gearbox 001.pdf

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Service 5

Service Department. Technical Information Printed in Czech RepublicS00.5318.00.20

Workshop ManualFABIA 2000

Automatic Gearbox 001Edition 07.00Gearbox code

ESK GJF GJG


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Service5

The Workshop Manual is intended only for use within the Organisation koda.It is not permitted to pass it on to other persons.

KODA AUTO a. s.

Printed in Czech RepublicS00.5318.00.20


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FABIA 2000 Automatic Gearbox 001

List of SupplementsEdition 04.05S00.5318.02.20

List of Supplements to Workshop Manual

FABIA 2000

Automatic Gearbox 001

Edition 07.00

Supplement

Edition Subject Article Number

07.00 Basic Edition S00.5318.00.20

1 12.02 Supplement to Basic Edition S00.5318.01.20

2 04.05 Supplement to Rep. - Gr. 00, 01, 37, 38, 39 S00.5318.02.20


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Table of ContentsEdition 04.05S00.5318.02.20

I

Table of Contents

00 Technical Data

Technical Data for the Gearbox .....................................................................

- Identification of the gearbox ............... ................. ................ ................ .........

- Identification characters, aggregate assignment, ratios, capacities .. .. .. .. .. .. .. .. .. .. .. .. .. .

- Capacity .. . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . .

Information and repair Instructions for the Automatic Gearbox 001 .......................

- Information on the Automatic Gearbox 001 .... .... ..... .... ..... .... .... ..... .... ..... .... .... ...

- Repair instructions ............... ................. ................. ................. ................ ..

- Explanation of the terms used in this workshop manual. ... ... ... ... ... ... ... ... ... ... ... ... ... .

01 Self-diagnosis, Electrical Test

Function of Self-diagnosis ...........................................................................

- Function of Self-diagnosis .............. ................. ................. ................. ...........

- Self-diagnosis technical data ................. ................ ................. ................. .....

Electric/Electronic Components and Fitting Locations ......................................

- Vehicle components ............... ................. ................. ................ .................

- Electric/electronic components of the gearbox .... ..... .... ..... .... .... ..... .... ..... .... .... ...

Performing self-diagnosis ............................................................................

- Test conditions ................ ................. ................ ................. ................. ......

- Work sequence ... . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . .

- Overview of selectable functions ..... ..... ..... ..... .... ..... ..... .... ..... ..... .... ..... .... .... ...

- Interrogating and erasing fault memory ..... .... .... ..... .... ..... .... .... ..... .... ..... .... .... ...

Fault Table and Initiating Basic Setting ..........................................................

- Fault table .. . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .- Initiating basic setting ................. ................. ................ ................. ..............

Reading measured value block .....................................................................

- List of display groups ................. ................. ................ ................. ..............

- Test table .. . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. .

Inspecting the solenoid valves and shift elements while driving ...........................

- Solenoid valves and position of the shift elements ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..

Electrical Test ...........................................................................................

- Test procedure ................ ................. ................ ................. ................. ......

- Check the wiring between the automatic gearbox control unit -J217- and the gearbox ... .32 Torque Converter

Torque Converter .......................................................................................

- Identification of the torque converter ..... ..... ..... .... ..... ..... .... ..... ..... .... ..... .... .... ...

- Draining the torque converter ..... ..... .... ..... ..... .... ..... ..... .... ..... ..... .... ..... .... .... ...

- Removing and installing gasket ring for torque converter ... ... ... ... ... ... ... ... ... ... ... ... ...

- Installing the torque converter .... ..... ..... .... ..... .... .... ..... .... ..... .... ..... ..... .... ..... ...

37 Control, housing

Checking shifting points .............................................................................

Measure limit speed of the hydraulic converter .................................................

Fault finding .............................................................................................

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- Before fault finding ................ ................. ................. ................. ................ .

- Safety measures ................ ................ ................ ................. ................. ....

- Fault finding table ............... ................ ................. ................. ................. ...

Inspecting gearshift mechanism ...................................................................

- Inspecting gearshift mechanism .............. ................. ................. ................. ...

- Inspecting and adjusting the selector lever control cable ... ... ... ... ... ... ... ... ... ... ... ... ...

Removing and Installing Shift Mechanism ......................................................- Removing and Installing Shift Mechanism ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..

- Removing and installing the selector lever control cable ... ... ... ... ... ... ... ... ... ... .. ... ... ..

- Removing and installing the selector lever grip ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

Disassembling and assembling the gearshift mechanism ...................................

- Adjusting latch spring with roller .... ..... ..... .... ..... ..... .... ..... ..... .... ..... ..... .... ..... ...

- Removing and installing selector lever lock solenoid -N110- .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

Removing and installing the gearbox .............................................................

- Removing ... . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . ..

- Installing .. . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . .Checking and topping up ATF level ...............................................................

- Inspecting ATF level ................. ................. ................ ................. ...............

- Topping up ATF ... . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . .

- Replacing ATF ................ ................. ................. ............... ................. .......

Disassembling and assembling the gearbox ....................................................

- Gearbox with shift elements ................. ................. ................ ................. ......

- Removing and installing ATF radiator and ATF filler tube ... ... ... ... ... ... ... ... ... ... ... ... ..

Disassembling and assembling planetary gear - Summary of components .............

- I - Removing and installing ATF pump up to large sun gear .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

- II - Removing and installing cover for gearbox housing up to the drive gear .. .. .. .. .. .. .. ..

Disassembling and assembling planetary gear - Assembly sequence ....................

- Disassembling planetary gear .... ..... .... .... ..... .... ..... .... ..... ..... .... ..... ..... .... ..... ...

- Assembling planetary gear ............... ................. ................. ................ .........

Adjusting work on planetary gear ..................................................................

- Overview ................ ................. ................ ................. ................. ............

- Adjusting reverse gear-brake -B1- .... ..... .... ..... ..... ..... .... ..... ..... ..... .... ..... ..... ....

- 2. Adjust 2nd and 4th gear-brake -B2- ..... ..... ..... ..... .... ..... ..... .... ..... ..... .... ..... ...

- Setting clutch clearance ................. ............... ................. ................. ............

38 Wheels, Control

Disassembling and assembling the ATF pump .................................................

Disassembling and assembling overrunning clutch ...........................................

1. Disassembling and assembling 1st through 3rd gear clutch -K1- .......................

Disassembling and assembling the reverse gear-clutch -K2- ...............................

Disassembling and assembling 3rd and 4th gear-clutch -K3- ...............................

Disassembling and assembling the reverse gear-brake -B1- ................................

Disassembling and assembling the piston for 2nd and 4th gear-brake -B2- .............

Removing and installing slide valve body - Summary of components ....................- Removing and installing ATF strainer .... ..... ..... .... ..... ..... .... ..... .... .... ..... .... ..... ...

- Solenoid valve -N93- .............. ................. ................. ................. ................ .

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- Removing and installing retaining plate with solenoid valves -N88- through -N92- .. .. .. .. .

Disassembling and assembling the parking position .........................................

39 Final drive, differential

Replacing flange shaft gasket rings ...............................................................

Disassembling and assembling the final drive ..................................................

- Repair overview of the final drive .... ..... ..... ..... .... ..... ..... .... ..... ..... .... ..... .... .... ...

- Disassembling and assembling the input shaft .... ..... .... ..... .... ..... ..... .... ..... ..... .... .

- Disassembling and assembling the differential ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

Adjusting the final drive .............................................................................

- Overview of adjusting works ............... ................. ................ ................ .........

- Adjusting works when replacing individual components ... ... ... ... ... ... ... ... ... ... ... ... ... .

- Adjusting the differential gear ..... ..... .... ..... ..... .... ..... ..... .... ..... ..... .... ..... .... .... ...

- Adjusting the input shaft .............. ................. ................ ................. ..............

