Service Manual VT2VT3 for Haima ZZ 1. Service information 1.1. Towing of the vehicle The VT3 transmission must not be towed. This is because there is no oil pressure in the primary pulley unless the engine is running and belt slip would therefore occur. Recovery must be conducted with the front wheels lifted clear of the ground (suspended tow). 1.2. Service intervals At least every 2year or 60.000 km the transmission needs a refill of the oil and a replacement of the oil filter. For this purpose, the gearbox is equipped with an oil drain plug and a top filler plug. The vehicle manufacturer can reduce the service interval of the transmission to match it with the standard service intervals for the vehicle. 1.3. Oil specification ESSO EZL799(A). or IDEMITSU CVTFEX1 or PETRONAS Tutela Transmission CVTPPT The use of other oil will lead to damages in the transmission and will result in rejection of warranty claims. Oil refillcheck procedure, see service instruction 2.1 Oil level checks procedure, see service instruction 2.2 1.4. CNG,LPG The risk of changing fuel system: the vehicle will has different or unstable out of torque, this will cause: Different performance Very bad driving adaption Fault code Clutch problem Clutch adaption problem Belt slipping Punch does not allow changing fuel system. Please use oil which we suggest one. Use another oil will cause CVT problem, and will be out of warranty
编号 页号 文 件 DOCUMENT 文件名称 TITLE Page / 95 发行日期 Release Date Set up by 审 核 发放号 Verified by Release No 批 准 受控状态 Approved By 更改单号 D-ASS-205-00 PUNCH Powertrain Service Manual VT2 for GreatWall Daisy/Dahlia (EN) 编 制 Modification Sheet No Number Status 版次 Version 00 更改记录 MODIFICATION REPORT 更改人 更改条款 Modification Modification Item Initial release 更改日期 Person Modification Date S Moerman 2009-06-05 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page / 95 PUNCH Powertrain Continuously Variable Transmission Service Manual VT2 for GreatWall Daisy/Dahlia PUNCH Powertrain Service manual VT2 Page of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page / 95 The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of going to print The right to change prices, specifications, equipment and maintenance instructions at any time without notice, is reserved as part of PUNCH Powertrain policy of continuous development and improvement No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, photocopying, recording, translating or by any other means without prior permission of PUNCH Powertrain No liability can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and accurate as possible (c)2007 PUNCH Powertrain Nanjing Co Ltd Service manual No 19 Hengguang Road, Xingang Development Zone Nanjing, China P.C: 210038 PUNCH Powertrain Service manual VT2 Page of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page / 95 Index General introduction 1.1 Conventional automatic transmission vs continiously variable transmission 1.2 Transmission cross section 1.3 Basic Principles of Continuously Variable Transmission 1.3.1 Group One – Mechanical Torque Flow 1.3.1.1 Planetary gear set 1.3.1.2 Multiplate clutches 10 1.3.1.3 Pulleys and steel belt 10 1.3.1.4 Intermediate shaft 11 1.3.1.5 Differential 12 1.3.1.6 Mechanical operation 13 1.3.1.6.1 Ratio changes 13 1.3.1.6.2 Selector lever in the Neutral or Park position 15 1.3.1.6.3 Selector lever in drive position 16 1.3.1.6.4 Selector lever in the Reverse position 17 1.3.2 Group Two – Control System .18 1.3.2.1 Oil pump 18 1.3.2.2 Variator control 19 1.3.2.3 Clamping force control 19 1.3.2.4 Ratio control 19 1.3.2.5 Transmission control unit 20 1.3.2.5.1 TCU interfaces 20 1.3.3 Group Three – External connections 21 1.3.3.1 Oil cooler connections 21 1.3.3.2 Selector shaft 22 1.3.3.3 Main connector .22 1.3.3.4 Torsional damper 22 1.4 Driving strategies .23 1.4.1 Behaviour in specific situations 23 1.4.1.1 Functionality in Park and Neutral 23 1.4.1.2 Functionality in D (or R) position 23 1.4.1.2.1 Normal operation 23 1.4.1.2.2 Engagements 24 1.4.1.2.3 Creeping 24 1.4.1.2.4 Idle stop (only in D) 24 1.4.1.2.5 Pull-away and stall speed 24 1.4.1.2.6 Pull-away support .25 1.4.1.2.7 Stall speed 25 1.4.1.2.8 Roll out and brake down 25 1.4.1.2.9 Engagements / disengagements during drive 26 1.4.1.3 Fault mode 26 Service information 27 2.1 Towing of the vehicle 27 2.2 Service intervals 27 PUNCH Powertrain Service manual VT2 Page of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page / 95 2.3 Oil specification 27 2.4 Wiring diagram 28 2.4.1 TCU Interfaces .28 2.4.2 Transmission connector layout 29 2.4.3 TCU wiring diagram .30 2.4.4 TCU Connector pin assignment VT2 31 2.4.5 Connections