Section :

Chassis / Power Train Ref. No. : CP-5013

Service Bulletin
Area Application : Europe Model Name : COROLLA, COROLLA VERSO Model Code : ZNR11#, NDE120#

Date : Page :

May.,2005 1 of 8

Subject : DTC P0810 Loss of Drive / Unable to Select Gears

This Service Bulletin is issued to inform you of production improvement for TMMT produced Corolla Verso and TMMT/TMUK produced MMC Corolla models with Multi-Mode Manual Transmission. 1. VEHICLE IDENTIFICATION NUMBER (VIN) NOTE This procedure is only applicable to vehicles made at Toyota Motor Manufacturing Turkey (TMMT) and Toyota Motor Manufacturing UK (TMUK). The distinguishing method is by checking the1st digit of the 17-digit VIN: N = Turkey S = UK

B083694E02

(a) The VIN is stamped on the cowl panel. It is also stamped on the manufacturer's plate as shown in the illustration. 2. DESCRIPTION OF PHENOMENON Impossible shifting during driving, N light turns ON. Driver unable to select gears, transaxle remains in Neutral. PRODUCTION IMPROVEMENT Change in MMT ECU logic to suit better to high load conditions. FIELD FIX PROCEDURE (a) Symptom Confirmation: 1. Confirm problem symptom and conditions. 2. Check for DTC's "Present Codes" and "History Codes" (see procedure below). 3. If DTC P0810 is present, please repair according to the Repair procedure given at the next page. (b) Checking DTC's If using Intelligent Tester I with software version 10.1 or higher, please check for all codes according to the procedure given in TSB CP-4008. OVERSEAS CUSTOMER SERVICE TECHNICAL DIV.

3. 4.

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Ref. No. : CP-5013 Page : 2 of 8

If using Intelligent Tester II, please follow Repair Manual (RM1100E1) page 05-671, Multimode transaxle DTC Check / Clear. Without using Intelligent Tester follow the procedure outlined in Repair Manual (RM1100E1) page 05-671, Multi-mode transaxle DTC Check / Clear, using service wire. SST 09843-18040 (c) Repair procedure: (1) Proceed step-by-step following the Field/fix repair procedure outlined below. 1. Confirm problem conditions. 2. Confirm Freeze-frame data. 3. Confirm clutch actuator rod pre-load. 4. Proceed with Field/fix.

Part No. Information :

* I I I I I I Prev.Part No 89530-64010 89530-64020 89530-12210 89530-12220 89530-12230 89530-12240 New Part No. COROLLA VERSO - TMMT Same as previous Same as previous Same as previous Same as previous Same as previous Same as previous Computer assembly, Transmission Control LHD Computer assembly, Transmission Control RHD Computer assembly, Transmission Control LHD w/ VSC Computer assembly, Transmission Control LHD w/o VSC Computer assembly, Transmission Control RHD w/ VSC Computer assembly, Transmission Control RHD w/o VSC Part Name

MMC COROLLA - TMMT, TMUK

* : INTERCHANGABILITY CODE
Prev. Part I Prev. Vehicle New Vehicle New Part (I) PV NV PP NP NI PV NV PP NP (NI) PV NV PP NP S Interchangeable as a set

In order to distinguish old and new parts a discrimination mark is placed on the ECU housing as outlined below.

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Service Bulletin
5. DISCRIMINATION MARK

Ref. No. : CP-5013 Page : 3 of 8

ECU:

Label:
Production Date, Lot No.

E110803E02

1. TMMT Corolla Verso If the production date shown on the label is October 13, 2004 or later, this indicates that the ECU was manufactured after the design was changed. Aplicable part No.
Part No. 89530-64010 89530-64020 Label Color Purple Light Blue

2. MMC Corolla - TMUK & TMMT If the production date shown on the label is November 10, 2004 or later, this indicates that the ECU was manufactured after the design was changed. Aplicable part No.
Part No. 89530-12210 89530-12220 89530-12230 89530-12240 Label Color Navy Gray Black Green

Example:

6.

HOW TO READ THE LABEL (a) Read the label. Year:

4 5 '04 year '05 year

Month:
Year Month Date
E110804E02

A B C

January February March

G H J

July August September

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Service Bulletin
D E F April May June

Ref. No. : CP-5013 Page : 4 of 8

K L M

October November December

Production Effective :
Model TMMT Corolla Verso TMMT MMC Corolla TMUK MMC Corolla VIN NMTER150-R030079 NMTE16R20R030068 NMTEC20E80R002904 SB1KC20E00E004709 Production Date October 22, 2004 November 26, 2004 November 25, 2004

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Service Bulletin
Chassis & Power Train
MMT

Ref. No. : CP-5013 Page : 5 of 8

F/Fix method for DTC P0810 on MMT for Corolla and Corolla Verso
1. Problem conditions (a) There are 4 possible cases. The repair method is different for each case as the cause is different.
case 1 2 3 4 Problem occurs during clutch disengagement disengagement engagement engagement and pre-load on the clutch actuator rod is correct (no clearance) not correct (some clearance) correct not correct

2.

