AL4 Transmission

CITROËN
TECHNICAL TRAINING
PRESENTATION OF THE AL4 AUTOMATIC TRANSMISSION
CITROËN UK LTD
221 BATH ROAD SLOUGH SL1 4BA
_________________
DEALER PERSONNEL DEVELOPMENT AND TRAINING
_________________
© CITROËN UK LTD. Reproduction whether partial or in full without written permis
sion from Citroën UK Ltd is forbidden
PDF created with pdfFactory trial version www.pdffactory.com
A
DOCUMENT SUMMARY PRESENTATION OF THE AL4 AUTOMATIC TRANSMISSION
The aim of this document is to give a brief description of the design and operat
ion of the electronically managed AL4 automatic transmission which offers precis
e, adaptive control as well as excellent gear changing quality. The following su
bjects are dealt with in this document: - Presentation of the transmission and v
arious pieces of information, - The selector control, - Lubrication, - The conve
rter, - The mechanism, - The ECU, - Auto-diagnostics, - The electrical circuit,
- Unit maintenance.
AL4 AUTOMATIC TRANSMISSION
© AUTOMOBILES CITROËN Toute reproduction ou traduction même partielle sans l'aut
orisation écrite d'AUTOMOBILES CITROËN est interdite et constitue une contrefaço
n
B
CONTENTS
CHAPTER 1 : PRESENTATION - GENERAL .............................
III III IV VVI INTRODUCTION.....................................................
......................... PRESENTATION .........................................
.................................... DESCRIPTION OF THE AL4 AUTOMATIC TRANSMISSI
ON .......... IDENTIFYING THE COMPONENTS OF THE AUTOMATIC TRANSMISSION..........
.................................................................... SPECIFICATI
ONS - SERVICING ..................................................... LAYOUT OF
THE AL4 AUTOMATIC TRANSMISSION .................... PAGE 1 PAGE 1 PAGE 2 PAGE 3
PAGE 5 PAGE 7 PAGE 8 PAGE 9 PAGE 11 PAGE 11 PAGE 13 PAGE 15 PAGE 17 PAGE 17 PAGE
18 PAGE 21 PAGE 21 PAGE 23 PAGE 27 PAGE 27 PAGE 31 PAGE 33 PAGE 35 PAGE 35 PAGE
36
VII - MISCELLANEOUS ADVICE......................................................
.......
CHAPTER 2 : SELECTOR CONTROL........................................
III SELECTOR LEVER .............................................................
............ PROGRAM SELECTOR...................................................
................
CHAPTER 3 : CHECKING THE OIL LEVEL ............................... CHAPTER 4 : T
HE TORQUE CONVERTER...............................
III DESCRIPTION.................................................................
................ CONVERTER LOCK-UP .............................................
.....................
CHAPTER 5 : THE EPICYCLIC GEAR TRAIN ...........................
III DESCRIPTION.................................................................
................ OPERATING PRINCIPLE ...........................................
.....................
CHAPTER 6 : ECU.................................................................
......
III III ECU FUNCTIONS...........................................................
................. OPERATING SUMMARY ............................................
..................... ECU CONNECTIONS ..........................................
............................
CHAPTER 7 : AUTO-DIAGNOSTIC ............................................
III FAULT WARNINGS .............................................................
............ MEMORISED FAULTS / DOWNGRADED MODES..........................
n
C
CONTENTS
CHAPTER 8 : WIRING DIAGRAM - XANTIA..............................
PETROL ENGINE/WITHOUT CRUISE CONTROL ILAYOUT....................................
....................................................... PETROL ENGINE/WITH CRUIS
E CONTROL ILAYOUT...............................................................
............................ DIESEL ENGINE/WITHOUT CRUISE CONTROL ILAYOUT.......
................................................................................
.... DIESEL ENGINE/WITH CRUISE CONTROL III LAYOUT...............................
............................................................ PARTS LIST.........
............................................................................ PAG
E 40 PAGE 41 PAGE 43 PAGE 43 PAGE 43 PAGE 44 PAGE 44 PAGE 44 PAGE 44 PAGE 45 PAG
E 39 PAGE 38 PAGE 37 PAGE 37
CHAPTER 9 : AFTER-SALES OPERATIONS ............................
III III IV VVI DOWNLOADING......................................................
........................ CONFIGURATION .........................................
.................................. PEDAL PROGRAMMING ...........................
...................................... INITIALISING THE "OLD OIL" COUNTER.......
................................. UPDATING THE "OLD OIL" COUNTER ...............
............................ TEST AFTER REPAIR WORK ............................
.............................
VII - CHANGING PARTS, OPERATIONS TO BE PERFORMED ............. VIII - AUTHORISED
OPERATIONS DURING THE WARRANTY PERIOD PAGE ....................................
....................................................... 46 IX XXI AUTOMATIC TRAN
SMISSION REPAIR BY THE CITROËN AUTOMATIC TRANSMISSION CENTRE, SOUTH WEST PARIS .
... SPECIAL TOOLING ............................................................
............. DIAGNOSTIC TOOLING ...............................................
............... 51
PAGE 47 PAGE 50
n
D
n
1 Chapter 1
PRESENTATION - GENERAL
I-
INTRODUCTION
AL4001D
• Electronically operated transverse automatic transmission. • Four forward gear
s and one reverse gear. • "Fuzzy logic" auto-adaptive ECU which controls the con
verter, gear changes and specific programs. • The maximum torque capacity is 210
mN. • Sealed transmission with reduced maintenance. • Transmission oil cooled b
y heat exchanger. • Current application: CITROËN XANTIA PHASE II vehicles with X
U Petrol and Diesel engines.
n
2 Chapter 1 II PRESENTATION Transmission layout • • • • • • • Hydraulic torque c
onverter with lock-up device. Primary shaft. Two "Simpson 2" type epicyclic gear
trains. Multiplate clutches. Multidisc and band brakes. Step down gear in centr
al position. Differential with sealed outputs.