of TCU to Transmission connector 32 2.5 Clutch adaptation procedure .33 Service instructions 35 3.1 Oil fill/check instruction 35 3.2 Exploded view service parts 36 3.3 Service parts list and torque information .37 3.4 Special tools and replacement of service parts 45 3.4.1 Special tools .45 3.4.2 Instructions for replacing of the service parts .50 3.4.2.1 Replacing differential seal .50 3.4.2.2 Replacing input shaft seal .51 3.4.2.3 Replacing oil seal selector shaft .54 3.4.2.4 Replacing primary cover 57 3.4.2.5 Replacing oil pump 58 3.4.2.6 Replacing primary ball bearing 60 3.4.2.7 Replacing secondary cover 64 3.4.2.8 Replacing oil pan 64 3.4.2.9 Replacing oil filter .66 3.4.2.10 Replacing drive mode sensor 68 3.4.2.11 Replacing hydraulic unit 70 3.4.2.12 Replacing output speed sensor and bracket 74 3.4.2.13 Replacing primary speed sensor 76 3.4.2.14 Replacing main connector and internal cable harness .76 3.5 Checklist of the electronic components in the transmission 80 Trouble shooting guide .82 4.1 Leaks 82 4.2 P-codes and actions 83 PUNCH Powertrain Service manual VT2 Page of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page / 95 General introduction The transmission's continuously variable ratio is achieved by means of a variator The variator consists of two cone pulleys located opposite to each other and a steel drive belt that loops around the two pulleys like a V-belt The variator ratio is transmitted through an intermediate shaft to the differential incorporated into the transmission housing This Student Information provides an overview of the transmission The design and function of the various assemblies of the transmission, the power transmission and the transmission control are described individually In addition, an overview is also provided for the transmission fluid cooling system and the external gearshift mechanism All spare parts and service tools are described, as well as the error codes and actions to be carried out Please remember that our training literature has been prepared for PUNCH Powertrain TRAINING PURPOSES only Repairs and adjustments MUST always be carried out according to the instructions and specifications in the service manual of the vehicle Please make full use of the training offered by PUNCH Powertrain Technical Training Courses to gain extensive knowledge of both theory and practice The stepless shifting pattern of the transmission provides a very comfortable drive, as well as having full vehicle performance, available at any time The advantages of using an automatic transmission of this type are: - Low engine revolutions at constant speeds - Improved emission control/fuel consumption - Low noise, vibration and harshness levels - Smooth acceleration - Flexible driving on mountain roads Because of its fully electronic control the VT2 pushes the limits of its predecessor even further PUNCH Powertrain Service manual VT2 Page of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page / 95 1.1 Conventional automatic transmission vs continiously variable transmission In the figure below the variograms of both a manual or normal stepped automatic transmission and the CVT are compared with each other With the conventional automatic transmission, a fixed number of ratios (gears) is available When the transmission performs an upshift, it has to follow the bold or dotted lines of the first image depending of the amount of throttle With the CVT, the whole range of ratios between the Low and the Overdrive lines is available for shifting as shown in the second image The shift point of both transmissions is related to the amount of throttle that is applied by the driver As more throttle is applied, the transmission performs its upshift at a higher engine speed With the conventional transmission it is clear that the engine speed drops back when shifting to a higher gear This is not the case with the CVT The CVT will upshift at a constant engine speed, by moving the pulleys as explained in the next part However, alternative shifting strategies are also possible This can help to create a quicker acceptance by new CVT drivers Figure Variogram stepped automatic transmission (left) and CVT transmission (right) PUNCH Powertrain Service manual VT2 Page of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page / 95 1.2 Transmission cross section 10 Torsional damper / Flywheel Fluid pump Reverse clutch Planetary gearing Forward clutch PUNCH Powertrain Steel belt Primary pulley Secondary pulley Intermediate shaft 10 Differential Service manual VT2 Page of 95 编号 页号 文 件 DOCUMENT Number D-ASS-205-00 Page / 95 1.3 Basic Principles of Continuously Variable