR FRONT RH

HINT:
The separation procedure for the RH side is the same as that for the LH side.
8. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
1. Remove the clip and castle nut.
2. Using SST, separate the lower arm.

SST
09628-00011
NOTICE:
Do not damage the lower ball joint dust cover.

Suspend SST with a piece of string or the equivalent.
9. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT:
10. SEPARATE TIE ROD END SUB-ASSEMBLY LH

1. Remove the cotter pin and castle nut.
2. Using SST, separate the tie rod end from the steering knuckle.
SST
09628-62011
NOTICE:
Do not damage the tie rod end dust cover.
11. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT:
12. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
1. Remove the nut and separate the stabilizer link from the shock absorber.
HINT:
If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold
the stud.
13. REMOVE FRONT STABILIZER LINK ASSEMBLY RH

HINT:
14. REMOVE FRONT AXLE ASSEMBLY LH

1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting
between the drive shaft and front axle.
HINT:
If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass
bar and hammer.
2. Push the front axle out of the vehicle to remove the drive shaft from the front
axle.
NOTICE:
Do not push the front axle further out of the vehicle than is necessary.
Do not damage the outboard joint boot.
Do not damage the speed sensor rotor.
Suspend the drive shaft with a piece of string or the equivalent.
15. REMOVE FRONT AXLE ASSEMBLY RH

HINT:
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
1. Using SST, remove the drive shaft.

SST
09520-01010
09520-24010 (09520-32040)
NOTICE:
Do not damage the oil seal.

Do not damage the inboard joint boot.
Do not drop the drive shaft.
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
1. Using a screwdriver and hammer, remove the drive shaft.
NOTICE:

18. REMOVE TRANSAXLE CASE OIL SEAL
1. Using SST, remove the oil seal.

SST
09308-00010
19. REMOVE TRANSMISSION CASE OIL SEAL
1. Using SST, remove the oil seal.

SST
09308-00010

INSTALLATION
for Preparation
1. INSTALL TRANSAXLE CASE OIL SEAL
1. Coat a new oil seal lip with MP grease.

2. Using SST and a hammer, install the oil seal.
SST
09636-20010
Drive in depth:
1.7 to 2.7mm (0.067 to 0.106 in.)
NOTICE:
Do not damage the oil seal lip.
2. INSTALL TRANSMISSION CASE OIL SEAL
1. Coat a new oil seal lip with MP grease.

2. Using SST and a hammer, install the oil seal.
SST
09316-60011 (09316-00011)
Drive in depth:
2.1 to 3.1mm (0.083 to 0.122 in.)
NOTICE:
Do not damage the oil seal lip.
3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

1. Coat the spline of the inboard joint with gear oil.
2. Align the inboard joint splines and install the drive shaft with a screwdriver and
hammer.
NOTICE:
Face the cut area of the front drive inboard joint hole snap ring downward.
HINT:
Confirm whether the drive shaft is securely driven in by checking the reaction
force and sound.
4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

HINT:
The installation procedure for the RH side is the same as that for the LH side.
5. INSTALL FRONT AXLE ASSEMBLY LH

1. Push the front axle out of the vehicle to align the spline of the drive shaft with the
front axle and insert the front axle.
NOTICE:
Check for any foreign matter on the speed sensor rotor and insertion part.
6. INSTALL FRONT AXLE ASSEMBLY RH

HINT:
7. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
1. Install the stabilizer link with the nut.

Torque:
74 N*m{ 755 kgf*cm , 55 ft.*lbf }
HINT:
the stud.
8. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT:
9. INSTALL TIE ROD END SUB-ASSEMBLY LH
1. Install the tie rod end onto the steering knuckle with a new castle nut.
Torque:
49 N*m{ 500 kgf*cm , 36 ft.*lbf }
NOTICE:
If the holes for the clip are not aligned, tighten the nut by a further turn of up to
60.
2. Install a new cotter pin.
10. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT:
11. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
1. Install the lower arm onto the steering knuckle with a new castle nut.
Torque:
98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }
NOTICE:
60.
2. Install a new clip.
12. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT:
13. INSTALL SPEED SENSOR FRONT LH
1. Install the speed sensor onto the steering knuckle with the bolt.
Torque:
8.5 N*m{ 87 kgf*cm , 75 in.*lbf }
NOTICE:
Check that the speed sensor tip and installation portion are free of foreign
matter.
Install the speed sensor without turning it from its original installation
angle.
2. Install the flexible hose and speed sensor with the bolt.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
NOTICE:
Install the flexible hose and speed sensor without twisting them.
14. INSTALL SPEED SENSOR FRONT RH

HINT:
15. INSTALL FRONT AXLE SHAFT LH NUT
1. Using a 30 mm socket wrench, install a new axle hub nut.

Torque:
216 N*m{ 2,203 kgf*cm , 160 ft.*lbf }
2. Using a chisel and hammer, caulk the axle hub nut.
16. INSTALL FRONT AXLE SHAFT RH NUT

HINT:
17. INSTALL FRONT WHEELS
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }
19. ADD TRANSAXLE OIL
20. INSPECT AND ADJUST TRANSAXLE OIL

NOTICE:


Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
21. INSPECT ABS SPEED SENSOR SIGNAL

()
22. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

()
23. CHECK FOR TRANSAXLE OIL LEAKAGE
SHIFT LEVER > COMPONENTS

for Preparation
1/2
2/2
SHIFT LEVER > ON-VEHICLE

INSPECTION
for Preparation
1. INSPECT SHIFT LOCK SOLENOID
1. Disconnect the indicator light wire connector.

2. Using an ohmmeter, measure the resistance between terminals 2 and 6.
Standard Resistance:
30 to 35 at 20C (68F)
If the resistance is not as specified, replace the shift lever assembly.
3. Check the solenoid operating sound when applying battery voltage across
terminals 2 and 6.
If the solenoid does not operate, replace the shift lever assembly.
4. Connect the indicator light wire connector.
2. INSPECT TRANSMISSION SHIFT MAIN SWITCH
1. Disconnect the indicator light wire connector.

2. Move the shift lever to the M position.
3. Using an ohmmeter, measure the resistance according to the value in the table
below.
Shift
Terminals
position
M
4-8
Specified
condition
Below 1
4. Move the shift lever to the E position.

5. Using an ohmmeter, measure the resistance according to the value in the table
below.
Shift
Terminals
position
E
4-8
Specified
condition
10 k or
higher
If the result is not as specified, replace the shift lever assembly.

6. Connect the indicator light wire connector.
3. INSPECT SHIFT LEVER POSITION SENSOR
1. Disconnect the shift lever position sensor connector.

2. Using an ohmmeter, measure the resistance according to the values in the table
below.
Shift
Terminals
position
Specified
condition
4 - 9 - 10 13
Below 1
4 - 2 - 10 6
Below 1
E, M
4-2-313
Below 1
11 - 5
Below 1
11 - 5 - 12
10 k or
higher
11 - 12
Below 1
If the result is not as specified, replace the shift lever assembly.

3. Connect the shift lever position sensor connector.
SHIFT LEVER > REMOVAL

for Preparation
1. REMOVE REAR CONSOLE BOX COVER
1. Disengage the 8 claws and remove the console box rear cover.
2. REMOVE REAR CONSOLE BOX ASSEMBLY
1. Remove bolt <F>.

2. Disengage the 2 clips and remove the console box rear.
3. REMOVE SHIFT LEVER ASSEMBLY
1. Disconnect the 2 connectors.

2. Remove the 4 bolts and shift lever assembly.
SHIFT LEVER > DISASSEMBLY

for Preparation
1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY
2. REMOVE POSITION INDICATOR LIGHT GUIDE
1. Disconnect the indicator light wire from the shift lever assembly
2. Disengage the 4 claws and remove the position indicator light guide from the shift
lever assembly.
3. Disengage the 4 claws and remove the position indicator housing from the
position indicator light guide.
3. REMOVE POSITION INDICATOR SLIDE COVER
4. REMOVE POSITION INDICATOR SLIDE COVER NO. 2
5. REMOVE SHIFT LOCK RELEASE BUTTON
1. Remove the shift lock release button and compression spring from the shift lever
assembly.
6. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY

1. Disconnect the indicator light wire connector from the shift lever assembly.
2. Remove the bulb and cap from the indicator light wire.
3. Using a screwdriver with its tip wrapped in protective tape, release the secondary
lock.
4. Put marks on wire harnesses 2 and 4.

5. Release the locking lugs of terminals 2, 4, 6 and 8, and pull the wire harness out
of the terminals.
SHIFT LEVER > REASSEMBLY

for Preparation
1. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY
1. Connect marked wire harnesses 2 and 4 to the indicator light wire connector as
shown in the illustration.
2. Connect wire harnesses 6 and 8 to the indicator light wire connector as shown in
the illustration.
3. Lock the secondary lock.
4. Install the bulb onto the indicator light wire.

5. Connect the indicator light wire connector onto the shift lever assembly.
2. INSTALL SHIFT LOCK RELEASE BUTTON
1. Apply MP grease to the shift lock release button and spring.

2. Install the shift lock release button and spring onto the shift lever.
3. INSTALL POSITION INDICATOR SLIDE COVER NO. 2
4. INSTALL POSITION INDICATOR SLIDE COVER
5. INSTALL POSITION INDICATOR LIGHT GUIDE
1. Engage the 4 claws to install the position indicator housing.
2. Engage the 4 claws to install the position indicator light guide.
3. Connect the indicator light wire onto the shift lever assembly.
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
SHIFT LEVER > INSTALLATION

for Preparation
1. INSTALL SHIFT LEVER ASSEMBLY
1. Install the shift lever assembly with the 4 bolts.

Torque:
12 N*m{ 122 kgf*cm , 8.9 ft.*lbf }
2. Connect the 2 connectors.
2. INSTALL REAR CONSOLE BOX ASSEMBLY
1. Engage the 2 clips and install the console box rear.

2. Install bolt <F>.
3. INSTALL REAR CONSOLE BOX COVER
1. Engage the 8 claws and install the console box rear cover.
MULTI-MODE MANUAL
TRANSAXLE ASSEMBLY >
COMPONENTS
for Preparation
1 / 10
2 / 10
3 / 10
4 / 10
5 / 10
6 / 10
7 / 10
8 / 10
9 / 10
10 / 10
MULTI-MODE MANUAL
REMOVAL
for Preparation
1. CLUTCH POSITION ADJUSTMENT

()
3. REMOVE COLUMN HOLE COVER SILENCER SHEET
1. Remove the floor carpet and 2 clips and remove the column hole cover silencer.
4. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY
1. Use a seat belt to fix the steering wheel assembly, in order to avoid breakage of
the spiral cable.
2. Place matchmarks on the sliding yoke of the steering intermediate shaft assembly
and the power steering.
3. Loosen bolt A, remove bolt B and separate the steering intermediate shaft
assembly.
5. REMOVE FRONT WHEELS
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE ENGINE UNDER COVER RH

1. Remove the filler plug and the gasket.
2. Remove the drain plug and gasket and drain the transaxle oil.
3. Install a new gasket and the drain plug.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
9. REMOVE HOOD SUB-ASSEMBLY
10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

1. Operate the wiper, then stop the windshield wiper motor in the automatic stop
position.
2. Remove the nut and front wiper arm.
11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

HINT:
Use the same procedure as for the LH side.
12. REMOVE HOOD TO COWL TOP SEAL
1. Disengage the 7 clips and remove the hood to cowl top seal.
13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for LHD)
1. Disengage the 2 hooks and remove cowl top ventilator louver center No. 1.
2. Disconnect the washer hose.

