Inspection Procedure
NOTE:^ * If you are working on a vehicle with 15,000 miles or less, go directly to A/T OIL JET KIT INSTALLATION.*
^ For questions about camera adjustment, camera mounting, or gear condition, call the RPO Tech Line at 888-997-7278, and select option # 2. Do not call the Automobile Tech Line.
^ For questions about camera warranty and camera software, call Canon Technical Support at 800-828-4040. Do not call the Special Tools Hotline.
^ The system requirements for using the Canon Digital Camera Solution Disk Version 17.1 software are Microsoft Windows 98, Me, 2000, or XP on a PC with built-in USB ports; PC with Pentium 150MHz or higher (Windows 98, Me, or 2000), or Pentium 300 MHz or higher (Windows XP). This software cannot be used on systems running Windows NT
1. 3.2CL and 3.2TL models: Go to step 5.
2. * "04 TL models: Remove the left side and left rear engine compartment covers.*
3. "04 TL models: Unbolt the air cleaner lid, detach the battery cable clips from the lid, then remove the lid and the intake air duct.
4. '04 TL models: Remove the two 10 mm bolts from the under-hood fuse/relay box. Then detach the engine harness clip from the fuse/relay box, and pull the fuse/relay box forward.
5. Clean the area around the ATF filler bolt, the countershaft speed sensor, and the ATF filter line.
6. * Unplug the countershaft speed sensor 3P connector, and remove the sensor mounting bolt. Gently twist the sensor left and right until it loosens, then remove the sensor and its 0-ring.
NOTICE
Do not use a screwdriver or pry tool to remove the countershaft speed sensor; you could damage the housing.*
7. Connect an air nozzle to the shop air supply. Insert the nozzle into the countershaft speed sensor hole, and blow air onto the top of 2nd gear for at least 15 seconds.
NOTE:
This step is very important; it removes residual ATF from the gear so you can see it more clearly. Make sure you blow air over the entire top of the gear. Do not use anything but compressed air for this step.
8. Use a clean shop towel to wipe the sensor hole bore.
9. Point the LED flashlight at the sensor hole to light up 2nd gear. Use a small, flat-tip screwdriver to scrape across the top of the gear teeth. This will help you get a clearer photo of the gear.
NOTE:
^ If the gear teeth are brighter where you scraped them, it is a first sign of gear overheating.
^ The angle cuts near the top of the gear teeth are not a defect in the gear; they are used to identify gears during A/T assembly.
10. * Ready the digital camera for use. Refer to these sources as needed:
^ The online animated version of the inspection procedure
^ Setting the Digital Camera in the Automatic Transmission Gear Inspection Guide
^ Powershot A75 Digital Camera User Guide
^ Powershot A75 Digital Camera Quick Start Guide*
11. Apply a color bar sticker to the base of the camera mount. Set the last six digits of the VIN on the numbering stamp, ink the stamp with the ink pad, and then stamp the VIN onto the color bar sticker.
NOTE:
For verification purposes, you need to use a new color bar sticker and the correct last six digits of the VIN for each vehicle you inspect.
12. On the camera mount, position the spacer below the bracket.
13. Remove the ATF filler bolt.
14. Use the ATF filler bolt to attach the camera mount to the A/T.
15. Attach the camera to the camera mount. Be careful not to damage the plastic threads in the bottom of the camera.
16. 3.2CL and 3.2TL models: Detach the throttle cable from the cable bracket on the driver's side of the bulkhead. Before taking any photos, move the throttle cable and the purge control hose out of the way.
17. '04 TL models: Make sure the fuse/relay box is out of the way.
18. Turn on the camera. Select Manual mode (M), turn on the macro (the flower icon appears in the lower right corner of the display), and set the digital zoom to 6.0x. Make sure the flash is turned on.
NOTE:
The digital zoom turns off after 1 minute if you do not press any buttons.
19. Point the LED flashlight at the countershaft speed sensor hole to light up 2nd gear. Keep the tip of the flashlight out of the image area.
20. Center the rectangular box in the camera display on the sensor hole, then press and hold the shutter button half way down until the box color changes from white to green. If the box color does not change to green, release the shutter button, and try again.
NOTE:
The image in the display will not look as good as the actual photo.
21. While continuing to hold the shutter button half way down, turn off the flashlight, and remove it from the area.
22. Gently squeeze the shutter button until the camera flash goes off and the image appears on the camera display.
23. Repeat steps 19 thru 22 to take five clear photos of the gear. If needed, reposition the camera mount to center your photos.
