6338026 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

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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 PDF created with pdfFactory trial version www.pdffactory.com

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.......................... 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

D 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 PDF created with pdfFactory trial version www.pdffactory.com

1 Chapter 1 PRESENTATION - GENERAL IINTRODUCTION 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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created ith pdfFactory trial version P/N - D - Gear change Exchanger oil flo setting AT ECU AL4005P Engine management computer

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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. AL4 AUTOMATIC TRANSMISSION © 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
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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. AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
ut oris
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11 Ch
pter 2 SELECTOR CONTROL ISELECTOR 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 AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
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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 AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
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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 . AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
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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. AL4 AUTOMATIC TRANSMISSION © 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
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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 AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
ut oris
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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. AL4 AUTOMATIC TRANSMISSION © 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
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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 9St
rting ring AL4011P 7 1 6 2 Drive end pl
te AL4027C 3 Converter 5 4 AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
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ns l'
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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. AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
ut oris
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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 AL4 AUTOMATIC TRANSMISSION © 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
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20 Ch
pter 4 AL4 AUTOMATIC TRANSMISSION © 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
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21 Ch
pter 5 THE EPICYCLIC GEAR TRAIN IDESCRIPTION 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 AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
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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 AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
ut oris
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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 PP des = Prim
ry step down pinion AL4017D Prim
ry AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
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24 Ch
pter 5 3rd ge
r F1 E1 C1 E2 PS1 F2 F3 C2 PS2 PP des P1 P2 Lock-up PP des = Prim
ry step down pinion AL4018D Prim
ry 4th ge
r F1 E1 C1 E2 PS1 F2 F3 C2 PS2 PP des P1 P2 Lock-up PP des = Prim
ry step down pinion AL4019D Prim
ry AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
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25 Ch
pter 5 Reverse F1 E1 C1 E2 PS1 F2 F3 C2 PS2 PP des P1 P2 Lock-up PP des = Prim
ry step down pinion 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 AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
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26 Ch
pter 5 AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
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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. AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
duction même p
rtielle s
ns l'
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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. AL4 AUTOMATIC TRANSMISSION © AUTOMOBILES CITROËN Toute reproduction ou tr
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ns l'
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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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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) 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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: 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 PDF created with pdfFactory trial version www.pdffactory.com

37 Chapter 8 WIRING DIAGRAM  XANTIA PETROL ENGINE/WITHOUT CRUISE CONTROL ILAYOUT AL4022P 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 PDF created with pdfFactory trial version www.pdffactory.com

38 Chapter 8 PETROL ENGINE/WITH CRUISE CONTROL ILAYOUT AL4023P 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 PDF created with pdfFactory trial version www.pdffactory.com

39 Chapter 8 DIESEL ENGINE/WITHOUT CRUISE CONTROL ILAYOUT AL4024P 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 PDF created with pdfFactory trial version www.pdffactory.com

40 Chapter 8 DIESEL ENGINE/WITH CRUISE CONTROL ILAYOUT AL4025P 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

42 Chapter 8 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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°) ..................................................... ............ ................................................................. .............. ............................................................... 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 PDF created with pdfFactory trial version www.pdffactory.com

49 Chapter 9 Note: Above for France. For UK contact warranty department, Citroën UK Ltd. 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 PDF created with pdfFactory trial version www.pdffactory.com

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 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

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. 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 PDF created with pdfFactory trial version www.pdffactory.com

53 Chapter 9 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 PDF created with pdfFactory trial version www.pdffactory.com