Transmission The VT2 consists of a number of elements that can be divided into three groups, depending upon their function Group One – Mechanical Torque Flow Elements providing the mechanical torque flow through the transmission Group Two – Control system These elements relate to the control system This system enables the transmission to transmit power and to vary the ratio in a proper way, according to load conditions and driver demand Group Three – External Connections Some elements have external connections with the transmission Some of these elements are either inside the gearbox, or immediately connected to it Others can be part of the system, but can be located elsewhere on the vehicle 1.3.1 Group One – Mechanical Torque Flow 1.3.1.1 Planetary gear set The planetary gear set enables the transmission to provide a drive torque in two directions, forward and reverse Engine torque always enters the transmission through the input shaft of the planet carrier This carrier can be directly connected to the sunwheel by closing the forward multi-plate clutches When it does, the epicyclic gear set rotates as one unit, and engine torque is transmitted directly to the primary pulley The planet gears not transmit any torque, therefore no mechanical loss will occur in the planetary gear set and the primary pulley will rotate in the same direction as the engine This is the forward drive mode In reverse mode, the annulus of the planetary gear set is held stationary by closing the reverse multi-plate clutches Three pairs of planet gears are driven by the planet carrier, forcing the sun-wheel to rotate in the opposite direction There is a small multiplication of torque being transmitted since the ratio of the epicyclic gear set is 1:1.1, in order to compensate for frictional losses within the planetary gear set itself Planet gears Input shaft Sun gear Annular gear Fig 4: Planet gears PUNCH Powertrain Service manual VT2 Page of 95 编号 页号 文 件 DOCUMENT Number D-ASS-205-00 Page 10 / 95 1.3.1.2 Multiplate clutches There are two Multiplate wet clutch packs; one forward and one reverse Each pack has three friction plates providing six friction surfaces The hydraulic pressure controls the clutches to allow the vehicle to move away smoothly by every throttle opening By controlling the clutch slip it also allows the vehicle to be held stationary after the drive gear is engaged Oil from the oil cooler is directed to the clutch plates to prevent overheating of the friction surfaces Forward clutch pack Reverse clutch pack Fig 5: Planetary gear set showing clutch plates 1.3.1.3 Pulleys and steel belt The main design feature of the CVT is a pair of steel "V " shaped pulleys connected by a steel drive belt The distance between centres of the primary and secondary pulley is 155 mm Each pulley consists of one fixed half and one axially slideable half, both having 11 degree sloping sides The proven 24 mm wide "Van Doorne" push type drive belt is used to transfer torque between the pulleys (applications for higher torque values can make use of a 30 mm drive belt) The belt is lubricated and cooled by an oil jet from a nozzle Both moving halves are situated diagonally opposite to each other in order to reduce misalignment of the drive belt during shifting Each moving half is connected to a hydraulic cylinder/piston Hydraulic pressure is controlled by the control system, described in the section titled ‘Hydraulic system’ Ball splines prevent the moving halves from rotating relatively to their fixed partners Torque transmitted by the planetary gear set acts directly onto the primary pulley, as the sunwheel is splined to it The steel drive belt transmits the power from the primary pulley to the secondary pulley and the power from the secondary pulley is then transmitted to the pinion shaft PUNCH Powertrain Service manual VT2 Page 10 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 81 / 95 When temp between 20°C and 40°C, we need to measure a resistance between 942 Ohm and 1121 Ohm Speed Sensor This is a complicated 'Two Wire' component with no easy way of checking the correct way of working Between pin and pin 11, we need to measure a resistance of app 24,3 MOhm Between pin and pin 12, we need to measure a resistance of app 24,3 MOhm NOTE: this method will not guarantee the correct function of the speed sensor Oil Pressure Sensor Between pin and pin 10, we need to measure a resistance of app 44,3 KOhm Clutch Pressure Regulator Between pin and 4, we need to measure a resistance of app 5,2 Ohm Primary Pressure Regulator Between pin and 3, we need to measure a resistance of app 5,2 Ohm Secondary Pressure Regulator