Control This is performed by: • the hydraulic unit, • the ECU, • a cable control
. Features • Lock-up of 2nd, 3rd and 4th gears. • Electronic control of all regu
lation and gear changing functions. • Three programs offered to driver: Auto ada
ptive - Sport - Snow • Gears and programs displayed on dashboard. • Cannot chang
e up a gear in the no load position. • User interface performed by a "stepped" s
elector grid with Shift-Lock safety function and program push buttons. • "1st" i
mposed position selected using push button. • Auto adaptive "Flash EEPROM" ECU.
• Downgraded operation in the event of a fault. • Closed loop operation. • On bo
ard diagnostics. • Selector lever not in position P reminder buzzer. Important:
The automatic transmission ECU management ECU so as to obtain: is linked to the
engine
good driving pleasure, efficient mechanical protection for transmission and engi
ne, increased operating safety, compliance with antipollution standards.
n
3 Chapter 1 III - DESCRIPTION OF THE AL4 AUTOMATIC TRANSMISSION A - CROSS SECTIO
N
22 21 10 11 12 13
14 1 15 3 2 16
17 7 8 9 19 20 6 5 4 18
AL4002P
n
4 Chapter 1 B - PARTS LIST 1 - Converter 2 - Input shaft 3 - Fitted oil pump 4 -
Secondary pinion of step down gear 5 - Park wheel 6 - Secondary shaft 7 - Drive
pinion 8 - Ring 9 - Differential unit 10 - Cover 11 - Adjustable plate 12 - Hyd
raulic distributor (DH) 13 - Manual valve 14 - Auxiliary hydraulic distributor (
DHA) 15 - Clutch E1 (Reverse and 1st) 16 - Clutch E2 (2nd, 3rd, 4th) 17 - Hub 18
- Brake F1 (4th) 19 - Brake F2 (Reverse) 20 - Brake F3 (1st and 2nd) 21 - Epicyc
lic gear train 22 - Primary pinion of step down gear
n
5 Chapter 1 IV - IDENTIFYING THE COMPONENTS OF THE AUTOMATIC TRANSMISSION A - AU
TOMATIC TRANSMISSION The automatic transmission identification is engraved on th
e rear housing.
20TP15 0000877
A B
AL4003D
A - Component reference B - Serial number
n
6 Chapter 1 B - ECU
SIEMENS
S108518006 A
0/ 02150 / 270234214 / 97253
M A D E N F R A N C E
1209263000
9630386980
BVA
7700103423
AL4004D
F C D E G SIEMENS
S108518006 A
0/ 02150 / 270234214 / 97253
M A D E I N F R A N C E
1209263000
9630386980
H I
BVA
7700103423
C - Siemens reference D - Siemens serial number E - Siemens number bar code F -
Serial number G - Software version H - Hardware version I - Customer number bar
code
n
7 Chapter 1 VSPECIFICATIONS - SERVICING A - FREQUENCY - CAPACITIES XANTIA Engine
Transmission capacity Draining capacity Exclusive oil Draining interval Top-up
interval Transmission lubrication Final drive lubrication Weight Torque capacity
B - GEARS XANTIA Engine Transmission type Tyres - circumference Gear ratios 1st
2nd 3rd 4th Reverse Step down gear Cylindrical torque Tachometric torque XUD9BT
F 20TP04 205/60R15 - 1.920 m Rd 0.367 0.667 1 1.407 -0.407 Rdem 2.72 1.5 1 0.71
-2.45 52x67 25x71 24x20 Vveh 11.55 21.00 31.48 44.30 12.81 XU10J4R 20TP05 XU7JP4
20TP06 XUD9 BTF/XU10J4R/XU7JP4 Approximately 6 litres Approximately 3 litres CI
TROËN 97.36.22 Lubricated for life 60 000 km Pressurised Pressurised ≈ 70 kg wit
h oil and ECU 210 mN from 2000 to 4500 rpm
185/65R15-1.895m Rd 0.367 0.667 1 1.407 -0.407 Rdem 2.72 1.5 1 0.71 -2.45 52x67
23x73 24x20 Vveh 10.20 18.53 27.79 39.10 11.31
Speeds in km/h are given for 1000 rpm. Rd = driveshaft ratio / Rdem = demultipli
cation ratio Vveh = Vehicle speed. Internal gear change safety thresholds: LEVER
POSITION 3 2 2 + press on "1" button of program selector R R + foot on brake
n
SAFETY THRESHOLD 113 km/h 73 km/h 35 km/h 15 km/h 25 km/h 155 km/h 103 km/h 48 k
m/h 19 km/h 34 km/h
8 Chapter 1 VI - LAYOUT OF THE AL4 AUTOMATIC TRANSMISSION
Selector ever
Prog. elec-tor
Buzzer
Rev
Final drive + differential
Epicyclic gear train
Dist.
MIL illumin request
Electro-hydraulic distributor
Automatic transmission
P u m p
Dist.
Oil.
Electro-hydraulics
Throttle potentio-meter
"Kick-down" info
Electr-onics
Mechanics (engine)
Braking info.
Cm = Engine torque ωm = Engine speed ωs = Gear train output speed
Cr = Torque at road heels ωe = Gear train input speed ωr = Road heel speed
n
PDF created ith pdfFactory trial version .pdffactory.com
P/N - D - Gear change
Exchanger oil flo setting
AT ECU
AL4005P
Engine management computer
Dist.
C o n v e r t e r
throttle α
Control p nel
ShiftLock S
Displ y counter
1st
9 Ch pter 1 VII - MISCELLANEOUS ADVICE A - TOWING The tr nsmission is lubric ted
when the engine is running since this drives the tr nsmission oil pump. Thus, w
hen towing, the drive wheels must be r ised off the ground. However, the vehicle
m y be towed with the drive wheels on the ground under exception l circumst nce
s nd provided th t the following conditions re complied with: • the selector l
ever must be in position N, • do not dd ny oil, • do not exceed 50 km/h over
dist nce of 50 km. B - DRIVING Never drive with the ignition switched off. Neve
r push the vehicle to try nd st rt it (not possible with utom tic tr nsmission
). Note: The utom tic tr nsmission is only lubric ted when the engine is runnin
g.