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Technical Data for the GearboxEdition 04.05S00.5318.02.20

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00-1 Technical Data for theGearbox

Identification of the gearbox

The Automatic 4-speed gearbox 001 engine is installedin the Fabia 2000 in combination with the 4 cylinder en-gine. Assignment 00-1page 2.

Location on the gearbox

Identification characters and manufacturing data ofthe gearbox -arrow-

Example:

The gearbox identification characters also appear onthe vehicle data stickers.

00 Technical Data

S37-0117

ESK 18 07 0

I I I I

Identifica-tion charac-

ters

Day Month Manufacturingyear (2000)


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Identification characters, aggregate assignment, ratios, capacities

Capacity

Planetary gear and final drive

The oil filling is for the planetary gear and final drive to-gether. Inspecting and filling Chapter 37-8.

Automatic gearbox 001

Gearbox Identification characters ESK GJF GJG

Manufac-tured

fromthrough

07.0011.02

12.02 12.02

Torque Converter Identification characters ACN ACN ACN

Slide valve body Identification characters CCC CCC CCC

Number of plates Inner Outer Inner Outer Inner Outer

Clutch -K1- 5 5 5 5 5 5

Clutch -K2- 2 2 2 2 2 2

Clutch -K3- 3 5 3 5 3 5

Brake -B1- 5 4 5 4 5 4

Brake band Brake -B2- (2nd gear)stepped piston in mm

57 + 36 57 + 36 57 + 36

Brake -B2- (4th gear)single piston in mm 44 44 44

Assignment Engine 1.4 ltr. - 55 kW 1.4 ltr. - 55 kW 1.4 ltr. - 55 kW

Ratios 1. Gear 2,875 2,875 2,875

2. Gear 1,510 1,510 1,513

3. Gear 1,000 1,000 1,000

4. Gear 0,726 0,726 0,726

Reverse 2,656 2,656 2,656

Intermediate gear No. of teeth Input gear 49 49 39

Output gear 53 53 42

Ratio 1,082 1,082 1,077Final drive No. of teeth Drive pinion 20 20 20

Pinion finaldrive

81 81 81

Ratio 4,050 4,050 4,050

Drive shaft flange 90 mm

Contents Automatic Gearbox 001

New filling 5.7 ltr.(filled for life)

Lubricant ATFSpare part no.:G 052 990 A2


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Information and repair Instructions for the Automatic Gearbox 001Edition 04.05S00.5318.02.20

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00-2 Information and repair In-structions for the Auto-matic Gearbox 001

Information on the Automatic Gearbox001

Information on this automatic gearbox can be found in Self-study Programme No. 40; 4 speed automaticgearbox 001.

Gearbox

The automatic 4 speed gearbox 001 is equipped with 4hydraulically controlled forward gears. With the torqueconverter lockup clutch closed the 3rd and 4th gear be-come mechanically driven gears by bypassing the con-verter slip.

Automatic Gearbox Control Unit -J217-

The control unit has two program options to meet the driv-er's preference for sporty (SPORT program) or for eco-nomic driving (ECO program).

These two programs are automatically selected in thecontrol unit.

Torque Converter

The torque converter is equipped with a torque converterlockup clutch. The closing of the torque converter lockupclutch is load and speed sensitive, and the torque con-verter lockup clutch can drive the 3rd and 4th gears me-chanically (without slip).

ATF

The ATF is filled for life. The ATF need not be changedwithin the scope of servicing.

Only use ATF with spare part number

G 052 990 A2

if ATF needs to be added.The ATF oil filling is for the planetary gear and final drivetogether. Inspecting and filling Chapter 37-8.

Repair instructions

Scrupulous care and cleanliness as well as the propertools are essential requirements for carrying out properand successful gearbox repairs. Obviously, the generallyvalid basic safety rules apply to repair work.

A number of generally valid notes for individual repair op-

erations - which are otherwise listed several times at nu-merous points in the workshop manual - are summarizedhere. They apply to this workshop manual.


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Special tools

The composition of the special tools used in the work-shop manual is listed in binder Workshop EquipmentCatalogue.

Gearbox

Do not run the engine or tow the vehicle when the oilpan of the gearbox has been removed or without ATFfilling.

When replacing the automatic gearbox check theATF, if necessary top up Chap. 37-8. Capacitiesand specification Chap. 00-1.

Secure the torque converter against dropping outwhen the gearbox is removed.

Thoroughly clean the connection points and their sur-roundings before releasing.

Before installing the gearbox check the fitting dimen-sion of the torque converter Chap. 32-1.

When installing pay attention to the correct position ofthe dowel sleeves.

Place removed parts on a clean surface and cover.Use foil and paper. Do not use fuzzy cloths!

Carefully cover or close opened components if the re-pair is not completed immediately.

Only install clean parts. Remove spare parts fromtheir wrapping immediately before fitting.

O-rings, gasket rings, gaskets

Always replace O-rings, gaskets and gasket rings. Before installing the gasket rings coat the outer cir-

cumference and sealing lips with ATF.

Before inserting the O-rings coat with ATF to preventthe rings being squashed during installation.

Never use other lubricants in the ATF area.

After installation check ATF level, if necessary correct.

Sealant

Clean contact surfaces thoroughly and apply sealant

-D 176 404 A2-. Pay attention to the sell-by-date of the sealant.

After applying the sealant screw the parts within 5minutes.

After installing, allow the sealant to dry for about 30minutes. Only then may ATF be filled in.

Locking elements

Do not over-extend the circlips, if necessary replace.

Circlips must be positioned in the base of the groove.

Replace roll pins. Fitting position: slot longitudinally topower flow.


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Bolts, nuts

Slacken and tighten nuts and bolts for attaching cov-ers and housings diagonally across.

Do not twist particularly sensitive parts - e.g. the slidevalve body - and slacken and tighten diagonallyacross in stages.

Tightening torques apply for non-oiled nuts and bolts.

Clean the thread of the screws that are inserted with alocking agent with a wire brush. Subsequently insertscrews with AMV 185 101 A1.

Replace the self-locking screws and nuts.

Bearings

Insert bearing in gearbox with ATF.

Insert the axial needle bearing in the correct fitting po-sition Chap. 37-10.

Before inserting heat the inner rings of the tapered-

roller bearing to approx. 100C. Do not mix up the outer and inner races of bearings of

the same size.

Always jointly replace tapered-roller bearings on thesame shaft and use products of the same manufactur-er.

Piston rings

Do not overwind when removing and installing.

Shims Gauge shims at several points with a micrometer. Dif-

ferent tolerances allow to measure the required thick-ness for each washer very precisely.

Inspect for burrs and damage. Install only shims whichare in perfect condition.

Inner plates

Place new inner plates in ATF for 15 minutes beforeinstalling.

Slide valve body

The slide valve body must be replaced if the shift ele-ments are burnt (plates).

Clutches

The clutches can be dismantled, assign defectiveparts (e.g. outer and inner plates) according to theirgearbox identification characters.

Before installing the piston moisten the sealing lipsand gasket rings with ATF.


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00-2page 5

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recognize faults,

react to faults,

store faults,

Determine measured values and to display them inthe measured value block.

Free wheel/Stator

Ensures the torque increase in the torque converter whenstarting.

Free wheel/Gearbox

Simplifies the technical effort of the gearshift without trac-tion interruption and ensures a uniform gearshift quality.

Gearbox speed sender -G38-

The sender determines the speed of clutch -K3- and

sends it to the automatic gearbox control unit.

Vehicle speed sender -G68-

The sender determines the speed of the output gear andsends it to the automatic gearbox control unit (not thespeedometer).

Gearbox oil temperature sender -G93-

Monitors the ATF temperature.

Clutches

Together with the brakes they shift the individual gears.