3. Disengage the 11 claws and clip.
4. Disconnect the washer hose and remove the cowl top ventilator louver subassembly.
14. REMOVE COWL TOP VENTILATOR LOUVER LH (for LHD)
1. Remove the 2 clips.

2. Disengage the 4 claws and remove the cowl top ventilator louver LH.
15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for RHD)
1. Disconnect the washer hose.

2. Disengage the 10 claws and clip and remove the cowl top ventilator louver subassembly.
16. REMOVE COWL TOP VENTILATOR LOUVER LH (for RHD)
1. Remove the clip.

2. Disengage the 4 claws and remove the cowl top ventilator louver LH.
17. REMOVE WINDSHIELD WIPER MOTOR AND LINK
1. Remove the 2 bolts.

2. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the
connector and remove the front wiper motor and link.
18. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2
1. Disengage the claws and remove cowl to resister duct No. 2.
19. REMOVE COWL TOP PANEL OUTER
1. Disengage the clamp and separate the wiper motor connector.
2. Remove the 9 bolts and the cowl top panel outer.
20. REMOVE AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Remove the air cleaner inlet No. 1.
21. REMOVE BATTERY HOLD DOWN CLAMP
22. REMOVE BATTERY CLAMP SUB-ASSEMBLY
23. REMOVE BATTERY
24. REMOVE BATTERY TRAY
25. REMOVE BATTERY CARRIER (for 1KR-FE)
1. Remove the 4 bolts and the battery carrier.
26. REMOVE BATTERY CARRIER (for 2SZ-FE)
27. REMOVE CLUTCH ACTUATOR ASSEMBLY
1. Remove the bolt and separate the wire harness bracket.
2. Disconnect the clutch stroke sensor connector and motor connector.

NOTICE:
Do not forcibly pull the connector as this may damage the wire harness.
3. Remove the 3 bolts and clutch actuator assembly.

NOTICE:
Loosen the bolts slowly, and be careful not to get your fingers caught as
the clutch actuator assembly moves due to the reaction force from the
clutch cover.
Do not drop the removed clutch actuator assembly or subject it to any
impacts.
28. DISCONNECT WIRE HARNESS
1. Remove the bolt, then disconnect the wire harness.
29. DISCONNECT CONNECTOR

1. Disconnect the shift stroke sensor connector.
2. Disconnect the select stroke sensor connector.
3. Disconnect the transmission revolution sensor connector.
4. Disconnect the back-up light switch connector.
5. Disconnect the neutral start switch connector.
6. Disconnect the shift and select motor connectors.
30. REMOVE STARTER ASSEMBLY (for 1KR-FE)
1. Remove the terminal cap.

2. Separate the harness clamp.
3. Remove the nut and disconnect terminal 30.
4. Disconnect the connector.
5. Remove the 2 bolts and remove the starter assembly.
31. REMOVE STARTER ASSEMBLY (for 2SZ-FE)
1. Remove the terminal cap.

2. Remove the nut and disconnect terminal 30.
3. Disconnect the connector.
4. Remove the 2 bolts and remove the starter assembly.
32. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 1KR-FE)

1. Remove the 4 bolts and 4 compression springs.
2. Remove exhaust pipe support No. 4 and the exhaust front pipe assembly.
3. Remove the 2 exhaust pipe gaskets.
33. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2SZ-FE)
1. Remove the 2 bolts and 2 compression springs.
2. Remove the 3 No. 4 exhaust pipe supports and remove the exhaust pipe assembly
front.
34. REMOVE FRONT AXLE SHAFT LH NUT
1. Using SST and a hammer, release the staked part of the axle hub nut.
SST
09930-00010
NOTICE:
Insert SST into the groove with the flat surface facing up.
Do not damage the tip of SST using grinders.
Completely unstake the staked part before removing the axle hub nut.
Do not damage the threads of the drive shaft.
2. Using a 30 mm socket wrench, remove the axle hub nut.
35. REMOVE FRONT AXLE SHAFT RH NUT

HINT:
36. SEPARATE SPEED SENSOR FRONT LH
1. Remove the bolt and separate the speed sensor and flexible hose.
2. Remove the bolt and separate the speed sensor from the steering knuckle.
NOTICE:
Keep the speed sensor tip and installation portion free of foreign matter.
Remove the speed sensor without turning it from its original installation
angle.
37. SEPARATE SPEED SENSOR FRONT RH

HINT:
38. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
1. Remove the clip and castle nut.
2. Using SST, separate the lower arm.

SST
09628-00011
NOTICE:
Do not damage the lower ball joint dust cover.

Suspend SST with a piece of string or the equivalent.
39. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT:
40. SEPARATE TIE ROD END SUB-ASSEMBLY LH

1. Remove the cotter pin and castle nut.
2. Using SST, separate the tie rod end from the steering knuckle.
SST
09628-62011
NOTICE:
Do not damage the tie rod end dust cover.
41. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT:
42. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
1. Remove the nut and separate the stabilizer link from the shock absorber.
HINT:
the stud.
43. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT:
44. REMOVE FRONT AXLE ASSEMBLY LH

1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting
between the drive shaft and front axle.
HINT:
If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass
bar and hammer.
2. Push the front axle out of the vehicle to remove the drive shaft from the front
axle.
NOTICE:

Suspend the drive shaft with a piece of string or the equivalent.
45. REMOVE FRONT AXLE ASSEMBLY RH

HINT:
46. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
1. Using SST, remove the drive shaft.

SST
09520-01010
09520-24010 (09520-32040)
NOTICE:

47. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
1. Using a screwdriver and hammer, remove the drive shaft.

NOTICE:

48. SUSPEND ENGINE ASSEMBLY (for 1KR-FE)
1. Install the 2 hangers in the correct direction.
Parts No.:
No. 1 engine hanger 12281-40030
Bolt 91671-80820
Torque:
28 N*m{ 286 kgf*cm , 21 ft.*lbf }
2. Attach the engine chain hoist to the hangers.
NOTICE:
Do not attempt to hang the engine by hooking the chain to any other part.
49. SUSPEND ENGINE ASSEMBLY (for 2SZ-FE)
1. Install the 2 hangers in the correct direction.

Parts No.:
Bolt 91671-80820
Torque:
35 N*m{ 357 kgf*cm , 26 ft.*lbf }
2. Attach the engine chain hoist to the hangers.
NOTICE:
Do not attempt to hang the engine by hooking the chain to any other part.
50. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Remove the bolt and separate the engine moving control rod.
2. Support the front suspension crossmember with a transmission jack.
3. Remove the 6 bolts and remove the suspension crossmember.
51. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET
1. Remove the 3 bolts and the engine moving control rod bracket.
52. SUPPORT MULTI-MODE MANUAL TRANSAXLE ASSEMBLY

1. Support the multi-mode manual transaxle with a transmission jack.
53. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for

1KR-FE)
1. Remove the bolt and nut, then separate the engine mounting insulator LH.
2. Remove the 4 bolts and the engine mounting insulator LH.
54. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZFE)
55. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KR-
FE)
1. Remove the 4 bolts and the engine mounting bracket LH.
56. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZFE)
57. REMOVE MULTI-MODE MANUAL TRANSAXLE ASSEMBLY
1. Remove the 9 bolts and multi-mode manual transaxle from the engine.
MULTI-MODE MANUAL
INSTALLATION
for Preparation
1. INSTALL MULTI-MODE MANUAL TRANSAXLE ASSEMBLY
1. Align the input shaft with the clutch disc and install the manual transaxle onto the
engine.
2. Install the 9 bolts.
Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf } for bolt A
39 N*m{ 398 kgf*cm , 29 ft.*lbf } for bolt B
NOTICE:
Insert dowel pins into dowel holes securely so that the end face of
transaxle assembly fits close against engine assembly before tightening the
bolts between the engine and transaxle.
Make sure that the dowel pins are not loose, bent, damaged or scratched
and then install the transaxle onto the engine with the contact surfaces of
the engine and transaxle flat against each other.
2. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KRFE)
1. Install the engine mounting bracket LH with the 4 bolts.

Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf }
3. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-FE)

Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf }
4. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KRFE)
1. Install the engine mounting insulator LH with the 4 bolts.

Torque:
2. Install the engine mounting bracket LH and engine mounting insulator LH with
the bolt and nut.
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf } for nut C
5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZFE)

Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf }
the bolt and nut.
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf }
6. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET
1. Install the engine mounting control bracket with the 3 bolts.

Torque:
39 N*m{ 398 kgf*cm , 29 ft.*lbf }
7. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

1. Support the front suspension crossmember with a transmission jack.
2. Provisionally install the front suspension crossmember onto the body with the 6
bolts.
Bolt
Underhead Length (mm)
38
99
45
3. By inserting SST into the datum holes in the front suspension crossmembers RH
and LH alternately, tighten bolts A, B and C on both sides to the specified torque,
in several steps.
SST
09670-00011
Torque:
70 N*m{ 714 kgf*cm , 52 ft.*lbf } for Bolt A
160 N*m{ 1,631 kgf*cm , 118 ft.*lbf } for Bolt B
95 N*m{ 969 kgf*cm , 70 ft.*lbf } for Bolt C
NOTICE:
Insert SST into the datum hole in a vertical orientation.

If SST can not be inserted into the datum hole vertically, loosen all the
bolts and then insert SST again.
4. Install the engine moving control rod with the bolt.

Torque:
120 N*m{ 1,224 kgf*cm , 89 ft.*lbf }
8. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

1. Coat the spline of the inboard joint with gear oil.
2. Align the inboard joint splines and install the drive shaft with a screwdriver and
hammer.
NOTICE:
Face the cut area of the front drive inboard joint hole snap ring downward.

HINT:
Confirm whether the drive shaft is securely driven in by checking the reaction
force and sound.
9. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

HINT:
10. INSTALL FRONT AXLE ASSEMBLY LH

1. Push the front axle out of the vehicle to align the spline of the drive shaft with the
front axle and insert the front axle.
NOTICE:
Check for any foreign matter on the speed sensor rotor and insertion part.
11. INSTALL FRONT AXLE ASSEMBLY RH

HINT:
12. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
1. Install the stabilizer link with the nut.