C - OPERATIONS ON ELECTRICAL COMPONENTS Never disconnect: • the b ttery whilst t
he engine is running, • the ECU whilst the ignition is switched on. Before recon
necting connector, check: • the condition of the v rious cont cts (bent, ruste
d...), • th t the mech nic l locking device is present nd check its condition.
During electric l inspections: • the b ttery must be correctly ch rged, • never
use power source gre ter th n 16 V, • never use tell-t le light.
© AUTOMOBILES CITROËN Toute reproduction ou tr duction même p rtielle s ns l' ut
oris tion écrite d'AUTOMOBILES CITROËN est interdite et constitue une contref ço
n
PDF cre ted with pdfF ctory tri l version www.pdff ctory.com
10 Ch pter 1 D - OPERATIONS ON MECHANICAL COMPONENTS Never pl ce the tr nsmissio
n on the ground unprotected. The converter ret ining pin must be inserted when t
he tr nsmission is removed. The centring pin must be used to couple the tr nsmis
sion to the engine. Remove the centring pin just before coupling the tr nsmissio
n to the engine.
n
11 Ch pter 2
SELECTOR CONTROL
I-
SELECTOR LEVER The selector lever, through the selector sh ft (on the tr nsmissi
on), oper tes the multifunction switch nd the m nu l v lve on the hydr ulic dis
tributor.
D
A
B
C E RI
AL4007D
A - Upper p rt B - Lower p rt C - Sleeve stop D - Control lever E - Locking plun
ger for the Shift-Lock function Ri - Initi l setting
n
12 Ch pter 2 The selector lever, loc ted on the centr l console, h s six positio
ns l id out on n offset or "stepped" grid. The lever h s mech nic l s fety de
vice which is unlocked by exerting r di l ction on the lever. Note: The ignit
ion must be switched on nd the br ke ped l pressed to unlock the selector lever
from position P. This is the Shift-Lock function.
C
Ri
G
AL4028C
C - Sleeve stop Ri - Initi l setting G - Control return with b ll joint
n
13 Ch pter 2 II PROGRAM SELECTOR This is loc ted on the centr l console next to
the selector lever nd h s 3 push buttons. The driver c n therefore inform the E
CU of his selection: • desired progr m, • 1st imposed → this is obt ined by pres
sing the "1" button of the selector with the selector lever in position 2 on the
grid.
P R N D 3 2
AL4006C
N D
Ge rs ch nge utom tic lly depending on vehicle speed nd engine lo d in ccord
nce with v rious ge r ch nging l ws. The ge r ch nging l ws re chosen by the EC
U s function of one of the three progr ms v il ble to the driver. The driver
c n select progr m by pressing one of the "S" or "*" progr m selector buttons
.
n
14 Ch pter 2 The following three progr ms re v il ble: • uto d ptive or "norm
l" (no buttons pressed): this is the b sic progr m; the ECU djusts the oper ti
on of the utom tic tr nsmission to the style of driving, the ro d nd engine lo
d; it promotes fuel economy, • "Sport" (S button pressed): this progr m promote
s sporty driving to the detriment of consumption. Ge rs re still ch nged utom
tic lly, • "Snow" (* button pressed): this progr m is suited to driving on low
dherence ground. In drive, this me ns th t either first ge r or first nd second
ge rs re no longer v il ble nd ge rs re ch nged down less frequently using
specific set of ch nging l ws. Furthermore, in the imposed positions 1, 2, 3,
the "Snow" set of l ws re used which t ke into ccount the restrictions rel tin
g to the chosen imposed position. Note: Every time the ignition is switched off
then on g in, the ECU utom tic lly switches to the "norm l progr m" configur t
ion.
n
15 Ch pter 3
CHECKING THE OIL LEVEL
Check the oil level every 60 000 kms. Prerequisites: • • • • • • • vehicle on ho
rizont l ground, check th t the tr nsmission is not in downgr ded mode, remove t
he filler plug 1 nd system tic lly dd 0.5 litres of oil to the tr nsmission, p
ress the br ke nd ch nge through ll the ge rs, selector lever in position P, e
ngine running t idle speed, oil temper ture 60 °C + 8 . -2
1
4 3
AL4008C
AL4009C
4
1 - Filler plug 2 - Tr nsmission housing 3 - Level plug 4 - Dr in plug
2
3
AL4010C
n
16 Ch pter 3 • Remove the level plug (3). • If oil stre ms out then st rts to dr
ip → close the level plug nd tighten to 2.4 md N. • If oil drips out or does no
t flow t ll → close the level plug (3), stop the engine, dd 0.5 litres of oil
to the tr nsmission, repe t the level checking procedure, the oil level is corr
ect if oil stre ms out nd then st rts to drip, close the level plug (3) nd tig
hten to 2.4 md N close the filler plug (1) nd tighten to 2.4 md N Too much oil
m y h ve the following consequences: • bnorm l he ting of the oil, • oil le ks.
Too little oil m y d m ge the tr nsmission. Note: An oil check is not included
in the PDI nor the first service.
n
17 Ch pter 4
THE TORQUE CONVERTER
The AL4 utom tic tr nsmission is fitted with st nd rd torque converter which
h s n dded lock-up device. IDESCRIPTION 123456789 8
Lock-up piston Double sided friction pl te Vibr tion d mper Impeller Turbine St
tor Free wheel Oil pump drive Autom tic drive tr nsmission input sh ft
9-
St rting ring
AL4011P
7 1
6 2
Drive end pl te
AL4027C
3
Converter
5
4
n
18 Ch pter 4 The torque converter consists of: • n impeller (4), linked to the
engine, • turbine (5), linked to the tr nsmission, • st tor (6), fitted on t
he free wheel (7) nd loc ted between the impeller nd the turbine, • lock-up
device oper ted by the ECU which consists of piston (1), friction pl te (2)
nd vibr tion d mper (3). The converter is secured to the engine drive pl te (
end pl te). Its role is to provide flexible nd utom tic link between the eng
ine nd the tr nsmission. It h s two oper ting ph ses: • the converter ph se whe
re it multiplies the engine torque by up to 2.2 times, • the coupling ph se wher
e it tr nsmits the engine torque with n efficiency of 0.98 (1 if it is locked u
p). II CONVERTER LOCK-UP A - GENERAL The clutch is hydr ulic lly oper ted by n
electrov lve controlled by the ECU. The clutch c n be in one of two st tes: • •
open st te → norm l converter oper tion, closed st te where it connects the impe
ller nd the turbine so s to tr nsmit ll of the engine torque → engine br ke
v il ble, reduction in fuel consumption, cooling of utom tic tr nsmission oil.