24. Remove the camera from the camera mount.
25. Remove the camera mount from the A/T.
26. Reinstall the countershaft speed sensor. Torque the bolt to 12 Nm (8.7 lb-ft). Plug in the 3P connector.
27. Slide the switch on the camera back to > (Play mode). Turn off the camera.
28. Load the camera software (Canon Digital Camera Solution Disk Version 17.1) onto an iN workstation. For loading instructions, refer to the Powershot A75 Quick Start Guide, step 6.
NOTE:
If you have any software-related problems, call Canon Technical Support at 800-828-4040.
29. Plug the USB interface cable into a USB port on the back of the workstation and into the digital terminal on the left side of the camera.
30. Turn on the camera.
NOTE:
The rest of the photo downloading steps are done at the workstation, not from the camera.
31. When you see the Camera Window Download Images screen on the workstation monitor, click on List Images.
32. Click on the images you want to download to the workstation.
33. Click on Download Image. The Download Setting menu comes up.
34. Click on Create New Folder. Name the new folder the 17-digit VIN you are currently working on. Click on Set as new, then click on OK.
35. To view a photo, double-click on it. Delete any photos you do not intend to use.
NOTE:
All digital photos used for this inspection must be retained at your dealership until further notice. If not, the warranty claim will be rejected. You need at least one good photo per VIN.
36. Use the Automatic Transmission Gear Inspection Guide (Reorder Number E2393) to match the gear color in your photos with one of the gear condition levels in the guide. To ensure a good match, hold the guide next to the monitor. Also, try getting a second opinion from at least one other person.
NOTE:
The gear color in your photos should be similar to the color in the inspection guide photos. If your photo colors are not similar, try viewing your photos on a different monitor.
^ * If you decide that the gear color in your photos matches condition level # 1 in the inspection guide, then install an A/T Oil Jet Kit. Go to A/T OIL JET KIT INSTALLATION. For 3.2CL and 3.2TL models, go to step 1, and detach the engine harness clips from the ATF oil line. Then go to step 11 of the procedure. For '04 TL models, go to step 4, and remove the air cleaner. Then go to step 8 of the procedure.*
^ If you decide that the gear color in your photos matches any condition level other than # 1 in the inspection guide, you must send your photos to the RPO Tech Line for review. Go to step 37.
37. Bring up the Warranty Automatic Transmission Order form on the iN:
^ From the iN main menu, click on SERVICE.
^ Click on Warranty A/T Order.
^ Enter the model and year of the vehicle you are working on, and then click on Search.
^ Click on Warranty Automatic Transmission Order to bring up the Warranty Automatic Transmission Order form.
38. Fill out all required fields on the form. Required fields have a red dot next to them.
NOTE:
For additional information on filling out this form and uploading images to the iN, refer to Quick Start Warranty A/T Order Images, listed under Job Aids in ISIS.
39. In the form's Service Bulletin 04-013/04-020 field, click on Yes.
40. Click on Image Upload, and browse for the VIN file you want to upload. Preview the photo if needed by double-clicking on it. If the photo is not clear, select another one. Do this step for each photo you are submitting.
NOTE:
You must upload your photos one at a time.
41. Click on Submit to send the A/T order form and your photos to the RPO Tech Line. They will review your photos and determine whether the A/T needs an A/T Oil Jet Kit or to be replaced.
^ * If the gear color is normal, the RPO Tech Line will cancel your order and direct you to install an A/T Oil Jet Kit. Go to A/T OIL JET KIT INSTALLATION. For 3.2CL and 3.2TL models, go to step 1, and detach the engine harness clips from the ATF oil line. Then go to step 11 of the procedure. For '04 TL models, go to step 4, and remove the air cleaner. Then go to step 8 of the procedure.
^ If the gear color indicates an overheating condition, your order will be processed, and a remanufactured A/T will be sent to you as soon as possible. To check if your order was accepted, go to the iN main menu, click on PARTS, Parts Ordering, and then Warranty A/T VIN Inquiry. Enter a date in the All Orders Accepted Since box, and then click on Submit. From the WARRANTY A/T VIN INQUIRY ACKNOWLEDGMENT screen, find the VIN you want, and look across at the STAT column to determine your order status.
^ When you get the remanufactured A/T, go to A/T REPLACEMENT.*
NOTE:
If you ordered a remanufactured A/T for a 3.2CL or 3.2TL, you may get an updated PCM and you may also get a new fuel pressure regulator (shipped separately). Make sure you complete the repair by installing the updated PCM, the fuel pressure regulator (if sent), and the remanufactured A/T at the same time.