JSD-Technical In

TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN JSD
CONTINUOUSLY VARIABLE TRANSAXLE SOFTWARE UPDATE
CERTAIN 2014-2017 TOYOTA Corolla
CERTAIN 2017 TOYOTA Corolla iM
CERTAIN 2016 SCION iM
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this
recall are required to successfully complete the most current version of the E-Learning course “Safety Recall and
Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians
performing this recall repair are required to currently hold at least one of the following certification levels:
• Certified Technician (Drivetrain)
• Expert Technician (Any specialty)
• Master Technician
• Master Diagnostic Technician
OPERATION FLOW CHART
Check the TIS Vehicle Inquiry System
to verify vehicle eligibility.
Not
Covered
No further action required.
Covered
Check for powertrain DTCs
Check for other powertrain DTCs
Is DTC P2820 present?
No
Yes
Are other powertrain DTCs present?
Yes
Obtain customer permission to
diagnose and repair.
No
Determine ECM Calibration ID
CVT Replacement Required
Permission Granted
Determine if the vehicle is still covered
by Toyota’s New Vehicle Powertrain
Warranty
Diagnose and repair the issue causing
the powertrain DTC(s)
In warranty
Permission NOT Granted
Does vehicle already have the latest
calibration ID?
Out of warranty
The Service Campaign cannot be
performed until the powertrain DTCs
are diagnosed and repaired.
Replace CVT
Contact DSPM to obtain authorization
to replace the CVT
No
Determine ECM Calibration ID
Reflash ECM
Replace CVT
Does vehicle already have the latest
calibration ID?
Perform all initializations
Yes
Determine ECM Calibration ID
No
(Software Update Not Required)
Reflash ECM
Install Authorized Modification Label
Does vehicle already have the latest
calibration ID?
Yes
Perform Solenoid Valve Inspection
No
Perform all initializations
Yes
Reflash ECM
Install Authorized Modification Label
Check for DTCs
Is P2820 Present?
Obtain authorization from TAS to
replace valve body
Yes
Perform all initializations
Fail inspection
Confirm results of Solenoid Valve
Inspection.
Replace valve body
Campaign complete.
Return the vehicle to the customer
Install Authorized Modification Label
Pass inspection
Campaign complete.
Return the vehicle to the customer
Campaign complete.
Return the vehicle to the customer
Refer to claim filing process #1
Refer to claim filing process #2
Refer to claim filing process #3
Campaign complete.
Return the vehicle to the customer
Refer to claim filing process #4
1
IDENTIFICATION OF AFFECTED VEHICLES
NOTE:
• Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this SSC and that the campaign
has not already been completed prior to dealer shipment or by another dealer.
• TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were
completed by another dealer.
PREPARATION
A. PARTS
Part Number
Part Description
Quantity
00451-00001-LBL*
Authorized Modification Label
1
*Labels can be ordered in packs of 25 from the MDC through the Dealer Daily Website
The following parts are ONLY needed for valve body replacement.
*DO NOT ATTEMPT TO ORDER THE PARTS BELOW UNTIL YOU HAVE PERFORMED THE SLP VALVE
TEST AND JUDGED THE VALVE BODY NO GOOD
Part Number
Part Description
Quantity
35410-12871
Body Assy, Transmission Valve
1
04008-28102
Gasket kit, valve body replacement *
1
* The kit above includes the following parts.
Part Number
35168-12091
35145-33010
90301-22019
90301-06004
90430-12008
90430-18008
Part Description
Gasket, Transaxle Oil Pan
Gasket, Transaxle Case
Ring, O
Ring, O
Gasket, Overflow Plug
Gasket, Refill Plug
Quantity
1
1
1
1
1
1
B. TOOLS & EQUIPMENT
• Standard Hand Tools
• Techstream
• Torque Wrench
• Work Gloves
• 6 mm Hexagon Socket Wrench • Protective Eyewear
-SST
GUIDE BOLTS (These were supplied to your dealership at the launch of JSD)
Guide Bolts
Application: Replacement of transmission
valve body assembly. 2 guide bolts / set
C. MATERIALS
• Protective Tape
• Plastic Bag
• String
• Lint Free Shop Cloth
• ATF CVT FE (4 L can) = 08886-02505 = Quantity 2
• Toyota genuine MP grease No.2
• Marker pen
2
BACKGROUND
Toyota previously announced Special Service Campaign J0D, which involved performing a software update to the
CVT control software to address the condition described below. Following the completion of the software update in
Special Service Campaign J0D, Toyota dealers received reports from some customers stating that the vehicle
experienced harsh shifting and/or abnormal engine RPM between shifts. These issues occurred close to the
completion date of the campaign and/or within relatively low mileage from the completion of the campaign remedy,
prompting Toyota to suspend Special Service Campaign J0D. Toyota has now identified the cause of these issues
and has developed a new remedy. Special Service Campaign JSD, which replaces Special Service Campaign J0D,
applies this new remedy. Owners of all vehicles previously involved in Special Service Campaign J0D, including
those who have previously completed Special Service Campaign J0D, are requested to visit an authorized Toyota
dealer to have Special Service Campaign JSD performed.