Lock-up is v il ble on 2nd, 3rd nd 4th ge rs ( nd 1st ge r in r re c ses). The
converter is locked up by inverting the direction of oil flow. The ECU controls
the two possible st tes of the lock-up using set of memorised l ws.
n
19 Ch pter 4 B - OPERATING PRINCIPLE OF THE LOCK-UP The lock-up piston (1) is us
ed to connect the impeller (4) to the turbine (5) vi the vibr tion d mper (3)
nd the friction pl te (2). 1 - Converter not locked up
AL4012D
1 5 b
In the unlocked mode, oil pressure rrives through the lock-up circuit ( ) so s
to free to lock-up piston from the clutch pl te. The oil then supplies the conv
erter nd the spring through the converter circuit (b).
2 4 3
2 - Converter locked up In the locked mode, the lock-up circuit ( ) is connected
to t nk. The oil therefore rrives through the converter circuit (b) into the c
onverter c using the lock-up piston to move. This llows the turbine to connect
with the impeller vi the vibr tion d mper nd double sided clutch pl te. Note:
The lock-up piston is joined to the rot ting impeller.
AL4013D
n
20 Ch pter 4
n
21 Ch pter 5
THE EPICYCLIC GEAR TRAIN
I-
DESCRIPTION To provide the four forw rd ge rs nd one reverse ge r, the AL4 uto
m tic tr nsmission h s SIMPSON type epicyclic ge r tr in. This consists of two
simple epicyclic ge r tr ins connected together. There re: • two sunwheels P1
nd P2, • two sets of pl net wheels S1 nd S2, • two pl net wheel c rriers PS1
nd PS2, • two rings C1 nd C2. The two ge r tr ins re connected in the followin
g m nner: • pl net wheel c rrier PS1 nd ring C2 re connected together, • pl ne
t wheel c rrier PS2 nd ring C1 re connected together. Ge r tr in n°1 is loc te
d on the re r housing side. Ge r tr in n°2 is loc ted on the converter side; the
movement system tic lly exits through its pl net wheel c rrier PS2.
F1 E1 E2 C1 S1 P1 PS1 P2
F2 C2 S2
F3
Prim ry pinion of the step down ge r Movement input housing PS2
AL4014D
n
22 Ch pter 5
Second ry pinion of the step down ge r
P2
C2
PS1
P1 Connection with PS1
PS2 C1
AL4015P
Prim ry pinion of the step down ge r
Ge r tr in specific tions Sunwheel P1 Sunwheel P2 Pl net wheel S1 Pl net wheel S
2 Ring C1 Ring C2
n
33 teeth 40 teeth 21 teeth 19 teeth 81 teeth 80 teeth
23 Ch pter 5 II OPERATING PRINCIPLE 1st ge r
F1 E1 C1 E2 PS1
F2
F3
C2
PS2
PP des P1 P2
Lock-up
PP des = Prim ry step down pinion
AL4016D
Prim ry
2nd ge r
F1 E1 C1 E2 PS1
F2
F3
C2
PS2
PP des P1 P2
Lock-up
AL4017D
Prim ry
n
24 Ch pter 5 3rd ge r
F1 E1 C1 E2 PS1
F2
F3
C2
PS2
PP des P1 P2
Lock-up
AL4018D
Prim ry
4th ge r
F1 E1 C1 E2 PS1
F2
F3
C2
PS2
PP des P1 P2
Lock-up
AL4019D
Prim ry
n
25 Ch pter 5 Reverse
F1 E1 C1 E2 PS1
F2
F3
C2
PS2
PP des P1 P2
Lock-up
AL4020D
Prim ry
T ble of moving p rts
GEAR 1 2 3 4 Reverse
DRIVING COMPONENT P1 PS1 - C2 P1 nd PS1 - C2 PS1 - C2 P1
REACTION COMPONENT P2 P2 none P1 PS1 - C2
RATIO 2.72 1.5 1 0.71 2.45
n
26 Ch pter 5
n
27 Ch pter 6
ECU
The ECU of the AL4 tr nsmission is n uto d ptive nd upgr d ble ECU with 56
tr ck Fl sh Eprom. IECU FUNCTIONS The ECU performs the following functions: A -
GEAR CHANGING LAWS The ECU h s 10 ge r ch nging l ws llowing the oper tion of t
he tr nsmission to be ltered to the driver's style of driving, to the chosen pr
ogr m nd to the intern l nd extern l conditions. The following l ws re theref
ore obt ined: • 6 l ws: for uto d ptivity, • 1 l w: for the snow progr m, • 1 l
w: "unlocked" for low temper ture oper tion, • 1 l w: for depollution when cold
(he ting), • 1 l w: for utom tic tr nsmission temper ture protection. B - PROG
RAMS The ECU m n ges three progr ms: uto d ptive, Sport nd Snow (upon driver's
request). C - AUTO-ADAPTIVENESS The ECU h s n uto d ptive progr m which llow
s it to chose the l w which will be the best suited to the following conditions
from the ten l ws listed bove: • driver's style of driving → 3 l ws = "economic
", Medium", "Sport ", • ro d profile nd vehicle lo d → 3 l ws = "slight incline
" (or "br king 1"), "sh rp incline" (or "br king 2"), "decline", • temper ture,
• selected progr m.