Between pin and 2, we need to measure a resistance of app 5,2 Ohm TCU No checking possible Remark: Ranges of resistor values can differ in function of the accuracy of the measuring equipment PUNCH Powertrain Service manual VT2 Page 81 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 82 / 95 Trouble shooting guide 4.1 Leaks Fault Action Leak from gearbox fluid pan gasket Ensure fluid pan bolts are correctly tightened Replace fluid pan gasket Replace drain plug Replace oil pan cpl Leak from gearbox drain plug Ensure plug is correctly tightened Replace drain plug Replace oil pan cpl Leak from primary cover Ensure that cover is correctly tightened Replace O ring Replace primary cover Leak from secondary cover Ensure that cover is correctly tightened Replace cover O-rings Replace secondary cover cpl Leak from selector shaft lever Replace selector shaft lever seal Leak from input shaft Replace input shaft seal Leak from differential oil seal(s) Replace oil seals Leak from fluid cooler pipe connections Ensure that pipes are correctly tightened Replace pipe to fluid cooler connection sealing rings Replace pipes PUNCH Powertrain Service manual VT2 Page 82 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 83 / 95 4.2 P-codes and actions General remark: Whenever there is an error (DTC) detected by the transmission electronics (TCU), the warning lamp on the dashboard will be activated or flashing When reading out the DTCs with the tester tool and a P-code is found, first check if this P-code is a sporadic fault, that did not occur in the last driving cycle (Should be indicated with an „H“ from History) If so, just delete the FC and check if it does not come back If not a sporadic fault, but currently active (Should be indicated with a „C“ from Currently), folow the action steps described below for each error code P0710 Oil temperature sensor fault Reaction from TCU Warning lamp Substitute transmission oil temperature Man actions: measure the oil temperature online with tester tool; if the signal value is feasible, just clear the FC and check if it does not come back check wiring (SG, SB, OC) measure resistance between two pins on transmission connector (20deg = 980 to 1000 Ohm) to see if sensor is defective If it's defective, skip next step and directly replace cable harness replace TCU by known good one replace transmission P2765 Primary pulley speed sensor fault Reaction from TCU High side* off，Warning lamp Man actions: measure the primary speed sensor value online with tester tool; if the signal value is feasible, just clear the FC and check if it does not come back check wiring (SG, SB, OC) replace TCU by known good one replace speed sensor P0720 Secondary pulley speed sensor fault Reaction from TCU Warning lamp, Substitute secundary pulley speed Man actions: measure the secundary speed sensor value online with tester tool; if the signal value is feasible, just clear the FC and check if it does not come back check wiring (SG, SB, OC) replace TCU by known good one replace speed sensor P0840 Secondary pressure sensor fault Reaction from TCU High side* off， Warning lamp 、 、 、 、 、 、 、 、 、 、 、 、 、 PUNCH Powertrain ： ， ： ： ： Service manual VT2 Page 83 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 84 / 95 Man actions: measure the actual and target secondary pressure online with tester tool; if the signal value is feasible, just clear the FC and check if it does not come back check wiring based on the values read out in step one (SG: bar (actual pressure), SB: 60 bar, OC: 60 bar) replace TCU by known good one replace hydraulic unit P0641 Pressure sensor supply fault Reaction from TCU High side* off，Warning lamp Man actions: measure the 5V supply voltage online with tester tool; if the signal value is feasible, just clear the FC and check if it does not come back measure voltage between pressure sensor supply and pressure sensor ground, based on result you get in step check wiring (SG, SB, OC) replace TCU by known good one P0651 DMS and speed sensor supply fault Reaction from TCU High side* off，Warning lamp Man actions: measure the 8.4V supply voltage online with tester tool; if the signal value is feasible, just clear the FC and check if it does not come back measure voltage between pressure sensor supply and pressure sensor ground, based on result you get in step check wiring (SG, SB, OC) replace TCU by known good one P0659 High side* SCB Reaction from TCU High side* off，Warning lamp Man actions: measure the HS voltage the same voltage level as the battery should be read out If so, check wiring (check if shortcut between battery + and VHS, transmission connector) This means fix the harness If not (same as battery) but higher than 3.4 V, then exchange the TCU P0658 High side* SCG or OC Reaction from TCU High side* off，Warning lamp Man actions: measure the HS voltage: compare it to the battery voltage If the battery voltage is ok, and the high side voltage is smaller than 3.4 V, then there is a SG If the battery voltage is ok, and the high side voltage is higher than 3.4 V, then it's an OC In both cases, check the harness, dependant on the type of problem 、 、 、 、 。 