6338026 AL4 Transmission

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CITROËN

TECHNICAL TRAINING

PRESENTATION OF THE AL4 AUTOMATIC TRANSMISSION CITROËN UK LTD

221 BATH ROAD SLOUGH SL1 4BA _________________

DEALER PERSONNEL DEVELOPMENT AND TRAINING _________________

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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

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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...

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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

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1 Chapter 1

PRESENTATION - GENERAL

I-INTRODUCTION AL4001D

• Electronically operated transverse automatic transmission. • Four forward gear s and one reverse gear. • "Fuzzy logic" auto-adaptive ECU which controls the con verter, gear changes and specific programs. • The maximum torque capacity is 210 mN. • Sealed transmission with reduced maintenance. • Transmission oil cooled b y heat exchanger. • Current application: CITROËN XANTIA PHASE II vehicles with X U Petrol and Diesel engines.

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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.

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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

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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

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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

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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

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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

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

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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

PDF created ith pdfFactory trial version .pdffactory.com P/N - D - Gear change

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Dist. C o n v e r t e r throttle α Control pnel ShiftLock S Disply counter 1st

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9 Chpter 1 VII - MISCELLANEOUS ADVICE A - TOWING The trnsmission is lubricted

when the engine is running since this drives the trnsmission oil pump. Thus, w

hen towing, the drive wheels must be rised off the ground. However, the vehicle

my be towed with the drive wheels on the ground under exceptionl circumstnce

s nd provided tht 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

distnce of 50 km. B - DRIVING Never drive with the ignition switched off. Neve

r push the vehicle to try nd strt it (not possible with utomtic trnsmission

). Note: The utomtic trnsmission is only lubricted when the engine is runnin

g.

C - OPERATIONS ON ELECTRICAL COMPONENTS Never disconnect: • the bttery whilst t

he engine is running, • the ECU whilst the ignition is switched on. Before recon necting connector, check: • the condition of the vrious contcts (bent, ruste

d...), • tht the mechnicl locking device is present nd check its condition.

During electricl inspections: • the bttery must be correctly chrged, • never

use power source greter thn 16 V, • never use tell-tle light.

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10 Chpter 1 D - OPERATIONS ON MECHANICAL COMPONENTS Never plce the trnsmissio

n on the ground unprotected. The converter retining pin must be inserted when t

he trnsmission is removed. The centring pin must be used to couple the trnsmis

sion to the engine. Remove the centring pin just before coupling the trnsmissio

n to the engine.

oristion écrite d'AUTOMOBILES CITROËN est interdite et constitue une contrefço

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11 Chpter 2

SELECTOR CONTROL

I-SELECTOR LEVER The selector lever, through the selector shft (on the trnsmissi

on), opertes the multifunction switch nd the mnul vlve on the hydrulic dis

tributor. D A B C E RI AL4007D

A - Upper prt B - Lower prt C - Sleeve stop D - Control lever E - Locking plun

ger for the Shift-Lock function Ri - Initil setting

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12 Chpter 2 The selector lever, locted on the centrl console, hs six positio

ns lid out on n offset or "stepped" grid. The lever hs mechnicl sfety de

vice which is unlocked by exerting rdil ction on the lever. Note: The ignit

ion must be switched on nd the brke pedl pressed to unlock the selector lever

from position P. This is the Shift-Lock function. C

Ri G

AL4028C

C - Sleeve stop Ri - Initil setting G - Control return with bll joint

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13 Chpter 2 II PROGRAM SELECTOR This is locted on the centrl console next to

the selector lever nd hs 3 push buttons. The driver cn therefore inform the E

CU of his selection: • desired progrm, • 1st imposed → this is obtined 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

Gers chnge utomticlly depending on vehicle speed nd engine lod in ccord

nce with vrious ger chnging lws. The ger chnging lws re chosen by the EC

U s function of one of the three progrms vilble to the driver. The driver

cn select progrm by pressing one of the "S" or "*" progrm selector buttons

.

