Aisin AF40-6 1.9 Multijet 16V 2.4 Multijet 20V 3.2 JTS · AISIN 6-speed cabling Solenoid valve pack...

ALFA 159 TRAINING MATERIAL Fiat Auto S.p.A. After Sales Training

Aisin AF40-6

1.9 Multijet 16V 2.4 Multijet 20V

3.2 JTS


1 AISIN AF40-6 GEARBOX

1.1 Description The AISIN AF 40-6 gearbox is an automatic, 6-speed gearbox used for the 1.9 JTD 16V and 2.4 JTD 20V engine versions. General features Type: automatic, 6-speed gearbox Engine: 1.9 JTD 16V and 2.4 JTD 20V Architecture: 3 clutches, 2 brakes, 1 free wheel, 2 epicyclical trains Hydraulics: 4 linear solenoids, 2 ON/OFF solenoids Electronics: built-it Neutral Start Switch and control unit, internal speed sensors and

cabling

NAME AF 40-6 VEHICLE 194 ENGINE VERSIONS 1.9 JTD 16V 2.4 JTD 16V

GEAR RATIO

1 4.148 2 2.370 3 1.556 4 1.155 5 0.859 6 0.686 R 3.394 Idle shaft 0.836 Differential 3.188

BRAKES AND CLUTCHES

CLUTCHES C1 1 flange, 6 discs, 6 plates

1 flange, 7 discs, 7 plates

C2 1 flange, 3 discs, 3 plates


C3 1 flange, 4 discs, 4 plates BRAKES B1 Band type

B2 2 flange, 6 discs, 5 plates


One-Way F1 Roller type

SOLENOIDS

Shift solenoid 2

Linear 6

LINE PRESSURE [KPa]

IDLING D 372 – 414

R 575 – 665

STALL D 1,350 – 1,460

R 1,905 – 2,125


Gearbox section:

1. Torque converter 2. Transmission gear 3. Transmission gear 4. Differential 5. C1, C2, C3: clutches 6. B1, B2, F1: brakes


1.2 Functions

Neutral Control When the vehicle is stopped with the lever in position “D”, the clutches will be automatically released, and the gearbox will be set to neutral. Thus, the torque converter will not be stressed; moreover, fewer vibrations will occur, and fuel consumption will be lowest. This functions will not be implemented on rough terrain and uphill roads: in the latter instance, the gearbox will remain engaged, thus ensuring a “hill holder” effect.

Reverse gear control By moving the lever from “N” to “R”, the reverse gear will not be engaged if the vehicle speed exceeds 11 r.p.m.

Adaptivity

MODE DESCRIPTION

ADAPTIVE It is used during normal driving. Both the sports and the economy modes are automatically selected according to the driving conditions.

SPORTS With this mode, the lock-up actuation and gear shifting points are higher, to achieve a higher engine revs number.

WINTER/LOW GRIP In case of ice, snow and low grip conditions in general, the vehicle will be started in the third speed to avoid front wheel slipping.

TIP

By moving the lever from “D” to “+/-“, the driver may choose the gear shifting point in a sequential fashion. In any case, the control unit will change the gear automatically to avoid out-of-revs conditions, or vice versa to avoid jerks when the engine speed is too low.

HIGH TEMPERATURE In case of too high gearbox oil temperature, the control unit will advance lock-up actuation in order to avoid excessive slipping in the torque converter and, thus, cause the temperature to decrease.

HEATING In this case, on the contrary, converter slipping will be enhanced in order to heat the oil.

RISE The rise will be automatically detected with a control unit algorithm based on the revs number increase: the gear shifting points will be increased.

DESCENT Conversely, the system will, when the vehicle is riding downhill, make use of a few tricks in order to avoid prolonged use of the brakes (lock-up, etc.).

FAST ON This control calculates the driver’s performance requests through the pressure on the accelerator pedal and regulates, accordingly, the gear shifting points.

BRAKE ASSISTANCE

On the contrary, the exhaust brake is used in this case to help the driver in case of deceleration (which is measured, once again, through the accelerator pedal).