Problem Condition Confirmation Method: (a) Judge the problem condition by confirming problem condition (cases 1, 2, 3 or 4) using the following flow chart (refer to method described in next sheets to determine Clutch (dis)engagement - by "Freeze frame data" - and "Pre-load" condition):

1) Check DTC

NO

2) Are there freeze frame data of P0810? YES 3) During clutch disengagement? YES NO

4) Is the pre-load on the clutch rod correct?

NO

4) Is the pre-load on the clutch rod correct?

NO

YES Case 1 Case 2

YES Case 3 Case 4

E110748E02

1) Confirm DTC. Is there DTC P0810? 2) Are there freeze frame data of P0810? 3), 4) Which case is the problem vehicle? Note: If Freeze Frame data cannot be checked, handle as cases 1 or 2 depending on Pre-load OVERSEAS CUSTOMER SERVICE TECHNICAL DIV.

Service Bulletin
If Pre-load cannot be judged clearly, handle as case 2. 3. Confirmation Method of Freeze Frame Data P0810: Clutch Position Control Freeze Frame Data
Item Engine Coolant Temperature Vehicle Speed Theoretical Engine Torque Shift Position (Current) Clutch Motor Current MMT Select Motor Current MMT Gear Position (Target) Cold Condition Judgement Shift Lever Switch Signal 2 Shift Lever Switch Signal 4 Shift Lever Check Signal 1 Shift Lever Check Signal 3 Ignition Signal Steering SW Signal Down Brake Switch Signal 2 STA Switch Signal Possibility of T/M Uplock Learning-T/M Open Open Open Open #NAME? Gnd Open OFF No Exec Data 86 40 17 8.53414 24 0 3 69 Nm mm A A Unit Item Engine Revolution Accelerator Pedal Angle Clutch Position (Current) Select Position (Current) Shift Motor Current MMT Gear Position (Current) Shift Lever Position Judge Shift Lever Switch Signal 1 Shift Lever Switch Signal 3 Shift Lever Switch Signal 5 Shift Lever Check Signal 2 T/M Reverse Switch Signal Steering Switch Signal Up Brake Switch Signal 1 STP Switch Signal Mode Changes Learn-Clutch Standby Point Learn-Clutch Stopper Point

Ref. No. : CP-5013 Page : 6 of 8

Data 2118.75 10.8 37.404 25.37209 0 3 E Open Gnd Open Gnd Open Gnd Open OFF 38 Exec Exec rpm % mm mm A

Unit

Check "Clutch Motor Current MMT" whether "more than 22A" or "less than-22A". And also please check both "Shift Motor Current MMT" and "Select Motor Current MMT" are "0A". HINT: When "Clutch Motor Current MMT" is "more than 22A", Problem condition is "during clutch engagement". When "Clutch Motor Current MMT" is "less than -22A", Problem condition is "during clutch disengagement". The example shown above is "during clutch engagement". 4. Confirmation method of the pre-load on the clutch actuator rod (a) Checking method: (1) Turn the ignition switch to OFF and keep it there.

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Service Bulletin

Ref. No. : CP-5013 Page : 7 of 8

(2) As shown in the illustrations below, put the finger lightly on the clutch actuator rod nut and apply small load in Up & Down direction. (Load applied by the finger is approx. 2N.) Check whether or not the rod moves in between the fork hook.

Fork

Rod nut

Fork hook

E110751E02

Judgement: If the rod nut does not move in Up & Down direction with approx. 2N load Pre-load adjustment on the clutch actuator rod is correct. If the rod nut moves in Up & Down direction with approx. 2N load Pre-load adjustment on the clutch actuator rod is incorrect. HINT: On the normal nominal condition, the load in the clutch actuator rod direction is 96N. 5. Field /Fix repair
Case 1 Problem Condition 1. During the clutch disengagement 2. The pre-load on the clutch actuator rod is correct. Cause 1. Decreasing of clutch release efficiency F/Fix parts 1. MMT-ECU 2. Grease F/Fix procedure 1. Replace the MMT-ECU by C/M one. 2. Clean the clutch release support and apply the grease. 3. MMT-ECU initialization 1. Replace the MMT-ECU by C/M one. 2. Clean the clutch release support and apply the grease. 3. Replace the clutch disc and the clutch cover. 4. MMT-ECU initialization

1. During the clutch disengagement 2. The pre-load on the clutch actuator rod is not correct.

1. Decreasing of clutch release efficiency 2. Too much LCC adjustment due to the low clutch release efficiency

1. 2. 3. 4.

MMT-ECU Grease LCC Clutch Disc

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Service Bulletin
Case 3 Problem Condition 1. During the clutch engagement 2. The pre-load on the clutch actuator rod is correct. 1. During the clutch engagement 2. The pre-load on the clutch actuator rod is not correct. Cause 1. Clutch actuator internal lock 1. MMT-ECU 4 1. Clutch actuator internal lock 2. Not correct installation of the clutch actuator at a vehicle factory 1. MMT-ECU

Ref. No. : CP-5013 Page : 8 of 8

F/Fix parts

F/Fix procedure 1. Replace the MMT-ECU by C/M one. 2. MMT-ECU initialization 1. Replace the MMT-ECU by C/M one. 2. Reinstall the clutch actuator according to the repair manual. 3. MMT-ECU initialization

OVERSEAS CUSTOMER SERVICE TECHNICAL DIV.