Selector lever lock solenoid -N110-

Located in the gearshift mechanism close to the selectorlever. Prevents the (unintentional) shifting of the selectorlever from positions P and N, as long as the brakepedal is not pressed.

Solenoid valves

Open and shut the oil galleries to the clutches andbrakes.

Multi-function switch -F125-

Electric switch with different functions. Further informa-tion on this can be found in Self-study ProgrammeNo. 40; 4 speed Automatic Gearbox 001.

Emergency running mode

Status of the control unit, to ensure further safe opera-

tion in the event of a detected faults, to protect the gear-box from damage and to thereby restrict the drivingbehaviour as little as possible.


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Information and repair Instructions for the Automatic Gearbox 001 Edition 04.05S00.5318.02.20

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Parking position

When the vehicle is standing the parking gear is blockmechanically thereby protecting the vehicle against (un-intentional) rolling off.

Planetary gear

The mechanical part of the automatic gearbox that isswitched via clutches and brakes without power flow in-terruption.

Slide valve body

Located below the gearbox and is surrounded by the oilpan of the gearbox. Its valves regulate the hydraulic pres-sure and distribute it via the oil galleries to the gearshiftelements (clutches and brakes).

Automatic Gearbox Control Unit -J217-

The electronic control unit determines the shifting points.The function of the gearbox is monitored via self-diagno-sis. If components or sensors fail an emergency runningprogramme is activated to maintain driveability.

LC (torque converter lockup clutch)

Mechanically transmits the engine torque to the gearbox.


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Function of Self-diagnosisEdition 07.00S00.5318.00.20

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01-1 Function of Self-diagno-sis

Function of Self-diagnosis

The control of the automatic gearbox is electronic/hy-draulic.

The term self-diagnosis is related to this electric/elec-tronic control.

Additionally required information means

Self-study programme No. 40

Control unit -J217 with driving situation circuits(Fuzzy Logic)

The driving situation and road resistance dependentshifting point determination occurs automatically.

Advantages:

shifting occurs with a focus on economic consumption

greatest engine power is always available

individual adaptation of the shifting points to all drivingsituations

shifting points modified as required

Functions of gearbox control unit

The automatic gearbox control unit -J217- receives infor-mation from components that influence the shift controlsand sends this information to the slide valve body with thesolenoid valves which drives the shift elements throughthe hydraulic shift controls.

The control unit is equipped with a fault memory to beable to rapidly determine the origin of the damage if anelectric/electronic component fails or in the event of a lineinterruption. Faults are detected by eletric signals and arestored in the fault memory.

Fault recognition of the gearbox control unit

The control unit detects faults while the vehicle is beingoperated and stores them in the fault memory Chap.01-4.

After analysing the information it makes a distinction be-tween sporadic and currently present (static) faults andstores them.

If the fault is not indicated for a given time or over a long

driving distance is becomes a sporadic fault.

A fault is also sporadic if the fault memory is not erasedafter repair.

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During fault interrogation sporadic faults are displayedusing -V.A.G 1552- as sporadically occurring faults.SP appears on the right of the display.

If after a given period or a long driving distance this spo-radic fault no longer occurs, the fault is erased from thefault memory.

Fault memory

The fault memory of the control unit is a permanentmemory. Stored faults are not erased if the control unit isdead. If for a long period of time e.g. the vehicle battery isdisconnected or if the control unit plug was disconnectedthe fault memory content is preserved.

Safety function of the gearbox control unit

If faults occur while driving, the control unit may activatereplacement functions or emergency programmes.These may influence the shifting function and quality.

In emergency running mode, the 3rd gear and reversegear can be engaged by activating the selector lever.

If the fault occurs in P, N or R, P, N or R will alsobe activated in emergency running mode.

The gearbox will be activated in emergency runing modeuntil the fault is stored or if it is not detected by the controlunit over a given period of time.

Faults that may result in emergency runningmode

Line interruption, short-circuit, defective electric or hy-draulic components.

Safety measures

If test and measuring devices are required during testdrives observe the following:

Always secure the test and measuring devices on therear seat and have a second person operate themthere. If the test and measuring devices are operatedfrom the passenger seat the passenger could be in-

jured by the release of the passenger airbag in theevent of an accident.

Vehicle system tester -V.A.G 1552-

Functions, detected or performed by the vehicle systemtester -V.A.G 1552- Chap. 01-3.

Electrical faults that influence the driveability can be de-termined with vehicle system tester -V.A.G 1552-.


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Self-diagnosis technical data

Memory

Permanent memory

Volatile memory

yesno

Data output

Vehicle system test Flashing code output

yesno

Final control diagnosis no

Basic setting yes Chap. 01-4

Coding control unit no

Reading measured valueblock

yes Chap. 01-5

Electric/Electronic compo-nents and fitting locations

Chap. 01-2


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Electric/Electronic Components and Fitting LocationsEdition 07.00S00.5318.00.20

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01-2 Electric/Electronic Components and Fitting Locations

Vehicle components

Gearbox components 01-2page 5

1 - Engine control unit

Fitting location and removingand installing Fig. 1 in01-2page 2

Signal transfer occurs overthe data BUS drive

If the control units of the engineor gearbox are replaced the sys-tem must be put into basic set-ting Chap. 01-4

2 - Selector lever position dis-

play -Y6- Fitting location Fig. 7 in

01-2page 4 Signal transfer occurs over

the data BUS drive

3 - Diagnostic connection

Fitting location Fig. 2 in01-2page 2

4 - Selector lever lock solenoid-N110-

Fitting location and removingand installing Chap. 37-2

is switched by the vehiclevoltage control unit -J519-

5 - Brake light switch -F-

Fitting location Fig. 4 in01-2page 3

Signal transfer occurs via thedata BUS drive of the ABSwith EDL control unit -J104-

6 - Relay for starter interlock switch -J207-

Fitting location Fig. 5 in 01-2page 3 is switched by the vehicle voltage control unit -J519-

7 - Accelerator pedal position sender -G79- Fitting location and removing and installing Fig. 3 in 01-2page 2 generates the kick-down signal Signal transfer occurs over the data BUS drive of the engine control unit

8 - Gearbox

Electric/electronic components of the gearbox 01-2page 5

9 - Automatic Gearbox Control Unit -J217-

Fitting location Fig. 6 in 01-2page 3 removing Fig. 6 in 01-2page 3 Control unit is checked by self-diagnosis Chap. 01-3

S01-0102

1

9

8

3

7

4

5

6

2

Note


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Fitting locations

Fig. 1: Engine control unit

Fitting location: The control unit is located at bulkhead.

Removing and installing the control unit Engine,Fuel Injection; Rep. Gr. 24

Fig. 2: Diagnostic connection

Fitting location: The diagnostic connector is located be-

hind the storage area -arrow- on the driver's side.

Fig. 3: Accelerator pedal position sender -G79-

Fitting location: The accelerator pedal position sender-G79- -arrow- is a component part of the gas pedal.

The accelerator pedal position sender -G79- generatesthe Kick-down signal, when the accelerator pedal issuddenly pressed down fully.

For self-diagnosis

Signal can only be checked in the measured value block

Chap. 01-5.Removing and installing accelerator pedal positionsender -G79-

Engine, Mechanics; Rep. Gr. 20

S24-0373

S01-0104

S01-0105


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01-2page 3

01

Fig. 4: Brake light switch -F-

Fitting location: The brake light switch -F- -arrow- is locat-ed in the foot controls.

For self-diagnosis

Signal can be checked in the measured value block Chap. 01-5.

Removing and installing the brake light switch

Running gear; Rep. Gr. 45

Fig. 5: Relay for starter interlock switch -J207-

Fitting location: The relay is located on the relay carrier

-1- above the vehicle voltage control unit -2-.The relay carrier is located behind the storage area onthe driver's side.

The relay is identified with number 53.