3
SAFETY PRECAUTIONS
CRITICAL INFORMATION - READ THOROUGHLY
An ECM could be damaged if an error occurs in the communication while reflashing the ECM. Confirm
all work is performed as described in these instructions.
1. STABILIZE THE POWER TO THE PERSONAL COMPUTER
SIDE
a) Be sure to connect the personal computer to an external AC
power supply.
NOTE:
The ECM could be damaged if the battery voltage of the
personal computer drops while reflashing.
b)
Exit all applications except Techstream 2.0 (TIS
Techstream / Techstream Lite).
c)
Turn off the screen saver and power saving mode of the
personal computer so that the power to the hard disk is kept
supplied.
NOTE:
If the screen saver or power saving mode launches while
reflashing, the communication may be disconnected,
resulting in damage of the ECM.
d)
DO NOT block the ventilation opening for the cooling fan of
the personal computer.
NOTE:
If the ventilation opening for the cooling fan is blocked with
a sheet cover or the like, the personal computer may be
heated excessively, causing the operation of the personal
computer to stop.
Due to the stop of the operation, the communication for
reflashing signals could be stopped, resulting in damage of
the ECM.
4
ECM CALIBRATION ID VERIFICATION AND DTC(s) CHECK
1. CHECK FOR DTC’S
a. Using a Techstream, perform a Health Check to check for any
Diagnostic Trouble Codes.
b. If DTC P2820 is present, preform one of the two options below. An
example of each option is shown on the next page. ONLY 1 OF
THE 2 OPTIONS IS REQUIRED FOR PARTS RELEASE
-
Run and save a Customer Health Check/Diagnostic
Report to prove DTC 2820 is present. CLICK HERE
to access instructions on how to create and save a
diagnostic report
-
Take a screenshot of the vehicle Health Check to
prove DTC P2820 is present.
c. CVT assembly replacement is required at this point. Toyota will
require this screenshot/Diagnostic report prior to releasing parts for
this repair. Refer to the Dealer Letter for complete parts ordering
instructions.
• Parts will not be released if screenshot of
Health Check or diagnostic report is not
provided.
d. If CVT assembly replacement is required, see T-SB-0289-17
(Toyota) or S-SB-0002-18 (Scion) for repair instructions.
Note: This Service Campaign covers only the ECM reflash,
as detailed in these instructions. It does not cover the
diagnosis or replacement of any other parts on the vehicle.
5
•
Example of required Diagnostic Report:
•
Example of required screenshot:
VIN and DTC P2820
•
If vehicle is out-of-warranty, DSPM authorization is required prior to
proceeding with CVT assembly replacement. Refer to the Dealer Letter for
further instructions.
6
2. DETERMINE CALIBRATION ID
a. Identify the Calibration ID for the ECM in the Health Check Results.
b. Referencing the table below, verify if the ECM has the updated Calibration.
ECM Calibrations
Vehicle Specification
Model
MY
Engine
Shift Type
Current CID
New CID
302Y6000
302Y6100
2ZR-FAE
Gate
302Y6200
302Y6500
302Y6300
302Y6400
302W8000
302W8100
2014
Gate
302W8200
302W8500
302W8300
302W8400
COROLLA
2ZR-FE
302Y7000
302Y7100
Sequential
302Y7200
302Y7500
302Y7300
302Y7400
302U1000
2ZR-FAE
Gate
2015
2016
302U1100
302U1300
302U1200
30Z58000
2ZR-FE
Gate
30Z58100
30Z58300
7
ECM Calibrations
Vehicle Specification
Model
MY
2015
2016
Engine
Shift Type
Current CID
New CID
Gate
30Z58200
30Z58300
30Z59000
2ZR-FE
Sequential
30Z59100
30Z59300
30Z59200
30ZC1000
COROLLA
2ZR-FAE
Gate
30ZC1100
30ZC1200
30ZC2000
Gate
2017
30ZC2100
30ZC2200
2ZR-FE
30ZC3000
Sequential
30ZC3100
30ZC3200
30W01000
iM
2016
2ZR-FAE
Sequential
30W01100
30W01200
30W03000
COROLLA iM
2017
2ZR-FAE
Sequential
30W03100
30W03200
8
ECM REFLASH PROCEDURE
1.
VEHICLE PREP
a. Prior to vehicle shut down perform the following steps:
• Vehicle in the IG on position.