Torque:
74 N*m{ 755 kgf*cm , 55 ft.*lbf }
HINT:
the stud.
13. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT:
14. INSTALL TIE ROD END SUB-ASSEMBLY LH
1. Install the tie rod end onto the steering knuckle with a new castle nut.
Torque:
49 N*m{ 500 kgf*cm , 36 ft.*lbf }
NOTICE:
60.
2. Install a new cotter pin.
15. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT:
16. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
1. Install the lower arm onto the steering knuckle with a new castle nut.
Torque:
98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }
NOTICE:
60.
2. Install a new clip.
17. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT:
18. INSTALL SPEED SENSOR FRONT LH
1. Install the speed sensor onto the steering knuckle with the bolt.
Torque:
8.5 N*m{ 87 kgf*cm , 75 in.*lbf }
NOTICE:
Check that the speed sensor tip and installation portion are free of foreign
matter.
Install the speed sensor without turning it from its original installation
angle.
2. Install the flexible hose and speed sensor with the bolt.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
NOTICE:
Install the flexible hose and speed sensor without twisting them.
19. INSTALL SPEED SENSOR FRONT RH

HINT:
20. INSTALL FRONT AXLE SHAFT LH NUT
1. Using a 30 mm socket wrench, install a new axle hub nut.
Torque:
216 N*m{ 2,203 kgf*cm , 160 ft.*lbf }
2. Using a chisel and hammer, caulk the axle hub nut.
21. INSTALL FRONT AXLE SHAFT RH NUT

HINT:
22. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 1KR-FE)
1. Using vernier calipers, measure the free length of the compression spring.
Minimum length (Front Side):
40.5 mm (1.594 in.)
Minimum length (Rear Side):
38.5 mm (1.516 in.)
If the length is not as specified, replace the compression spring.
2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket
until its surface is flush with the exhaust manifold.
NOTICE:
Install the exhaust pipe gasket in the correct direction.

Do not damage the outer surface of the exhaust pipe gasket.
Do not reuse the exhaust pipe gasket.
Do not push in the gasket with the exhaust pipe when connecting it.
3. Install the 3 exhaust pipe support No. 4.
4. Install the exhaust front pipe assembly and a new exhaust pipe gasket with the 4
compression springs and 4 bolts.
Torque:
43 N*m{ 439 kgf*cm , 32 ft.*lbf }
23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2SZ-FE)
1. Using vernier calipers, measure the free length of the compression spring.
Minimum length:
40.5 mm (1.594 in.)
If the length is not as specified, replace the compression spring.
2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket
until its surface is flush with the exhaust manifold.
NOTICE:
Install the exhaust pipe gasket in the correct direction.

Do not damage the outer surface of the exhaust pipe gasket.
Do not reuse the exhaust pipe gasket.
Do not push in the gasket with the exhaust pipe when connecting it.
3. Install the 3 No. 4 exhaust pipe supports.
4. Install the exhaust pipe assembly front with the 2 compression springs and 2 bolts.
Torque:
43 N*m{ 439 kgf*cm , 32 ft.*lbf }
24. INSTALL STARTER ASSEMBLY (for 1KR-FE)
1. Install the starter assembly with the 2 bolts.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }
2. Connect the connector.
3. Connect terminal 30 with the nut.
Torque:
9.8 N*m{ 100 kgf*cm , 87 in.*lbf }
4. Close the terminal cap.
5. Install the harness clamp.
25. INSTALL STARTER ASSEMBLY (for 2SZ-FE)
1. Install the starter assembly with the 2 bolts.

Torque:
37 N*m{ 377 kgf*cm , 27 ft.*lbf }
3. Connect terminal 30 with the nut.
Torque:
9.8 N*m{ 100 kgf*cm , 87 in.*lbf }
4. Close the terminal cap.
26. CONNECT CONNECTOR

1. Connect the shift and select motor connectors.
2. Connect the neutral start switch connector.
3. Connect the back-up light switch connector.
4. Connect the transmission revolution sensor connector.
5. Connect the select stroke sensor connector.
6. Connect the shift stroke sensor connector.
27. CONNECT WIRE HARNESS
1. Connect the wire harness with the bolt.

Torque:
26 N*m{ 260 kgf*cm , 19 ft.*lbf }
28. INSTALL CLUTCH ACTUATOR ASSEMBLY

NOTICE:
Perform the following procedure ((1) to (5)) to set a new clutch actuator in the
clutch clamp position because it is not originally placed in that position.
(1) Connect the clutch stroke sensor connector and motor connector to the clutch
actuator.
(2) Connect the battery negative terminal.
(3) Perform clutch position adjustment (clutch clamp position)
()
(4) Disconnect the battery negative terminal.
(5) Disconnect the clutch stroke sensor connector and motor connector.
1. Apply grease to the clutch release lever.

Sealant:
Toyota Genuine Release Hub Grease or Equivalent
2. Set the clutch actuator to the transaxle and provisionally tighten the 3 bolts.
NOTICE:
Keep the clearance between the bolt head and actuator flange.
3. Gently hold down the clutch actuator assembly toward flat surface of transmission
assembly and slide it so that the convex portion of the clutch actuator rod comes
into contact with the concave portion of the release lever.
NOTICE:
Do no apply excessive load to them during the operation.

Make sure that the convex portion of the clutch actuator rod is securely
fitted into the concave portion of the release lever.
1KR-FE and 2SZ-FE clutch actuators have their own discrimination stamp
on the housing upper.
Engine
Discrimination Color
1KR-FE Green
2SZ-FE Blue
4. Tighten the 3 bolts by hand while holding the clutch actuator assembly.
NOTICE:
Support the clutch actuator assembly until all the 3 bolts are tightened.
5. Tighten the 3 bolts to the specified torque in the order A, B, and C, as shown.
Torque:
17 N*m{ 173 kgf*cm , 13 ft.*lbf }
6. Connect the clutch stroke sensor connector and motor connector.
7. Install the wire harness bracket onto the transaxle with the bolt.
Torque:
13 N*m{ 131 kgf*cm , 9.5 ft.*lbf }
29. INSTALL BATTERY CARRIER (for 1KR-FE)
1. Install the battery carrier with the 4 bolts.

Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
30. INSTALL BATTERY CARRIER (for 2SZ-FE)

Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
31. INSTALL BATTERY TRAY
32. INSTALL BATTERY
33. INSTALL BATTERY HOLD DOWN CLAMP
34. INSTALL AIR CLEANER INLET NO.1 (for 2SZ-FE)
1. Install the air cleaner inlet No. 1.
35. INSTALL COWL TOP PANEL OUTER
1. Install the cowl top panel outer with the 9 bolts.

Torque:
6.5 N*m{ 66 kgf*cm , 58 in.*lbf }
2. Engage the clamp and install the wiper motor connector wire harness.
36. INSTALL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2
1. Engage the 2 claws and install cowl to register duct No. 2.
37. INSTALL FR WIPER MOTOR AND LINK ASSEMBLY

2. Slide the wiper link as shown in the illustration and engage the rubber pin with
the body.
3. Install the front wiper motor and link with the 2 bolts.
Torque:
5.5 N*m{ 56 kgf*cm , 49 in.*lbf }
38. INSTALL COWL TOP VENTILATOR LOUVER LH (for LHD)
1. Engage the 4 claws and install the cowl top ventilator louver LH.
2. Install the 2 clips.
39. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for LHD)
1. Connect the washer hose.
2. Engage the 11 claws and install the cowl top ventilator louver sub-assembly.
3. Install the clip.
5. Engage the 2 hooks and install cowl top ventilator louver center No. 1.
40. INSTALL COWL TOP VENTILATOR LOUVER LH (for RHD)
1. Engage the 4 claws and install the cowl top ventilator louver LH.
41. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for RHD)
1. Engage the 10 claws and install the cowl top ventilator louver sub-assembly.
42. INSTALL HOOD TO COWL TOP SEAL
1. Engage the 7 clips and install the hood to cowl top seal.
43. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
1. Scrape any metal powder off the serrated part of the wiper arm with a round file
or the equivalent (when reinstalling).
2. Clean the wiper pivot serrations with a wire brush.
position.
4. Align the blade tip with the mark on the windshield glass, as shown in the
illustration.
5. Tighten the nut of the front wiper arm.
Torque:
26 N*m{ 265 kgf*cm , 19 ft.*lbf }
44. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
1. Scrape any metal powder off the serrated part of the wiper arm with a round file
or the equivalent (when reinstalling).
2. Clean the wiper pivot serrations with a wire brush.
position.
4. Align the blade tip with the mark on the windshield glass, as shown in the
illustration.
5. Tighten the nut of the front wiper arm.
Torque:
26 N*m{ 265 kgf*cm , 19 ft.*lbf }
45. INSTALL HOOD SUB-ASSEMBLY
46. INSPECT HOOD SUB-ASSEMBLY
1. Check that the clearance measurements are within the standard ranges.
Standard:
Area
Measurement
Area
Measurement
1.7 to 5.7 mm
(0.067 to 0.224 in.)
-1.55 to 2.45 mm
(-0.061 to 0.096 in.)
-2 to 2 mm
(-0.079 to 0.079 in.)
1.75 to 5.75 mm
(0.067 to 0.226 in.)
4.45 to 10.45 mm
(0.175 to 0.411 in.)
-1.25 to 2.75 mm
(-0.049 to 0.108 in.)
-0.95 to 5.05 mm
(-0.037 to 0.199 in.)
-1.5 to 1.5 mm
(-0.059 to 0.059 in.)
7.55 to 13.55 mm
2.0 to 5.0 mm
(0.297 to 0.533 in.)

F
1.65 to 5.65 mm
(0.065 to 0.222 in.)
(0.079 to 0.197 in.)

-
47. ADJUST HOOD SUB-ASSEMBLY
1. Loosen the hood side hinge bolts.

2. Move the hood to adjust the clearance to within the standard range.
3. Tighten the hood side hinge bolts after the adjustment.
Torque:
13 N*m{ 133 kgf*cm , 10 ft.*lbf }
4. Adjust the height of the hood front end by turning the cushion rubber.
HINT:
The cushion rubber can be raised and lowered by turning it.
5. Adjust the hood lock.

1. Loosen the 3 bolts.
2. Adjust the hood lock position so that the striker can enter it smoothly.
3. Tighten the 3 bolts after the adjustment.
Torque:
7.5 N*m{ 76 kgf*cm , 66 in.*lbf }
48. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY
1. Align the matchmarks and install the sliding yoke onto the intermediate shaft.
Torque:
28 N*m{ 290 kgf*cm , 21 ft.*lbf }
2. Tighten bolt A.
Torque:
28 N*m{ 290 kgf*cm , 21 ft.*lbf }
49. INSTALL COLUMN HOLE COVER SILENCER SHEET
1. Install the column hole cover silencer sheet with the 2 clips.
2. Install the floor carpet.

NOTICE:


Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
52. INSTALL ENGINE UNDER COVER RH
53. INSTALL ENGINE UNDER COVER LH
54. INSTALL FRONT WHEELS

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }
56. INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE ECU

()
57. LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM

()

()
59. INSPECT ABS SPEED SENSOR SIGNAL

()
60. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

()
61. CHECK FOR EXHAUST GAS LEAKAGE
62. CHECK FOR TRANSAXLE OIL LEAKAGE
MULTI-MODE MANUAL
TRANSAXLE UNIT >
COMPONENTS
for Preparation
1/3
2/3
3/3
MULTI-MODE MANUAL
TRANSAXLE UNIT >
DISASSEMBLY
for Preparation
1. REMOVE SHIFT STROKE SENSOR
2. REMOVE CLUTCH RELEASE FORK
3. REMOVE CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL
4. INSPECT NEUTRAL POSITION
1. Remove the plug from the shift and select actuator.