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14 Chpter 2 The following three progrms re vilble: • utodptive or "norm l" (no buttons pressed): this is the bsic progrm; the ECU djusts the operti

on of the utomtic trnsmission to the style of driving, the rod nd engine lo d; it promotes fuel economy, • "Sport" (S button pressed): this progrm promote

s sporty driving to the detriment of consumption. Gers re still chnged utom

ticlly, • "Snow" (* button pressed): this progrm is suited to driving on low

dherence ground. In drive, this mens tht either first ger or first nd second

gers re no longer vilble nd gers re chnged down less frequently using specific set of chnging lws. Furthermore, in the imposed positions 1, 2, 3,

the "Snow" set of lws re used which tke into ccount the restrictions reltin

g to the chosen imposed position. Note: Every time the ignition is switched off then on gin, the ECU utomticlly switches to the "norml progrm" configurt

ion.

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15 Chpter 3

CHECKING THE OIL LEVEL

Check the oil level every 60 000 kms. Prerequisites: • • • • • • • vehicle on ho rizontl ground, check tht the trnsmission is not in downgrded mode, remove t

he filler plug 1 nd systemticlly dd 0.5 litres of oil to the trnsmission, p

ress the brke nd chnge through ll the gers, selector lever in position P, e

ngine running t idle speed, oil temperture 60 °C + 8 . -2

1 4 3 AL4008C AL4009C 4

1 - Filler plug 2 - Trnsmission housing 3 - Level plug 4 - Drin plug

2 3

AL4010C

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16 Chpter 3 • Remove the level plug (3). • If oil strems out then strts to dr

ip → close the level plug nd tighten to 2.4 mdN. • 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 trnsmission, repet the level checking procedure, the oil level is corr

ect if oil strems out nd then strts to drip, close the level plug (3) nd tig

hten to 2.4 mdN close the filler plug (1) nd tighten to 2.4 mdN Too much oil

my hve the following consequences: • bnorml heting of the oil, • oil leks.

Too little oil my dmge the trnsmission. Note: An oil check is not included

in the PDI nor the first service. AL4 AUTOMATIC TRANSMISSION

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17 Chpter 4

THE TORQUE CONVERTER

The AL4 utomtic trnsmission is fitted with stndrd torque converter which

hs n dded lock-up device. IDESCRIPTION 123456789 8

Lock-up piston Double sided friction plte Vibrtion dmper Impeller Turbine St

tor Free wheel Oil pump drive Automtic drive trnsmission input shft

9-Strting ring AL4011P 7 1 6 2 Drive end plte AL4027C 3 Converter 5 4

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18 Chpter 4 The torque converter consists of: • n impeller (4), linked to the

engine, • turbine (5), linked to the trnsmission, • sttor (6), fitted on t

he free wheel (7) nd locted between the impeller nd the turbine, • lock-up

device operted by the ECU which consists of piston (1), friction plte (2) nd vibrtion dmper (3). The converter is secured to the engine drive plte (

end plte). Its role is to provide flexible nd utomtic link between the eng

ine nd the trnsmission. It hs two operting phses: • the converter phse whe

re it multiplies the engine torque by up to 2.2 times, • the coupling phse wher

e it trnsmits 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 hydruliclly operted by n

electrovlve controlled by the ECU. The clutch cn be in one of two sttes: • •

open stte → norml converter opertion, closed stte where it connects the impe

ller nd the turbine so s to trnsmit ll of the engine torque → engine brke

vilble, reduction in fuel consumption, cooling of utomtic trnsmission oil.

Lock-up is vilble on 2nd, 3rd nd 4th gers (nd 1st ger in rre cses). The

converter is locked up by inverting the direction of oil flow. The ECU controls the two possible sttes of the lock-up using set of memorised lws.

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19 Chpter 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 vibrtion dmper (3)

nd the friction plte (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 plte. 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 tnk. The oil therefore rrives through the converter circuit (b) into the c

onverter cusing the lock-up piston to move. This llows the turbine to connect

with the impeller vi the vibrtion dmper nd double sided clutch plte. Note:

The lock-up piston is joined to the rotting impeller.