Removing and installing the relay

Remove the storage area on the driver's side BodyWork; Rep. Gr. 68.

Remove the relay from the relay carrier.

Fig. 6: Automatic Gearbox Control Unit -J217-

The control unit -arrow- is located behind the battery onthe battery tray.

Removing the control unit

Switch off ignition, open engine compartment cover.

Unlock the multi-pin connector and unplug it from thecontrol unit.

S01-0107

S01-0108

1

2

S01-0111


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01-2page 4

01

Release the two screws -arrows- and remove the con-trol unit.

The installation occurs in reverse order.

Initiate basic setting Chap. 01-4.

Perform self-diagnosis Chap. 01-3.

Fig. 7: Selector lever position indicator -Y6-

Fitting location: in the dash panel insert

Removing and installing: Electrical System;Rep. Gr. 90

For self-diagnosis:

In the event of emergency running mode and if the controlunit is operational all segments of the selector lever posi-tion indicator -Y6- light up in the dash panel insert.

In the event of emergency running mode and if the controlunit fails there is no indication of the selector lever posi-tions.

S01-0109

S01-0108S01-0103


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01-2page 5

01

Electric/electronic components of the gearbox

1 - 6 Nm

2 - Wiring loom

3 - Vehicle speed sender -G68-

with connection cable Fitting location and removing

and installing Fig. 9 in01-2page 6

is checked by self-diagnosis

4 - 6 Nm

5 - 6 Nm

6 - Gearbox speed sender -G38-

with connection cable Fitting location and removing

and installing Fig. 9 in01-2page 6


7 - Gearbox8 - Wiring loom

for the solenoid valves andgearbox oil temperaturesender -G93-

Fitting location and removingand installing Fig. 8 in01-2page 5

9 - Multi-function switch -F125-

adjust Fig. 10 in 01-2page 6


10 - 3 Nm

11 - Lever

for gearshift shaft

12 - 17 Nm

Fitting locations

Fig. 8: Wiring loom for the solenoid valves andgearbox oil temperature sender -G93-

Fitting location: The wiring loom is located in the oil panunder the slide valve body.

Removing and installing the wiring loom

The wiring loom can be replaced with the gearbox mount-ed without having to remove the slide valve body.

S37-0059

10

12 10

1

9

11

8

6

5

4

3

2

7

S37-0066


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01-2page 6

01

Drain ATF Chap. 37-8.

Removing the oil pan Chap. 38-2.

Disconnect the plug connection at gearbox.

Unlock the connector -arrows- and remove from gear-box housing.

Unclip gearbox oil temperature sender -G93- -3-.

Release plug connection -4- from the solenoid valve 6-N93-.

Disconnect the plug connection -1- for the solenoidvalves.

Unhook the wiring loom from the holder -2-.


Clean the sealing surface of the oil pan at the gearboxand at the oil pan and coat with sealant:

D176 404 A2

when installing Chap. 37-11.

Top up ATF Chap. 37-8.

Tightening torques:

Oil pan at gearbox: 8 Nm

Fig. 9: Gearbox speed sender -G38- and vehiclespeed sender -G68-

Fitting location: The sender is located at the top of thegearbox.

-A- -G38- with connection cable-B- -G68- with connection cable

Removing and installing sender

Disconnect the plug connection at wiring loom.

Remove screw, pull out sender.

Replace O-ring.


Tighten screw to 6 Nm.

Fig. 10: Adjust multi-function switch.

Requirements

Adjustment of the selector lever control cable O.K. Chap. 37-4

Selector lever in N

Screws -arrows- released

Insert a 4 mm drill bit -A- through the gearshift lever inthe adjusting hole of the multi-function switch.

Tighten screws -arrows- on the multi-function switchin this position to 3 Nm.

Remove drill bit.

S37-0083

3

1

2

4

A B

S37-0065

123

DN

R

P

A

S37-0060


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01

01-3 Performing self-diagnosis

Special tools, test and measuring equipment andauxiliary items required


Diagnostic cable -V.A.G 1551/3-

Test conditions

Battery voltage at least 11.5 V

Earth connection to engine and gearbox O.K.

Fuses according to current flow diagram O.K.

Work sequence

The connector is located behind the storage area on thedriver's side.

Unclip the cover and fold down. Connect vehicle system tester -V.A.G 1552- with the

diagnostic cable -V.A.G 1551/3-

Once the vehicle system tester has been connected:

Switch on ignition or start engine depending on thedesired function.

If because of an input error data transfer fault is dis-played, remove the cable from the vehicle systemtester, re-connect and repeat the steps.

If one of the following messages appears in the dis-play, carry out fault finding as specified in the faultfinding program diagnostic cable. Current flow dia-grams, fault finding electrical system, fitting locationsor operating instructions of the vehicle system test-er.

Operate the vehicle system tester by following the in-dication on the display:

Read-out on display:

Press and for address word 02 and confirm theentry with .

The vehicle system tester -V.A.G 1552- displays the con-trol unit identification, e. g.:

Control unit identification

Depending on the fitting status (program status) the con-trol unit may indicate a different control unit identification

V.A.G 1552

V.A.G 1551/3

S01-0087

Note

Vehicle system test HELP

The control unit does not respond


Fault in communication set-up


K cable does not connect to earth


K cable doest not connect to pos. term.


Enter address word XX

0 2

Q

001927731H AG4 Gearbox 001 JEG2944 ->


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Performing self-diagnosis Edition 07.00S00.5318.00.20

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01

than the one shown in this example. Assignment of thecontrol unit Spare part catalogue.

001927731H = Part No. of the control unit (for currentcontrol unit version see spare parts catalogue)

AG4 Gearbox 001 = Automatic gearbox 4 speed 001

2944 = Data status (Software version of the controlunit)

Press .


Further procedure, see repair sequences.

After pressing an overview of the possible func-tions is displayed.

Overview of selectable functions

Interrogating and erasing fault memory



Diagnostic cable -V.A.G 1551/3-

Interrogating fault memory

Connect vehicle system tester -V.A.G 1552-. Switch

on the ignition and select the gearbox control unit withAddress word 02 01-3page 1.

Press and for the function Interrogate faultmemory and confirm the entry with .

The display shows the number of faults stored in thememory or no fault detected! . will be displayed.

If no fault is stored in the memory:

Select function 06 End output and confirm entry with.

If one or more faults are stored in the memory:

Press .


Select function XX

HELP

Operation Page

01 - Interrogating control unit ver-sion Performing self-diag-nosis

01-3page 1

02 - Interrogating fault memory 01-3page 2

04 - Initiating basic setting Chap. 01-4

05 - Erasing fault memory 01-3page 2

06 - Ending output

08 - Reading measured valueblock

Chap. 01-5

0 2

Q

X faults detected

Q


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Performing self-diagnosisEdition 07.00S00.5318.00.20

01-3page 3

01

Read-out of fault number on display, e.g.:

Press .

Read-out of fault source with fault type on display, e.g.:

Press .

The stored faults are displayed in sequence.


Refer to the fault table to remove the indicated faults Chap. 01-4.

During testing and installation other control units mayalso detect faults, e.g. pulled-out connectors. This is whyyou must conclude the self-diagnosis by interrogatingand erasing the fault memories of all control units. For

this you must proceed as follows:

Press twice for address word Automatic test se-quence and confirm entry with .

The -V.A.G 1552- sends all known address words in se-quence.

Erasing fault memory

Test conditions

Fault eliminated

Fault memory interrogated 01-3page 2.

After fault elimination the fault memory must again be in-terrogated and subsequently erased.

Press and for the function Erase fault memoryand confirm the entry with .


If the ignition has been switched off between interrogatefault memory and erase fault memory, the fault memo-ry will not be erased.


Perform a test drive. Again interrogate the fault mem-ory. No fault must be displayed.