n
28 Ch pter 6 D - GEAR CHANGE UP PREVENTION DUE TO SUDDEN REMOVAL OF FOOT FROM AC
CELERATOR This function prevents the tr nsmission from ch nging up to higher g
e r when the foot is suddenly removed from the cceler tor ped l; this llows th
e engine br ke to be m int ined whilst deceler ting. E - GEAR LOCKING FOLLOWING
A LAW CHANGE For re sons of s fety nd comfort, the tr nsmission is prevented fr
om ch nging up or down ge r too quickly if the l w h s just ch nged. F - CHANG
E DOWN The ECU is tot lly responsible for ch nging down the ge rs s function
of engine lo d, vehicle speed nd driving conditions. The ECU uthorises doubl
e ch nge down (from 4th to 2nd nd 3rd to 1st) or forces single ch nge down. F
urthermore, the ECU provides ch nge down function in the event of sust ined br
king in order to nticip te downw rd ge r ch nges nd so s to provide the engi
ne br ke. G - MOMENTARY SWITCH TO SPORT PROGRAM So s to provide better power t
ke-up in the norm l progr m, the ECU tempor rily switches to more sporty l w w
hen the cceler tor ped l is suddenly pressed down. H - KICKDOWN The kickdown or
der is given by the utom tic tr nsmission ECU fter the cceler tor ped l is pr
essed down fully nd depending on vehicle speed. I - MANAGEMENT OF IMPOSED GEARS
The ECU is tot lly responsible for ch nging to imposed ge rs in terms of oper t
ion nd s fety (ch nging limits). J - CONTROLLING THE LINE PRESSURE The ECU work
s out the v lue of line pressure with closed loop feedb ck. The reference v lue
is function of the turbine torque to overcome.
n
29 Ch pter 6 K - MANAGING GEAR CHANGES When the ECU decides to ch nge ge r, it
must oper te the v rious electrov lves involved in precise order nd in ccor
d nce with timers which re function not bly of the engine lo d nd vehicle sp
eed. This provides good overl p between the receiver which is emptying nd the
one which is filling up. L - OPERATING THE CONVERTER LOCK-UP CLUTCH This functi
on optimises the converter oper tion by locking it up to s ve fuel, to obt in en
gine br king, to encour ge cooling of the tr nsmission oil nd to prevent slip.
A l w which depends on vehicle speed, throttle position nd ge r eng ged is used
to decide whether to lock the converter up or not. M - TORQUE REDUCTION This fu
nction is used to incre se driving ple sure by reducing the engine torque when c
h nging ge r. This ction consists of moment rily reducing the ignition dv nce
in ccord nce with pre-progr mmed t ble provided by the engine m n gement comp
uter. N - IDLE SPEED COMPENSATION This function is used to ttenu te the dr ggin
g effect of the tr nsmission when it is being driven through the engine m n geme
nt computer (idle reference speed). O - AUTOMATIC TRANSMISSION PROTECTION • Reve
rse ge r s fety: for vehicle speed > Threshold. • Incorrect oper tions: − on the
automatic transmission: change from N → D or N → R prohibited if N > threshold.
The change is authorised if N < threshold or after a timer. P SHIFT LOCK FUNC
TION This function locks the selector lever in position P when the ignition is s
witched on. The lever is unlocked by pressing the brake pedal.
n
30 Chapter 6 Q CONTROL PANEL DISPLAY The ECU informs the driver of the positio
n of the selector lever and the choice of program using the liquid crystal displ
ay on the control panel. The ECU may also warn the driver of a transmission prob
lem by flashing the sport and snow display. R "OLD OIL" FUNCTION Using the par
ameters of automatic transmission oil temperature and the time for which the oil
is subject to a high temperature, the ECU increments an "old oil" counter. When
this reaches the calibrated maximum valve, the ECU orders the "Sport" and "Snow
" warning lights to flash on the control panel to warn the driver that the autom
atic transmission oil needs changing. S SAFETY DIAGNOSTIC The ECU: • permane
ntly checks its supplies and that its sensors and actuators are operating correc
tly, • validates and stores operating faults, • talks with after sales tools thr
ough line K, • provides a downgraded mode, • asks the engine management computer
to illuminate the engine management light in the event of a fault leading to a
deterioration in the level of vehicle pollution (only on fiscal level L4). T C
ONFIGURATION DOWNLOADING The ECU can be upgraded; its program can be updated b
y downloading. The configuring operation is used to configure the automatic tran
smission ECU depending on the options which are not fitted to the vehicle. U O
THER FUNCTIONS The following three functions, inherent to automatic transmission
, are performed by the multifunction switch: 1 Buzzer This tells the driver th
at he is leaving his vehicle without having put the selector lever in position P
. 2 Illumination of reversing lights in position R. 3 Prevention from starti
ng engine when not in positions P or N.
