Hyundai i-30: Dual Clutch Transmission Control System / Inhibitor Switch

Hyundai i30 (PD) 2018-2024 Service Manual / DCT(Dual Clutch Transmission) System / Dual Clutch Transmission Control System / Inhibitor Switch

Description and operation
Description
•
The inhibitor switch is installed on top of transmission, and is connected to the shift lever through shift cable.
•
Inhibitor switch signals (S1, S2, S3, S4) are transmitted to the TCM according to the driver's shift lever control.

Specifications
Specifications
Item
Specification
Power supply
 12V
Output type
 Combination of output signals

Signal Code Table

P
Pst (P - R)
R
Nst (R - N)
N
N-D
D
Signal "1"
 12V
 12V
 0
 0
 0
 0
 0
Signal "2"
 0
 12V
 12V
 12V
 0
 0
 0
Signal "3"
 0
 0
 0
 12V
 12V
 12V
 0
Signal "4"
 0
 0
 0
 0
 0
 12V
 12V

Components and components location
Components

1. Inhibitor switch
 2. Manual control lever

Troubleshooting
Fault Diagnosis
Fault Diagnosis for Symptom
Major Symptom
Expected Cause
Items to Check and Measures
Shift lever not operating
Gear not marked on cluster
Shock occurs while shifting lever Warning lamp ON
Engine OFF while vehicle is parked
Inhibitor switch circuit abnormal
Inhibitor switch function abnormal
 Check the inspection FLOW and replace the inhibitor switch
Inhibitor switch "N" setting faulty
 Adjust "N" setting using "N" setting jig (refer to automatic transmission system - "inhibitor switch")
Shift cable separation faulty
 Adjust shift cable separation (refer to automatic transmission system - "inhibitor switch")
Poor ground condition on reversing light circuit
 Check the ground condition on reversing light and retighten it
Inhibitor switch vehicle side circuit abnormal
Check the connection of junction box power terminal, fuse (TCU2) terminal and replace the junction box or adjust the gap
Check inside the inhibitor switch connector for foreign substance and whether terminal is bent
Poor ground condition on inhibitor switch wire
 Check the ground condition of wire and retighten it
Poor inhibitor unit (disconnection/short-circuit)
 Replace inhibitor switch (refer to inhibitor switch inspection)

Repair procedures
Inspection
  
•
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.
Inspection flow

Items to check
1.
Inspect DTC code.
2.
Inspect whether N setting matches.
–
Adjust N setting (refer to automatic transmission system - "inhibitor switch")
3.
Inspect shift cable separation.
–
Adjust shift cable separation (refer to automatic transmission system - "shift cable")
4.
Inspect whether connector is connected.
–
Inspect connector thoroughly for looseness, poor connection, bending, corrosion, contamination, deformation, or damage.
–
Turn ignition key "ON" and engine "OFF" and measure the power supplied to inhibitor switch circuit and voltage between ground.
Specification : approx. 12 V
–
Fix the pin wiring when connector pin wiring is faulty (refer to ETM - "wiring repair").
5.
Inspect ground condition on reversing light circuit.
–
Check the ground location of reversing light (refer to ETM - "harness location map").
–
Reattach reversing light if ground condition is faulty.
6.
Inspect wiring connection on junction box power terminal and fuse lamp.
–
Check whether fuse holder is separated and holder is holding the fuse tight.
–
Attach tester fuse to check if it is connected appropriately.
–
Check whether fuse capacity is appropriate for each circuit.
–
Check if fuse is damaged.
–
Check pulling of fuse fixing wiring, inflow of foreign substance, and arrangement condition of terminal.
–
Relocate the terminal that has been pulled and inspect using the method explained above.
–
When problem is not solved, refer to the circuit diagram wiring repair instructions to fix or replace the terminal.
7.
Inspect inhibitor switch signal.
–
Turn ignition key "ON" and engine "OFF".
–
Measure the voltage between each terminal and chassis ground when shifting lever to "P, R, N, D" range.
Specified value: refer to specification "signal code" table
Removal
1.
Turn ignition switch OFF and disconnect the battery negative (-) terminal.
2.
Make sure vehicle does not roll before setting shift lever to "N" position.
3.
Remove the air cleaner assembly and air duct.
(Refer to Engine Mechnical System - "Air Cleaner")
4.
Disconnect the inhibitor switch connector (A).
5.
Loosen the shift cable mounting nut (A).
Tightening torque :
9.8 - 13.7 N.m (1.0 - 1.4 kgf.m, 7.2 - 10.1 lb-ft)

6.
Remove the manual control lever (A) after loosening the mounting nut.
Tightening torque :
17.4 - 24.5 N.m(1.8 - 2.5 kgf.m, 13.0 - 18.1 lb-ft)

7.
Remove the inhibitor assembly (B) after loosening the mounting bolts (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

Installation
1.
Check that the shift lever is placed in the "N" position.
2.
Lightly tighten the inhibitor switch mounting bolts (A) after installing the inhibitor switch (B).
3.
Lightly tighten the manual control lever mounting nut after installing the manual control lever (A).
4.
Align the hole in the manual control lever with the "N" position hole of the inhibitor switch and then insert the inhibitor switch guide pin (09480-A3800).
5.
Tighten the nut (A) and bolts (B) with the specified torque.
Tightening torque :
(A) 17.7 - 24.5 N.m (1.8 - 2.5 kgf.m, 13.0 - 18.1 lb-ft)
(B) 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

6.
Lightly tighten the nut (A) after connected the shift cable (B) in the manual control lever (C).
7.
Push shift cable (C) lightly to "F" direction shown to eliminate free play of shift cable.
8.
Tighten the nut (A) with the specified torque.
Tightening torque :
9.8 - 13.7 N.m (1.0 - 1.4 kgf.m, 7.2 - 10.1 lb-ft)

9.
Remove the inhibitor switch guide pin (SST No. : 09480-A3800) from the hole.
10.
Connect the inhibitor switch connector (A).

11.
Install the air cleaner and air duct.
(Refer to Engine Mechanical System - "Air Cleaner")
  
•
Check that operating surely at each range of the inhibitor switch corresponding to each position of shift lever.

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