DP0 / AL4 Technical Note

Technical Note3720A X65, and DP0 Special notes on Clio II equipped with the DP0 automatic gearbox CLIO II

77 11 320 582

JANUARY 2009

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

Edition Anglaise

All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.

© Renault s.a.s 2008

Specialnotes on Clio II equipped with the DP0 automatic gearboxContentsPage

Special notes on Clio II equipped with the DP0 automatic gearbox

Contents Page

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal Refitting

23A 23A

23A 23A

10A-1

AUTOM UTOMA ATIC TIC GEAR GEARBO BOX X Automatic gearbox: Precautions for repair

23A-1

Automatic gearbox: Identifi cation

23A-2

Automatic gearbox: Specifications

23A-3

Automatic gearbox: List and location of components

23A-4

Automatic gearbox: Removal - Refitting

23A-6

Automatic gearbox oil: Dr aining - Refilling

23A-17

Gearbox oi oil pr pressure: Check

23A-21

Hydraulic distributor: Removal - Refitting

23A-22

Hydraulic distribution wiring: Removal - Refitting

23A-26

Flow regulation solenoid valve: Removal - Refitting

23A-28

Gearbox oil cooler: Removal - Refitting

23A-30

Differential output seal: Removal - Refitting

23A-32

37A 37A

AUTOM UTOMA ATIC TIC GEAR GEARBO BOX X Multifunction switch: Removal - Refitting

23A-34

Multifunction switch: Adjusting

23A-36

Speed sensor: Removal Refitting

23A-37

Pressure sensor: Removal Refitting

23A-40

Automatic gearbox converter: Removal Refitting

23A-42

Converter seal: Removal Refitting

23A-44

Automatic transmission transmission connector: Removal Refitting

23A-46

Automatic transmission transmission computer: Removal Refitting

23A-48

MECH MECHAN ANIC ICAL AL COMP COMPON ONEN ENT T CON CONTR TROL OLS S Automatic gear control cable: Adjusting

37A-1

Gear control unit: Removal Refitting

37A-3

Specialnotes on Clio II equipped with the DP0 automatic gearboxContentsPage

Special notes on Clio II equipped with the DP0 automatic gearbox

Contents Page

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal Refitting

23A 23A

23A 23A

10A-1

AUTOM UTOMA ATIC TIC GEAR GEARBO BOX X Automatic gearbox: Precautions for repair

23A-1

Automatic gearbox: Identifi cation

23A-2

Automatic gearbox: Specifications

23A-3

Automatic gearbox: List and location of components

23A-4

Automatic gearbox: Removal - Refitting

23A-6

Automatic gearbox oil: Dr aining - Refilling

23A-17

Gearbox oi oil pr pressure: Check

23A-21

Hydraulic distributor: Removal - Refitting

23A-22

Hydraulic distribution wiring: Removal - Refitting

23A-26

Flow regulation solenoid valve: Removal - Refitting

23A-28

Gearbox oil cooler: Removal - Refitting

23A-30

Differential output seal: Removal - Refitting

23A-32

37A 37A

AUTOM UTOMA ATIC TIC GEAR GEARBO BOX X Multifunction switch: Removal - Refitting

23A-34

Multifunction switch: Adjusting

23A-36

Speed sensor: Removal Refitting

23A-37

Pressure sensor: Removal Refitting

23A-40

Automatic gearbox converter: Removal Refitting

23A-42

Converter seal: Removal Refitting

23A-44

Automatic transmission transmission connector: Removal Refitting

23A-46

Automatic transmission transmission computer: Removal Refitting

23A-48

MECH MECHAN ANIC ICAL AL COMP COMPON ONEN ENT T CON CONTR TROL OLS S Automatic gear control cable: Adjusting

37A-1

Gear control unit: Removal Refitting

37A-3

ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting REFITTING

Essential special tooling Mot. 582-01

10A

Flywheel locking tool.

I - REFITTING PREPARATION OPERATION a

Essential equipment

Check that the drive plate is not damaged (run-out tolerance of 0.2 mm on the external diameter).

diagnostic tool

II - DRIVE PLATE REFITTING OPERATION Tightening torques m drive plate bolts

a

Fit the drive plate.

55 N.m

REMOVAL I - REMOVAL PREPARATION OPERATION a

Remove the automatic gearbox (see 23A, Automatic gearbox, Automatic gearbox: Removal - Refitting, page 23A-6) (23A, Automatic gearbox).

a

Disconnect the battery, starting with the negative terminal.

a

Fit the (Mot. 582-01) to immobilise the starter motor ring gear.

II - DRIVE PLATE REMOVAL OPERATION

103433 a

Note: Apply LOCTITE FRENBLOC to the bolt threads. a

Fit the drive plate bolts without tightening them (2) .

a

Immobilise the starter ring gear using the tool (Mot. 582-01) .

a

Torque tighten the drive plate bolts (55 N.m) .

III - FINAL OPERATION a

103433 a

IMPORTANT When connecting the battery, carry out the necessary programming (see Battery : Removal - Refitting ) (80A, Battery).

Remove: - the drive plate mounting mounting bolts (1) , - the drive drive plate, plate,

Remove the tool (Mot. 582-01) .

a

-the (Mot. 582-01) .

10A-1

Reconnect the battery, starting with the positive terminal.

ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting a

Refit the automatic gearbox (see 23A , Automatic gearbox, Automatic gearbox: Removal - Refitting, page 23A-6) (23A, Automatic gearbox).

a

Check conformity using the diagnostic tool.

10A-2

10A

AUTOMATIC GEARBOX Automatic gearbox: Precautions for repair I - PRECAUTIONS DURING REPAIR Weight: 70 kg Vehicles fitted with DP0 automatic transmissions use systems called « Shift lock » and « Lock up » . The purpose of the « Shift Lock » function is to prevent the gear lever from being moved without the brake pedal being simultaneously depressed.

