aisin AF40

AL FA 159 TRAINING TRA INING MATERIAL

Fiat Auto S.p.A. After Af ter Sales Tr ain ainin in g

Aisin AF40-6 1.9 Multijet 16V 2.4 Multijet 20V 3.2 JTS

AL FA 159 TRAINING MATERIAL

Fiat Auto S.p.A. Af ter Sales Traini ng

1 AISIN AF40-6 GEARBOX 1.1 Description The AISIN AF 40-6 gearbox is an automatic, 6-speed gearbox used for the 1.9 JTD 16V and 2.4 JTD 20V engine versions. General featur es     

Type: automatic, 6-speed gearbox Engine: 1.9 JTD 16V and 2.4 JTD 20V Architecture: 3 clutches, 2 brakes, 1 free wheel, 2 epicyclical trains Hydraulics: 4 linear solenoids, 2 ON/OFF solenoids Electronics: built-it Neutral Start Switch and control unit, internal speed sensors and cabling

NAME VEHICLE ENGINE VERSIONS

GEAR RATIO

1 2 3 4 5 6 R Idle shaft Differential CLUTCHES

AF 40-6 194 1.9 JTD 16V 4.148 2.370 1.556 1.155 0.859 0.686 3.394 0.836 3.188 1 flange, 6 discs, 6 plates 1 flange, 3 discs, 3 plates

C1 C2

BRAKES AND CLUTCHES

BRAKES

One-Way

1 flange, 4 discs, 4 plates

B1

Band type

B2


F1

Roller type 2

Linear

IDLING LINE PRESSURE [KPa]

1 flange, 7 discs, 7 plates 1 flange, 4 discs, 4 plates

C3

Shift solenoid SOLENOIDS

2.4 JTD 16V

6 D

372 – 414

R

575 – 665

D

1,350 – 1,460

R

1,905 – 2,125

STALL



Gearbox section:

1.

Torque converter

2.

Transmission gear

3.

Transmission gear

4.

Differential

5.

C1, C2, C3: clutches

6.

B1, B2, F1: brakes

Fiat Auto S.p.A. After Sales Tr ainin g



1.2 Functions Neutral Contro l When the vehicle is stopped with the lever in position “D”, the clutches will be automatically released, and the gearbox will be set to neutral. Thus, the torque converter will not be stressed; moreover, fewer vibrations will occur, and fuel consumption will be lowest. This functions will not be implemented on rough terrain and uphill roads: in the latter instance, the gearbox will remain engaged, thus ensuring a “hill holder” effect. Reverse gear cont rol By moving the lever from “N” to “R”, the reverse gear will not be engaged if the vehicle speed exceeds 11 r.p.m. Ad apt iv it y MODE ADAPTIVE SPORTS WINTER/LOW GRIP

TIP

HIGH TEMPERATURE HEATING RISE

DESCENT

FAST ON

BRAKE ASSISTANCE

DESCRIPTION It is used during normal driving. Both the sports and the economy modes are automatically selected according to the driving conditions. With this mode, the lock-up actuation and gear shifting points are higher, to achieve a higher engine revs number. In case of ice, snow and low grip conditions in general, the vehicle will be started in the third speed to avoid front wheel slipping. By moving the lever from “D” to “+/-“, the driver may choose the gear shifting point in a sequential fashion. In any case, the control unit will change the gear automatically to avoid out-of-revs conditions, or vice versa to avoid jerks when the engine speed is too low. In case of too high gearbox oil temperature, the control unit will advance lock-up actuation in order to avoid excessive slipping in the torque converter and, thus, cause the temperature to decrease. In this case, on the contrary, converter slipping will be enhanced in order to heat the oil. The rise will be automatically detected with a control unit algorithm based on the revs number increase: the gear shifting points will be increased. Conversely, the system will, when the vehicle is riding downhill, make use of a few tricks in order to avoid prolonged use of the brakes (lock-up, etc.). This control calculates the driver’s performance requests through the pressure on the accelerator pedal and regulates, accordingly, the gear shifting points. On the contrary, the exhaust brake is used in this case to help the driver in case of deceleration (which is measured, once again, through the accelerator pedal).



1.3 Components Control unit

The B connector is connected to the gearbox cabling, in the pin-to-pin configuration. The A connector is connected to the front cable:

1

Key switch signal

2

N.C.

3

N.C.

4

K line

5

Steering lock signal

6

CAN L

7

CAN H

8

CAN H

9

Ground

10

N.C.

11

Power supply

12

N.C.

13

Reversing light relay

14

CAN L

15

N.C.

16

N.C.



Input/output managed by the control unit The interface with the automatic transmission system manages the information through the following serial lines: C-CAN (information, data) K line (diagnosis) I/O SIGNAL Key status System failure warning light Max. gearbox oil temperature warning light Gear ON display Gear selection System diagnosis Vehicle speed Brake pedal pressed for recovery (brake light contact) Driver’s side front door status Acoustic indicator actuation Start enable to NBS Reversing light control Engine water temperature Engine torque variation request MIL warning light ignition request

I O O O I I/O I I I O O O I O O

TYPE OF TRANSMISSION CAN CAN CAN CAN CAN K CAN CAN CAN CAN on/ off @GND on/ off @+15 CAN CAN CAN



Cabling The cabling is located inside the gearbox and is connected, inside the valve body, to the following items: speed sensors;  oil temperature sensor;  solenoids. 

Cabling pin-out

The cabling is connected to the gearbox control unit by means of a pin-to-pin connector made by Aisin.



You can easily see the difference compared with the AISIN 5-speed gearbox fitted to the 2.2 petrol engine version:

NSW built into the control unit

AISIN 6-speed cab li ng Solenoid valve pack The purpose of the solenoid valve pack is to supply, through solenoids actuated by the control unit signals, the hydraulic pressure generated by the oil pump to the brakes, clutches and lock-ups. Moroever, part of the oil is reserved for component lubrication.