、 、 、 、 、 、 、 、 。 ： 。 ： 。 ： 、 ， ： 、 PUNCH Powertrain Service manual VT2 Page 84 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 85 / 95 (mention the pin nbs) If, after checking, the harness is ok, change the TCU If the battery voltage was not ok, then check the battery P0702 Watchdog test failed (during init) Reaction from TCU High side* off，Warning lamp Man actions: replace TCU P0962 EDS1* (primary pulley) SCG Reaction from TCU High side* off，Warning lamp Man actions: measure resistance of EDS1 - should be 5.05 Ohm +- 6% check wiring (SG) replace hydraulic unit P0963 EDS1* (primary pulley) SCB Reaction from TCU High side* off，Warning lamp Man actions: measure resistance of EDS1 check wiring (SB) replace hydraulic unit P0960 EDS1* (primary pulley) OC Reaction from TCU High side* off，Warning lamp Man actions: measure resistance of EDS1 check wiring (OC) replace hydraulic unit P0966 EDS2* (secondary pulley) SCG Reaction from TCU High side* off，Warning lamp Man actions: measure resistance of EDS2 check wiring (SG) replace hydraulic unit P0967 EDS2* (secondary pulley) SCB Reaction from TCU High side* off，Warning lamp Man actions: measure resistance of EDS2 check wiring (SB) replace hydraulic unit P0964 EDS2* (secondary pulley) OC Reaction from TCU ： ： 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 PUNCH Powertrain 。 ： ： ： ： ： Service manual VT2 Page 85 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 86 / 95 High side* off，Warning lamp Man actions: measure resistance of EDS2 check wiring (OC) replace hydraulic unit P0902 EDS3* (clutch) SCG Reaction from TCU High side* off，Warning lamp Man actions: measure resistance of EDS3 check wiring (SG) replace hydraulic unit P0903 EDS3* (clutch) SCB Reaction from TCU High side* off，Warning lamp Man actions: measure resistance of EDS3 check wiring (SB) replace hydraulic unit P0900 EDS3* (clutch) OC Reaction from TCU High side* off，Warning lamp Man actions: measure resistance of EDS3 check wiring (OC) replace hydraulic unit P1763 Start lock SCG or OC Reaction from TCU High side* off，Warning lamp Man actions: Check the wiring P1764 Start lock SCB Reaction from TCU High side* off，Warning lamp Man actions: Check the wiring P0930 Shift lock SCG Reaction from TCU High side* off，Warning lamp Man actions: check the wiring P0931 Shift lock SCB or OC Reaction from TCU High side* off，Warning lamp Man actions: 、 、 、 、 、 、 、 、 、 、 、 、 ： ： ： ： ： ： ： PUNCH Powertrain Service manual VT2 Page 86 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 87 / 95 check the wiring P1768 Backlight SCG Reaction from TCU High side* off，Warning lamp Man actions: check the wiring P1769 Backlight SCB or OC Reaction from TCU High side* off，Warning lamp Man actions: check the wiring PXXXX Error lamp SCG Reaction from TCU High side* off，Warning lamp Man actions: check the wiring PXXXX Error lamp SCB or OC Reaction from TCU High side* off，Warning lamp Man actions: check the wiring P0868 Operation readiness time-out Reaction from TCU High side* off，Warning lamp Man actions: check oil level and oil type replace pump replace hydraulic unit replace transmission P0811 Clutch (forward or reverse) slipping Reaction from TCU Warning lamp，Clutch open Man actions: measure the clutch pressure and the difference speed online with tester tool; if the signal value is feasible, just clear the FC and check if it does not come back If it's not feasible (for example 10 bar clutch pressure and a high difference speed), go to the next step check oil level and oil type replace hydraulic unit replace transmission P0730 Ratio control fault Reaction from TCU High side* off，Warning lamp Man actions: ： ： ： ： ： 、 、 、 、 ： 、 、 、 、 、 PUNCH Powertrain ： Service manual VT2 Page 87 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 88 / 95 、 check signal from speed sensors with the tester tool, as well as target current and actual current for the primary pressure and target and actual primary pressure itself; depending on previous results, speedsensor problem or hydraulic pressure problem check oil type and oil level replace speed sensors or hydraulic unit replace pump replace transmission P1765 Secondary