Note: For repair operations when the battery is faulty, refer to the notice on board the vehicle. The purpose of the « Lock up » or converter lockup is to connect the automatic transmission directly to the engine. This function is carried out by a « mini clutch » in the converter. The « Lock up » is driven by the automatic transmission computer. As the automatic gearbox is lubricated under pressure, lubrication is only provided when the engine is running. Consequently, Consequently, and to avoid serious damage, it is essential to comply with the following instructions: - never allow the vehicle to coast with the ignition switched off (i.e. when going down a hill); the damage that this may cause cannot be stressed highly enough, - never push the vehicle (e.g. to get get to a petrol station, station, unless the precautions in the « Towing » section have been taken). The vehicle only has drive when the engine is running. It is therefore impossible to start the engine in a vehicle with an automatic transmission by pushing the vehicle.

II - TOWING The vehicle should preferably be towed in all cases on a tow truck or with the front wheels raised. Nonetheless, if this is impossible, in exceptional circumstances the vehicle may be towed at low speed (maximum 12mph (20 km/h) over a maximum distance of 18 miles (30 km) (lever in N position).

23A-1

23A

AUTOMATIC GEARBOX Automatic gearbox: Identification

117304

The automatic transmission series number can be found in two places: on a label on the hydraulic distributor cover (1 ) and etched onto the outer casing (2) on the wheel side.

23A-2

23A

AUTOMATIC GEARBOX Automatic gearbox: Specifications Vehicles fitted with this type of automatic gearbox use two systems called:

23A

K7M

- « Shift Lock » - « Lock Up » K4J or K4M

Lowering

Final drive

52:67

21:73

Lowering

Final drive

52:67

23:70

Gear ratios (epicyclic gear train output) 1 st

2 nd

3 rd

4th

REVERSE

0.367

0.667

1

1.407

0.407

23A-3

AUTOMATIC GEARBOX Automatic gearbox: List and location of components

23A

127735

(1 )

DP0 gearbox

(2 )

Oil overflow pipe

(3 )

Level-setting cap

(4 )

Hydraulic distributor

(5 )

Hydraulic distributor casing seal

(6 )

Hydraulic distributor housing

(7 )

Torque converter

(8 )

Control pinion

(9 )

Vehicle speed sensor

(10)

Multifunction switch

(11)

Output lever

(12)

Filler plug

(13)

Connector support

(14)

Sleeve stop

(15)

Filter pad

(16)

Input speed sensor

(17)

Heat exchanger

(18)

Output speed sensor

(19)

Control solenoid valve

(20)

Pressure sensor

13787

23A-4

(21)

Modulating solenoid valve

(22)

« Lock up » solenoid valve (converter lock-up)

(23)

Selector solenoid valve 4

AUTOMATIC GEARBOX Automatic gearbox: List and location of components (24)


(25)


(26)


(27)


(28)


13785

(29)

Green connector (multifunction switch)

(30)

Yellow connector (electrohydraulic interface)

(31)

Green connector (line pressure)

(32)

Yellow connector (turbo input speed)

(33)

Blue connector (output speed)

23A-5

23A

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

E7J or K4J or K4M

Tightening torques m

Essential special tooling Tav. 476

Ball joint extractor.

Mot. 1390

Support for removing/refitting the engine - gearbox assembly.

Mot. 1453

lower ball joint nut

55 N.m (D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J or K4M or K7J

Multiple-adjusting engine mounting support with retaining straps.

or K9K or L7X )

shock absorber base bolt

Essential equipment

180 N.m (D4D or D4F or D7D or D7F or E7J or F4R or F8Q

steering wheel lock

or F9Q or K4J or K4M or K7J

component jack

or K9K or L7X )

suspended engine mounting nut on the automatic transmission

Tightening torques m upper gearbox bell housing and starter bolts

45 N.m

converter mounting nuts on the drive plate

30 N.m

engine tie-bar bolts

or K4M or K7J or K9K or L7X )

track rod end nut

65 N.m (D4D or D7F or E7J or F4R or F8Q or F9Q or K4J



45 N.m (D4D or D4F or D7D

WARNING

or D7F or E7J or F4R or F8Q or F9Q or K4J

Observe the following instructions to avoid damaging the rotary switch beneath the steering wheel:


modular connector support bolts

40 N.m (D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J

or D4F or D7D

gearbox bell housing and starter bolts


- Before the steering column and the steering rack are uncoupled, the steering wheel must be immobilised with the wheels straight for the duration of the operation using a steering wheel lock.


- Any doubts regarding the correct centring of the rotary switch calls for the steering wheel to be removed in order to perform the centring procedure described in the (see 8 4 A, Control Signals) .


wheel bolts

90 Nm

brake calliper bolts

40 Nm

In this case, only qualified personnel who have received training may carry out the operation.

23A-6


23A

E7J or K4J or K4M


The automatic transmission is removed from below after the steering rack has been disconnected from its sub-frame.

a

Position the vehicle on a two-post lift.

a

Remove the front wheels.

103213 a

Disconnect: - the multifunction switch cable ball joint (5) , - the multifunction switch cable (6 ) .

a

Remove: - the two mounting bolts (7) from the wiring mounting, - the wiring mounting,

103210 a

Disconnect:

- the engine speed sensor.

- the battery, starting with the negative terminal, - the two connectors (1 ) . a

Remove the bolt (2) .

a

Detach the wiring harness from the battery tray.

a

Remove: - the air intake sleeve (3 ) , - the four battery mounting bolts and the nut (4) , - the battery mounting.

13785 a

IMPORTANT Protect the connector by sliding it into a waterproof plastic bag. a

23A-7

Disconnect the modular connector ( 8 ) by releasing the connector slide mechanism.


23A

E7J or K4J or K4M a

Remove the engine undertray.

a

Disconnect the oxygen sensor.

a

Remove: - the track rod end using the (Tav. 476), - the left-hand driveshaft, - the right-hand driveshaft, - the steering box mountings (without damaging the power assisted steering pipes, attach the steering box so that it does not obstruct anything).

98755

13797 a

Disconnect the speed sensor connector.

a

Remove:

a

Position the (Mot. 1390) (9) .

a

Remove the sub-frame.

a

Fit the component jack under the automatic gearbox without lifting it.

a

Place hose clamps on the cooling unit pipes.

- the lower engine - manifold strut, - the starter, - the engine tie-bar, - the exhaust downpipe.

13122 a

Position the (Mot. 1453) (10) .

a

Attach the cooling unit and remove the engine subframe.

a

Rotate the crankshaft clockwise to access the three drive plate - converter connecting nuts and remove them.