Comply with the safety instructions for test drives Chap. 01-1.

->

Fault number: 00258 035

Solenoid valve 1 -N88 ->

Short-circuit to earth

Q

Note

0

Q

Note

0 5

Q

Vehicle system test ->

Fault memory erased

Note

Q

Note


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Fault Table and Initiating Basic SettingEdition 07.00S00.5318.00.20

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01

01-4 Fault Table and Initiating Basic Setting

Fault table

The fault table is ordered according to the 5-digit fault code on the left.

If parts are output as faulty: First check the cables and connectors to these parts as well as the earth leads of thesystem by referring to the current diagram. Only if no fault is detected here should the part be replaced. This appliesin particular for faults that are output as sporadically occurred(SP) faults.

If the display of the vehicle system tester -V.A.G 1552- reads Documentation, the required text is to be found inthe fault table according to the fault code.

Read-out on -V.A.G 1552- Possible cause of fault Rectifying fault

00258Solenoid valve 1 -N88-

Open circuit/Short-circuit topos. term.

Short-circuit to

earth

Line interruption

Line short-circuit to earth orpositive

Solenoid valve 1 -N88- de-

fective

Reading measured valueblock, display group number004 Chap. 01-5.

Performing electrical test, test

step 5 Chap. 01-7.00260Solenoid valve 2 -N89-


Short-circuit toearth

Line interruption


Solenoid valve 2 -N89- de-fective


Performing electrical test, teststep 6 Chap. 01-7.




Line interruption








Line interruption








Line interruption





00268Solenoid valve 6 -N93- Open circuit/Short-circuit to

pos. term.


Line interruption Line short-circuit to earth or

positive




00281Vehicle speed sender-G68-

No signal Line interruption or short-cir-cuit to earth

Vehicle speed sender -G68-defective



Replacing vehicle speedsender -G68- Chap. 01-2.

Note


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01

00293Multi-function switch-F125-

undefined switchstatus

No signal

Line interruption

Multi-function switch -F125-not adjusted

Multi-function switch -F125-defective


Adjusting multi-function switch-F125- Chap. 37-4.

Performing electrical test, teststep 2 Chap. 01-7.00296Kick-down switch -F8-


Line interruption

Accelerator pedal positionsender -G79- defective

Data BUS defective


Inspecting accelerator pedalposition sender -G79- Engine, Fuel Injection;Rep. Gr. 24.

Testing data BUS Electricalsystem; Rep. Gr. 90.

00297Gearbox speed send-er -G38-

No signal Line interruption Gearbox speed sender

-G38- defective



00300Gearbox oil tempera-ture sender -G93-


Line interruption

Gearbox oil temperaturesender -G93- defective



00350

Earth return Modula-tion valves

Outlet does not

connect/Short-circuit to positive

Line interruption

Automatic gearbox controlunit -J217- defective

Check wiring and plug con-

nections according to the cur-rent flow diagram CurrentFlow Diagrams, ElectricalFault Finding and Fitting Lo-cations.

Replacing control unit Chap. 01-2.

Put system in basic setting 01-4page 4

00526Brake light switch -F-

Short-circuit topositive terminal

Line interruption

Brake light switch -F- defec-

tive Data BUS defective

Reading measured valueblock, display group number

004

Chap. 01-5. Testing data BUS Electrical

system; Rep. Gr. 90.

Inspecting brake light switch-F- Running Gear;Rep. Gr. 45.

00529Speed informationmissing

No signal Line interruption

Data BUS defective


Inspecting engine control unit Engine, Fuel Injection;

Rep. Gr. 01. Testing data BUS Electrical

system; Rep. Gr. 90.



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01-4page 3

01

00545Engine/gearbox elec-trical connection

Open circuit/Short-circuit toearth

Short-circuit topositive terminal

Line interruption or short-cir-cuit

no connection engine/gear-box control unit

the signal for the ignition-tim-ing adjustment is not or in-

correctly transmitted fromthe engine to the gearboxcontrol unit

Data BUS defective


Inspecting engine control unit Engine, Fuel Injection;Rep. Gr. 01.


Put system in basic setting 01-4page 4

00652Gear monitoring

Implausible sig-nal

electric/hydraulic fault

Clutch or slide valve bodydefective

While driving determine inwhich gear the fault occurs.

Carry out fault finding accord-ing to fault finding table Chap. 37-3.

00777

Accelerator pedal po-sition sender -G79-

No signal Line interruption

Accelerator pedal positionsender -G79- defective

Data BUS defective

Reading measured value

block, display group number003 Chap. 01-5.


Inspecting accelerator pedalposition sender -G79- Engine, Fuel Injection;Rep. Gr. 24.

01166Signal for enginetorque

Implausible sig-nal

Line interruption

the signal for the enginetorque is not or incorrectly

transmitted from the engineto the gearbox control unit


Testing data BUS Electricalsystem; Rep. Gr. 90.01192Clutch for torque con-verter lockup

Clutch for torqueconverter lockupdefective

mechanical fault

Line interruption

Lockup clutch slips


Slide valve body defective



01236Selector lever lock so-lenoid -N110-


Open circuit/Short-circuit to

pos. term.

Line interruption or short-cir-cuit to earth

Selector lever lock solenoid-N110- defective

Vehicle voltage control unit-J519- defective


Inspecting vehicle voltagecontrol unit -J519- Electrical System;Rep. Gr. 90.

Replacing selector lever locksolenoid -N110- Chap. 37-6.

01312Data BUS drive

defective

no communica-tion

Data BUS wires and plugconnections defective

Control units on data BUSdefective or incorrectly cod-ed


Inspecting control units atdata BUS Engine, Fuel In-jection; Rep. Gr. 01



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01-4page 4

01

Only after having determined the possible cause of the fault and having eliminated the following faults:

mechanical fault

hydraulic fault

or affected electric/electronic components and wiring

should the automatic gearbox control unit -J217- be replaced Chap. 01-2, and the system be put in basic setting 01-4page 4.

Initiating basic setting

Perform the basic setting after the following repairs:

Engine replacement Removing and installing the gearbox

Replacing or coding the engine control unit

Replacing the accelerator pedal position sender -G79-

Replacing the automatic gearbox control unit -J217-

Connect vehicle system tester -V.A.G 1552-, enteraddress word 02 gearbox electronics and keepswitching until select function XX is displayed Chap. 01-2


Press and for the function initiating basic set-ting.

Do not activate the accelerator pedal yet.


Confirm the entry with .


Press keys , and .

Confirm the entry with .

013144AV Control unit

no communica-tion

wrong equip-ment


Fault in system engine

Engine control unit possiblyincorrectly coded



01316Brake control unit

no communica-tion


Fault in ABS system

Inspecting ABS control unit Running Gear;Rep. Gr. 45.


65535 Control unit de-fective

Automatic gearbox controlunit -J217- defective

Replacing control unit Chap. 01-2.

Put system in basic setting 01-4page 4.



Select function XX

0 4

Note

Vehicle system test Q

04 - Basic setting

Q

Basic setting

Enter display group number XXX

0 0 0

Q


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01-4page 5

01


This puts the system in basic setting.

Depress accelerator pedal up to kickdown and main-tain in this position for 3 seconds.

press.

Read-out on display: Release accelerator pedal again

System in basic setting 0->


Select function XX


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01


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Reading measured value blockEdition 07.00S00.5318.00.20

01-5page 1

01

01-5 Reading measured valueblock



Diagnostic cable -V.A.G 1551/3-Work sequence

Connect vehicle system tester -V.A.G 1552-. Switchon the ignition and select the gearbox control unit withAddress word 02 Chap. 01-1.


Press and for the function Read measured val-ue block and confirm with .


Enter display group number 01-5page 1.

Further procedure, see repair sequences.