• Transaxle in the P range.
• Parking brake engaged.
• Turn off all electrical accessories (i.e. climate control, audio system, etc.)
b. Headlight switch in the DRL OFF position.
c. Turn off the vehicle.
2. CONNECT THE GR8
a. Set the GR8 to Power Supply Mode to help maintain 13.5 volts during ECM reprogramming.
•
•
A battery charger set to power supply mode MUST be used during reflash.
ECU damage may occur if the correct battery charge setting is not used.
3. REFLASH THE ECM
a. Click yes on the Health Check results screen or follow the links above to begin the reflash
process.
NOTE:
• Reflash procedure takes about 15 minutes.
• In case reflash failed EVEN ONCE, replace the ECM. (Refer to TIS for instructions on
2ZR-FAE ENGINE CONTROL / ECM or 2ZR-FE ENGINE CONTROL / ECM)
After ECM replacement recheck the calibration ID and perform the reflash if it is NOT
the new calibration ID.
• For general reprogramming procedures, refer to T-SB-0134-16.
• Confirm the latest version of Techstream software is being used.
•
•
If the Techstream does not have sufficient battery power the reflash will fail.
Confirm the DLC3 cable is in good condition before attempting reflash.
4. CONTINUOUSLY VARIABLE TRANSAXLE SYSTEM INITIALIZATION
Refer to the CVT transaxle system initialization in the repair manual on TIS.
5. ATTACH THE AUTHORIZED VEHICLE MODIFICATION LABEL
a. Fill out the label.
b. Affix the label to the under-side of the hood.
1
2
3
4
5
ECM P/N
New Calibration ID
Dealer Code
Date Completed
Campaign Code (XXX)
9
DRIVING INSPECTION
Ensure that the ECM calibration ID is the latest.
Make sure to understand the entire procedure before inspection.
Click the play button to watch a video on how to analyze the data you collected during your test drive
1. PREPARE FOR THE INSPECTION
a. Connect the Techstream to the DLC3
b. Turn ON the A/C
Confirm there are NO POWERTRAIN
DTC’s present before performing test
drive
c. Click Here to download the data zip file for JSD
d. Once you download the data file you will need to
install it. Open the folder batch2 after you download
the data file
e. Double-click JSD List Install to install the data file
10
You must download the JSD data file
before proceeding to ensure the
correct data PIDs are selected before
the test drive
f. After downloading the data file for JSD, Select Engine
and ECT ECU and go to the data list.
g. Click on the drop-down menu located on the bottom of
the screen and select “JSD Test Drive”
NOTE: The “JSD Test Drive” selection will only
appear on the drop-down menu after downloading
the data file
h. After selecting JSD confirm the following data PIDs
are shown
(1) Vehicle Speed
(2) Accelerator Position
(3) Stop light Switch
(4) A/T Oil Temperature 1
(5) SPD (NIN)
(6) Lock Up
Make sure to select ONLY the 6 items
above. DO NOT display other items as
the sampling time becomes longer.
e)
Click the "Graph" button to represent the data in charts.
f)
Double click on the PID’s listed to the left to make the
graphs display
g) Click the "Overlap" button.
NOTE:
Display the charts overlapped.
h)
Warm up the transmission until the A/T Oil Temperature
reaches 40°C (104°F).
11
2. PERFORM DRIVING INSPECTION
Always Safety First During Inspection
•
•
•
•
•
•
Secure cables using tape so that they DO NOT contact pedals, shift lever or steering wheel.
Never operate Techstream while driving. Be sure to stop the vehicle at a safe place to operate.
Always comply with the traffic laws such as speed limits of the inspection location.
Always keep enough distance from surrounding vehicles.
If any warning light comes on during driving, stop inspecting and stop the vehicle at a safe place.
When vehicle distances or speed limits cannot be ensured, stop inspecting and restart.
-In this inspection, fully depress the accelerator pedal to accelerate the vehicle from 0MPH (0km/h) to
40MPH (64 km/h).
-After reaching 40MPH (64 km/h), fully release the accelerator pedal and allow the vehicle to coast for
more than 10 seconds, and then inspect the RPM of the SPD (NIN) PID.
-Redo the procedure if you had to use the brake pedal or accelerator pedal due to surrounding
conditions while coasting for 10 seconds.
-It is recommended that you perform and record this test drive 3 separate times to ensure you perform
the test drive correctly, However, it is only necessary to do the test drive once if you are sure you
completed it correctly.
a)
Reconfirm that the A/T Oil Temperature is higher than
104°F (40°C) and the A/C is ON.
b)
Confirm that no powertrain DTC displayed.
c)
Move and stop the vehicle to a place where the inspection
can be performed.
d)
Confirm that the vehicle is at a stop and vehicle speed is
0MPH (0Km/h).
e)
Click the "Record" button to start recording of data.