pulley pressure too low Reaction from TCU High side* off，Warning lamp Man actions: measure the actual and the target pressure in dynamic driving situations like tip ins, launch, check oil level and oil type replace hydrailic unit replace oil pump replace transmission P1766 Secondary pulley pressure too high Reaction from TCU Warning lamp Man actions: measure the actual and the target pressure in dynamic driving situations like tip ins, launch, check oil level and oil type replace hydrailic unit replace oil pump replace transmission P0701 Double fault requiring high side* open Reaction from TCU High side* off，Warning lamp Man actions: check other FCs P0218 High oil temperature Reaction from TCU Warning lamp Man actions: Check oil cooler Try to reproduce in normal driving condition - if not reproducable, ask customer about driving conditions when the FC occurred while trying to reproduce it, you can check the transmission temperature with the tester tool T_trans > 120 (longer than the filter time of 30 minutes!); measures to avoid further temperature increase P1767 Critical oil temperature 、 、 、 、 、 、 、 、 、 、 、 、 、 、 、 ： ： ： ： 、 、 、 PUNCH Powertrain 。 Service manual VT2 Page 88 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 89 / 95 ： Reaction from TCU High side* off，Warning lamp Man actions: try to reproduce in normal driving condition - if not reproducable, ask customer about driving conditions when the FC occurred (uphill driving or high speed driving?) check oil cooler check the oil level T_trans > 140; high side of pressure regulator currents opens -> open clutch you have to find the cause of the problem, because high side opens when this FC occurs again! P0219 Powertrain speed out of range Reaction from TCU High side* off，Warning lamp Man actions: should never occur in principle check the fuel cut off of the engine (does it limit the engine speed to 6000 rpm?) P2766 Primary pulley speed unplausible Reaction from TCU High side* off，Warning lamp Man actions: check with the tester tool if other speed information (engine speed, output speed, vehicle speed) is also missing; if so, fix that problem first and check if this FC still occurs check with the tester tool the n_s1 signal if the clutch is closed and compare with engine speed (difference should be smaller than 200 rpm) - this for the whole range of engine speeds (up till 6000 rpm) check wire harness check sensor position, angle; same with trigger wheel; check if there's no object in front of the sensor (piece of the belt, or…) - note: this is a mechanical fault; electrical faults are triggered by other FCs replace primary speed sensor exhange the TCU to make sure change the transmission P0721 Secondary pulley speed unplausible Reaction from TCU Warning lamp, Increased clamping level 0, substitute secundary pulley speed Man actions: check with the tester tool if other speed information (engine speed, pulley speed, vehicle speed) is also missing; if so, fix that problem first and check if this FC still occurs check with the tester tool the signal (vehicle speed based on n_ab) and compare with vehicle speed (difference should be smaller than kph) - 、 、 、 、 、 ： 、 、 ： 、 、 、 、 、 、 、 ： 、 、 PUNCH Powertrain Service manual VT2 Page 89 of 95 编号 页号 文 件 DOCUMENT 、 、 Number D-ASS-205-00 Page 90 / 95 check wire harness check sensor position, angle; same with trigger wheel; check if there's no object in front of the sensor (piece of the belt, or…) - note: this is a mechanical fault; electrical faults are triggered by other FCs replace secondary speed sensor exhange the TCU to make sure change the transmission P0944 Insufficient clamping force (VSM) Reaction from TCU Warning lamp, Clutch open Man actions: if it has occurred often, it indicates there are often secondary pressure drops (for longer than 6s!) -> check oil level first then replace transmission, because there is no way to find the root cause for this problem (pump, hydraulic unit, …) P0810 End of Line (EoL) clutch adaptation not finished Reaction from TCU Warning lamp flashing Man actions: A new TCU has probably been installed or SW on the TCU has been updated Perform a clutch adaptation as described in 2.5 Clutch adaptation procedure If this is performed correctly, the warning lamp will go out and the error code will disappear after driving cycles (Key off/on) P1762 Current stuck Reaction from TCU High side* off，Warning lamp Man actions: check FC15 to FC23 + actions replace TCU with a known good one P0882 Battery or high side* voltage too low Reaction from TCU High side* off，Warning lamp Man actions: check the freeze frame if it's a historical fault: it has information on battery voltage when this FC occurred (so you can distinguish if the battery, or the highside caused this FC); if not an historical fault, check it directly = next step check with the tester tool the highside voltage and/or the battery voltage threshold depends on temperature: look up in software now you have distinguished if it is the battery or the highside If the battery is the problem: check wiring (fuse, main relay) from battery to TCU replace/check battery if the highside is the problem: check the wiring from the gearbox to the TCU replace TCU P0883 Battery or high side* voltage too high Reaction from TCU High side* off，Warning lamp 、 、 、 。 