2. Look through the plug and check that the slit of the shift and select shaft is in the
position shown in the illustration.
If not, turn it with a screwdriver.
5. REMOVE LOCK BALL ASSEMBLY NO.1
1. Using an 18 mm socket wrench, remove the lock ball assembly from the transaxle
case.
6. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Using SST, remove the park/neutral position switch with the gasket from the
transaxle case.
SST
09817-16011
7. REMOVE SHIFT AND SELECT ACTUATOR ASSEMBLY

2. Tap the actuator flange with a plastic hammer to remove it.
8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Using SST, remove the back-up light switch with the gasket from the transaxle
case.
SST
09817-16011
9. REMOVE TRANSMISSION REVOLUTION SENSOR
1. Remove the bolt and transmission case protector.

2. Remove the bolt and transmission revolution sensor.
3. Using a small screwdriver, remove the O-ring from the transmission revolution
sensor.
10. REMOVE REVERSE IDLER GEAR SHAFT BOLT
1. Remove the reverse idler gear shaft lock bolt with the gasket from the
transmission case.
11. REMOVE MANUAL TRANSMISSION CASE

2. Using a brass bar and hammer, tap the projection of the transmission case and
remove the case.
3. Remove the shim from the transmission case.
12. REMOVE SHIFT HEAD SET SLOTTED SPRING PIN
1. Using a pin punch and hammer, drive out the 2 slotted spring pins out of gear
shift heads No. 1 and No. 3.
13. REMOVE GEAR SHIFT FORK SHAFT NO.1
1. Remove the set bolt from gear shift fork No. 1.

2. Pull out gear shift fork shaft No.1 and the snap ring from the transaxle case.
3. Remove gear shift head No.1 and gear shift fork No. 1.
4. Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork
shaft No. 1.
1. Using a magnetic finger, remove the straight pin from gear shift fork No. 3.
2. Using 2 screwdrivers and a hammer, remove the 2 snap rings from gear shift fork
shaft No. 3.
3. Cover gear shift fork shaft No.3 with a piece of cloth gear shift fork shaft No. 3 at
the upper edge with pliers as shown in the illustration, and pull gear shift fork
shaft No. 3 out of the transaxle case to remove gear shift fork No. 3, compression
spring and gear shift head No. 3.
15. REMOVE REVERSE IDLER GEAR SHAFT
1. Remove the reverse idler gear shaft from the transaxle case.
16. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Remove the 2 bolts and reverse shift arm bracket from the transaxle case.
1. Using a magnetic finger, remove the straight pin from the reverse shift fork.
2. Shift hub sleeve No. 2 into the 3rd gear, as shown.
3. Remove the set bolt from gear shift fork No. 2.

4. Pull out gear shift fork snap rings, gear shift fork and the reverse shift fork from
the transaxle case.
shaft No. 2.
6. Remove the reverse shift fork from gear shift fork shaft No. 2.
shaft No. 2.
8. Remove gear shift fork No. 2 from gear shift fork shaft No. 2.
18. REMOVE INPUT SHAFT
1. Remove the input shaft assembly from the manual transaxle case.
19. REMOVE OUTPUT SHAFT

1. Remove the output shaft assembly from the manual transaxle case.
20. REMOVE FRONT DIFFERENTIAL CASE
1. Remove the differential case assembly from the front transaxle case.
21. REMOVE OIL RECEIVER PIPE NO. 2
1. Remove the oil receiver pipe No. 2 from the manual transmission case.
NOTICE:
Do not damage oil receiver pipe No. 2.
22. REMOVE TRANSMISSION MAGNET
1. Remove the transmission magnet from the front transaxle case.
23. REMOVE FRONT TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the front transaxle case oil seal.
24. REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST, remove the output shaft front bearing (outer race) from the front
transaxle case.
SST
09308-00010
25. REMOVE OUTPUT SHAFT COVER
1. Remove the output shaft cover from the front transaxle case.
26. REMOVE TRANSMISSION CASE OIL SEAL
1. Using a screwdriver, remove the transmission case oil seal.
27. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing and the
shim.
SST
09950-60010 (09951-00560)
09950-70010 (09951-07200)
28. REMOVE TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the transaxle case oil seal from the front transaxle
case.
29. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using a brass bar and hammer, remove the front differential case front tapered
roller bearing.
30. REMOVE INPUT SHAFT REAR BEARING SHIM
1. Remove the input shaft rear bearing shim.
31. REMOVE OUTPUT SHAFT REAR BEARING
1. Using SST, remove the output shaft rear bearing.
SST
09527-30010
09612-65014 (09612-01030, 09612-01050)
32. REMOVE OUTPUT SHAFT REAR BEARING SHIM
1. Remove the output shaft rear bearing shim.
MULTI-MODE MANUAL
TRANSAXLE UNIT > INSPECTION
for Preparation
1. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
1. Using a micrometer, measure the outer diameter of the reverse idler gear shaft.
Standard outer diameter:
15.97 to 15.98 mm (0.6287 to 0.6291 in.)
Minimum outer diameter:
15.97 mm (0.6287 in.)
If the outer diameter is less than the minimum, replace the reverse idler gear shaft.
2. Using a caliper gauge, measure the inside diameter of the reverse idler gear.
Standard inside diameter:
16.04 to 16.05 mm (0.6315 to 0.6319 in.)
Maximum inside diameter:
16.05 mm (0.6319 in.)
If the inside diameter exceeds the maximum, replace the reverse idler gear.
2. INSPECT REVERSE SHIFT FORK
1. Using a caliper gauge, measure the inside diameter of the reverse shift fork.
14.27 to 14.42 mm (0.5591 to 0.5677 in.) for A
14.01 to 14.03 mm (0.5516 to 0.5524 in.) for B
14.42 mm (0.5677 in.) for A
14.03 mm (0.5524 in.) for B
If the inside diameter exceeds the maximum, replace the reverse shift fork.
3. INSPECT GEAR SHIFT FORK SHAFT NO.1
1. Using a micrometer, measure the outer diameter of gear shift fork shaft No. 1.
13.97 to 13.98 mm (0.5500 to 0.5504 in.)
13.97 mm (0.5500 in.)
If the outer diameter is less than the minimum, replace gear shift fork shaft No. 1.

13.97 to 13.98 mm (0.5500 to 0.5504 in.)
13.97 mm (0.5500 in.)
13.97 to 13.98 mm (0.5500 to 0.5504 in.)
13.97 mm (0.5500 in.)
6. INSPECT GEAR SHIFT FORK NO.1
1. Using vernier calipers, measure the inside diameter of gear shift fork No. 1.
Standard inside diameter and thickness:
9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A
9.9 to 10.0 mm (0.3898 to 0.3937 in.) for B
14.00 to 14.02 mm (0.5512 to 0.5520 in.) for C
If the inside diameter and thickness are outside the specifications, replace gear
shift fork No. 1.
9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A

14.00 to 14.02 mm (0.5512 to 0.5520 in.) for B
shift fork No. 2.
9.9 to 10.0 mm (0.3898 to 0.3937 in.) for A
14.00 to 14.02 mm (0.5512 to 0.5520 in.) for B
shift fork No. 3.
9. INSPECT GEAR SHIFT HEAD NO.1
1. Using vernier calipers, measure the inside diameter of gear shift head No. 1.
14.00 to 14.05 mm (0.5512 to 0.5531 in.)
14.05 mm (0.5531 in.)
If the inside diameter exceeds the maximum, replace gear shift head No. 1.
10. INSPECT GEAR SHIFT HEAD NO.3
1. Using vernier calipers, measure the inside diameter of gear shift head No. 3.
14.00 to 14.05 mm (0.5512 to 0.5531 in.) for A
14.2 to 14.4 mm (0.5591 to 0.5669 in.) for B

14.05 mm (0.5531 in.) for A
14.4 mm (0.5669 in.) for B
If the inside diameter exceeds the maximum, replace gear shift head No. 3.
MULTI-MODE MANUAL
TRANSAXLE UNIT >
REASSEMBLY
for Preparation
1. INSTALL TRANSAXLE CASE STRAIGHT PIN
1. Install the transaxle case straight pin.

Standard depth:
10.5 to 11.5 mm (0.4134 to 0.4528 in.)
2. INSTALL OUTPUT SHAFT COVER
1. Install the output shaft cover as shown in the illustration.
3. INSTALL OUTPUT SHAFT FRONT BEARING
1. Using SST and a press, press in the output shaft front bearing (outer race).
SST
09950-60010 (09951-00510)
09950-70010 (09951-07150)
4. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, press in the front differential case front tapered roller
bearing (outer race).
SST
09350-32014 (09351-32111, 09351-32130)
5. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Install the shim onto the manual transmission case.

HINT:
When re-using the output shaft rear tapered roller bearing, first install a shim of
the same thickness as before. If installing a new output shaft rear tapered roller
bearing, first select and install a shim which is thinner than the original.
2. Using SST and a press, press in the FR differential case rear tapered roller bearing
(outer race).
SST
09950-60010 (09951-00620)
09950-70010 (09951-07100)
6. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
1. Coat the differential case assembly with gear oil, and install it onto the front
transaxle case.
2. Install the manual transmission case with the 13 bolts.

Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
HINT:
Manual transmission case side: 8 bolts
Front transaxle case side: 5 bolts
3. Using SST and a torque wrench, turn the differential case assembly right and left
2 or 3 times to allow the bearings to settle.
SST
09564-32011
4. Using SST and a torque wrench, measure the preload.
SST
09564-32011
Preload (at starting):
New bearing:
0.78 to 1.57 N*m (7.95 to 16.00 kgf*cm, 6.9 to 13.89 in.*lbf)
Used bearing:
0.49 to 0.98 N*m (5.00 to 9.99 kgf*cm, 4.3 to 8.67 in.*lbf)
5. Select another shim.
Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)

AA
2.10 (0.0827)
HH
2.45 (0.0965)
QQ
2.80 (0.1102)
BB
2.15 (0.0847)
JJ
2.50 (0.0984)
RR
2.85 (0.1122)
CC
2.20 (0.0866)
KK
2.55 (0.1004)
SS
2.90 (0.1142)
DD
2.25 (0.0886)
LL
2.60 (0.1024)
TT
2.95 (0.1161)
EE
2.30 (0.0906)
MM
2.65 (0.1043)
UU
3.00 (0.1181)
FF
2.35 (0.0925)
NN
2.70 (0.1063)
GG
2.40 (0.0945)
PP
2.75 (0.1083)
6. Remove the 13 bolts and the manual transmission case from the front transaxle
case.
7. INSTALL OUTPUT SHAFT REAR BEARING
1. Install the output shaft rear bearing shim onto the manual transmission case.
HINT:
When re-using the output shaft rear tapered roller bearing, first install a shim of
the same thickness as before. If installing a new output shaft rear tapered roller
bearing, first select and install a shim which is thinner than the original.
2. Using SST and a press, press in the output shaft rear bearing (outer race).
SST
09950-60010 (09951-00570)
09950-70010 (09951-07200)
8. ADJUST OUTPUT SHAFT BEARING PRELOAD
1. Install the output shaft assembly and the differential case assembly onto the front
transaxle case.
2. Install the manual transmission case onto the front transaxle case with the 13
bolts.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
3. Using SST and a torque wrench, turn the output shaft assembly and differential
case assembly right and left 2 or 3 times to allow the bearings to settle.
SST
09564-32011
4. Using SST and a torque wrench, measure the preload.
SST
09564-32011
Preload (at starting):
New bearing:
3.46 to 6.91 N*m (35.3 to 70.5 kgf*cm, 30.6 to 61.2 in.*lbf) for 1KR-FE
3.18 to 6.35 N*m (32.4 to 64.7 kgf*cm, 28.1 to 56.2 in.*lbf) for 2SZ-FE
Used bearing:
2.16 to 4.32 N*m (22.0 to 44.1 kgf*cm, 19.1 to 38.2 in.*lbf) for 1KR-FE
1.98 to 3.97 N*m (20.2 to 40.5 kgf*cm, 17.5 to 35.1 in.*lbf) for 2SZ-FE
5. Select another output shaft rear bearing shim.
Mark
Thickness
Thickness
Mark
mm (in.)
mm (in.)
1.55
(0.0610)
1.95
(0.0768)
1.60
(0.0630)
2.00
(0.0787)
1.65
(0.0650)
2.05
(0.0807)
1.70
2.10
(0.0669)
(0.0827)
1.75
(0.0689)
2.15
(0.0846)
1.80
(0.0709)
2.20
(0.0866)
1.85
(0.0728)
2.25
(0.0886)
1.90
(0.0748)
6. Remove the 13 bolts and the manual transmission case from the front transaxle
case.
7. Remove the output shaft assembly from the front transaxle case.
9. INSTALL INPUT SHAFT REAR BEARING SHIM
1. Using vernier calipers, accurately measure dimensions A and B.