1

Control unit

2

Torque converter

3

Solenoid valve pack

4

Brakes/clutches

5

Oil radiator

6

Oil pump

7

Epicyclical gears



Solenoids

Linear solenoids: four linear solenoids are provided, which control, in a linear fashion, the hydraulic pressure of almost all the brakes/clutches

ON/OFF solenoids: two ON/OFF solenoids are provided, which control the “B2” brake for the exhaust brake in the first gear

SLT linear solenoid: it controls, in a linear fashion, the line pressure depending on the throttle signal and the engine torque

SLU linear solenoid: it controls, in a linear fashion, the lock-up pressure with regard to: throttle signal engine revs gearbox input speed gearbox output speed




Sensors Lever posit ion sensor (NSW) NCA

The position sensor is of the Hall-effect type and is built into the body of the control unit. It informs the control unit of the gear lever position

Linear characteristic of the position sensor

Oil temperature sensor

The oil temperature sensor is a NTC and is built into the cabling.



Features: Temperature 10 °C 25 °C 110 °C

Resistance 5.62-7.31 (kΩ) 3.5 (kΩ) 0.22-0.27 (kΩ)

Input/output sp eed sensors

1.input 2.output The input speed sensor measures the rotation speed input to the gears, i.e. the converter turbine speed. The output speed sensor measures the rotation speed of the gear that conveys the motion to the differential.

1.4 Tests Stall test The purpose of the stall test is to check correct operation, mainly of the gearbox and the torque converter. It is carried out with the gear lever in positions “D” or “R”. The test procedure is as follows:    

lock the four wheels and engage the handbrake; press the brake pedal fully down with your left foot; position the gear lever to “D”, press the accelerator pedal fully down, then verify the maximum revs number reached; move the gear lever to “R”, then check again the maximum revs number.

The standard value is 2,730 r.p.m.



1.5 Proc edures Oil level check





Position the vehicle on a lift.



With the coolant cold, start the engine and move the speed selector twice from position "P" to position "D" and viceversa with the brake pedal depressed.



Maintain the selector in each position for 2 seconds.



Adjust the transmission fluid temperature between 80-85°C, connecting the Examiner, to allow the automatic transmission fluid cooling circuit thermostat valve to open, then stabilise at a temperature of 35-45°C.

Remove the automatic transmission fluid level check plug (1a) and check that fluid emerges from the drain plug hole (1b).



If no fluid emerges, proceed as follows 

Retighten the automatic transmission fluid level check plug.



Remove the automatic transmission fluid filler plug.



Add 0.5 litres of the specified fluid to the filler opening 1.



Automatic transmission Fluid



With the brake pedal depressed, move the gear selector twice from position "P" to position "D" and viceversa, maintaining the selector in each position for 2 seconds.



Set the selector to "P" and operate the parking brake (it is advisable to use chocks to lock the wheels).



Remove the automatic transmission fluid level check plug and check that fluid emerges from the drain plug hole.



If no fluid emerges, repeat the above operations.



Clean oil traces from the drain hole area and tighten the automatic.



Transmission fluid level check plug to the specified torque.

Oil Tutela Gi/Vi

3.320 kg





Before tightening, check that the o-ring fitted to the plug is undamaged.



Replace the o-ring if it is damaged.





Au to mat ic tr ansmi ss io n f lu id level c hec k plu g: 0.6 -0.8 daNm

Tighten the automatic transmission fluid drain plug to the recommended torque.



Au tomati c t ran sm is si on fi ll er p lu g: 2.4 -3.6 daNm





Automatic transmission Fluid for 1.9 JTD 16v, 2.4 JTD 20v & 3.2 JTS:



Oil Type : TUTELA GI/VI



Replacing gearbox from spare part department : 2.84 Litres @ 15 deg c



Changing oil d uring service : 3.89 Litres @ 15 deg c



Total refilling after gearbox opening : 7.14 Litres @ 15° deg c





1.6 GEAR CONTROLS    

The request to change gear may take place in the following ways: - sequential (manual) or automatic via the selector lever - sequential (manual) via the steering wheel controls (where present). Selector lever

P = Park  R = Reverse  N = Neutral  D= Drive, automatic forward gear  + = Shift from higher transmission ratio in sequential mode  - = Shift from lower transmission ratio in sequential mode  Manual sequential command from selector lever  The 6 gear changes can be managed sequentially by moving the lever to the right and raising it in the +  direction engages a higher ratio whilst lowering it in the - direction engages a lower ratio.  Each gear engaged is shown by a number on the instrument panel display.  Automatic command from selector lever  The automatic command D can be selected from the sequential operation in any driving conditions.  The optimum ratio is selected by the gearbox electronic control unit depending on the engine speed and load  conditions.  Manual sequential command from steering wheel (where present)  The change can be managed sequentially via the controls on the steering wheel. 


    

 




To use the controls of the steering wheel, the gear lever must be in a (manual) sequential position: Operating the lever on the steering wheel in the + direction engages a higher ratio Ooperating the lever on the steering wheel in the +-direction engages a lower ratio Au to mat ic dr iv ing m od e select io n (w her e present) It is possible to select different driving modes by pressing the SPORT/WINTER button on the gearbox control panel.

The following d rivin g modes are available: NORMAL: gear changes at low engine speeds, favouring comfort and reduced consumption  SPORT: gear changes at higher engine speeds, enhancing sporty driving  WINTER: programme for setting off on roads in poor grip conditions. The selection mode remains in force until the button is pressed again or the engine is switched off.

aisin AF40

Recommend Documents