23A-8


23A

E7J or K4J or K4M

II - REMOVING THE AUTOMATIC GEARBOX

13790 103211 a

a

Remove:

Secure the converter with string to prevent it being dislodged.

- the gearbox support,

REFITTING

- the earth strap from the gearbox. a

Tilt the engine - automatic gearbox assembly downwards as far as possible.

a

WARNING - Always replace the converter mounting nuts, and the inertia flywheel mounting nuts, if they were removed.

WARNING Do not damage the air conditioning compressor.

- Check that the centring rings are in place.

a

Remove the upper gearbox bell housing bolts.

a

Disconnect the automatic transmission from the engine, taking care not to dislodge the converter.

I - REFITTING THE GEARBOX a

WARNING Do not damage the air conditioning compressor.

23A-9


23A

E7J or K4J or K4M

13122 a

Remove the (Mot. 1453) (11) .

a

Remove the hose clamps on the cooling unit pipes

a

Refit the subframe.

13790 a

Detach the converter.

a

Couple the automatic gearbox to the engine, paying attention to the converter.

a

Refit and torque tighten the upper gearbox bell housing and starter bolts (45 N.m) .

a

Refit: - the earth strap on the gearbox, - the gearbox support.

II - FINAL OPERATION a

Refit and torque tighten the three converter mounting nuts on the drive plate (30 N.m) .

a

Turn the crankshaft anti-clockwise until the three mounting nuts of the drive plate - converter connection can no longer be accessed.

a

Refit the engine subframe and detach the cooling unit.

98755 a

Remove the (Mot. 1390) (12) .

a

Replace the exhaust downpipe seal.

a

Refit: - the exhaust downpipe, - the lower engine - manifold strut.

a

Refit the engine tie-bar.

a

Refit and torque tighten the engine tie-bar bolts (65 N.m ( D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J or K4M or K7J or K9K or L7X ) ).

a

Refit the starter.

23A-10


23A

E7J or K4J or K4M a

Refit and torque tighten the gearbox bell housing and starter bolts (45 N.m (D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J or K4M or K7J or K9K or L7X )).

a

Reconnect the speed sensor connector.

a

Refit: - the steering box mountings (detach the steering box if it is causing an obstruction during the removal operation, taking care not to damage the power-assisted steering pipes). - the right-hand driveshaft, - the left-hand driveshaft, - the track rod end.

a

Reconnect the oxygen sensor.

a

Refit the engine undertray.

a

Take the connector out of its plastic bag. 103213 a

Refit: - the engine speed sensor, - the wiring harness support, - the two mounting bolts (14) of the wiring mounting.

a

Reconnect: - the multifunction switch cable (15) , - the multifunction switch cable ball joint (16) .

13785 a

Reconnect the modular connector ( 13) by refitting the connector slide mechanism.

a

Refit and torque tighten the modular connector support bolts (20 N.m (D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J or K4M or K7J or K9K or L7X )).

23A-11


23A

E7J or K4J or K4M - the track rod end nut (40 N.m ( D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J or K4M or K7J or K9K or L7X )). a

Lower the vehicle on the two-post lift.

a

Couple the steering rack to the subframe.

a

When refitting the automatic gearbox to the engine, make sure that the converter is perfectly engaged in the input shaft (the end of the studs is on a level with the gasket face).

a

Fill the automatic gearbox and check the level (see 23A , Automatic gearbox) .

a

If replacing the oil, reset the auto-adaptives using command RZ005 «effacements des autoadaptatifs » and reset the automatic transmission computer oil ageing counter with command CF074 « Ecriture date vidange huile de boîte » .

a

After running command RZ005, it is important to carry out a test drive performing all gear changes, both up and down, several times in order to store the new values.

103210 a

Refit: - the battery mounting, - the four battery mounting bolts and the nut (17) , - the air intake sleeve (18) .

a

Detach the wiring harness from the battery tray.

a


WARNING When connecting the battery, carry out the necessary programming (see 80A, Battery) . a

Reconnect: - the battery, starting with the positive terminal, - the two connectors (20) .

a

Refit the wheels.

a

Refit and tighten to torque: -the wheel bolts (90 Nm) , -the brake calliper bolts (40 Nm), -the lower ball joint nut (55 N.m (D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J or K4M or K7J or K9K or L7X )),

-the shock absorber base bolt (180 N.m ( D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J or K4M or K7J or K9K or L7X )) ,

-the suspended engine mounting nut on the automatic transmission (60 N.m (D4D or D4F or D7D or D7F or E7J or F4R or F8Q or F9Q or K4J or K4M or K7J or K9K or L7X )),

23A-12


23A

K7M a

Essential special tooling

- the battery,

Tav. 476

Ball joint extractor.

Mot. 1390

Support for removing/refitting the engine - gearbox assembly.

Mot. 1453

Remove:

- the front wheels, - the air filter unit, - the battery tray.

Multiple-adjusting engine mounting support with retaining straps.

Essential equipment component jack diagnostic tool

Tightening torques m 30 N.m

converter mounting nuts on the drive plate engine tie-bar bolts

65 N.m (K7M )

gearbox bell housing and starter bolts

45 N.m (K7M )

modular connector support bolts

20 N.m (K7M ) a

lower ball joint nut

- the multifunction switch cable by loosening the sleeve stop (2) .

40 Nm

brake calliper bolts

Disconnect: - the multifunction switch cable ball joint (1) ,

90 Nm

wheel bolts

55 N.m (K7M )

shock absorber base bolt

180 N.m (K7M )

suspended engine mounting nut on the gearbox

40 N.m (K7M )

track rod end nut

40 N.m (K7M )

exchanger bolts

14825

Note: Do not move the orange ring during this operation. It may break when removed or refitted. If this happens, do not replace the control cable as the absence of this part will not affect the operation of the system.

mounting


Place the vehicle on a two-post lift.

a

Disconnect the battery, starting with the negative terminal.

23A-13


23A

K7M

13785 a

Disconnect the modular connector (3) by releasing the connector slide mechanism.

IMPORTANT Protect the connector by sliding it into a waterproof bag.

14821 a

Remove: - the left-hand driveshaft using the tool (Tav. 476), - the right-hand driveshaft using the tool (Tav. 476) , - the steering box mountings (without damaging the power-assisted steering pipes, attach it so that it does not obstruct anything).

a

Disconnect the speed sensor connector.

a

Remove: - the starter, - the engine tie-bar, - the exhaust downpipe.