2. Select an input shaft rear bearing shim that brings the value within the
specifications.
Shim thickness:
Shim thickness (B - A) should be more than 0 mm (0 in.) and less than 0.1 mm
(0.0039 in.)
Thickness
Thickness
Mark
Mark
mm (in.)
mm (in.)
F
1.80
(0.0709)
2.15
(0.0846)
1.85
(0.0728)
2.20
(0.0866)
1.90
(0.0748)
2.25
(0.0886)
1.95
(0.0768)
2.30
(0.0906)
2.00
2.35
(0.0787)
(0.0925)
2.05
(0.0807)
2.40
(0.0945)
2.10
(0.0827)
3. Install the input shaft rear bearing shim.
10. INSTALL TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, install a new transmission case oil seal into the manual
transmission case.
SST
09950-60010 (09951-00370)
09950-70010 (09951-07150)
Drive in depth:
2.1 to 3.1 mm (0.083 to 0.122 in.)
2. Coat the tip of the transmission oil seal with MP grease.
11. INSTALL TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, install the transaxle case oil seal to the front transaxle
case.
SST
09316-60011 (09316-00011)
Drive in depth:
1.7 to 2.7 mm (0.067 to 0.106 in.)
2. Coat the tip of the transmission case oil seal with MP grease.
12. INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, install the front transaxle case oil seal into the front
transaxle case.
SST
09710-20011 (09710-06071)
09950-70010 (09951-07150)
Drive in depth:
14.4 to 15.4 mm (0.567 to 0.606 in.)
2. Coat the tip of the front transaxle case oil seal with MP grease.
13. INSTALL TRANSMISSION MAGNET
1. Clean the transmission magnet and then install it onto the front transaxle case.
14. INSTALL OIL RECEIVER PIPE NO. 2
1. Install oil receiver pipe No. 2 onto the manual transmission case.
NOTICE:
Do not damage oil receiver pipe No. 2.
15. INSTALL FRONT DIFFERENTIAL CASE
1. Coat the differential case tapered roller bearings with gear oil, and install them
onto the front transaxle case.
16. INSTALL OUTPUT SHAFT
1. Install the output shaft assembly onto the front transaxle case.
17. INSTALL INPUT SHAFT
1. Coat the sliding and rotating surfaces of the input and output shafts assembly with
gear oil, and install them onto the front transaxle case.
18. INSTALL GEAR SHIFT FORK SHAFT NO.2
1. Install gear shift fork No. 2 onto gear shift fork shaft No. 2.
2. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft
No. 2.
3. Install the reverse shift fork onto gear shift fork shaft No. 2.
No. 2.
5. Shift hub sleeve No. 2 into the 3rd gear, as shown.
6. Install gear shift fork shaft No. 2 with the 2 snap rings.
7. Install gear shift fork No.2 and reverse shift fork onto the transaxle case.
8. Set gear shift fork No. 2 onto hub sleeve No. 2.
9. Install the set bolt onto gear shift fork No. 2.
Torque:
16 N*m{ 160 kgf*cm , 12 ft.*lbf }
10. Using a magnetic finger, install the straight pin into the reverse shift fork.
NOTICE:
Insert the straight pin along the groove on gear shift fork shaft No. 2, as shown in
the illustration.
19. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Install the reverse shift arm bracket onto the transaxle case with the 2 bolts.
Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
NOTICE:
Fit the edge of the reverse shift fork into the hole in the reverse shift arm bracket.
20. INSTALL REVERSE IDLER GEAR SHAFT
1. Coat the reverse idler gear shaft with gear oil, and install it onto the transmission
case.
NOTICE:
Set the top of the reverse shift arm bracket into the groove on the reverse idler
gear, as shown in the illustration.
2. Align the mark on the reverse idler gear shaft with the bolt hole, as shown in the
illustration.
1. Install gear shift fork No. 3, the compression spring and gear shift head No. 3 onto
gear shift fork shaft No. 3.
2. Install gear shift fork shaft No. 3 onto the transaxle case together with gear shift
fork No. 3, the compression spring and shift head No. 3.
3. Set gear shift fork No. 3 onto hub sleeve No. 3.
4. Using a screwdriver and hammer, tap 2 new snap rings onto gear shift fork shaft
No. 3.
5. Using a magnetic finger, install the straight pin onto gear shift fork No. 3.
No. 1.
2. Set gear shift fork No. 1 onto the reverse gear.

3. Set gear shift head No. 1 onto gear shift fork No. 1.
4. Install gear shift fork shaft No. 1 onto the transaxle case with the snap ring.
NOTICE:
Insert the straight pin along the groove on gear shift fork shaft No. 1, as shown in
the illustration.
5. Install the set bolt onto gear shift fork No. 1.
Torque:
16 N*m{ 160 kgf*cm , 12 ft.*lbf }
23. INSTALL SHIFT HEAD SET SLOTTED SPRING PIN
1. Using a pin punch and hammer, tap the 2 slotted spring pins into the No. 1 and
No. 3 gear shift heads.
Drive in depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
24. INSTALL INPUT SHAFT REAR BEARING SHIM
1. Install the input shaft rear bearing shim onto the transmission case.
HINT:
Install the previously selected shim.
25. INSTALL MANUAL TRANSMISSION CASE
1. Apply FIPG to the transmission case, as shown in the illustration.

FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
NOTICE:
Assemble the parts within 10 minutes of application.
2. Coat the 13 bolts with sealant.

Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
3. Install the transmission case onto the transaxle case with the 13 bolts.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
26. INSTALL REVERSE IDLER GEAR SHAFT BOLT
1. Apply sealant to the reverse idler gear shaft lock bolt threads.
Sealant:
2. Install the reverse idler gear shaft lock bolt with a new gasket.
Torque:
29 N*m{ 300 kgf*cm , 22 ft.*lbf }
27. INSTALL TRANSMISSION REVOLUTION SENSOR
1. Install a new O-ring onto the transmission revolution sensor.

2. Install the transmission revolution sensor with the bolt.
Torque:
7.8 N*m{ 80 kgf*cm , 69 in.*lbf }
3. Install the transmission case protector with the bolt.
Torque:
18 N*m{ 185 kgf*cm , 13 ft.*lbf }
28. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY
1. Apply FIPG to the transmission case as shown.

FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
2. Apply sealant to the actuator set bolt threads.
Sealant:
3. Install the shift and select actuator with the 6 bolts and wire harness clamp.
Torque:
18 N*m{ 184 kgf*cm , 13 ft.*lbf }
29. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Using SST, install the park/neutral position switch with a new gasket onto the
transaxle case.
Torque:
40 N*m{ 410 kgf*cm , 30 ft.*lbf }
SST
09817-16011
30. INSTALL LOCK BALL ASSEMBLY NO.1
1. Apply sealant to the lock ball assembly threads.

Sealant:

2. Using an 18 mm socket wrench, install the lock ball assembly onto the
transmission case.
Torque:
37 N*m{ 375 kgf*cm , 27 ft.*lbf }
31. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
1. Using SST, install the back-up light switch with a new gasket onto the transaxle
case.
SST
09817-16011
Torque:
40 N*m{ 410 kgf*cm , 30 ft.*lbf }
32. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL
33. INSTALL CLUTCH RELEASE FORK
34. INSTALL SHIFT STROKE SENSOR
INPUT SHAFT > COMPONENTS

for Preparation
1/2
2/2
INPUT SHAFT > DISASSEMBLY

for Preparation
1. INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance:
0.35 mm (0.0138 in.)
If the clearance exceeds the maximum, replace the 3rd gear synchronizer ring.
2. INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance:
0.10 to 0.50 mm (0.0039 to 0.0197 in.)
Maximum clearance:
0.50 mm (0.0197 in.)
If the clearance exceeds the maximum, replace the 5th gear synchronizer ring.
3. INSPECT 3RD GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 3rd gear radial clearance.

Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing
or the shaft.
4. INSPECT 4TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 4th gear radial clearance.

Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 4th gear needle roller bearing
or the shaft.

Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)

Maximum clearance:
0.058 mm (0.0023 in.)
or the shaft.
6. REMOVE 5TH GEAR
1. Using SST and a press, remove the input shaft rear radial ball bearing, hub sleeve
No. 3, 5th gear synchronizer ring and 5th gear from the input shaft.
SST
09950-00020
09612-24014 (09612-10061)
HINT:
Support the input shaft by hand to prevent it from dropping off.

Set the claw of SST between the 4th gear and 5th gear, as shown in the
illustration.
NOTICE:
Do not excessively tighten SST.
7. REMOVE TRANSMISSION CLUTCH HUB NO.3
1. Remove the 2 shifting key springs No. 1 from the transmission clutch hub No. 3.
2. Remove the transmission hub sleeve No. 3 from the transmission clutch hub No.
3.
3. Remove the 3 shifting keys No. 3 from the transmission clutch hub No. 3.
8. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
1. Remove the 5th gear needle roller bearing from the input shaft.
9. REMOVE 5TH GEAR BEARING SPACER
1. Remove the 5th gear bearing spacer from the input shaft.

Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance:
0.55 mm (0.0217 in.)