1.3 Components

Control unit

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

1 Key switch signal

2 N.C.

3 N.C.

4 K line

5 Steering lock signal

6 CAN L

7 CAN H

8 CAN H

9 Ground

10 N.C.

11 Power supply

12 N.C.

13 Reversing light relay

14 CAN L

15 N.C.

16 N.C.


Input/output managed by the control unit The interface with the automatic transmission system manages the information through the following serial lines: C-CAN (information, data) K line (diagnosis)

SIGNAL I/O TYPE OF

TRANSMISSION

Key status I CAN

System failure warning light O CAN

Max. gearbox oil temperature warning light O CAN

Gear ON display O CAN

Gear selection I CAN

System diagnosis I/O

K

Vehicle speed I CAN

Brake pedal pressed for recovery (brake light contact)

I CAN

Driver’s side front door status I CAN

Acoustic indicator actuation O CAN

Start enable to NBS O on/ off @GND

Reversing light control O on/ off @+15

Engine water temperature I CAN

Engine torque variation request O CAN

MIL warning light ignition request O CAN


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

Cabling pin-out

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


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

AISIN 6-speed cabling

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

NSW built into the control unit


1 Control unit 2 Torque converter 3 Solenoid valve pack 4 Brakes/clutches 5 Oil radiator 6 Oil pump 7 Epicyclical gears


Solenoids

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

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

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

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


Sensors Lever position sensor (NSW)

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

Linear characteristic of the position sensor

Oil temperature sensor

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

NCA


Features:

Temperature Resistance 10 °C 5.62-7.31 (kΩ) 25 °C 3.5 (kΩ)

110 °C 0.22-0.27 (kΩ)

Input/output speed sensors

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

1.4 Tests

Stall test The purpose of the stall test is to check correct operation, mainly of the gearbox and the torque converter. It is carried out with the gear lever in positions “D” or “R”. The test procedure is as follows: lock the four wheels and engage the handbrake; press the brake pedal fully down with your left foot; position the gear lever to “D”, press the accelerator pedal fully down, then verify the

maximum revs number reached; move the gear lever to “R”, then check again the maximum revs number.

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


1.5 Procedures

Oil level check Position the vehicle on a lift.

With the coolant cold, start the engine and move the speed selector

twice from position "P" to position "D" and viceversa with the brake pedal depressed.

Maintain the selector in each position for 2 seconds.

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

Remove the automatic transmission fluid level check plug (1a) and

check that fluid emerges from the drain plug hole (1b).


If no fluid emerges, proceed as follows

Retighten the automatic transmission fluid level check plug.

Remove the automatic transmission fluid filler plug.

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

Automatic transmission Fluid Oil Tutela Gi/Vi 3.320 kg

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

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

Remove the automatic transmission fluid level check plug and check

that fluid emerges from the drain plug hole.

If no fluid emerges, repeat the above operations.

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

Transmission fluid level check plug to the specified torque.


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

Replace the o-ring if it is damaged.

Automatic transmission fluid level check plug: 0.6 -0.8 daNm

Tighten the automatic transmission fluid drain plug to the

recommended torque. Automatic transmission filler plug: 2.4 -3.6 daNm

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

Oil Type : TUTELA GI/VI

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

Changing oil during service : 3.89 Litres @ 15 deg c

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


1.6 GEAR CONTROLS

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

P = Park R = Reverse N = Neutral D= Drive, automatic forward gear + = Shift from higher transmission ratio in sequential mode - = Shift from lower transmission ratio in sequential mode Manual sequential command from selector lever The 6 gear changes can be managed sequentially by moving the lever to the right and

raising it in the + direction engages a higher ratio whilst lowering it in the - direction engages a lower ratio. Each gear engaged is shown by a number on the instrument panel display. Automatic command from selector lever The automatic command D can be selected from the sequential operation in any driving

conditions. The optimum ratio is selected by the gearbox electronic control unit depending on the

engine speed and load conditions. Manual sequential command from steering wheel (where present) The change can be managed sequentially via the controls on the steering wheel.


To use the controls of the steering wheel, the gear lever must be in a (manual) sequential position:

Operating the lever on the steering wheel in the + direction engages a higher ratio Ooperating the lever on the steering wheel in the +-direction engages a lower ratio Automatic driving mode selection (where present) It is possible to select different driving modes by pressing the SPORT/WINTER button on

the gearbox control panel.

The following driving modes are available: NORMAL: gear changes at low engine speeds, favouring comfort and reduced

consumption SPORT: gear changes at higher engine speeds, enhancing sporty driving

WINTER: programme for setting off on roads in poor grip conditions. The selection mode remains in force until the button is pressed again or the engine is

switched off.

Aisin AF40-6 1.9 Multijet 16V 2.4 Multijet 20V 3.2 JTS · AISIN 6-speed cabling Solenoid valve pack...

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Transcript of Aisin AF40-6 1.9 Multijet 16V 2.4 Multijet 20V 3.2 JTS · AISIN 6-speed cabling Solenoid valve pack...