List of display groups


Select function XX

0 8

Q

Reading measured value block

Enter display group number XXX

Read-out on display (example) Displaygroupnumber

Displayfield

Denomination

Reading measured value block 1 001 1

2

34

Vehicle speed sender -G68-

gearbox speed sender-G38-engine speedgear engaged

20 km/h 1500 rpm 1520 rpm 1


34

Accelerator pedal valuesolenoid valve 6 -N93- (ad-justment in %)ATF temperaturebattery voltage

0 % 35 % 30.0 C 12.5 V


234

Vehicle speed sender -G68-accelerator pedal valuegear engagedsolenoid valve 4 -N91- (ad-justment in %)

20 km/h 0 % 1 4 %


Selector lever positionmulti-function switchswitch positionsshift outputs

D 00001000 01000000 00000110


2

3

4

Engine control unit at dataBUSABS control unit at dataBUSdash panel insert at dataBUS

not assigned

Engine 1 ABS 1 Combi 1


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01-5page 2

01

If the nominal values are reached in all display fields:

press.


Press and for the function End output and con-firm with .

Test table


Select function XX

0 6

Q

Dis-play

groupnumb

er

Dis-playfield

Denomination Test conditions Display onV.A.G. 1552

Measures for deviations from nomi-nal value

001 1 Vehicle speedsender -G68-

while driving ...km/h The display in the dash panel insert andthe values on V.A.G. 1552 may differslightly from one another.

Inspecting vehicle speed sender-G68- Chap. 01-7.

2 Gearbox speedsender -G38-

with engine runningwhile driving

.../min Inspecting gearbox speed sender-G38- Chap. 01-7.

3 Engine speed with engine running .../min The display in the dash panel insert andthe values on V.A.G. 1552 may differslightly from one another.

Perform self-diagnosis of enginecontrol unit Engine, Fuel Injec-tion; Rep. Gr. 01.

Testing data BUS Electrical sys-tem; Rep. Gr. 90.

4 gear engaged while driving Inspecting solenoid valve Chap.01-7.Neutral 1

Reverse (upto approx. 10

km/h)

1

1 hydraulic 12 hydraulic 2

3 hydraulic 3H

3 mechanic 3M

4 hydraulic 4H

4 mechanic 4M


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01-5page 4

01

004 1 Selector leverposition

Inspecting selector leverin

Multi-function switch -F125- Chap. 01-7.

P PR R

N N

D D

3 3

2 2

1 1

2 Multi-functionswitch -F125-

Inspecting selector leverin

Multi-function switch -F125- Chap. 01-7.

P 00000001

R 00000010

N 00000100

D 00001000

3 00010000

2 00100000

1 01000000

3 ignore first six positions

Kick-down sig-nal

Kick-down signal Inspecting accelerator pedal positionsender -G79- Engine, Fuel Injec-tion; Rep. Gr. 23 oder 24.


7. Posi-

tion

available 1

not available 0

Brake lightswitch -F-

Brake Inspecting brake light switch -F- Running Gear; Rep. Gr. 45.8. Posi-

tionactivated 1

not activated 0

Dis-play

groupnumb

er

Dis-playfield




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Reading measured value blockEdition 07.00S00.5318.00.20

01-5page 5

01

004 4 Solenoid valve4 -N91- for

lockup clutch

1. Posi-tion

activated 1 Inspecting solenoid valve 4 -N91- Chap. 01-7.

not activated 0Selector leverlock solenoid

-N110-

2. Posi-tion

selectorlever in

Por in N

engaged 1 Inspecting selector lever lock sole-noid -N110- Chap. 37-6.

Inspecting brake light switch -F- Running Gear; Rep. Gr. 45.

Activatebrake orselectorlever inR, D,

3, 2, 1

switched off 0

Deactivation ofair conditioning

3. Posi-tion

is switchedoff

1 Testing air conditioning systemAir conditioning; Rep. Gr. 87.


is notswitched off

0

Ignition-timingadjustment

4. Posi-tion

switched on(only dis-played whenshiftinggears)

1 Perform self-diagnosis of enginecontrol unit Engine, Fuel Injec-tion; Rep. Gr. 01.

Perform basic setting Chap. 01-4.

switched off 0

Solenoid valve3 -N90- 5. Posi-tion activated 1 Inspecting solenoid valve 3 -N90- Chap. 01-7.not activated 0Solenoid valve

5 -N92-6. Posi-

tionactivated 1 Inspecting solenoid valve 5 -N92-

Chap. 01-7.not activated 0

Solenoid valve2 -N89-

7. Posi-tion

activated 1 Inspecting solenoid valve 2 -N89- Chap. 01-7.not activated 0

Solenoid valve1 -N88-

8. Posi-tion

activated 1 Inspecting solenoid valve 1 -N88- Chap. 01-7.not activated 0

Dis-play

groupnumb

er

Dis-playfield




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01-5page 6

01

125 1 Engine controlunit

Engine at data BUS 1 Testing data BUS Electrical sys-tem; Rep. Gr. 90.

Perform self-diagnosis of enginecontrol unit Engine, Fuel Injec-tion; Rep. Gr. 01.

not at data

BUS

0

2 ABS controlunit

ABS at data BUS 1 Testing data BUS Electrical sys-tem; Rep. Gr. 90.

Perform self-diagnosis of ABS Running Gear; Rep. Gr. 45.

not at dataBUS

0

3 Dash panel in-sert Combi at data BUS 1 Testing data BUS Electrical sys-tem; Rep. Gr. 90.

Perform self-diagnosis of the dashpanel insert Electrical System;Rep. Gr. 90.

not at dataBUS

0

4 not assigned

Dis-play

groupnumb

er

Dis-playfield




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Inspecting the solenoid valves and shift elements while drivingEdition 07.00S00.5318.00.20

01-6page 1

01

01-6 Inspecting the solenoidvalves and shift elementswhile driving

The solenoid valves and shift elements can be inspectedwhile driving in measured value block 08, display group004 ( Chap. 01-5).

Observe the safety instructions in Chap. 01-1.

The table indicates the activated solenoid valves -N88-, -N89- and -N92- in the individual gears. Theycontrol the position of the corresponding shift ele-ments in the gears.

Solenoid valve -N91- controls the modulation valve forthe lockup clutch.

Solenoid valves -N90- and -N93- are valves that influ-ence gearshifting indirectly to offer great shifting com-fort. -N90- = time delay valve, -N93- = main pressurevalve (is not displayed in display group number 004).

The display on vehicle system tester -V.A.G 1552- is8-digit (e.g.: 01000011).

Only consider positions 1, 3, 7 and 8.

Test conditions

Selector lever in position D

Vehicle speed higher than 10 km/h

Solenoid valves and position of the shift elements

X = closed shift element

K1 = 1st through 3rd gear clutch

K2 = Reverse gear clutch

K3 = 3rd and 4th gear clutch

B1 = Reverse and 1st gear brake

B2 = 2nd and 4th gear brake

F = Free wheel

LC = Lockup clutch

Note

Solenoid valves Shift elements

Gear N91 Disregard display N92 N89 N88 K1 K2 K3 B1 B2 F LC

1 0 1 0 1 X X

2 0 1 1 1 X X

3H 0 0 1 0 X X

3M 1 0 1 0 X X X

4H 0 0 1 1 X X

4M 1 0 1 1 X X X


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Electrical TestEdition 04.05S00.5318.02.20

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01

01-7 Electrical Test


Hand multimeter (e.g. -V.A.G 1526 C-)

Measuring tool set-V.A.G 1594 C-

Adapter cable -V.A.G 1598/18-A-Additionally required information means

Binder Current Flow Diagrams, Electrical FaultFinding and Fitting Locations Fabia 2000

Test requirements

Battery voltage at least 11.5 volts

Fuses according to current flow diagram O.K.

Earth connections O.K.