11. REMOVE 5TH GEAR SHAFT SNAP RING
1. Using a snap ring expander, remove the 5th gear shaft snap ring from the input
shaft.
HINT:
Do not damage the journal surface of the input shaft.
12. REMOVE 5TH GEAR THRUST WASHER
1. Remove the 5th gear thrust washer from the input shaft.
13. REMOVE 5TH GEAR THRUST WASHER BALL
1. Using a magnetic finger, remove the ball from the input shaft.
14. REMOVE 4TH GEAR
1. Remove the 4th gear from the input shaft.
15. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
1. Remove the 4th gear needle roller bearing from the input shaft.
16. REMOVE 4TH GEAR BEARING SPACER
1. Remove the 4th gear bearing spacer from the input shaft.
17. REMOVE 4TH GEAR SYNCHRONIZER RING
1. Remove the 4th gear synchronizer ring from the clutch hub No. 2.
18. REMOVE CLUTCH HUB NO.2 SETTING SHAFT SNAP RING
1. Using a snap ring expander, remove the clutch hub No. 2 setting shaft snap ring
from the input shaft.
HINT:
19. REMOVE 3RD GEAR
1. Using SST and a press, remove the hub sleeve No. 2, 3rd gear synchronizer ring
and 3rd gear from the input shaft.
SST
09950-00020
NOTICE:
Do not excessively tighten SST.

Support the input shaft by hand to prevent it from dropping off
1. Remove the 2 shifting key springs No. 1 from the transmission clutch hub No. 2.
2. Remove the transmission hub sleeve No. 2 from the transmission clutch hub No.
2.
3. Remove the 3 shifting keys No. 2 from the transmission clutch hub No. 2.
21. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
1. Remove the 3rd gear needle roller bearing from the input shaft.
22. REMOVE INPUT SHAFT FRONT BEARING
1. Using a press, remove the input shaft front bearing from the input shaft.
SST
09950-00020
HINT:
Support the input shaft by hand to prevent it from dropping off.
INPUT SHAFT > INSPECTION

for Preparation
1. INSPECT INPUT SHAFT
1. Check the input shaft for wear and damage.

2. Using a dial indicator, check the input shaft runout.
Maximum runout:
0.03 mm (0.0012 in.)
If the runout exceeds the maximum, replace the input shaft.
3. Using a micrometer, measure the outer diameter of the input shaft journal surface.
Standard:
Measured
Part
Outer Diameter mm
(in.)
25.502 to 25.515
(1.0040 to 1.00453)
30.985 to 31.000
(1.2199 to 1.2205)
C, D
33.985 to 34.000
(1.3380 to 1.3386)
23.002 to 23.015
(0.9056 to 0.9091)
22.967 to 23.000
(0.9042 to 0.9055)
If the outer diameters are below the minimum, replace the input shaft.
2. INSPECT 3RD GEAR
1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.
39.015 to 39.031 mm (1.5360 to 1.5367 in.)
39.031 mm (1.5367 in.)
If the inside diameter exceeds the maximum, replace the 3rd gear.
3. INSPECT 4TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
39.015 to 39.031 mm (1.5360 to 1.5367 in.)
39.031 mm (1.5367 in.)

If the inside diameter exceeds the maximum, replace the 4th gear.
4. INSPECT 5TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 5th gear.
36.015 to 36.031 mm (1.4179 to 1.4185 in.)
36.031 mm (1.4185 in.)
If the inside diameter exceeds the maximum, replace the 5th gear.
5. INSPECT 3RD GEAR SYNCHRONIZER RING
1. Check for wear and damage.

2. Coat the 3rd gear cone with gear oil.
3. Turn the 3rd gear synchronizer ring in one direction while pushing it against the
3rd gear cone.
4. Check that the ring locks.
If the synchronizer ring does not lock, replace the synchronizer ring or the 3rd
gear.
5. Using a feeler gauge, measure the clearance between the synchronizer ring back
and the gear spline end.
Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 3rd
gear.
6. INSPECT 4TH GEAR SYNCHRONIZER RING

2. Coat the 4th gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 4th gear
cone.
If the synchronizer ring does not lock, replace the synchronizer ring or the 4th
gear.
Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 4th
gear.
7. INSPECT 5TH GEAR SYNCHRONIZER RING
2. Coat the 5th gear cone with gear oil.

3. Turn the synchronizer ring in one direction while pushing it against the 5th gear
cone.
If the synchronizer ring does not lock, replace the synchronizer ring or the 5th
gear.
Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 5th
gear.
8. INSPECT TRANSMISSION HUB SLEEVE NO.2
1. Using vernier calipers, measure the clearance between the transmission hub
sleeve No. 2 and the shift fork No. 2.
Standard clearance (A-B):
0.15 to 0.35 mm (0.0059 to 0.0138 in.)
If the clearance is outside the specifications, replace the transmission hub sleeve
No. 2 and gear shift fork No. 2.
9. INSPECT TRANSMISSION HUB SLEEVE NO.3
1. Using vernier calipers, measure the clearance between the transmission hub
sleeve No. 3 and the shift fork No. 3.
0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is outside the specifications, replace the transmission hub sleeve
No. 3 and gear shift fork No. 3.
INPUT SHAFT > REASSEMBLY

for Preparation
1. INSTALL INPUT SHAFT FRONT BEARING
1. Using SST and a press, install a new input shaft front bearing onto the input shaft.
SST
09515-10010
2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
1. Coat the 3rd gear needle roller bearing with gear oil, and install it onto the input
shaft.
3. INSTALL 3RD GEAR
1. Coat the 3rd gear with gear oil, and install it onto the input shaft.
4. INSTALL 3RD GEAR SYNCHRONIZER RING
1. Coat the 3rd gear synchronizer ring with gear oil, and install it onto the 3rd gear.
5. INSTALL TRANSMISSION CLUTCH HUB NO.2
1. Install the 3 shifting keys No. 2, 2 shifting key springs and transmission hub
sleeve No. 2 onto the clutch hub No. 2.
NOTICE:
Assemble the transmission hub sleeve No. 2 and transmission clutch hub No. 2 in
the correct orientations, as shown in the illustration.
2. Using SST and a press, install the transmission clutch hub sleeve No. 2 onto the
input shaft.
SST
09506-35010
6. INSTALL CLUTCH HUB NO.2 SETTING SHAFT SNAP RING
1. Select a snap ring that allows the minimum axial play.

Standard clearance:
0.1 mm (0.0039 in.) or less.
Thickness
Thickness
Mark
Mark
mm (in.)
mm (in.)
A
2.28
(0.0898)
2.46
(0.0969)
2.34
(0.0921)
2.52
(0.0992)
2.40
(0.0945)
2.58
(0.1016)
2. Using a snap ring expander, install the new snap ring onto the input shaft.
HINT:
7. INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum clearance:
0.35 mm (0.0138 in.)
If the clearance exceeds the maximum, replace the 3rd gear synchronizer ring.
8. INSPECT 3RD GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 3rd gear radial clearance.

Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing
or the shaft.
9. INSTALL 4TH GEAR SYNCHRONIZER RING
1. Coat the 4th gear synchronizer ring with gear oil, and install it onto transmission
clutch hub No. 2.
10. INSTALL 4TH GEAR BEARING SPACER
1. Coat the 4th gear bearing spacer with gear oil, and install it onto the input shaft.
11. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
1. Coat the 4th gear needle roller bearing with gear oil, and install it onto the input
shaft.
12. INSTALL 4TH GEAR
1. Coat the 4th gear with gear oil, and install it onto the input shaft.
13. INSTALL 5TH GEAR THRUST WASHER BALL
1. Install the 5th gear thrust washer ball onto the input shaft.
14. INSTALL 5TH GEAR THRUST WASHER
1. Coat the 5th gear thrust washer with gear oil, and install it onto the input shaft.
15. INSTALL 5TH GEAR SHAFT SNAP RING
1. Select a snap ring, using the table below, that makes the thrust clearance of the
5th gear thrust washer less than 0.1 mm (0.0039 in.).
Mark
Thickness
mm (in.)
Mark
Thickness
mm (in.)
2.28
(0.0898)
2.46
(0.0969)
2.34
(0.0921)
2.52
(0.0992)
2.40
(0.0945)
2.58
(0.1016)
2. Using a snap ring expander, install a new snap ring onto the input shaft.
HINT:
Standard clearance:
0.1 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance :
0.55 mm (0.0217 in.)

Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
or the shaft.
18. INSTALL 5TH GEAR BEARING SPACER
1. Coat the 5th gear bearing spacer with gear oil, and install it onto the input shaft.
19. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
1. Coat the 5th gear needle roller bearing with gear oil, and install it onto the input
shaft.
20. INSTALL 5TH GEAR
1. Coat the 5th gear with gear oil, and install it onto the input shaft.
21. INSTALL 5TH GEAR SYNCHRONIZER RING
1. Coat the 5th gear synchronizer ring with gear oil, and install it onto the 5th gear.
1. Install the 3 shifting keys No. 3, 2 shifting key springs No. 1 and transmission hub
sleeve No. 3 onto the transmission clutch hub No. 3.
NOTICE:
Assemble the transmission hub sleeve No. 3 and the transmission clutch hub No.
3 in the correct orientations, as shown in the illustration.
2. Place the 5th gear synchronizer ring on the 5th gear, and align the synchronizer
ring slots with the shifting keys No. 3.
3. Using SST and a press, press the No. 3 hub sleeve into the input shaft.
SST
09515-10010
NOTICE:
Install the transmission hub sleeve No. 3 in the correct orientation, as shown in
the illustration.
23. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING
1. Using SST and a press, install a new input shaft rear radial ball bearing onto the
input shaft.
SST
09515-10010
Standard clearance:
0.10 to 0.50 mm (0.0039 to 0.0197 in.)
Maximum clearance:
0.50 mm (0.0197 in.)

Standard clearance:
0.015 to 0.058 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
or the shaft.
OUTPUT SHAFT > COMPONENTS

for Preparation
1/2
2/2
OUTPUT SHAFT > DISASSEMBLY

for Preparation
1. REMOVE OUTPUT SHAFT REAR BEARING
1. Using SST and a press, remove the output shaft rear bearing.
SST
09950-60010 (09951-00220)
09950-70010 (09951-07100)
2. INSPECT 1ST GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 1st gear thrust clearance.

Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance:
0.45 mm (0.0177 in.)

If the clearance exceeds the maximum, replace the 1st gear synchronizer ring.
3. INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 2nd gear thrust clearance.

Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance:
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the 2nd gear synchronizer ring.
4. INSPECT 1ST GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 1st gear radial clearance.

Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:
0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 1st gear needle roller bearing
or the shaft.
5. INSPECT 2ND GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 2nd gear radial clearance.

Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:
0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing
or the shaft.
6. REMOVE COUNTER 5TH GEAR SHAFT SNAP RING
1. Using 2 screwdrivers and a hammer, remove the counter 5th gear shaft snap ring
from the output shaft.
7. REMOVE 4TH DRIVEN GEAR
1. Using a press, remove the 5th driven gear and 4th driven gear from the output
shaft.
8. REMOVE OUTPUT SHAFT SPACER
1. Remove the output shaft spacer from the output shaft.
9. REMOVE 2ND GEAR
1. Using SST and a press, remove the 3rd driven gear and 2nd gear from the output
shaft.
SST
09950-00020
10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
1. Remove the 2nd gear needle roller bearing from the output shaft.
11. REMOVE 2ND GEAR BEARING SPACER
1. Remove the 2nd gear bearing spacer from the output shaft.
12. REMOVE 2ND GEAR SYNCHRONIZER RING
1. Remove the 2nd gear synchronizer ring from the reverse gear.
13. REMOVE CLUTCH HUB NO.1 SHAFT SNAP RING
1. Using 2 screwdrivers, remove the clutch hub No. 1 shaft snap ring from the output
shaft.
HINT:
Do not damage the journal surface of the output shaft.
14. REMOVE 1ST GEAR
1. Using a press, remove the transmission clutch hub No. 1 and 1st gear from the
output shaft.
15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
1. Remove the 1st gear needle roller bearing from the output shaft.
16. REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST and a press, remove the output shaft front bearing from the output
shaft.
SST
09950-00020
1. Remove the 2 shifting key springs No. 1, 3 shifting keys No. 1 and reverse gear
from the transmission clutch hub No. 1.
OUTPUT SHAFT > INSPECTION

for Preparation
1. INSPECT OUTPUT SHAFT
1. Using a dial indicator, check the shaft runout.