Make sure to click on the button with
the vehicle stopped.
12
< FLOWCHART >
B. Start recording data.
C. Accelerate the vehicle.
(Accelerator position from 0
to 100%)
D. Confirm vehicle speed is
64km/h (40MPH)
Release the accelerator.
(Accelerator position 0%)
E. Finish recording after
allowing the vehicle to coast
for 10 sec.
It is recommended to repeat the
procedure 3 times.
• Confirm A/C ON.
• Confirm 0km/h (0MPH).
• A/TOil Temperature is higher than 40°C (104°F).
• Confirm that the Techstream displays the required data items.
(1) Vehicle Speed
(4) A/T Oil Temperature 1
(2) Accelerator Position
(5) SPD (NIN)
(3) Stop light Switch
(6) Lock Up
• Accelerate the vehicle to 40MPH (64km/h) with the accelerator
position 100%.
• Release the accelerator after reaching 40MPH (64km/h).
Allowable Range:
35~45MPH (+/-5MPH)
56~72km/h (+/-8 km/h)
Requirements：
No brake or accelerator pedal operation within the 10 seconds
of the coast period.
NOTICE:
If safety cannot be ensured due to surrounding conditions,
stop inspecting and prioritize safety.
If the requirements are not satisfied, redo the inspection.
A. • Stop the vehicle.
• Check the vehicle
condition.
f)
With the vehicle stopped, fully depress the accelerator pedal (wide open throttle) so that the accelerator
position becomes 100 % and accelerate the vehicle to 40MPH (64 km/h),
g)
Once you achieve 40MPH fully release the accelerator pedal (foot off gas pedal) and allow the vehicle to
coast for more than 10 seconds.
Repeat the procedure from step 2. (a) if the inspection is interruppted by any of the following
situations.
• The accelerator pedal or brake pedal has been operated within 10 seconds after releasing
the accelerator pedal.
• The accelerator position could not be changed from 0 to 100% (you were unable to go
wide open throttle)
• The vehicle speed is more than +/-5MPH (+/-8km/h) out of the allowable range.
13
h)
Move the vehicle to a safe place and click on the “Stop”
and save the data.
Make sure to click on the button with
the vehicle stopped.
i)
It is recommended to perform the inspection in this
manner 3 times in total. (Repeat the procedure from step
2. (a) two more times.)
YOU WILL BE REQUIRED TO RETAIN ALL SAVED FILES FOR 90 DAYS FROM THE REPAIR
DATE. DO NOT DELETE ANY FILES THAT ARE NOT OLDER THAN 90 DAYS
3. SAVE THE TECHSTREAM FILE
a. To save the file click File then click Save As to save the
file to your computer
b. Use the default file name when saving the file to your
computer. If you accidentally delete the default name then
save the file with the VIN in the name
NOTE: Work with the other technicians in the dealership
to help organize the techstream files
You will need to save every sucessful
Techstream file for potentional review
or data recovery from Toyota. You
must retain each file for 90 days from
the repair date.
DO NOT DELETE any techstream file
before 90 days that is created after a
successful test drive.
4. WHERE TO SAVE THE TECHSTREAM FILES
(RECOMMENDED PROCEDURE)
NOTE: This step is recommeded to help organize the files to
make them more managable
a. First you need to locate where the files are saved.
Techstream defaults the save path to the following
location.
-Local Disk (C:)
- Users
- Public
- Public Documents
- Techstream
- User
- Default
b. Go to the Default file
14
c. Once in the Default folder, create a new folder and name it
the year
d. Once you create a folder for the year, open that file and
create another folder for the current month.
(example: July)
e. Save all the Techstream files in the month they were
recoded. So, if you record a file in July, save it in the July
folder
NOTE: This will allow you to keep track of the files and
help to know when you can delete the files that
are older than 90days
DO NOT DELETE any techstream file
that is NOT OLDER THAN 90 Days
5. PERFORM HEALTH CHECK
a)
Check for DTCs.
(1) Check whether or not DTC P2820 is displayed.
NOTE:
If other DTCs are displayed, repair according to the repair manual.
Did DTC P2820 display after test drive?
YES
Go back to Step 1 in Section VI for CVT
parts release steps and repair
information
NO
Proceed to the next step
15
6. ANALYZE THE DRIVING DATA (Only when DTC P2820 is not displayed at Health check)
Click the play button to watch a video on how to analyze the data you collected during your test drive
a)
Select Open Scan Data File.
b)
Select the file to review. Use the VIN to locate the correct
file
Work with the other technicians in the
dealership to help organize the
techstream files
c)
Select Engine and ECT / Data List / Data to display the
saved data.