14823 a

Remove: - the engine wiring mounting bolts, - the wiring mounting (4) , - the Top Dead Centre sensor (5) .

a

Position the hose clamps and disconnect the exchanger.

a

Disconnect the oxygen sensor.

23A-14


23A

K7M a

Tilt the engine / automatic transmission assembly downwards as far as possible.

WARNING Take care not to damage the air conditioning compressor.

98755 a

a

Remove the upper gearbox bell housing bolts and studs.

a

Fit the component jack.

a

Remove the lower gearbox bell housing bolts and studs.

a

Disconnect the automatic transmission from the engine, taking care not to dislodge the converter.

a

Secure the converter with string to prevent it being dislodged.

REFITTING a

Fit the subframe support trolley ( 6) (Mot. 1390).

WARNING - Always replace the converter mounting nuts. - Check that the centring dowels are in place.

I - REFITTING THE GEARBOX a

Detach the converter.

a

Couple the automatic gearbox to the engine, paying attention to the converter.

a

Remove the component jack.

a

Refit the upper gearbox bell housing bolts and studs.

a

Refit:

14278 a

Position the (Mot. 1453).

a

Attach the cooling assembly.

a

Remove the engine subframe.

a

a

- the gearbox support.

II - FINAL STAGE

Rotate the crankshaft clockwise to access the three drive plate - converter connecting nuts and remove them.

II - REMOVING THE AUTOMATIC GEARBOX Remove:

- the earth strap on the gearbox,

a

Refit and torque tighten the three converter mounting nuts on the drive plate (30 N.m) .

a

Turn the crankshaft anti-clockwise until the three mounting nuts of the drive plate - converter connection can no longer be accessed.

a

Refit the engine subframe and detach the cooling unit.

a

Remove:

- the gearbox support ,

- the engine support tool,

- the earth strap from the gearbox.

- the subframe support trolley.

23A-15


23A

K7M a

Refit the exhaust downpipe.

- the brake calliper bolts (40 Nm),

a

Refit the engine tie-bar.

- the lower ball joint nut (55 N.m (K7M )),

a

Refit and torque tighten the engine tie-bar bolts (65 N.m (K7M )).

- the shock absorber base bolt (180 N.m (K7M )),

a

Refit the starter.

a

Refit and torque tighten the gearbox bell housing and starter bolts (45 N.m (K7M )).

a

Refit: - the steering box mountings (detach the steering box if it was a hindrance during removal, avoiding damaging the power-assisted steering pipes), - the right-hand driveshaft,

- the suspended engine mounting nut on the gearbox (40 N.m (K7M )), - the track rod end nut (40 N.m (K7M )), - the exchanger mounting bolts () . a

Refit the battery.

a

Connect the battery, starting with the positive terminal.

a

Top up the oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining - Refilling , page 23A17 ) .

a

When replacing the oil, use the diagnostic tool to:

- the left-hand driveshaft. a

Connect: - the oxygen sensor,

- reset the auto-adaptive shift patterns,

- the exchanger.

- reset the oil age counter in the automatic transmission computer.

a

Remove the hose clamps.

a

Refit: - the TDC sensor, - the wiring harness support, - the engine wiring mounting bolts.

a

Take the connector out of its plastic bag.

a

Connect the modular connector by refitting the connector slide mechanism.

a

Refit and torque tighten the modular connector support bolts (20 N.m (K7M )). Note: Do not move the orange ring during this operation. It may break when removed or refitted. If this happens, do not replace the control cable as the absence of this part will not affect the operation of the system.

a

Connect the multifunction switch.

a

Lock the sheath stop.

a

Connect the multifunction switch cable ball joint.

a

Refit: - the battery tray, - the air filter unit, - the front wheels.

a

Refit and tighten to torque: -the wheel bolts (90 Nm) ,

23A-16

AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling

23A

Tightening torques m 9 N.m

overflow pipe level-setting plug

35 N.m

filler cap

35 N.m

Gearbox

DP0

Oil capacity (adjust until overflows) (litre) Drain capacity

Total capacity

3.5

6

I - OIL SERVICE a

Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

107912 a

Note:

- the level-setting plug (1) ,

Drain the automatic transmission oil when the oil is warm (60˚C maximum), in order to remove as many impurities as possible.

- the oil overflow pipe (2) using an 8 mm Allen key (3) . a

a

Remove:

Let the oil flow.

Remove: - the engine undertray bolts,

Note:

- the engine undertray.

Always replace the oil overflow pipe with a new one whenever it is removed. a

Refit a new oil overflow pipe.

a

Tighten to torque: - the overflow pipe (9 N.m) , - the level-setting plug (35 N.m).

II - FILLING a

23A-17

Remove the air resonator (see Air resonator: Removal - Refitting ) (12A, Fuel mixture).


23A

110245

110236 a

Park the vehicle on level ground.

a

It is essential to shift the selector lever to the Park position.

a

Remove the filler cap (5 ) .

a

Use a funnel with a 15:100 filter to prevent impurities from entering the system.

a

Fill the automatic gearbox with 3.5 litres of new oil recommended by the manufacturer (see Automatic gearbox oil: Specifications ) (Technical Note 6012A, 04, Lubricants).

a

Run the engine at idle speed.

a

Connect the diagnostic tool.

a

Establish dialogue with the automatic gearbox computer.

a

Monitor the gearbox oil temperature parameter.

a

Wait for the temperature to reach 60˚C ± 1.

101743 a

Unclip the gear lever control cable ( 4) on the gearbox by: - squeezing the gear lever control cable clip at (A) , - pulling the pin at (B) , - lifting the gear lever cable at (C) .

23A-18


23A

III - LEVEL a

Park the vehicle on level ground. Note: The level MUST be checked according to the procedure described below.