Test procedure

The automatic gearbox control unit -J217- -arrow- is lo-cated on the battery tray.

Switch off ignition, unlock multi-pin connector and re-move from automatic gearbox control unit -J217-.

Plug adapter cable -V.A.G 1598/18-A- into the multi-pin connector -arrow 1- and lock in -direction of arrow2-.

The adapter cable -V.A.G 1598/18-A- allows to check thewiring according to the Current Flow Diagram.

Set the correct measuring range on the measuringtool before connecting the measuring cables. Other-wise the electronic components may be destroyed!

The indicated nominal values apply for an ambienttemperature of 0 C to 40 C.

If the measured values deviate from the nominal val-ues, determine fault according to Current Flow Dia-gram.

If the measured values only differ slightly from thenominal values, clean the bushes and plugs of the testdevices and measuring cables and repeat test. Beforereplacing the relevant components check their wiringand connections. Specifically for nominal values be-low 10 repeat resistance measurement on compo-nent.

S01-0111

2

1

V.A.G1598/18

N37-0139


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Electrical Test Edition 04.05S00.5318.02.20

01-7page 2

01

Multi-pin connector of the automatic gearbox control unit -J217- (bushes on -V.A.G 1598/18-)

Overview of test steps

Only perform the test steps listed per component inthe fault table and the measured value block.

1 - Earth (terminal 31) 35 - Vehicle speed sender -G68-

2 - not assigned 36 - Vehicle speed sender -G68-

3 - not assigned 37 - not assigned


5 - K cable of diagnosis 39 - not assigned

6 - not assigned 40 - Multi-function switch -F125- (position R)

7 - not assigned 41 - Multi-function switch -F125- (position N)

8 - not assigned 42 - Multi-function switch -F125- (position P)

9 - Gearbox speed sender -G38- 43 - Multi-function switch -F125- (position 3)

10 - Gearbox speed sender -G38- 44 - Multi-function switch -F125- (position D)

11 - not assigned 45 - Power supply (terminal 15)



14 - not assigned 48 - Solenoid valve 1 -N88-15 - Data BUS high 49 - Solenoid valve 2 -N89-

16 - Data BUS low 50 - Solenoid valve 3 -N90-


18 - Multi-function switch -F125- (position 1) 52 - not assigned

19 - Multi-function switch -F125- (position 2) 53 - not assigned



22 - Power supply (terminal 30) 56 - not assigned

23 - not assigned 57 - not assigned24 - not assigned 58 - not assigned

25 - Solenoid valve 6 -N93- 59 - not assigned

26 - Solenoid valve 4 -N91- 60 - not assigned




30 - not assigned 64 - Earth return (for valve diagnosis)


32 - not assigned 66 - Power supply for solenoid valve 5 -N92-

33 - Gearbox oil temperature sender (ATF) -G93- 67 - not assigned

34 - Gearbox oil temperature sender (ATF) -G93- 68 - Terminal 15 outlet for multi-function switch-F125-


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01-7page 3

01

Test table

Tested component Test step Tested component Test step

Power supply for automaticgearbox control unit -J217-

Perform test step 1 Solenoid valve 3 -N90- Perform test step 7

Multi-function switch -F125- Perform test step 2 Solenoid valve 4 -N91- Perform test step 8Vehicle speed sender -G68- Perform test step 3 Solenoid valve 5 -N92- Perform test step 9

Gearbox speed sender-G38-

Perform test step 4 Solenoid valve 6 -N93- Perform test step 10

Solenoid valve 1 -N88- Perform test step 5 Gearbox oil temperaturesender -G93-

Perform test step 11Solenoid valve 2 -N89- Perform test step 6

Switch on measuring range: Voltage measurement (20V=)

Teststep

Adapter cable-V.A.G 1598/18- bushes

Test covers Test conditions

additionalworks

Specifica-tion

Measures for deviationsfrom nominal value

1 22 + 1 Supply voltage for theautomatic gearboxcontrol unit -J217-(terminal 30)

Ignition off approx. bat-tery voltage

Test cable from contact1 to earth CurrentFlow Diagrams, Electri-cal Fault Finding andFitting Locations.

Test cable from contact22 to terminal 30 Current Flow Dia-

grams, Electrical FaultFinding and Fitting Lo-cations.

Check battery Electrical System;Rep. Gr. 27.

45 + 1 Supply voltage for theautomatic gearboxcontrol unit -J217-(terminal 15)

Ignition off approx. bat-tery voltage

Test cable from contact1 to earth CurrentFlow Diagrams, Electri-cal Fault Finding andFitting Locations.

Test cable from contact45 to terminal 15 Current Flow Dia-grams, Electrical FaultFinding and Fitting Lo-cations.

Check battery Electrical System;Rep. Gr. 27.


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01

2 68 + 1 Multi-function switch-F125-

Ignition on approx. bat-tery voltage

Check plug connectionon multi-function switch

for contact corrosion ifnecessary replace.

Adjusting multi-functionswitch Chap. 37-4.

Check wiring from auto-matic gearbox controlunit -J217- to the multi-function switch -F125- 01-7page 6.

Replacing multi-func-tion switch -F125-

Chap. 37-4.

42 + 1 Multi-function switch-F125-

Selector leverposition P

approx. bat-tery voltage

Selector leverposition R, N, D, 3, 2, 1

0- 1 V


Selector leverposition R


Selector leverposition P, N, D, 3, 2, 1

0 - 1 V

41 + 1 Multi-function switch-F125- Selector leverposition N approx. bat-tery voltage

Selector leverposition P, R, D, 3, 2, 1

0 - 1 V


Selector leverposition D


Selector leverposition P, R,N, 3, 2, 1

0 - 1 V

43 + 1 Multi-function switch

-F125-

Selector lever

position 3

approx. bat-

tery voltage Selector lever

position P, R,N, D, 2, 1

0 - 1 V


Selector leverposition 2


Selector leverposition P, R,N, D, 3, 1

0 - 1 V


Selector leverposition 1


Selector leverposition P, R,N, D, 3, 2

0 - 1 V

Switch on measuring range: Voltage measurement (20V=)

Teststep



additionalworks

Specifica-tion



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01-7page 5

01

Switch on measuring range: Resistance measurement (20 k)

Teststep



additionalworks

Specifica-tion


3 35 + 36 Vehicle speed sender

-G68-

min. 0.4 k Check wiring from auto-matic gearbox controlunit -J217- to the vehi-cle speed sender -G68-prfen 01-7page 6.

Replacing vehiclespeed sender -G68- Chap. 01-2.

max. 0.6 k

4 9 + 10 Gearbox speed send-er -G38-

min. 0.4 k Check wiring from auto-matic gearbox controlunit -J217- to the gear-box speed sender -G38-check 01-7page 6.

Replacing gearboxspeed sender -G38- Chap. 01-2.

max. 0.6 k

Switch on measuring range: Resistance measurement (200 )

Teststep



additionalworks

Specifica-tion


5 48 + 1 Solenoid valve 1-N88-

Ignition off 924 Check wiring from auto-matic gearbox controlunit -J217- to the sole-noid valve 01-7page 6.

Replacing solenoidvalve Chap. 38-8.


Ignition off 924


Ignition off 924


Ignition off 924


Ignition off 924


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01-7page 6

01

After the electrical test

Connect the multi-pin connector -arrow 1- to the pinsof the automatic gearbox control unit -J217- and sub-sequently lock the multi-pin connector -arrow 2-.

When inserting make sure the guides are placed on thecontrol unit pins.

Check the wiring between the automaticgearbox control unit -J217- and the gear-box


Hand multimeter (e.g. -V.A.G 1526 C-)

Measuring tool set -V.A.G 1594 C-

Adapter cable -V.A.G 1598/18-A-



Switch on measuring range: Resistance measurement (20 k)

Teststep



additionalworks

Specifica-tion


10 25 + 1 Solenoid valve 6

-N93- Ignition off 924 Check wiring from auto-

matic gearbox controlunit -J217- to the sole-noid valve 01-7page 6.