n
31 Chapter 6 II OPERATING SUMMARY
3 1 2
4
5
7
4
5
9
4
11
12
33
A 36
6
B 13 14 15 16 16 15 14 13
8
C 17 EOBD
10 13 14
16
1 32 19 31 34 18
30
35
R 28
29
27
26
25
24
23
22
21
20
AL4021P
Load information A Petrol engine with double track potentiometer B Petrol en
gine with single track potentiometer C Diesel engine
n
32 Chapter 6 Parts list REF. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 33 34 35 36 DESCRIPTION Accelerator pedal
Kickdown function on accelerator cable Double track throttle potentiometer TDC
sensor Engine coolant temperature probe Petrol injection ECU Single track thrott
le potentiometer Petrol injection ECU Potentiometer on injection pump load lever
Diesel injection ECU Torque reduction electrovalve Kickdown information Engine
load information Engine speed + engine coolant temperature information Engine to
rque information (provided by injection ECU) Torque reduction request informatio
n + idle speed compensation request information Illumination of EOBD light reque
st information (only on versions with L4 depollution) LED display (control panel
) Diagnostic socket Sequence electrovalve Pressure modulating electrovalve Oil f
low modulating electrovalve Transmission oil temperature probe Transmission oil
pressure sensor Transmission input speed sensor Transmission output speed sensor
Multifunction switch Reversing lights Starter motor prevention relay Shift lock
actuator Gear lever Program selector (Sport, Snow, Normal, 1st imposed) Brake p
edal (braking information) Stop switch Automatic transmission ECU Not in positio
n P reminder buzzer Throttle position information (throttle potentiometer)
n
33 Chapter 6 III ECU CONNECTIONS PIN N° 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 22 23 23 24 25 26 27 28 29 30 31 DESCRIPTION Output: supply
(+) for sequence electrovalves (EVS1 to EVS6) Output: supply to electrovalve co
ntrolling flow in heat exchanger Output: air conditioning compressor cut off com
mand Output: display (on instrument panel) Output: torque reduction request /idl
e speed compensation / Output: illumination of EOBD light request information (*
) (to engine management computer) Output: sequence electrovalve EVS3 (earth) Out
put: sequence electrovalve EVS4 (earth) Output: sequence electrovalve EVS2 (eart
h) Output: sequence electrovalve EVS1 (earth) Output: shift lock actuator contro
l Output: heat exchanger oil flow electrovalve control (EPDE) Output: sequence e
lectrovalve EVS5 (earth) Output: sequence electrovalve EVS6 (earth) Input: kickd
own control Input: brake redundant contact (brake opening contact) L diagnostic
line K diagnostic line Output: lock up electrovalve Output: main pressure electr
ovalve / / Input: engine torque information / Throttle position information inpu
t (driver's wishes information) Supply (+) to oil pressure sensor Supply ( ) to
oil pressure sensor Supply (+) to modulating electrovalves (pressure EVM, lock u
p EVM) Supply (+) to ECU Supply to ECU (common earth with engine management ECU)
/ Input: multifunction switch position S2 contact COMMENTS
not used
depending on version L4 version
n
34 Chapter 6
PIN N° 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 51 52 52 53 5
4 55 56 56
DESCRIPTION Input: multifunction switch S3 contact Input: multifunction switch S
4 contact Input: multifunction switch Parking/Neutral contact / Input: program s
elector, "1" button Input: multifunction switch S1 contact /
COMMENTS
Input: program selector: snow button Input: program selector, normal/sport butto
n Electronic earth for multifunction switch Input: stop lights contact (brake cl
osing contact) / Input: signal (+) from turbine speed sensor Input: signal ( ) f
rom turbine speed sensor Signal ( ) from automatic transmission output speed sen
sor Signal (+) from automatic transmission output speed sensor Input: engine spe
ed information (TDC) / Supply ( ) for throttle potentiometer double track potent
iometer / Supply (+) for throttle potentiometer double track potentiometer / Sig
nal ( ) from oil temperature probe Signal (+) from oil temperature probe Input:
signal from line pressure sensor Input: signal from throttle potentiometer /
EMC: engine management ECU EOBD: European On Board Diagnosis
n
35 Chapter 7
AUTO DIAGNOSTIC
IFAULT WARNINGS The appearance of certain faults in the system causes the SPORT
and SNOW warning lights to flash. The sport and snow warning lights flash in the
following cases: • when the transmission oil is too hot (extinguish when oil ha
s cooled), • when the transmission oil is old (oil counter value at calibrated m
aximum value), • when there is a break in the serial link between the transmissi
on ECU and the control panel. The "SPORT" and "SNOW" warning lights flash if the
re is a fault on the following components or information: • transmission ECU, •
ECU supply, • oil pressure sensor, • supply to sequence electrovalves (EVS1 to E
V6), • regulation fault in main hydraulic pressure, • multifunction switch, • se
quence electrovalves (EVS1 to EV6), • main pressure modulating electrovalve (pre
ssure EVM), • converter lock up modulating electrovalve (lock up EVM), • oil flo
w electrovalve in heat exchanger, • main hydraulic pressure electrovalve, • acce
lerator pedal not programmed, • input speed and output speed, • input speed and
engine speed, • output speed and engine speed, • engine speed information, • ped
al position, • supply to analogue sensors.
n
36 Chapter 7 II MEMORISED FAULTS / DOWNGRADED MODES There are 6 levels of downgr
aded mode depending on the fault detected. FAULT FOUND Level 1 kick down input
Level 2 Level 3 transmission oil temperature engine torque information display
control shift lock actuator vehicle speed lock up modulating electrovalve torque
reduction output pressure sensor supply to sensors brake switch input heat exch
anger flow modulating electrovalve (EPDE) throttle position information suppli
ed by the injection ECU and torque information missing Level 4 engine speed
transmission input speed sensor EFFECT no effect on operation of transmission sl
ight degradation in operation, impact on driving comfort large degradation in op
eration of the transmission (reduced gear changing quality, loss of functions)
Level 5 Level 6
large degradation in operation of the transmission (loss of functions, or downgr
aded functions) throttle potentiometer information Switches to 3rd hydraulic the
next time the ignition is engine torque information multifunction switch (loss
of reverse gear switched on. safety when driving) If the vehicle is in 4th gear,
this gear is maintained and supply to analogue sensors pressure modulating elec
trovalve 3rd gear is automatically main pressure regulation engaged the next tim
e the heat exchanger oil flow modulating ignition is switched on. electrovalve c
ontrol This downgraded mode is called differed stopping input speed and output s
peed mode input speed and engine speed output speed and engine speed ECU not wor
king Switches to 3rd hydraulic. sequence electrovalves This downgraded mode is c
alled stopping mode supply to sequence electrovalves accelerator pedal position
not programmed Transmission in stopping mode: a loud bang may be felt when movin
g the lever from P ⇒ R or N ⇒ R. In hydraulic emergency mode, gear changing safe
ty limits are no longer provided.