110252 a

Place a container under the level-setting plug ( 6) .

a

Open the level-setting plug (6) , leaving the engine running.

a

If the oil does not flow out or the quantity collected is below 0.1 litres :

a

It is essential to shift the selector lever to the Park position.

a

Fill the automatic transmission with 0.5 litre of new oil.

a

Run the engine at idle speed.

a

Connect thediagnostic tool.

a


a

Monitor the gearbox oil temperature parameter.

a

Wait for the temperature to reach 60˚C ± 1.

a

Place a container under the level-setting plug.

a

Open the cap again .

a

If the oil does not flow or if the quantity collected is below 0.1 litres :

- Switch off the engine,

- Switch off the engine,

-add 0.5 litre of oil,

- add 0.5 litre of oil,

- let the automatic transmission cool to 50˚C,

- let the automatic transmission cool to 50˚C,

- run the engine at idle speed,

- run the engine at idle speed,

- connect the diagnostic tool,

- connect the diagnostic tool,

- establish dialogue with the automatic transmission computer,

- establish dialogue with the automatic transmission computer,

- monitor the gearbox oil temperature parameter,

- monitor the gearbox oil temperature parameter,

- wait for the temperature to reach 60˚C ± 1,

- wait for the temperature to reach 60˚C ± 1,

- place a container under the level-setting plug (6 ) ,

- place a container under the level-setting plug,

- open the level-setting plug.

- open the level-setting plug.

a

Repeat these operations until more than 0.1 litres of oil is recovered in the container.

a

Refit the level-setting plug (6) .

a

Torque tighten the filler cap (35 N.m).

a

Repeat these operations until more than 0.1 litres of oil is recovered in the container. Note: When the oil is replaced, the electronic oil ageing counter must be reset (inside the computer).

a

Refit the air resonator (see Air resonator: Removal - Refitting ) (12A, Fuel mixture).

a

Clip the gear lever control cable on to the gearbox.

a


23A-19

AUTOMATIC GEARBOX Automatic gearbox oil: Draining - Refilling a

Enter the date of the oil change using the diagnostic tool(see Fault finding - Configurations and programming) (23A, Automatic transmission).

23A-20

23A

AUTOMATIC GEARBOX Gearbox oil pressure: Check Essential special tooling Bvi. 1215-01

Automatic transmission oil pressure gauge kit. (in a kit), 25 bar pressure gauge.

Some fault finding procedures on the automatic gearbox involve taking the line pressure using a pressure gauge. The aperture for taking the oil pressure is located close to the pressure sensor.

13791 a

To take the oil pressure, remove the bolt ( 1) and fit the pressure measurement union (466.06) from the kit (Bvi. 1215-01).

a

The pressure value displayed must be between 2.7 and 3 bar for an engine running at idle speed.

23A-21

23A

AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting

23A

Essential special tooling Bvi. 1462

Ball plate adjusting screw.

Tightening torques m distributor

7.5 N.m

ball detent plate bracket bolt

9 N.m

ball detent plate bolt

8 N.m

hydraulic bolts

hydraulic cover bolts

distributor

10 N.m

REMOVAL 110245

I - REMOVAL PREPARATION OPERATION a

a

a

Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). Remove:

Unclip the automatic transmission control cable.

II - OPERATION FOR REMOVAL OF PART CONCERNED

- the engine undertray bolts, - the engine undertray. a

Drain the automatic gearbox oil (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-17) .

a

Remove: - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture), - the battery (see Battery : Removal - Refitting ) (80A, Battery), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery).

110233 a

Remove: - the bolts (1 ) of the hydraulic distributor cover, - the hydraulic distributor cover.

23A-22


23A

II - REFITTING OPERATION FOR PART CONCERNED

110232 a

Remove the hydraulic distributor bolts (2) .

a

Disconnect the hydraulic distributor solenoid valve connectors (3) .

a

Remove the hydraulic distributor.

13789 a

Connect the connectors of the hydraulic distributor solenoid valves.

a

Refit the hydraulic distributor with its reinforcement plate.

REFITTING I - REFITTING PREPARATION OPERATION a

Always replace the hydraulic distributor cover seal.

110227 a

Check that the hydraulic distributor slide is properly engaged with the notched sector lug ( 6 ) .

a

Tighten to torque and in order the hydraulic distributor bolts (7.5 N.m) .

23A-23


23A

ADJUSTING THE BALL DETENT PLATE

110229

119433

a

Put the multifunction switch lever in the first position selected using a hose clip and a bolt ( 8) in the mechanism housing.

a

Fit the ball detent plate by fitting the bearing (9) into the groove ( 12) for the notched sector (13) corresponding to the first selected.

a


a

Fit without tightening the ball detent plate bracket bolt (10) .

a

Fit the tool (Bvi. 1462) (11) in place of the bolt (7) .

a

Screw the tool (Bvi. 1462) in fully whilst holding the ball detent plate.

a

Tighten to torque the ball detent plate bracket bolt (9 N.m).

a

Remove the tool (Bvi. 1462).

a

Refit the ball detent plate bolt (7) .

a

Torque tighten the ball detent plate bolt (8 N.m).

a

Refit: - a new seal on the hydraulic distributor cover, - the hydraulic distributor cover.

a

Torque tighten the hydraulic distributor cover bolts (10 N.m).


Clip on the automatic transmission control cable.

a

Refit: - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection),

23A-24

AUTOMATIC GEARBOX Hydraulic distributor: Removal - Refitting - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the battery (see Battery : Removal - Refitting ) (80A, Battery), - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture). a

Top up the automatic transmission (see 23A, Automatic gearbox, Automatic gearbox oil: Draining Refilling, page 23A-17) .

a


23A-25

23A

AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting

23A

Tightening torques m automatic transmission connector bolts

4.5 N.m



a

Remove: - the engine undertray bolts, - the engine undertray. 133277

a

a


a

Disconnect the automatic transmission connector by pulling out the slide ( 1 ) .

a

Remove the bolts (2 ) from the automatic transmission connector.

Remove: - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture),


- the battery (see Battery: Removal - Refitting ) (80A, Battery), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the hydraulic distributor (see 2 3 A , Automatic gearbox , Hydraulic distributor: Removal - Refitting , page 23A-22) ,

110224 a

- the left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (19D, Engine mounting).

23A-26

Remove the yellow connector (3 ) from the automatic transmission connector.