。 ： ： ： 、 、 ： 、 、 、 、 、 、 PUNCH Powertrain ： Service manual VT2 Page 90 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 91 / 95 Man actions: check the freeze frame if it's a historical fault: it has information on battery voltage when this FC occurred (so you can distinguish if the battery, or the highside caused this FC); if not an historical fault, check it directly = next step check with the tester tool the highside voltage and/or the battery voltage threshold depends on temperature: look up in software now you have distinguished if it is the battery of the highside if the battery is the problem: ask customer if he did a jump start (= 24V) if the battery is the problem: check wiring (fuse, main relay) from battery to TCU if the batteryis the problem: replace/check battery if the highside is the problem: check the wiring from the gearbox to the TCU replace TCU, replace/check alternator P2787 Clutch temperature too high Reaction from TCU Warning lamp，Clutch open Man actions: Check how many times this FC has occurred If only one (or a few times), look into freeze frame and ask customer about special driving condition You can delete the FC Can only occur when throttle and brake are applied at the same time for a certain period Delete error code and see if it comes back replace TCU can be sticking throttle valve, replace throttle valve P0727 Hardwired engine speed unplausible Reaction from TCU Warning lamp Man actions: check if the engine reports an error as well (with the tester tool); if so fix this engine problem check wiring input signal TCU - it is a frequency signal (900 rpm engine speed should give a 30 Hz signal, 3000 rpm gives 100 Hz) replace TCU by a known good one P1761 EDS current fault Reaction from TCU High side* off，Warning lamp Man actions: check sum of low side currents with high side current, and compare each EDS actual current with its target with the tester tool, check the actual currents of the EDSs with the target currents; if you find one of these being different, check the wiring of this EDS (also inside the gearbox) replace TCU by a known good one replace hydraulic unit U0301 Vehicle configuration mismatch Reaction from TCU 、 、 、 、 、 、 。 ： 、 、 、 、 、 、 、 ： ： 、 、 、 、 PUNCH Powertrain ： Service manual VT2 Page 91 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 92 / 95 High side* off，Warning lamp Man actions: Check if the combination of TCU HW and TCU SW is valid If there is new SW flashed in ECU or TCU: the SW on the newly flashed controller must be wrong (incompatibity between engine and transmission controller) P0706 Drive mode sensor single line error Reaction from TCU Warning lamp, Substitute lever position Man actions: check with the tester tool which line is affected and what the problem is; for example line B short cut battery (this FC indicates one of the lines is faulty) check wiring of the affected line between transmission and TCU replace TCU by a known good one replace drive mode sensor P0705 Drive mode sensor multiple lines error Reaction from TCU High side* off，Warning lamp Man actions: check with the tester tool which lines are affected and what the problem is; for example line B short cut battery and … (this FC indicates that there is more than one line faulty) check wiring of the affected lines between transmission and TCU replace TCU by a known good one replace drive mode sensor P0571 Brake signal error Reaction from TCU Warning lamp, Brake signal on Man actions: check with the tester tool the status of the brake signal check wiring of brake signal replace TCU P0955 Tip mode signals error Reaction from TCU Warning lamp, No manual mode Man actions: check wiring from shifter to TCU replace TCU by a known good one replace shifter U0415 ABS function error Reaction from TCU Increased clamping level 0* Substitute detection function of blocked and spinning wheels Man actions: check ABS system 、 、 ： 、 、 、 、 、 、 、 、 、 、 、 、 、 PUNCH Powertrain ： 。 ： ： ： ， Service manual VT2 Page 92 of 95 编号 页号 文 件 DOCUMENT U0001 Number D-ASS-205-00 Page 93 / 95 CAN bus off Reaction from TCU High side* off Warning lamp Man actions: if this problem is present in all other controllers, there is a wiring problem (shortcut between CAN high and CAN low): check vehicle harness if the fault is only stored in the TCU: replace TCU by a known good one U0121 CAN ABS communication failed Reaction from TCU Increased clamping level 0* Substitute detection function of blocked and spinning wheels Substitute front left wheel speed Substitute front right wheel speed Substitute rear left wheel speed Substitute rear right wheel speed Man actions: check the ABS controller and the CAN connection from the ABS controller (probably this fault is reported in other controllers as well) U0100 CAN ECU communication failed Reaction from TCU Warning lamp，Emergency mode* active Increased clamping level 0* No manual mode, Activate internal driving strategy Substitute engine torque Substitute engine cooling water temperature Accelerator pedal value fixed Stop transmitting on CAN Man actions: check the engine controller and the CAN connection from the enginecontroller (probably this fault is reported in other controllers as well) U1012 CAN engine speed signal error Reaction from TCU High side* off Warning lamp Man actions: check the MCU controller (motor speed sensor and sensor wiring) U1013 CAN accelerator pedal signal error Reaction from TCU Warning lamp Accelerator pedal value fixed Man actions: check the EMS controller (accelerator pedal sensor and sensor wiring) U1014 CAN engine torque signals error Reaction from TCU Warning lamp，Emergency mode* active, No manual mode Activate internal driving strategy Substitute engine torque Man actions: check the EMS controller U1016 CAN wheel speed error - front left ： ， 、 、 ： ， ， ， ， ， ： ， ， ， ， ， ： ， ： ， ： ， PUNCH Powertrain Service manual VT2 Page 93 of 95 文 件 DOCUMENT ： 编号 页号 Number D-ASS-205-00 Page 94 / 95 Reaction from TCU Increased clamping level 0* Substitute detection function of blocked and spinning wheels Substitute front left wheel speed Man actions: check the ABS controller (wheel speed sensor and sensor wiring) U1017 CAN wheel speed error - front right Reaction from TCU Increased clamping level 0* Substitute detection function of blocked and spinning wheels Substitute front right wheel speed Man actions: check the ABS controller (wheel speed sensor and sensor wiring) U1018 CAN wheel speed error - rear left Reaction from TCU Increased clamping level 0* Substitute detection function of blocked and spinning wheels Substitute rear left wheel speed Man actions: check the ABS controller (wheel speed sensor and sensor wiring) U1019 CAN wheel speed error - rear right Reaction from TCU Increased clamping level 0* Substitute detection function of blocked and spinning wheels Substitute rear right wheel speed Man actions: check the ABS controller (wheel speed sensor and sensor wiring) ， ： ， ： ， ： ， ， ， ， ， Note: -High side*: is the supply voltage for the pressure regulators When error code occurs and High side is switched off, then the clutch goes open and the vehicle can not move anymore until you a KEY ON/OFF -Increased clamping level 0*: secondary pressure is at a fixed level, but a higher level than normal operating conditions, lower than max -Increased clamping level 1*: secondary pressure is at a fixed level, maximum pressure -EDS1*: primary pulley pressure regulator -EDS2*: secondary pressure regulator -EDS3*: clutch pressure regulator -Emergency mode*: Also called “Limp Home Mode” Is activated when -CAN bus is off -CAN ECU communication failed -CAN engine torque signals have an error All engine and ABS related messages will be substituted immediately (safety reactions): -Throttle pedal = fixed -Engine torque map instead of the engine torque -Engine cooling temperature = fixed -Wheel speeds = substituted by the output shaft speed of the gearbox PUNCH Powertrain Service manual VT2 Page 94 of 95 文 件 DOCUMENT 编号 页号 Number D-ASS-205-00 Page 95 / 95 -Engine speed = substituted by the hard wired engine speed if available -The clutch will open and close much more brutal, as if there is no calibration on it -The maximum engine speed will be limited to 3200 rpm, even if the throttle pedal is fully pressed -The maximum vehicle speed will be about 90 kph -The gearbox will shift but within basic driving strategy The overall CVT working principle will become BASIC and this is proven to be suitable enough to get to the nearest workshop only -After 2sec, Tip mode (+/- or Sport) will not be possible anymore and warning lamp will be on PUNCH Powertrain Service manual VT2 Page 95 of 95