Warning: Warning:
n
37 Chapter 8
WIRING DIAGRAM XANTIA
PETROL ENGINE/WITHOUT CRUISE CONTROL ILAYOUT
AL4022P
n
38 Chapter 8
PETROL ENGINE/WITH CRUISE CONTROL ILAYOUT
AL4023P
n
39 Chapter 8
DIESEL ENGINE/WITHOUT CRUISE CONTROL ILAYOUT
AL4024P
n
40 Chapter 8
DIESEL ENGINE/WITH CRUISE CONTROL ILAYOUT
AL4025P
n
41 Chapter 8 II PARTS LIST BB00 Battery BF00 Passenger compartment fuse box
BMF1 Maxi fuse box C001 Diagnostic socket CA00 Ignition switch M000 MC10 M
C16 MM07 Earths
0004 Control panel 1005 Starting prohibition relay 1316 Throttle position
sensor 1621 Automatic transmission vehicle speed sensor 1630 Automatic trans
mission ECU 1631 Torque reduction electrovalve 1635 Automatic transmission e
lectro hydraulic unit 1637 Automatic transmission kickdown switch 1638 Autom
atic transmission shift lock actuator 1640 Automatic transmission program sele
ctor 1642 Shift lock control relay 2100 Stop switch 7307 Cruise control sa
fety relay 10 Starting function, current generation 12 Injection sup
ply function 21 Stop lights function 22 Reversing lights function 30
Passenger compartment lighting function 73 Cruise control function
80 Air conditioning function
n
42 Chapter 8
n
43 Chapter 9
AFTER SALES OPERATIONS
I
DOWNLOADING This operation is to be performed in the following cases: • when the
automatic transmission ECU is updated, • to adapt the automatic transmission EC
U to an upgraded engine management computer, The downloading operation must be f
ollowed by: • a pedal programming operation, • configuration, • a road test. IMP
ORTANT: The engine management computer must be upgraded every time the automatic
transmission ECU is upgraded. Following the procedure on the ELIT or PROXIA/LEX
IA diagnostic tool to perform a downloading operation.
II
CONFIGURATION This operation is to be performed in the following cases: • replac
ement of ECU, • downloading to ECU. A new or newly downloaded ECU is always conf
igured with the following three options: • with or without shift lock, • with or
without air conditioning, • with or without EOBD (L4 depollution standard). The
ECU configuration operation consists of preventing the options not fitted to th
e vehicle from being subject to the diagnostic procedure. Follow the procedure o
n the ELIT or PROXIA/LEXIA diagnostic tool to perform a configuration operation.
n
44 Chapter 9 III PEDAL PROGRAMMING This operation is to be performed in the fo
llowing cases: • replacement of ECU, • replacement of automatic transmission, •
updating by downloading, • replacement or adjustment of accelerator cable, • rep
lacement of or downloading (XUD9BTF/XU7JP4/L4), • replacement of throttle potent
iometer, • replacement of diesel injection pump. Follow the procedure on the ELI
T or PROXIA/LEXIA diagnostic tool to perform a pedal programming operation. IV
INITIALISING THE "OLD OIL" COUNTER This procedure will be active from update n°
13 of the diagnostic tools. The aim of this operation is to tell the automatic t
ransmission ECU that the transmission oil has just been changed. VUPDATING THE "
OLD OIL" COUNTER This procedure will be active from update n° 13 of the diagnost
ic tools. It consists of making the transmission ECU memorise the "old oil" coun
ter should the ECU be replaced without changing the oil. Note: If the oil counte
r cannot be read from an old ECU, change the transmission oil. VI TEST AFTER R
EPAIR WORK The ECU permanently adapts itself to the transmission. Thus, when rep
lacing the transmission, the ECU or another transmission component, a road test
must be performed choosing a route which allows frequent gear changes and the us
e of all gears. All the programs should also be selected. This test is absolutel
y essential so that the ECU can adapt itself to the transmission by comparing re
ference values with actual values. The difference recorded is then memorised to
allow optimum gear changing quality. to engine management computer
n
45 Chapter 9 VII CHANGING PARTS, OPERATIONS TO BE PERFORMED
COMPONENT REPLACED
Transmission (1)
OPERATION TO BE PERFORMED
Adjust multifunction switch + Initialise old oil counter (2) + Road test Initial
ise old oil counter (2) Adjust control inside transmission + Road test
COMMENTS
requires diagnostic tool + multimeter
Transmission oil Replace hydraulic distributor components (hydraulic distributor
, electrovalves) Heat exchanger oil flow modulating electrovalve Transmission in
put speed sensor Transmission output speed sensor Main pressure sensor Oil tempe
rature probe
requires diagnostic tool special tool
Do not drain transmission Check oil level
Remove hydraulic distributor
Replace or adjust accelerator cable Replace throttle potentiometer Replace diese
l injection pump (with potentiometer on load lever) Replace injection ECU Multif
unction switch Replace transmission ECU
Program accelerator pedal Program pedal Program pedal
Requires transmission to be drained. Requires electrical harness inside transmis
sion to be removed. Requires control inside transmission to be adjusted. Check o
il level Check operation of kickdown switch requires diagnostic tool
Program pedal Adjust switch Read old oil counter in old ECU (2), note the value
+ Configure new ECU + Update oil counter in new ECU from value stored in old one
(2) (3) + Program accelerator pedal + Road test
download automatic transmission ECU multimeter download engine management comput
er
(1) (2) (3)
New transmissions are supplied filled with oil Possible from update n° 13 of dia
gnostic tools If the oil counter cannot be read from an old ECU, replace the tra
nsmission oil.
n
46 Chapter 9 VIII AUTHORISED OPERATIONS DURING THE WARRANTY PERIOD Transmissio
n fitted Authorised replacements: • • • • • • • • • • • • • • • • • • • • • drai
n and fill oil, download/configure ECU, program pedal, initialise/update "old oi
l" counter, hydraulic distributor cover seal, selector shaft seal, driveshaft se
als, seal between closing plate and transmission housing, gear selector control,
heat exchanger and its seals, accessible plugs, support brackets and control pi
ns, complete hydraulic distributor, electrovalves and pressure regulators on hyd
raulic distributor, speed sensors (turbine speed, engine speed, vehicle speed),
transmission oil temperature probe, electrical harness inside transmission, TDC
sensor, selector lever position switch, oil pressure sensor, relays, transmissio
n ECU (*).