If you recorded more than one than 1
test drive you will need to review all
test drives
16
d)
Click on the “Graph” button on the bottom of the screen
Inspection Requirements：
• A/T Oil Temperature is higher than 40°C (104°F).
• A/C is ON.
• The accelerator position went from 0 % to 100 % (Wide Open Throttle) and after reaching 40MPH
(64km/h), you removed your foot from the accelerator pedal and accelerator position is 0%.
• Vehicle speed is 40MPH (64km/h) , allowable range: +/-5MPH (+/-8km/h).
• Neither the accelerator or brake pedal has been operated within 10 seconds after releasing the
accelerator pedal.
• Stop light Switch remainded OFF until the end of the test
• Lock Up ON when accelerating and Lock Up OFF when coasting.
NOTE: If you decide to record 3 test drives they do not have to be recorded in the same file.
e)
Locate and zoom into the test drive area.
(1) Click and hold the mouse and drag it over the test drive
area.
NOTE: To easily locate the test drive inspection area,
look for where you went Wide Open Throttle
f)
Set up the graph display.
(2) Click on SPD (NIN) to select a graph.
(3) Click on the "Menu" button of SPD.
(4) Select "GRAPH TYPE2 (Affects All)"
17
g)
h)
You can now inspect the difference in RPM using the scale
to the left.
Check and make sure you have selected the SPD (NIN)
PID on the bottom of the screen so the scale on the left is
correct
Standard Good Value：The RPM difference is less than
250 rpm in the inspection range.
• DO NOT inspect the first big drop (undershoot) or anything before it when measuring the
RPM
NOTE:
• Confirm that a scale of SPD (NIN) represents 50 rpm.
• The recorded time of the data can be checked at (sec) on the graph.
Judgment
Check Result
OK
RPM difference is
less than
250 rpm.
NG
RPM difference is
greater than or
equal to 250 rpm
even at one
place.
To do
CAMPAIGN COMPLETE
Return the vehicle to
the customer
Valve body assembly
replacement is required.
Go to next page and follow
the instructions on how to
release the parts for valve
body replacement
18
SUBMIT TECHSTREAM DATA TO TAS
(Only follow these steps if the valve body failed the driving inspection)
Click the play button to watch a video on how to create a TAS case for JSD
(1) Open TIS
(2) From the TIS tab, go to the Tech Assistance page
(3) Once on the Tech Assistance Page scroll down and click
the “On-line” link.
DO NOT CALL TAS FOR
JSD PARTS RELEASE
You only need to create the TAS
case for JSD parts release
(4)
Enter the following information on the Dealer TAS Case
Create page.
(a) Enter the VIN
(b) Service Category = Drivetrain
(c) Section = CVT
(5) Once you have filled out the selection above click Continue
followed by the Create a TA Case button
19
(6) Fill out the following information
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Dealer Phone (optional)
Direct Contact Phone
Repair Date
Repair Order Number
Customer Last Name
Odometer
Service Category = Drivetrain
Section = CVT
Sub-Component = Unknown
Symptom Code = Gap/Poor
Fit/Loose/Tolerance
(7) For Condition Description you must include the following
information
a. -Title (JSD Valve Body Request - Valve Body Failed
Test)
- Dealer Code (XXXXX)
-Valve Body Part Number (XXXXX-XXXXX)
-Gasket Kit Part Number (XXXXX-XXXXX)
-Parts Order Reference Number (XXXXXX)
- (The Private Distributors such as GST and SET
may not require a Part Order Reference Number)
NOTE: If you judge the valve body to be NO GOOD
then you should place the order for the valve body
parts prior to creating the TAS case and obtain the
Parts Order Reference Number
(8) Select the Techstream File to attach to the TAS case
• You must attach the correct Techstream
file to the TAS case
• If you do not attach a techstream file
TAS will NOT APPROVE THE PARTS
RELEASE
• Work with other service technicians to
create a method to organize techstream
files so you can easily access the
correct files
(9) Once you fill out all the information and attach the
Techstream file go to the bottom of the page and click
Confirm Case Information
(10) Confirm all information is correct and that the Techstream
file has been attached.
(11) Click Create Case on the bottom of the page to create the
TAS case
20
(12) Confirm all information is correct and that the Techstream
file has been attached.
(13) Click Create Case on the bottom of the page to create the
TAS case
CHECK FOR TAS APPROVAL
(1) Go to the home page on TIS
(2) Click Refresh in the Inbox section
(3) Click on the TAS case to open it
(4) Scroll down to the Condition Description of the message to see if TAS has approved the valve body parts
request
(5) Once TAS approves your parts release request the parts will be shipped to the dealer through the normal
parts distribution.