AUTOMATIC GEARBOX Hydraulic distribution wiring: Removal - Refitting

23A

- the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the battery (see Battery: Removal - Refitting ) (80A, Battery), - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture). 117300 a

a

Remove the clip (4) from the cable feed opening using a screwdriver.

a

Top up the automatic transmission (see 23A, Automatic gearbox , Automatic gearbox oil: Draining Refilling, page 23A-17) .

a


Remove the hydraulic distributor wiring.

REFITTING I - REFITTING OPERATION FOR PART CONCERNED a

Refit: - the hydraulic distributor wiring, - the clip of the cable feed opening, - the connector of the hydraulic distributor wiring to the automatic transmission connector.


Refit the automatic transmission connector.

a

Torque tighten the automatic transmission connector bolts (4.5 N.m) .

a

Connect the automatic transmission connector.

a

Refit: - the left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (19D, Engine mounting), - the hydraulic distributor (see 2 3 A , Automatic gearbox , Hydraulic distributor: Removal - Refitting , page 23A-22) ,

23A-27

AUTOMATIC GEARBOX Flow regulation solenoid valve: Removal - Refitting


Tightening torques m flow control solenoid valve bolts

23A

10 N.m



a

Remove: - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture), - the battery (see Battery: Removal - Refitting ) (80A, Battery), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the engine undertray bolts,

133274 a

Disconnect the connector (1 ) from the flow control solenoid valve.

a

Unclip the flow control solenoid valve connector from the automatic transmission connector support.

a

Move the flow control solenoid valve wiring away from the automatic transmission wiring channel.

- the engine undertray, - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

13786-1 a

Remove: - the flow control solenoid valve bolts (2) , - the flow control solenoid valve.

23A-28

AUTOMATIC GEARBOX Flow regulation solenoid valve: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a

Refit the flow control solenoid valve.

a

Torque tighten the flow control solenoid valve bolts (10 N.m) .

a

Position the wiring of the flow control solenoid valve in the automatic transmission wiring channel.

a

Refit the connector of the flow control solenoid valve on the automatic transmission connector support.

a

Connect the flow control solenoid valve connector.


Refit: - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the engine undertray, - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the battery (see Battery: Removal - Refitting ) (80A, Battery), - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture).

23A-29

23A

AUTOMATIC GEARBOX Gearbox oil cooler: Removal - Refitting


Essential special tooling Mot. 1448

23A

Long nose pliers for hose clips.

Tightening torques m hollow bolt of the gearbox oil cooler

50 N.m



a

Remove: - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture), - the battery (see Battery : Removal - Refitting ) (80A, Battery), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) ,

133276 a

Separate the clips (1 ) on the gearbox oil cooler hoses using the tool (Mot. 1448).

a

Disconnect the hoses from the gearbox oil cooler.

a

Remove:

- the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection),

- the gearbox oil cooler hollow bolt ( 2) ,

- the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),

- the gearbox oil cooler,

- the gearbox oil cooler hollow bolt seal,

- the gearbox oil cooler seals.

- the engine undertray bolts, - the engine undertray.

REFITTING

a

Drain the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling).

a

Remove:

I - REFITTING PREPARATION OPERATION a

- the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

Always replace: - the gearbox oil cooler hollow bolt seal, - the gearbox oil cooler seals.

II - REFITTING OPERATION FOR PART CONCERNED a

Refit: - new seals on the gearbox oil cooler, - a new seal on the hollow bolt of the gearbox oil cooler, - the gearbox oil cooler.

a

23A-30

Torque tighten the hollow bolt of the gearbox oil cooler (50 N.m).

AUTOMATIC GEARBOX Gearbox oil cooler: Removal - Refitting a

Connect the hoses of the gearbox oil cooler.

a

Fit the clips on the gearbox oil cooler hoses using the tool (Mot. 1448).


Refit: - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the engine undertray, - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the battery (see Battery : Removal - Refitting ) (80A, Battery), - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture).

a

Fill the cooling circuit (see Cooling circuit: Draining - Refilling) (19A, Cooling).

23A-31

23A

AUTOMATIC GEARBOX Differential output seal: Removal - Refitting

23A

REFITTING


Fitting right-hand transmission output seal.

I - PREPARATION OPERATION FOR REFITTING THE DIFFERENTIAL OUTPUT SEAL

Bvi. 1875

Tool for fitting left-hand differential seal

a

Use SURFACE CLEANER to clean (see Recommended products for repairwork ) : - the universal joint shaft,

I - PREPARATION OPERATION FOR THE REMOVAL OF THE DIFFERENTIAL OUTPUT SEAL a

Position the vehicle on a two-post lift (see 02A, Lifting equipment, Two-post lift: Safety ).

a

Remove the engine undertray.

a

Remove the right-hand or left-hand driveshaft depending on the seal concerned (see 29A, Driveshafts, Front right-hand driveshaft or Front lefthand driveshaft : Removal - Refitting).

- the mating face of the seal. a

Parts always to be replaced: - the lip seal,

II - REMOVAL OPERATION FOR THE DIFFERENTIAL OUTPUT SEAL

101026 a

WARNING Failure to adhere to the following procedure may damage the gearbox. a

Deburr the aluminium gearbox casing around the inlet chamfer of the differential output seal (1 ) (lefthand side) using abrasive paper.

129983 a

Remove the faulty differential output seal using a screwdriver or a hook, taking care not to scratch the contact faces.

WARNING Do not drop the seal spring into the automatic transmission.

23A-32

Note: Failure to respect this advice may damage the seal and prevent it from sealing correctly.

AUTOMATIC GEARBOX Differential output seal: Removal - Refitting II - REFITTING OPERATION FOR THE DIFFERENTIAL OUTPUT SEAL

23A


Refit the right-hand or left-hand driveshaft depending on the seal concerned (see 29A, Driveshafts, Front right-hand driveshaft or Front left-hand driveshaft : Removal - Refitting).

a


a

Remove the vehicle from the two-post lift (see 02A, Lifting equipment, Two-post lift: Safety ).

Front left-hand seal:

117293

Front right-hand seal:

117291 a

Fit the seal in place using the tool (Bvi. 1459) (righthand side) or (Bvi. 1875) (left-hand side).

a

Guide the assembly until the tool is resting on the automatic transmission casing.