Maximum runout:
0.03 mm (0.0012 in.)
If the runout exceeds the maximum, replace the output shaft.
2. Using a micrometer, measure the outer diameter of the output shaft journal
surface.
Standard:
Measured
Part
Outer Diameter mm
(in.)
23.002 to 23.015
(0.9056 to 0.9061)
B, C
28.3 (1.1142)
D, E
33.985 to 34.000
(1.3380 to 1.3386)
25.002 to 25.015
(0.9843 to 0.9847)
If the outer diameters are below the minimum, replace the input shaft.
2. INSPECT 1ST GEAR
1. Using a cylinder gauge, measure the inside diameter of the 1st gear.
39.015 to 39.031 mm (1.5360 to 1.5367 in.)
39.031 mm (1.5637 in.)
If the inside diameter exceeds the maximum, replace the 1st gear.
3. INSPECT 2ND GEAR
1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.
39.015 to 39.031 mm (1.5360 to 1.5367 in.)
39.031 mm (1.5367 in.)

If the inside diameter exceeds the maximum, replace the 2nd gear.
4. INSPECT 1ST GEAR SYNCHRONIZER RING

2. Coat the 1st gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 1st gear
cone.
If the synchronizer ring does not lock, replace the synchronizer ring or the 1st
gear.
Standard clearance:
0.8 to 1.6 mm (0.031 to 0.063 in.)
Minimum clearance:
0.80 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 1st
gear.
5. INSPECT 2ND GEAR SYNCHRONIZER RING
2. Coat the 2nd gear cone with gear oil.

3. Turn the synchronizer ring in one direction while pushing it against the 2nd gear
cone.
If the synchronizer ring does not lock, replace the synchronizer ring or the 2nd
gear.
Standard clearance:
0.8 to 1.6 mm (0.031 to 0.063 in.)
Minimum clearance:
0.80 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchronizer ring or the 2nd
gear.
6. INSPECT REVERSE GEAR
1. Using vernier calipers, measure the clearance between the reverse gear and the
reveres gear fork.
0.15 to 0.35 mm (0.0059 to 0.0138 in.)
If the clearance is outside the specifications, replace the reverse gear fork and
reverse gear.
OUTPUT SHAFT > REASSEMBLY

for Preparation
1. INSTALL OUTPUT SHAFT FRONT BEARING
1. Using SST and a press, install the output shaft front bearing onto the output shaft.
SST
09710-22021 (09710-01051)
2. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
1. Coat the 1st gear needle roller bearing with gear oil, and install it onto the output
shaft.
3. INSTALL 1ST GEAR
1. Coat the 1st gear with gear oil, and install it onto the output shaft.
4. INSTALL 1ST GEAR SYNCHRONIZER RING
1. Coat the 1st gear synchronizer ring with gear oil, and install it onto the 1st gear.
1. Install 2 shifting key springs No. 1, 3 shifting keys No. 1 and the reverse gear
onto the transmission clutch hub No. 1.
2. Using SST and a press, install the transmission clutch hub No. 1 onto the output
shaft.
SST
09316-60011 (09316-00011, 09316-00071)
NOTICE:
Install the reverse gear assembly in the correct orientation, as shown in the
illustration.
6. INSTALL CLUTCH HUB NO.1 SHAFT SNAP RING
1. Select a snap ring that allows the minimum axial play.

Standard clearance:
0 to 0.1 mm (0 to 0.0039 in.)
Mark Thickness Mark Thickness
mm (in.)
mm (in.)
2.28
(0.0898)
2.46
(0.0969)
2.34
(0.0921)
2.52
(0.0992)
2.40
(0.0945)
2.58
(0.1016)
2. Using a snap ring expander, install the new snap ring onto the output shaft.
7. INSPECT 1ST GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 1st gear thrust clearance.

Standard clearance:
0.10 to 0.45 mm (0.0039 to 0.0177 in.)
Maximum clearance:
0.45 mm (0.0177 in.)
If the clearance exceeds the maximum, replace the 1st gear synchronizer ring.
8. INSPECT 1ST GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 1st gear radial clearance.

Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:
0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 1st gear needle roller bearing
or the shaft.
9. INSTALL 2ND GEAR BEARING SPACER
1. Coat the 2nd gear bearing spacer with gear oil and install it onto the output shaft.
10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
1. Coat the 2nd gear needle roller bearing with gear oil, and install it onto the output
shaft.
11. INSTALL 2ND GEAR SYNCHRONIZER RING
1. Coat the 2nd synchronizer ring with gear oil, and install it onto the reverse gear.
12. INSTALL 2ND GEAR
1. Coat the 2nd gear with gear oil, and install it onto the output shaft.
13. INSTALL 3RD DRIVEN GEAR
1. Using SST and a press, install the 3rd driven gear onto the output shaft.
SST
09316-60011 (09316-00041)
14. INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 2nd gear thrust clearance.

Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance :
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the 2nd gear synchronizer ring.
15. INSPECT 2ND GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 2nd gear radial clearance between the gear and
shaft.
Standard clearance:
0.015 to 0.056 mm (0.0006 to 0.0023 in.)
Maximum clearance:
0.056 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing
or the shaft.
16. INSTALL OUTPUT SHAFT SPACER
1. Install the output shaft spacer onto the output shaft.
17. INSTALL 4TH DRIVEN GEAR
1. Using SST and a press, install the 4th driven gear onto the output shaft.
SST
09223-00010
09316-60011 (09316-00021)
18. INSTALL 5TH DRIVEN GEAR
1. Using SST and a press, install the 5th driven gear onto the output shaft.
SST
09223-00010
09316-60011 (09316-00021)
19. INSTALL COUNTER 5TH GEAR SHAFT SNAP RING
1. Select a snap ring, using the table below, that makes the thrust clearance of the
5th driven gear less than 0.1 mm (0.0039 in.).
Mark
Thickness
Thickness
Mark
mm (in.)
mm (in.)
2.22
(0.0874)
2.52
(0.0992)
2.28
2.58
(0.0898)
(0.1016)
2.34
(0.0921)
2.64
(0.1039)
2.40
(0.0945)
2.70
(0.1063)
2.46
(0.0969)
2. Using a brass bar and hammer, tap the new snap ring onto the output shaft.
20. INSTALL OUTPUT SHAFT REAR BEARING
1. Using SST and a press, install the output shaft rear bearing onto the output shaft.
SST
09612-22011
DIFFERENTIAL CASE >

COMPONENTS
for Preparation
1/1
DIFFERENTIAL CASE >

DISASSEMBLY
for Preparation
1. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing.
SST
09950-00020
09950-00030
HINT:
Set the claw of SST to the bearing inner race at the indented part of the
differential case.
2. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing.
SST
09950-00020
09950-00030
3. REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place matchmarks on the front differential ring gear and the front differential
case.
2. Remove the 6 bolts. Using a hammer, remove the front differential ring gear from
the front differential case.
4. REMOVE FRONT DIFFERENTIAL CASE
1. Using a pin punch and hammer, remove the pinion shaft slotted spring pin.
2. Remove the pinion shaft from the differential case.

3. Remove the 2 pinion gears, 2 side gears and the 4 thrust washers from each gear.
DIFFERENTIAL CASE >

REASSEMBLY
for Preparation
1. INSTALL FRONT DIFFERENTIAL CASE
1. Install the appropriate thrust washers and side gears. Refer to the table below and
select thrust washers that bring the backlash to within the specifications. Select
washers of the same size for both sides.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Thickness mm (in.) Thickness mm (in.)
0.50 (0.0197)
0.75 (0.0295)
0.55 (0.0217)
0.80 (0.0315)
0.60 (0.0236)
0.85 (0.0335)
0.65 (0.0256)
0.90 (0.0354)
0.70 (0.0276)
0.95 (0.0374)
2. Install the thrust washers and the side gears into the differential case.
3. Install the pinion shaft.
4. Using a dial indicator, check the side gear backlash. Measure the side gear
backlash while holding one pinion gear toward the differential case.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is not within the specification, install a thrust washer of a different
thickness.
5. Using a pin punch and a hammer, install the pinion shaft slotted spring pin
through the front differential case and the hole in the pinion shaft.
6. Using a chisel and hammer, caulk the pin holes around the circumference of the
front differential case.
2. INSTALL FRONT DIFFERENTIAL RING GEAR
1. Using a heater, heat the front differential ring gear to 90 to 110C (194 to 230F).
2. Clean the contact surface of the front differential case.
3. Aligning the matchmarks, quickly install the front differential ring gear onto the
front differential case with the 6 bolts.
Torque:
124 N*m{ 1,260 kgf*cm , 91 ft.*lbf }
3. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case rear tapered roller
bearing.
SST
09350-32014 (09351-32120, 09351-32140)
4. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case front tapered roller
bearing.
SST
09350-32014 (09351-32120, 09351-32140)
SHIFT STROKE SENSOR >

COMPONENTS
for Preparation
1/2
2/2

REMOVAL
for Preparation
4. REMOVE BATTERY
8. REMOVE SHIFT STROKE SENSOR
2. Disconnect the shift stroke sensor connector.

3. Remove the 2 screws and the shift stroke sensor from the shift and select actuator.
4. Remove the O-ring from the shift stroke sensor.

INSPECTION
for Preparation
1. INSPECT SHIFT STROKE SENSOR
1. Connect the 3 dry batteries of 1.5 V in series.

2. Connect the battery positive (+) lead to terminal A and the negative (-) lead to
terminal B.
3. Turn the sensor arm and check the voltage between terminals B and C.
Reference: Voltage (Power source voltage at 4.5 V):
Sensor
Terminal (B - C) output
angle
voltage
55
4.05 V
2.25 V
-55
0.45 V
Voltage (Power source voltage at 4.7 to 5.3 V):
Sensor
angle
voltage
55
4.5 V
2.5 V
-55
NOTICE:
0.5 V
Do not apply more than 6 V.

Do not drop the clutch stroke sensor. If dropped, replace it with a new one.
If the voltage is not as specified, replace the stroke sensor.
INSTALLATION
for Preparation
1. INSTALL SHIFT STROKE SENSOR
1. Apply MP grease to a new O-ring.