21
REMOVE THE TRANSMISSION VALVE BODY ASSEMBLY
(ONLY PROCEED IF TAS APPROVED VALVE BODY REPLACEMENT. DO NOT
CONTINUE UNTIL YOU HAVE APPROVEAL FROM TAS)
NOTE:
DO NOT open the package of the NEW transmission valve body assembly until just before replacement.
COMPONENTS
22
23
Intrusion of fine foreign materials or
dust into the transmission may cause a
malfunction that results in a state
unable to travel. Sufficiently clean the
work area, tools, and equipment to be
used before starting work operation.
Take care not to allow air blowing to be
performed around.
Perform work operation quickly
without interruption so as not to allow
intrusion of foreign materials or dust
into the transmission.
Clean off oil off before disassembling,
knock the area to be cleaned with a lint
free cloth to absorb oil. DO NOT
perform a wiping action, or the lint free
cloth may be caught by burrs and lint
may be generated.
• Perform cleaning completely before
starting disassembly.
• DO NOT perform cleaning after
starting disassembly in principle, or
intrusion of foreign materials may
be caused.
• DO NOT use shop cloths, paper
towels, and/or work gloves for
disassembly, or foreign materials
such as lint may be generated.
• DO NOT perform air blow, or foreign
materials and dust may be thrown
up.
1. RECORD CUSTOMER SETTINGS
a)
When the battery cable is disconnected, the settings for the audio, air conditioning etc., may be reset.
Therefore, make a note of the settings before disconnecting the cable from the negative (-) battery terminal.
24
7. TAKE MEASURES AGAINST SECURITY OF NAVIGATION
SYSTEM
a) In some cases, a user password is set for restart of the
system after disconnection of the power supply. Obtain
confirmation from the customer in advance regarding
conditions of the system at the time of returning the vehicle to
the customer.
8. DISCONNECT THE BATTERY TERMINAL
NOTE:
• Disconnect the negative (-) battery terminal cable to
prevent sparks.
• For models with a HDD navigation system, wait at least
6 minutes before disconnecting the battery. It takes
approximately 6 minutes for the system to save
information and settings after the engine switch is
turned off.
9. LIFT THE VEHICLE
10. REMOVE THE ENGINE UNDER COVER LH (for Corolla)
a)
Remove the 2 bolts, 2 screws, 3 clips and engine under
cover LH.
11. REMOVE THE No.1 ENGINE UNDER COVER LH (for iM)
a)
Remove the 2 bolts, 4 screws, 7 clips and No. 1 engine
under cover.
12. REMOVE THE REAR ENGINE UNDER COVER LH (for iM)
a)
Remove the 5 clips and rear engine under cover LH.
13. REMOVE THE FRONT ENGINE MOUNTING BRACKET
LOWER REINFORCEMENT (for iM)
a) Remove the 2 bolts and front engine mounting bracket lower
reinforcement.
25
14. REMOVE THE FRONT SUSPENSION MEMBER
REINFORCEMENT LH (for iM)
a) Remove the 4 bolts and front suspension member
reinforcement LH.
15. DRAIN THE CVT FLUID
Reference the CVT fluid replacement in the repair manual on TIS.
16. REMOVE THE TRANSAXLE OIL (CVT) PAN SUBASSEMBLY
a) Remove the 16 bolts, transaxle oil (CVT) pan sub-assembly
and transaxle oil pan (CVT) gasket from the continuously
variable transaxle assembly.
NOTE:
Some fluid will remain in the transaxle oil (CVT) pan subassembly. Remove all the bolts, and carefully remove the
transaxle oil (CVT) pan sub-assembly.
b)
Remove the Transaxle Oil (CVT) Pan Gasket from the
transaxle oil pan sub-assembly.
17. REMOVE THE OIL STRAINER
a)
Unscrew 3 bolts and remove the oil strainer from the
transmission valve body assembly.
Bolt A: (2) 16mm in length
Bolt B: (1) 25mm in length
NOTE:
Additional fluid will flow out when removing the oil strainer.
b)
Remove the O-ring from the oil strainer.
Take care to ensure there is no
contamination on the oil strainer.
c)
Break the removed O-ring and store it in a replacement part
box etc.
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18. REMOVE THE TRANSMISSION HARNESS
a)
Disconnect 5 connectors of transmission harness from the
transmission valve body assembly.
DO NOT remove respective solenoid
valves from the transmission valve
body.
(1) To remove the connector, apply the needle-nose plier
end to the male connector tab.
(2) Gently hold the needle-nose plier and then push the
male connector tab out.
Remove the connector as shown in the
illustration to avoid breakage.
(3) Pull out the male connector.
b) Remove the bolt and oil temperature sensor clamp.
c) Remove the oil temperature sensor.
NOTE:
Additional fluid will flow out when removing the oil
temperature sensor.
d)
e)
Remove the O-ring from the oil temperature sensor.