23A-33

AUTOMATIC GEARBOX Multifunction switch: Removal - Refitting

23A


4.5 N.m



a

Place the control lever in Neutral.

a

Remove: - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture), - the battery (see Battery: Removal - Refitting ) (80A, Battery), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),

133277 a

Disconnect the automatic transmission connector by pulling the slide (1 ) .

a



- the engine undertray bolts, - the engine undertray, - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

110245 a

Unclip the automatic transmission control cable.

a

Remove the automatic transmission control cable.

23A-34

AUTOMATIC GEARBOX Multifunction switch: Removal - Refitting

23A


Refit: - the multifunction switch in the Neutral position, - the automatic transmission control linkage.

a

Adjust the multifunction switch (see 23A , Automatic gearbox, Multifunction switch: Adjusting, page 23A-36 ) .

a

Refit the multifunction switch connector to the automatic transmission connector.

a

Clip on the automatic transmission control cable.

II - FINAL OPERATION

110224 a

Remove the green connector ( 5) from the automatic transmission connector.

a


a


a

Refit: - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the engine undertray, - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the battery (see Battery: Removal - Refitting ) (80A, Battery),

110234 a

Mark the position of the automatic transmission control linkage (6) .

a

Remove: - the automatic transmission control linkage, - the multifunction switch bolts (7) , - the multifunction switch.

23A-35

- the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture).

AUTOMATIC GEARBOX Multifunction switch: Adjusting

Tightening torques m multifunction bolts

switch

10 N.m

ADJUSTMENT

110242 a

Put the multifunction switch into the Neutral position.

a

Place the test probes of an ohmmeter on the multifunction switch position check tabs.

a

Turn the multifunction switch by hand until the electric contact is closed (resistance at contact terminals to be measured 0 Ω with a tolerance of 60 Ω)

a

Torque tighten the multifunction switch bolts (10 N.m).

a

Check that the resistance at the contact terminals is still 0 Ω with a tolerance of 60 Ω after tightening.

a

Check that the system and gear selection are working correctly.

23A-36

23A

AUTOMATIC GEARBOX Speed sensor: Removal - Refitting

23A

Tightening torques m input speed sensor bolt

10 Nm

output speed sensor bolt

10 Nm

automatic transmission connector bolts

4.5 N.m



a

Remove: - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture), - the battery (see Battery: Removal - Refitting ) (80A, Battery), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) ,

133277 a


a


- the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the engine undertray bolts, - the engine undertray, - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

23A-37

AUTOMATIC GEARBOX Speed sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED

23A

2 - Output speed sensor

1 - Input speed sensor

110224 a

Remove the blue connector ( 5) from the automatic transmission connector.

110224 a

Remove the yellow connector (3) from the automatic transmission connector.

a

Unclip the input speed sensor wiring from the automatic transmission wiring channel.

133278 a

Remove: - the output speed sensor bolt (6) , - the output speed sensor.

13786-1 a

Remove: - the input speed sensor bolt (4 ) , - the input speed sensor.

23A-38

AUTOMATIC GEARBOX Speed sensor: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED 1 - Input speed sensor a

Refit the input speed sensor.

a

Torque tighten the input speed sensor bolt (10 Nm).

a

Clip the input speed sensor wiring to the automatic transmission wiring channel.

a

Refit the input speed sensor connector to the automatic transmission connector.

2 - Output speed sensor a

Refit the output speed sensor.

a

Torque tighten the output speed sensor bolt (10 Nm).

a

Refit the output speed sensor connector to the automatic transmission connector.



a


a


a

Refit: - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the engine undertray, - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the battery (see Battery: Removal - Refitting ) (80A, Battery), - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture).

23A-39

23A

AUTOMATIC GEARBOX Pressure sensor: Removal - Refitting

23A

Tightening torques m pressure sensor bolts

8.5 N.m

pressure sensor wiring bolt

9 N.m

automatic transmission connector bolts

4.5 N.m



a

Remove: - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture),

133277

- the battery (see Battery: Removal - Refitting ) (80A, Battery),

a


- the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) ,

a


- the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection),


- the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the engine undertray bolts, - the engine undertray, - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

110224 a

Remove the green connector (3 ) from the automatic transmission connector.

a

Unclip the oil pressure sensor wiring from the automatic transmission wiring channel.

23A-40

AUTOMATIC GEARBOX Pressure sensor: Removal - Refitting a

23A

Refit: - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the engine undertray, - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the battery (see Battery: Removal - Refitting ) (80A, Battery),

110251 a

Remove: - the pressure sensor wiring bolt (4) , - the pressure sensor bolts (5) , - the pressure sensor.


Refit: - the pressure sensor, - the pressure sensor wiring bolt.

a

Tighten to torque: -the pressure sensor bolts (8.5 N.m) , -the pressure sensor wiring bolt (9 N.m) .

a

Clip the pressure sensor wiring to the automatic transmission wiring channel.

a

Refit the pressure sensor connector to the automatic transmission connector.



a


a


23A-41

- the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture).

AUTOMATIC GEARBOX Automatic gearbox converter: Removal - Refitting

23A

Essential equipment diagnostic tool



a


a

Remove the automatic gearbox (see 23A, Automatic gearbox, Automatic gearbox: Removal - Refitting, page 23A-6)


110228 a

Check the position of the converter in relation to the « engine - gearbox » mating face using a rule and a slide. The value should be ( X) = 18.22 mm ± 1.


Refit the automatic gearbox (see 23A , Automatic gearbox, Automatic gearbox: Removal - Refitting , page 23A-6) .

a

Top up the automatic transmission (see 23A, Automatic gearbox , Automatic gearbox oil: Draining Refilling, page 23A-17) .

Checking the converter setting point

141450 a

Remove the automatic gearbox converter (1) taking care that it does not deviate from its shaft.

I - REFITTING OPERATION FOR PART CONCERNED a

a

Lift the vehicle until the wheels are raised off the ground by a few centimetres.

a

Connect the diagnostic tool .

a

Start the engine.

a


a

Monitor the automatic transmission oil temperature parameter.

a

The check should be done at an oil temperature of between 60˚C and 80˚C.

a

Put the lever in position D.

a

Establish dialogue with the injection computer to display the engine speed.

Refit the automatic gearbox converter.