2. Install the new O-ring onto the stroke sensor.
3. Set the stroke senor so that the sensor side and the actuator side sensor arms are in
the positions shown in the illustration.
4. Turn the stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m{ 20 kgf*cm , 18 in.*lbf }
5. Connect the shift stroke sensor connector.
6. Install the wire harness bracket onto the transaxle with the bolt.
Torque:
13 N*m{ 131 kgf*cm , 9.5 ft.*lbf }

Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }

Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
5. INSTALL BATTERY

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }
9. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION ECU

()
10. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM

()

()
SELECT STROKE SENSOR >

COMPONENTS
for Preparation
1/2
2/2

REMOVAL
for Preparation
4. REMOVE BATTERY
8. REMOVE SELECT STROKE SENSOR
2. Disconnect the select stroke sensor connector.

3. Remove the 2 screws and select stroke sensor from the shift and select actuator.
4. Remove the O-ring from the select stroke sensor.

INSPECTION
for Preparation
1. INSPECT SELECT STROKE SENSOR
1. Connect the 3 dry batteries of 1.5 V in series.

2. Connect the battery positive (+) lead to terminal A and the negative (-) lead to
terminal B.
3. Turn the sensor arm and check the voltage between terminals B and C.
Reference: Voltage (Power source voltage at 4.5 V):
Sensor
angle
voltage
55
4.05 V
2.25 V
-55
0.45 V
Voltage (Power source voltage at 4.7 to 5.3V):
Sensor
angle
voltage
55
4.5 V
2.5 V
-55
NOTICE:
0.5 V
Do not apply more than 6 V.

Do not drop the clutch stroke sensor. If dropped, replace it with a new one.
If the voltage is not as specified, replace the stroke sensor.
INSTALLATION
for Preparation
1. INSTALL SELECT STROKE SENSOR

2. Install the new O-ring onto the stroke sensor.
3. Set the stroke sensor so that the sensor side and the actuator side sensor arms are
in the positions shown in the illustration.
4. Turn the stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m{ 20 kgf*cm , 18 in.*lbf }
5. Connect the select stroke sensor connector.
6. Install the wire harness bracket onto the transaxle with the bolt
Torque:
13 N*m{ 131 kgf*cm , 9.5 ft.*lbf }

Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }

Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
5. INSTALL BATTERY

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }
9. INITIALIZATION OF MULTI-MODE MANUAL TRANSMISSION ECU

()
10. LEARNING OF MULTI-MODE MANUAL TRANSMISSION SYSTEM

()

()
TRANSMISSION REVOLUTION
SENSOR > COMPONENTS
for Preparation
1/1
SENSOR > REMOVAL
for Preparation

1. Remove the filler plug and the gasket.
2. Remove the drain plug and gasket and drain the transaxle oil.
3. Install a new gasket and the drain plug.
Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
2. REMOVE TRANSMISSION REVOLUTION SENSOR
1. Disconnect the revolution sensor connector.
2. Remove the bolt and transmission case protector.
3. Remove the bolt and transmission revolution sensor.

4. Using a screwdriver, remove the O-ring from the transmission revolution sensor.
SENSOR > INSPECTION
for Preparation
1. INSPECT TRANSMISSION REVOLUTION SENSOR
1. Using an ohmmeter, measure the resistance between the terminals.

560 to 680 at 20 C(68F)
If the resistance is not as specified, replace the revolution sensor.
SENSOR > INSTALLATION
for Preparation
1. INSTALL TRANSMISSION REVOLUTION SENSOR
1. Install a new O-ring onto the transmission revolution sensor.

2. Install the transmission revolution sensor with the bolt.
Torque:
7.8 N*m{ 80 kgf*cm , 69 in.*lbf }
3. Install the transmission case protector with the bolt.

Torque:
18 N*m{ 185 kgf*cm , 13 ft.*lbf }
4. Connect the revolution sensor connector.

NOTICE:


Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }
BACK-UP LIGHT SWITCH >

COMPONENTS
for Preparation
1/4
2/4
3/4
4/4

REMOVAL
for Preparation
4. REMOVE BATTERY
8. SUPPORT MULTI-MODE MANUAL TRANSAXLE ASSEMBLY
9. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KRFE)
10. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZFE)
11. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KRFE)
12. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZFE)
13. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Disconnect the back-up light switch connector.

2. Separate the back-up light switch wire harness from the 2 clamps.
3. Using SST, remove the back-up light switch and gasket from the transaxle case.
SST
09817-16011

INSPECTION
for Preparation
1. INSPECT BACK-UP LIGHT SWITCH ASSEMBLY

Condition
Specified condition
Released
Below 1
Pushed
10 k or higher
If the result is not as specified, replace the back-up light switch.

INSTALLATION
for Preparation
1. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
1. Using SST, install the back-up light switch with a new gasket onto the transaxle
case.
SST
09817-16011
Torque:
40 N*m{ 410 kgf*cm , 30 ft.*lbf }
2. Install the back-up light switch wire harness into the 2 clamps.
3. Connect the back-up light switch connector.
2. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 1KRFE)

Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf }
3. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (for 2SZ-FE)

Torque:
64 N*m{ 653 kgf*cm , 47 ft.*lbf }
4. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 1KRFE)

Torque:
the bolt and nut.
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf } for nut C
5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (for 2SZFE)

Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf }
the bolt and nut.
Torque:
52 N*m{ 530 kgf*cm , 38 ft.*lbf }

Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }

Torque:
17 N*m{ 175 kgf*cm , 13 ft.*lbf }
9. INSTALL BATTERY

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }
PARK / NEUTRAL POSITION

SWITCH > COMPONENTS
for Preparation
1/1

SWITCH > REMOVAL
for Preparation
1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Disconnect the park/neutral position switch connector.
2. Using SST, remove the park/neutral position switch with the gasket from the
transaxle case.
SST
09817-16011

SWITCH > INSPECTION
for Preparation
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY

Condition
Specified condition
Released
Below 1
Pushed
10 k or higher
If the result is not as specified, replace the park/neutral position switch.

SWITCH > INSTALLATION
for Preparation
1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
SST
09817-16011
1. Using SST, install the park/neutral position switch with a new gasket onto the
transaxle case.
Torque:
40 N*m{ 410 kgf*cm , 30 ft.*lbf }
2. Connect the park/neutral position switch connector.
SHIFT AND SELECT ACTUATOR >

COMPONENTS
for Preparation
1/1

DISASSEMBLY
for Preparation
1. REMOVE SELECT STROKE SENSOR
1. Remove the 2 screws and select stroke sensor.

2. Remove the O-ring from the select stroke sensor.

INSPECTION
for Preparation
1. INSPECT SHIFT AND SELECT ACTUATOR ASSEMBLY
1. Check the resistance between the terminals of the shift motor.
Tester
connection
1-2
Specified
condition
0.1 to 100
If the resistance is not as specified, replace the shift and select actuator.
2. Check the resistance between the terminals of the select motor.

Tester
connection
1-2
Specified
condition
0.1 to 100
If the resistance is not as specified, replace the shift and select actuator.

REASSEMBLY
for Preparation
1. INSTALL SELECT STROKE SENSOR

2. Install the new O-ring onto the select stroke sensor.
3. Set the stroke sensor so that the sensor side and the actuator side sensor arms are
in the positions shown in the illustration.
4. Turn the select stroke sensor clockwise and fix it with the 2 screws.
Torque:
2.0 N*m{ 20 kgf*cm , 18 in.*lbf }
MULTI-MODE MANUAL
TRANSAXLE ECU >
COMPONENTS
for Preparation
1/2
2/2
MULTI-MODE MANUAL
TRANSAXLE ECU > REMOVAL
for Preparation
1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER

()
2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (for RHD)
1. Slightly deform the upper part of the glove compartment door assembly to release
the 2 stoppers and open the glove compartment door assembly until it becomes
horizontal.
2. Pull the glove compartment door assembly out horizontally to disengage the hinge
portion and remove the glove compartment door assembly.
NOTICE:
Pull the glove compartment door out horizontally, otherwise, installation failure
caused by excessive play around the hinge portion will result.
3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for LHD)

3. Disengage the clip and remove the transmission control ECU.
4. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for RHD)
2. Remove the bolt and screw, then remove the transmission control ECU.
MULTI-MODE MANUAL
TRANSAXLE ECU > REMOVAL
for Preparation
1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER

()
2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (for RHD)
1. Slightly deform the upper part of the glove compartment door assembly to release
the 2 stoppers and open the glove compartment door assembly until it becomes
horizontal.
2. Pull the glove compartment door assembly out horizontally to disengage the hinge
portion and remove the glove compartment door assembly.
NOTICE:
Pull the glove compartment door out horizontally, otherwise, installation failure
caused by excessive play around the hinge portion will result.
3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for LHD)

3. Disengage the clip and remove the transmission control ECU.
4. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY (for RHD)
2. Remove the bolt and screw, then remove the transmission control ECU.

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MULTI-MODE MANUAL

TRANSAXLE SYSTEM >

Ignition Switch off

Ignition Switch on (IG)

Ignition Switch on (ACC)

2.PRECAUTION REGARDING ON-VEHICLE INSPECTION

3.PRECAUTION REGARDING PARTS REMOVAL AND INSTALLATION

1. INITIALIZATION OF MULTIMODE MANUAL

1. INITIALIZATION OF MULTIMODE MANUAL

Clutch disc and

4.TROUBLESHOOTING INITIALIZATION AND LEARNING (ENGINE DOES NOT

1.Check for DTC output

2.Check clutch position learning condition

Notexec (Not executed)

Execute learning again ()

Check clutch system

3.Check T/M gear position learning condition

Notexec (Not executed)

Execute learning again ()

4.Check whether gear is in neutral

Other than Neutral

5.Check whether park/neutral position switch is ON

Check transmission assembly

1. Check whether the park/neutral position switch is ON ().

Check park/neutral position switch

Perform initialization and learning again (If g

5.TROUBLESHOOTING INITIALIZATION AND LEARNING (VEHICLE DOES

1.Check for DTC output

2.Check clutch position learning condition

Notexec (Not executed)

Execute learning again ()

Check clutch system

3.Check T/M gear position learning condition

Notexec (Not executed)

Execute learning again ()

4.Check clutch standby point learning condition

Notexec (Not executed)

Execute learning again (Ignition switch off to

Check clutch system

6.Inspect accelerator pedal position sensor signal

4. Check that value of the Accelerator Pedal Angle changes in accordance

Check engine control system and CAN comm

7.Rev up engine with transmission in neutral

Check engine control system

Perform initialization and learning again (If g

Check clutch system

6.PRECAUTIONS REGARDING USE OF SHIFT LOCK RELEASE BUTTON

Gear shifted to neutral when

7.OTHER PRECAUTIONS REGARDING MULTI-MODE MANUAL

Set the gear in neutral when revving the engine.

8.PRECAUTION REGARDING ELECTRONIC THROTTLE CONTROL SYSTEM

9.PRECAUTION REGARDING USE OF INTELLIGENT TESTER

Read its instruction books before using the tester.

MULTI-MODE MANUAL TRANSMISSION SYSTEM OUTLINE

FUNCTIONS OF MAIN COMPONENTS

Illuminates to alert the driver when a malfunction occurs in the

Indicates the present gear position. The indicator flashes if the

Indicates E-mode or M-mode.

Illuminates when the sporty [Es] pattern is selected during normal

Sounds if the following conditions met simultaneously:

Shift lever position

Actuated by the transmission control ECU. Engages and