Break the removed O-ring and store it in a replacement part
box etc.
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f)
g)
Cover the disconnected connectors with a
plastic bag and tape in order to prevent intrusion
of foreign matters.
Raise the wires and connectors and hold them
with a string.
19. REMOVE THE TRANSMISSION VALVE BODY
ASSEMBLY
a) Unscrew the 13 bolts and remove the
transmission valve body assembly from the
transmission case.
Bolt A: (2) 20mm in length
Bolt B: (7) 35mm in length
Bolt C: (4) 45mm in length
NOTE:
• The fluid may flow out for a few minutes
after removing the transmission valve body
assembly.
• The transmission valve body assembly
weighs approximately 4.6kg.
b)
Put a mark on the removed transmission valve
body assembly and store them in a replacement
parts box etc.
c)
Remove transaxle case gasket from the transmission case.
As soon as removal of the
transmission assembly is complete,
install the transmission valve body
assembly without ANY interruption to
avoid contamination.
d)
Break the removed gasket and store it in a replacement part
box etc.
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INSTALL THE TRANSMISSION VALVE BODY ASSEMBLY
1. INSTALL THE TRANSMISSION VALVE BODY ASSEMBLY
a)
b)
Apply a small amount of Toyota genuine MP grease No.2 to
the NEW transaxle case gasket.
Install the gasket to the transmission case.
To prevent the transaxle case gasket
from falling off, ensure that it is
properly installed to the transmission
case.
NOTE:
Transaxle case gasket is non-directional.
c)
Install the 2 guide bolts at the positions shown
in the illustration.
Make sure to use the guide bolts,
since the valve body may slide
and cause the transaxle case
gasket to fall off.
• When installing the NEW
transmission valve body
assembly, fit it into the
transmission case carefully as
to NOT damage the top of the
sub strainers that are
positioned at the back of the
transmission valve body
assembly.
• When installing the NEW
transmission valve body
assembly, hold the
transmission valve body
assembly horizontally to
prevent the manual valve from
falling off.
d)
Pull out the manual valve as shown in the
illustration.
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e)
Match the position of the holes of the NEW
transmission valve body assembly to the guide
bolts and hold the valve body assembly in
place.
f) Ensure that the projection of the manual valve
lever sub-assembly and the groove of the
manual valve are matching as shown.
NOTE:
If the projection is not matching the groove,
relocate the manual valve.
g)
Push to install the NEW transmission valve
body assembly to the transmission case and
hold it in place.
h)
Holding the transmission valve body assembly,
install the 2 bolts (35 mm in length) to position
B.
Make sure to start torqueing from
the 2 bolts shown in the
illustration, since they will be the
installation position standard.
i)
Temporarily tighten the bolts manually until they
sit properly on the transmission valve body
assembly.
j)
k)
Remove the 2 guide bolts.
Temporarily tighten the remaining 11 bolts
manually until they sit properly.
Bolt A: (2) 20mm in length
Bolt B: (5) 35mm in length
Bolt C: (4) 45mm in length
l) Tighten the 2 bolts.
Torque: 10.8 N*m (110 kgf*cm, 8 ft.*lbf)
m) Every time one of the bolts is completetightened, clean the bolt head and put a yellow
paint mark
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n) Tighten the other 11 bolts evenly.
Torque: 10.8 N*m (110 kgf*cm, 8 ft.*lbf)
o)
Every time one of the bolts is completetightened, clean the bolt head and put a yellow
paint mark.
20. REINSTALL THE TRANSMISSION HARNESS
a)
Apply Toyota genuine CVT fluid to NEW O-ring and fit it to
the oil temperature sensor.
b) Reinstall the oil temperature sensor.
c) Reinstall the oil temperature sensor clamp with the bolt.
Torque: 10.8 N*m (110 kgf*cm, 8 ft.*lbf)
d)
Reconnect the 5 connectors and install the
transmission harness to the transmission valve.
Make sure to install the connector
to the position shown in the
illustration. If the installation
position is mistaken, the CVT
assembly may malfunction or
need to be replaced.
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INTERMEDIATE INSPECTION
21. INTERMEDIATE INSPECTION
a)
Perform the intermediate inspection to ensure
the following 3 points.
(1) The projection of the manual valve lever subassembly is properly matched to the groove
of the manual valve.
(2) The connector is installed at the proper
position.
(3) Each of the 13 bolt head has the yellow paint
mark as a sign of complete-tightening.
–
–
22. REINSTALL THE OIL STRAINER
a)
Apply Toyota genuine CVT fluid to the NEW O-ring and then
fit it into the oil strainer.
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b)
Tighten the 3 bolts evenly, temporarily reinstall the oil strainer
to the transmission valve body assembly.