23A-42

AUTOMATIC GEARBOX Automatic gearbox converter: Removal - Refitting a

Accelerate fully, keeping the brakes applied, the wheels should not rotate. Note: Full load should not be maintained for more than 5 seconds. Beyond this, there is a high risk of destroying the converter or the automatic transmission.

a

Check that the engine speed stabilises at 2600 rpm ± 150. Note: Once the measurement has been taken, release the accelerator and keep the brakes applied until the engine speed stabilises to idle speed.

23A-43

23A

AUTOMATIC GEARBOX Converter seal: Removal - Refitting

II - REFITTING OPERATION FOR PART CONCERNED


23A

Fitting converter lip seal.



a

Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).

a

Remove the automatic gearbox (see 23A, Automatic gearbox, Automatic gearbox: Removal - Refitting, page 23A-6) Note: The converter contains a large amount of oil which could escape when it is being removed.

a

Remove the converter by withdrawing it as far as possible without deviating from its axis.

117292 a

Refit a new pre-lubricated seal to the stop, using the tool (Bvi. 1457) (1 ) .

II - OPERATION FOR REMOVAL OF PART CONCERNED a

Remove the seal using a screwdriver, taking care not to scratch the contact surfaces.

REFITTING I - REFITTING PREPARATION OPERATION a

Always replace the torque converter seal.

110228 a

Check the positioning of the converter in relation to the engine - automatic gearbox coupling face using a rule and a slide. The value should be (X) = 18.22 mm ± 1.


23A-44

Refit the automatic gearbox (see 23A , Automatic gearbox, Automatic gearbox: Removal - Refitting , page 23A-6) .

AUTOMATIC GEARBOX Converter seal: Removal - Refitting a

Connect the battery (see Battery : Removal - Refitting) (80A, Battery).

23A-45

23A

AUTOMATIC GEARBOX Automatic transmission connector: Removal - Refitting

- the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres),


23A

- the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

4.5 N.m


13785

(1 )

Green connector (multifunction switch)

(2 )

Yellow connector (electrohydraulic interface)

(3 )

Green connector (line pressure)

(4 )

Yellow connector (input speed)

(5 )

Blue connector (output speed)

133277

REMOVAL

a


a


I - REMOVAL PREPARATION OPERATION a


a

Remove: - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture), - the battery (see Battery: Removal - Refitting ) (80A, Battery), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the engine undertray bolts, - the engine undertray,

23A-46

AUTOMATIC GEARBOX Automatic transmission connector: Removal - Refitting

23A

- the petrol injection computer (see Petrol injection computer: Removal - Refitting ) (17B, Petrol in jection), - the automatic transmission computer (see 23A, Automatic gearbox, Automatic transmission computer: Removal - Refitting , page 23A-48) , - the battery (see Battery: Removal - Refitting ) (80A, Battery), - the air resonator (see Air resonator: Removal Refitting) (12A, Fuel mixture).

110224 a

Remove the connectors from the automatic transmission connector.

a

Remove the automatic transmission connector.


Refit: - the connectors to the automatic transmission connector, - the automatic transmission connector.

a


a



Refit: - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front left-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the engine undertray, - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),

23A-47

AUTOMATIC GEARBOX Automatic transmission computer: Removal - Refitting

23A

Essential equipment diagnostic tool


Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).


132693 a

Remove: - the automatic transmission computer retaining strap (2) , - the automatic transmission computer (3) .


- the automatic transmission computer,

132692 a

Refit:

Disconnect the connector (1) from the automatic transmission computer.

- the automatic transmission computer retaining strap. a

Connect the automatic transmission computer connector.


Connect the battery (see Battery : Removal - Refitting ) (80A, Battery).

When replacing the automatic transmission computer: a

Connect the diagnostic tool .

a

Enter the oil age value using the parameter PR133 « Oil age counter » and make a note of the value.

a

Copy the value into the memory of the new computer using the command VP015 « Oil age report » .

23A-48

AUTOMATIC GEARBOX Automatic transmission computer: Removal - Refitting a

Verify the entry using the parameter « Oil age counter » .

a

Enter the after-sales operation date using the command VP009 «Write date of last After-Sales operation »

a

Carry out a road test so that the new computer stores the programming.

23A-49

23A

MECHANICAL COMPONENT CONTROLS Automatic gear control cable: Adjusting

37A

WARNING The automatic gearbox control cable is adjusted with the gear selector and the multifunction switch in the DRIVE position.

ADJUSTMENT I - ADJUSTMENT PREPARATION OPERATION a

Remove: - the battery (see Battery : Removal - Refitting ) (80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery).

II - ADJUSTMENT OPERATION 127732 a

Lift the lock ( 2) upwards. In this position, the cable end is free to slide axially.

127730 a

Unlock the cable end by pushing the sliding tab ( 1) in the direction of the arrow until it clicks. 127738 a

37A-1

Put the gearbox output lever (3 ) in the DRIVE position, placing the lever parallel to the mark ( 4 ) on the multifunction switch.

MECHANICAL COMPONENT CONTROLS Automatic gear control cable: Adjusting

127731 a

Press the lock in the direction of the arrow (5) to release the sliding tab.

a

Lock the cable end by pressing the sliding tab in the direction of the arrow ( 6) until it clicks.


Refit: - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the battery (see Battery : Removal - Refitting ) (80A, Battery).

a

Check that the system and gear selection are working correctly.

37A-2

37A

MECHANICAL COMPONENT CONTROLS Gear control unit: Removal - Refitting

37A

Tightening torques m gear control unit nuts

12 N.m



a

Move the gear lever to the Neutral position.

a

Remove: - the battery (see Battery : Removal - Refitting ) (80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment).

133880

133881 133884 a

Remove the exhaust pipe clip ( 1) .

a

Disconnect the downstream oxygen sensor connector.

a

Remove the bolts ( 2) from the exhaust pipe rubber mounting bushes.

a

Let the exhaust pipe rest on the rear axle.

37A-3

MECHANICAL COMPONENT CONTROLS Gear control unit: Removal - Refitting

37A


133882 a

Remove: 110245

- the heat shield clips (3 ) , - the heat shield (4 ) .

110243 a

Remove: - the end of the automatic gearbox control cable from the multifunction switch ball joint by pressing at ( 5) , - the control cable sleeve stop from the automatic gearbox connector support by pulling the catch at (6) .

37A-4

DP0 / AL4 Technical Note

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