AL4013D

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20 Chpter 4

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21 Chpter 5

THE EPICYCLIC GEAR TRAIN

I-DESCRIPTION To provide the four forwrd gers nd one reverse ger, the AL4 uto

mtic trnsmission hs SIMPSON type epicyclic ger trin. This consists of two

simple epicyclic ger trins connected together. There re: • two sunwheels P1 nd P2, • two sets of plnet wheels S1 nd S2, • two plnet wheel crriers PS1

nd PS2, • two rings C1 nd C2. The two ger trins re connected in the followin

g mnner: • plnet wheel crrier PS1 nd ring C2 re connected together, • plne

t wheel crrier PS2 nd ring C1 re connected together. Ger trin n°1 is locte

d on the rer housing side. Ger trin n°2 is locted on the converter side; the

movement systemticlly exits through its plnet wheel crrier PS2.

F1 E1 E2 C1 S1 P1 PS1 P2 F2 C2 S2

F3

Primry pinion of the step down ger Movement input housing PS2

AL4014D

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22 Chpter 5

Secondry pinion of the step down ger

P2 C2 PS1 P1 Connection with PS1 PS2 C1 AL4015P

Primry pinion of the step down ger

Ger trin specifictions Sunwheel P1 Sunwheel P2 Plnet wheel S1 Plnet wheel S

2 Ring C1 Ring C2

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33 teeth 40 teeth 21 teeth 19 teeth 81 teeth 80 teeth

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23 Chpter 5 II OPERATING PRINCIPLE 1st ger F1 E1 C1 E2 PS1 F2 F3 C2 PS2 PP des P1 P2 Lock-up

PP des = Primry step down pinion

AL4016D Primry 2nd ger F1 E1 C1 E2 PS1 F2 F3 C2 PS2 PP des P1 P2 Lock-up

AL4017D Primry

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24 Chpter 5 3rd ger F1 E1 C1 E2 PS1 F2 F3 C2 PS2 PP des P1 P2 Lock-up

AL4018D Primry 4th ger F1 E1 C1 E2 PS1 F2 F3 C2 PS2 PP des P1 P2 Lock-up

AL4019D Primry

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25 Chpter 5 Reverse F1 E1 C1 E2 PS1 F2 F3 C2 PS2 PP des P1 P2 Lock-up

AL4020D Primry

Tble of moving prts

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

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26 Chpter 5

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27 Chpter 6

ECU

The ECU of the AL4 trnsmission is n utodptive nd upgrdble ECU with 56

trck Flsh Eprom. IECU FUNCTIONS The ECU performs the following functions: A -

GEAR CHANGING LAWS The ECU hs 10 ger chnging lws llowing the opertion of t

he trnsmission to be ltered to the driver's style of driving, to the chosen pr

ogrm nd to the internl nd externl conditions. The following lws re theref

ore obtined: • 6 lws: for utodptivity, • 1 lw: for the snow progrm, • 1 l w: "unlocked" for low temperture opertion, • 1 lw: for depollution when cold

(heting), • 1 lw: for utomtic trnsmission temperture protection. B - PROG

RAMS The ECU mnges three progrms: utodptive, Sport nd Snow (upon driver's

request). C - AUTO-ADAPTIVENESS The ECU hs n utodptive progrm which llow

s it to chose the lw which will be the best suited to the following conditions

from the ten lws listed bove: • driver's style of driving → 3 lws = "economic

", Medium", "Sport ", • rod profile nd vehicle lod → 3 lws = "slight incline

" (or "brking 1"), "shrp incline" (or "brking 2"), "decline", • temperture,

• selected progrm.