Bolt A: (2) 16mm in length
Bolt B: (1) 25mm in length
• When installing the oil strainer to
the transmission valve body
assembly, prevent the O-ring from
being caught and apply pressure to
the area below the A bolt at the 12
o’clock position as shown while
keeping the strainer level.
• Prevent the transmission wiring
from being caught between the
transmission valve body assembly
and the oil strainer.
c) Tighten the 3 bolts.
Torque: 10.8 N*m (110 kgf*cm, 8 ft.*lbf)
23. REINSTALL THE TRANSAXLE OIL (CVT) PAN SUBASSEMBLY
a) Remove the 3 oil cleaner (CVT) magnets from the transaxle
oil (CVT) pan sub-assembly.
b) Clean off any metal particles adhered to the 3 oil cleaner
(CVT) magnets.
c) Clean the transaxle oil (CVT) pan sub-assembly and remove
any metal particles, sludge, etc.
d)
Install the NEW transaxle oil pan (CVT) gasket.
Clean the mating surfaces of the
transaxle oil (CVT) pan sub-assembly
and the transmission case with wipes
to remove grease, moisture and/or dirt
(DO NOT use brake cleaner).
e)
Tighten the 16 bolts evenly, and temporarily reinstall the
transaxle oil (CVT) pan sub-assembly to the transmission
case.
Prevent the transmission wiring from
being caught between the
transmission case and transaxle oil
(CVT) pan sub-assembly by pushing
wiring to the center of transaxle.
f) Tighten the 16 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
24. RECONNECT THE BATTERY TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
25. REFILL THE CVT FLUID
Refer to the CVT fluid replacement in the repair manual on TIS.
(a) Add fluid to the refill hole using the correct amount of fluid.
Reference Capacity:
3.5 liters (3.7 US qts, 3.1 Imp. qts.)
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26. CHECK FOR FLUID LEAKS
27. REINSTALL THE ENGINE UNDER COVER LH (for Corolla)
a)
Reinstall the engine under cover LH with the 2 bolts, 2
screws and 3 clips.
28. REINSTALL THE FRONT SUSPENSION MEMBER
REINFORCEMENT LH (for iM)
a) Reinstall the front suspension member reinforcement LH to
the front cross member sub-assembly and front suspension
crossmember sub-assembly with the 4 bolts.
Torque: 99 N*m (1010 kgf*cm, 73 ft.*lbf)
Temporarily tighten the bolt (A) and
bolt (B), and then fully tighten the 4
bolts in the order of (C), (B), (D) and
(A).
29. REINSTALL THE FRONT ENGINE MOUNTING BRACKET
LOWER REINFORCEMENT (for iM)
a) Reinstall the front engine mounting bracket lower
reinforcement to the front cross member sub-assembly and
front suspension crossmember sub-assembly with the 2
bolts.
Torque: 99 N*m (1010 kgf*cm, 73 ft.*lbf)
30. REINSTALL THE REAR ENGINE UNDER COVER LH (for iM)
a)
Reinstall the rear engine under cover LH with the 5 clips.
31. REINSTALL THE No.1 ENGINE UNDER COVER LH (for iM)
a)
Reinstall the No. 1 engine under cover with the 2 bolts, 4
screws and 7 clips.
32. CHECK AND CLEAR DTCs
a)
b)
Clear the Diagnostic Trouble Codes.
Using Techstream perform a Health Check and confirm no current DTCs are present.
33. CONTINUOUSLY VARIABLE TRANSAXLE SYSTEM INITIALIZATION
Refer to the CVT transaxle system initialization in the repair manual on TIS.
34. TEST DRIVE
a)
Test drive the vehicle to confirm proper vehicle operation.
35. PERFORM SETTING AFTER CONNECTION OF THE BATTERY TERMINAL
a)
After connecting the terminal, perform setting of systems.
(1) Restore the data recorded in disconnection of the battery terminal.
(2) Memorize steering angle neutral point.
(3) Servo motor initialization (for Corolla)
(4) Operate back door lock (for iM ).
34
-
◄ VERIFY REPAIR QUALITY ►
Confirm the ECM Calibration has been updated successfully
Confirm that you have performed and saved the SLP Valve drive pattern file
Confirm you have performed all initializations
Confirm that an Authorized Modification Label has been installed
If you have any questions regarding this SSC, please contact your regional representative
APPENDIX
A. CAMPAIGN DESIGNATION DECODER
Examples:
A0D = Launched in 2010, Remedy Phase, 4th Campaign Launched in 2010
B1E = Launched in 2011, Interim Phase, 5th Campaign Launched in 2011
C1C = Launched in 2012, Interim Phase, 3rd Campaign Launched in 2012
B. RECALL PARTS DISPOSAL
As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the
vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery
return.
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