Note: If the oil in the transmission is burnt, always replace the heat exchanger
. (*) only after approval. Transmission removed Authorised replacements (dependi
ng on transmission architecture): • torque converter, • inter housing gasket, •
whole transmission (*). IMPORTANT: When returning a transmission under warranty,
return it with its heat exchanger. (*) only after approval.
n
47 Chapter 9 The operating procedures for the various authorised operations are
given in the corresponding after sales document. Replacing the whole AL4 transmi
ssion or its ECU must be subject to prior approval. This approval is given by th
e Regional Headquarters for France. The point of sale fills in the "request for
replacement approval" (copy enclosed) and sends this duly completed request to t
he Regional Headquarters. After being analysed, additional technical assistance
will be proposed in order to complete the diagnostic or replacement approval wil
l be faxed back to the point of sale on the approval request. For UK, contact wa
rranty department at Citroën UK or follow After Sales procedure for UK RHD vehic
les. IX AUTOMATIC TRANSMISSION REPAIR BY THE CITROËN AUTOMATIC TRANSMISSION CE
NTRE, SOUTH WEST PARIS Conditions • The vehicle is not under contractual warrant
y (1 year). • Preliminary checks (level and quality of oil, adjustments relating
to transmission, etc…) and any repairs (repairs with or without removing transm
ission) must have been performed. Procedure • Send the centre the duly completed
approval sheet by fax. • Upon receiving the work request, the centre will speci
fy its provisional repair time by telephone or fax. • The centre will send the p
oint of sale special packaging for transport purposes with blanks and the conver
ter lock corresponding to the AL4 automatic transmission. • Remove the transmiss
ion from the vehicle. • Package the transmission (leave oil / water exchanger fi
tted) and attach the photocopy of the workshop customer work order, the approval
request sheet and the works order. • Send the transmission to the centre using
GEFCO transport (specific procedure). • Transmission will be returned by GEFCO a
fter repair. • Return empty special packaging to GEFCO with blanks and converter
lock.
n
48 Chapter 9
REQUEST FOR REPLACEMENT APPROVAL OR ASSISTANCE FOR MB3/4HP20/AL4 AUTOMATIC TRANS
MISSION
Warranty start Vehicle type Engine type Transmission type ECU type V.I.N or DAM
N° Transmission N° Mileage Date Stamp
1) VEHICLE IMMOBILISED
YES
NO
Form by:
completed Telephone
Fax
2) CUSTOMER complaint ..........................................................
......................................................
................................................................................
...............................................................................
3) OIL
Check at 80°C Check at 60°C (AL4) Leak
appearance level
coloured level insufficient
oil burnt level normal dripping
normal too much oil flowing
Location ...............................................
For the next section, only complete relevant sections:
Accelerator pedal programmed (MB3 or AL4) YES NO
4) OPERATING FAULT
gears do not change random changes delay engaging N D or N R problem in imposed
gears slipping slipping then knocking knocking no drive other ..................
...............................................
when changing up sudden fault when driving stationary when changing down engine
cold engine warm progressive degradation occasionally when changing gears which
ones ? ........................................................................
when changing lever position, state positions...................................
........................................... coherence between lever position/con
trol panel display of P→ 1 YES NO
5) NOISE
conditions type of noise when driving metallic when accelerating friction NO Eng
ine ECU identification ........................ Engine: when decelerating whinin
g stationary cyclic
6) MEMORISED FAULTS
Warning light flashing (if fitted): YES Transmission ECU identification ........
..... Transmission:
7) POINT OF SALE COMMENTS:
e.g. associated variables ................................... ..................
............................................................ ...................
...........................................................
8) RESPONSE TO APPROVAL REQUEST
(Approval n°) ..................................................... ............
................................................................. ..............
...............................................................
n
49 Chapter 9 Note: Above for France. For UK contact warranty department, Citroën
UK Ltd.
n
50 Chapter 9 XSPECIAL TOOLING Box ( ) 0338
A
B
C
D
E
F
G
H1
H2
J1
J2
K
L
M1
M2
N1
N2
P
AL4026D
A B C D E F G H1 H2 J1 J2 K L M1 M2 N1 N2 P

Drift 2 sockets for removing refitting converter Right hand driveshaft seal extr
actor Tool for holding converter Ball joint extractor Tool for fitting converter
lip seal Hook for removing lip seal from converter Tool for fitting left hand d
riveshaft seal Guide for fitting left hand driveshaft seal Tool for fitting righ
t hand differential output seal Guide for fitting right hand differential output
seal Tool for fitting selector shaft seal Interface harness for checking AL4 au
tomatic transmission Screw for setting internal selector control Shim for adjust
ing internal selector control Gear changing shaft seal extractor Gear changing s
haft seal extractor Socket for removing transmission mounting
n
51 Chapter 9 XI DIAGNOSTIC TOOLING ELIT unit: 4125 T This tool is used for: •
identifying ECUs, • reading faults, • erasing faults, • measuring parameters, •
activating actuators, • programming accelerator pedal, • configuring ECUs, • upd
ating the ECU by downloading. PROXIA station: 4165 T This tool is used for: • id
entifying ECUs, • reading faults, • erasing faults, • measuring parameters, • ac
tivating actuators, • programming accelerator pedal, • configuring ECUs, • updat
ing the ECU by downloading, • consulting wiring diagrams.
n
52 Chapter 9 LEXIA station: 4171 T This tool is used for: • identifying ECUs, •
reading faults, • erasing faults, • measuring parameters, • activating actuators
, • programming accelerator pedal, • configuring ECUs, • updating the ECU by dow
nloading, • consulting wiring diagrams. Terminal box and harness: 4187 T Using a
voltmeter and an ohmmeter, this tool is used to check: • sensors and actuators,
• automatic transmission harness.
n
53 Chapter 9
n

AL4 Transmission

Diunggah oleh

Informasi Dokumen

Deskripsi Asli:

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

AL4 Transmission

Diunggah oleh

Hak Cipta:

Format Tersedia

CITROËN

Anda mungkin juga menyukai