Replacing solenoidvalve Chap. 38-8.

11 33 + 34 Gearbox oil tempera-ture sender -G93-

Ignition off Check wiring from auto-matic gearbox controlunit -J217- to the gear-box oil temperaturesender -G93- prfen 01-7page 6

Replacing gearbox oiltemperature sender-G93- Chap. 01-2.

ATF tempera-ture

approx. 30 C 2.2 k

approx. 70 C 0.5 k approx. 110 C 0.2 k

N37-0292

2

1

Note


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01-7page 7

01

Plug connections on gearbox

1 - 68-pin plug to automatic gearbox control unit -J217-

2 - 2-pin plug to vehicle speed sender -G68-

3 - 2-pin plug to gearbox speed sender -G38-

4 - 8-pin plug to the solenoid valves and to the gearboxoil temperature sender -G93-

5 - 10-pin plug to the multi-function switch -F125-

Switch off ignition, unlock multi-pin connector and re-move from automatic gearbox control unit -J217-.

Remove battery and battery tray. Electrical system;Rep. Gr. 27.

Plug adapter cable -V.A.G 1598/18-A- into the multi-pin connector -1- and lock in direction of arrow -2-.

Inspect wiring to the vehicle speed sender -G68-

Disconnect the 2-pin plug connection and check thewiring for interruption.

S01-0110

1

4

3

5

2

2

1

V.A.G

1598/18

N37-0139

1 2

S37-0063


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If this test of the wiring does not show any unauthorised deviations, replace the vehicle speed sender -G68- Chap.01-2.

Inspect wiring to the gearbox speed sender-G38-

Disconnect the 2-pin plug connection and check thewiring for interruption.

If this test of the wiring does not show any unauthorised deviations, replace the gearbox speed sender -G38- Chap.01-2.


Vehicle speed sender-G68-


Specification Measures for deviations from nom-inal value

1 35 less than 1.5 Remove line interruption accordingto Current Flow Diagram Current Flow Diagrams, Electri-cal Fault Finding and Fitting Loca-

tions.

Check plug for:

Contact corrosion

Water penetration

Leakage

2 36 less than 1.5

Note

1 2

S37-0062


Gearbox speed send-er -G38-


Specification Measures for deviations from nomi-nal value

1 9 less than 1.5 Remove line interruption according

to Current Flow Diagram Current Flow Diagrams, Electri-cal Fault Finding and Fitting Loca-tions.

Check plug for:

Contact corrosion

Water penetration

Leakage

2 10 less than 1.5

Note


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Inspect wiring to the plug of the solenoid valvesand to the gearbox oil temperature sender -G93-

Disconnect the 8-pin plug and check the wiring for in-terruptions.

If this test of the wiring does not show any unauthorised deviations, replace the gearbox oil temperaturesender-G93-,the wiring in the slide valve body or the solenoid valves Chap. 01-2.

Inspect wiring to the multi-function switch-F125-

Disconnect the 10-pin plug and check the wiring for in-

terruptions.

1

7 8

6

S37-0061


Plug to the solenoid valves

and to the gearbox oil tem-perature sender -G93-

Adapter cable

-V.A.G 1598/18-bushes

Specification Measures for deviations from nom-

inal value

1 48 less than 1.5 Remove line interruption accordingto Current Flow Diagram Current Flow Diagrams, Electri-cal Fault Finding and Fitting Loca-tions.

Check plug for:

Contact corrosion

Water penetration

Leakage

2 49 less than 1.5

3 26 less than 1.5

4 66 less than 1.5

5 25 less than 1.5

6 33 less than 1.5

7 34 less than 1.5

8 50 less than 1.5

Note

S37-0064

1

7 10

6


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If this test of the wiring does not show any unauthorised deviations, replace the multi-function switch -F125- Chap.01-2.


Multi-function switch-F125-


Specification Measures for deviations fromnominal value

1 Pins 1 and 2 are not connected to the automaticgearbox control unit -J217-. Remove line interruption accord-

ing to Current Flow Diagram Current Flow Diagrams, Elec-trical Fault Finding and FittingLocations.

Check plug for:

Contact corrosion

Water penetration

Leakage

2

3 68 less than 1.5

4 42 less than 1.5

5 40 less than 1.5

6 41 less than 1.5

7 44 less than 1.5

8 43 less than 1.5

9 19 less than 1.5

10 18 less than 1.5

Note


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Torque ConverterEdition 07.00S00.5318.00.20

32-1page 1

32

32-1 Torque Converter

Identification of the torque converter

There are different torque converters. Identification oc-curs with identification characters -arrow-.

Assignment torque converter/gearbox Chap. 00-1.

Torque converter identification characters

(Gearbox installed)

Remove cover plate -arrow-.

Draining the torque converter

The torque converter must be drained if the ATF is soiledby metal swarf or if the gearbox is submitted to a majoroverhaul.

Removing and installing gasket ring fortorque converter


Drive bushing -T30024-

Ejection lever -MP 3-418-

32 Torque Converter

S32-0006

S32-0007

N32-0024


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Torque ConverterEdition 07.00S00.5318.00.20

32-1page 3

32

The converter is correctly installed if the dimension be-tween the screw-on flange of the gearbox housing andthe contact surface guide studs of the converter is of 18mm.

N32-0030


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Checking shifting pointsEdition 07.00S00.5318.00.20

37-1page 1

37

37-1 Checking shifting points

Before checking the shifting points

Perform self-diagnosis and eliminate any faults. if necessary initiate basic setting.

Checking ATF level Chap. 37-8.

Inspecting engine adjustment Workshop Manual ofthe relevant engine.

Gearbox shifts too soon or too late to the next gear

When inspecting the shifting points take into account thatthe speedometer may deviate from the nominal valuewithin the authorised tolerance.

To inspect the shifting points connect -V.A.G 1552- Chap. 01-3.

H = Hydraulic shift (with converter slip)

M = Mechanical shift (without converter slip)

Position of the shift elements in the individual gears Chap. 01-6.

Only the kick-down shifting points are indicated.

Shifting points in km/h

37 Control, housing

Gearbox identification charac-ters Automatic Gearbox 001

Gearshifts Kickdown

km/h1)

1) While driving: The assistance of a second mechanic is required to read off the nominal values.

ESK 1 H - 2 H 3642

2 H - 3 H 7581

3 H - 3 M 7581

3 M - 4 H 122128

4 H - 4 M 122128


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Measure limit speed of the hydraulic converter Edition 04.05S00.5318.02.20

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Fault findingEdition 07.00S00.5318.00.20

37-3page 1

37

37-3 Fault finding

This fault finding table lists faults and their possible caus-es.



Before fault finding

Perform the following tasks before fault finding:

1 - Perform self-diagnosis, this includes:

Compare control unit identification

Interrogating fault memory

Reading measured value block

eliminating electric/electronic faults

2 - Always check the ATF level

Chap. 37-8

The gearbox function is impaired if the ATF filling level istoo high or too low.

3 - In the event of complaints about the tractionforce and shifting comfort of the gearbox: Meas-uring the fixed brake speed

Chap. 37-2

Please note that these measurements will cause the ATFtemperature to rise sharply, therefore always check theATF level beforehand (!).

4 - Check whether the vehicle engine or other ve-hicle systems work perfectly, as disturbances tothese systems may also influence the automaticgearbox.

If the automatic gearbox does not shift smoothly oncethese tasks have been carried out, proceed with faultfinding according to this fault program.

Safety measures

Comply with the safety instructions for test drives Chap. 01-1.

Inspecting the shift element

gearbox 001.pdf

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