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28 Chpter 6 D - GEAR CHANGE UP PREVENTION DUE TO SUDDEN REMOVAL OF FOOT FROM AC

CELERATOR This function prevents the trnsmission from chnging up to higher g

er when the foot is suddenly removed from the ccelertor pedl; this llows th

e engine brke to be mintined whilst decelerting. E - GEAR LOCKING FOLLOWING

A LAW CHANGE For resons of sfety nd comfort, the trnsmission is prevented fr

om chnging up or down ger too quickly if the lw hs just chnged. F - CHANG

E DOWN The ECU is totlly responsible for chnging down the gers s function

of engine lod, vehicle speed nd driving conditions. The ECU uthorises doubl

e chnge down (from 4th to 2nd nd 3rd to 1st) or forces single chnge down. F

urthermore, the ECU provides chnge down function in the event of sustined br king in order to nticipte downwrd ger chnges nd so s to provide the engi

ne brke. G - MOMENTARY SWITCH TO SPORT PROGRAM So s to provide better power t

ke-up in the norml progrm, the ECU temporrily switches to more sporty lw w

hen the ccelertor pedl is suddenly pressed down. H - KICKDOWN The kickdown or

der is given by the utomtic trnsmission ECU fter the ccelertor pedl is pr

essed down fully nd depending on vehicle speed. I - MANAGEMENT OF IMPOSED GEARS

The ECU is totlly responsible for chnging to imposed gers in terms of opert

ion nd sfety (chnging limits). J - CONTROLLING THE LINE PRESSURE The ECU work

s out the vlue of line pressure with closed loop feedbck. The reference vlue

is function of the turbine torque to overcome.

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29 Chpter 6 K - MANAGING GEAR CHANGES When the ECU decides to chnge ger, it

must operte the vrious electrovlves involved in precise order nd in ccor

dnce with timers which re function notbly of the engine lod nd vehicle sp

eed. This provides good overlp 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 opertion by locking it up to sve fuel, to obtin en

gine brking, to encourge cooling of the trnsmission oil nd to prevent slip.

A lw which depends on vehicle speed, throttle position nd ger engged is used

to decide whether to lock the converter up or not. M - TORQUE REDUCTION This fu nction is used to increse driving plesure by reducing the engine torque when c

hnging ger. This ction consists of momentrily reducing the ignition dvnce

in ccordnce with pre-progrmmed tble provided by the engine mngement comp

uter. N - IDLE SPEED COMPENSATION This function is used to ttenute the drggin

g effect of the trnsmission when it is being driven through the engine mngeme

nt computer (idle reference speed). O - AUTOMATIC TRANSMISSION PROTECTION • Reve rse ger sfety: for vehicle speed > Threshold. • Incorrect opertions: − 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 SHIFTLOCK 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.

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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 aftersales 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

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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

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21 20 AL4021P

Load information A Petrol engine with double track potentiometer B Petrol en

gine with single track potentiometer C Diesel engine

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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)

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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 cutoff 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: lockup 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, locku

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

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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

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35 Chapter 7 AUTODIAGNOSTIC

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 lockup modulating electrovalve (lockup 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.

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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 lockup 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:

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37 Chapter 8

WIRING DIAGRAM XANTIA

PETROL ENGINE/WITHOUT CRUISE CONTROL ILAYOUT AL4022P

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38 Chapter 8

PETROL ENGINE/WITH CRUISE CONTROL ILAYOUT AL4023P

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39 Chapter 8

DIESEL ENGINE/WITHOUT CRUISE CONTROL ILAYOUT AL4024P

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40 Chapter 8

DIESEL ENGINE/WITH CRUISE CONTROL ILAYOUT AL4025P

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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

lectrohydraulic unit 1637 Automatic transmission kickdown switch 1638 Autom

atic transmission shiftlock 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

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42 Chapter 8

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43 Chapter 9

AFTERSALES 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

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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

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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.

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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.

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47 Chapter 9 The operating procedures for the various authorised operations are given in the corresponding aftersales 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.

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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 ND or NR 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

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7) POINT OF SALE COMMENTS:

e.g. associated variables ... ... ... ... ...

8) RESPONSE TO APPROVAL REQUEST

(Approval n°) ... ... ... ... ...

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49 Chapter 9 Note: Above for France. For UK contact warranty department, Citroën UK Ltd.

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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 removingrefitting 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

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51 Chapter 9 XI DIAGNOSTIC TOOLING ELIT unit: 4125T 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: 4165T 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.

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52 Chapter 9 LEXIA station: 4171T 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: 4187T Using a

voltmeter and an ohmmeter, this tool is used to check: • sensors and actuators, • automatic transmission harness.

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53 Chapter 9

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