Al4 Automatic Transmission
Al4 Automatic Transmission
Al4 Automatic Transmission
OF THE AL4
AUTOMATIC
TRANSMISSION
R e f N o : 2 . 3 . 1 4 2 Revised January 2005
C i t ro ë n Tra i n i n g
NOTE TO READERS
This document contains information of a confidential nature.
It is therefore strictly reserved for the use of CITROËN trainers and may not be
distributed to people outside the relevant departments.
DOCUMENT SUMMARY
PRESENTATION OF THE
AL4 AUTOMATIC TRANSMISSION
The aim of this document is to give a brief description of the design and operation of
the electronically managed AL4 automatic transmission which offers precise,
adaptive control as well as excellent gear changing quality.
- Lubrication,
- The converter,
- The mechanism,
- The ECU,
- Auto-diagnostics,
- Unit maintenance.
CONTENTS
II - Presentation............................................................................ Page 2
CONTENTS
PRESENTATION - GENERAL
I- INTRODUCTION
AL4001D
• "Fuzzy logic" auto-adaptive ECU which controls the converter, gear changes
and specific programs.
• Current application: Various CITROËN vehicles with Petrol and Diesel engines.
II - PRESENTATION
Transmission layout
• Hydraulic torque converter with lock-up device.
• Primary shaft.
• Two "Simpson 2" type epicyclic gear trains.
• Multiplate clutches.
• Multidisc and band brakes.
• Step down gear in central 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 regulation and gear changing functions.
• Three programs offered to driver:
Auto adaptive - Sport - Snow
• Gears and programs displayed on dashboard.
• Cannot change up a gear in the no load position.
• User interface performed by a "stepped" selector grid with Shift-Lock safety
function and program push buttons.
• "1st" imposed position selected using push button (depending on application).
• Auto adaptive "Flash EEPROM" ECU.
• Downgraded operation in the event of a fault.
• Closed loop operation.
• On board diagnostics.
• Selector lever not in position P reminder buzzer (depending on application).
A - CROSS SECTION
22 21 10 11 12 13
14
1
15
3
16
17
7
19 18
8
20
9
5 4
AL4002P
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 - Hydraulic 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 - Epicyclic gear train
22 - Primary pinion of step down gear
A - AUTOMATIC TRANSMISSION
20TP15 A
0000877 B AL4003D
A - Component reference
B - Serial number
B - ECU
SIEMENS M
A 1209263000
S108518006 A D
BVA
F
R
A
N
C 7700103423
E
AL4004D
C G
SIEMENS M
A 1209263000
S108518006 A D
9630386980
D H
E
I
0/ 02150 / 270234214 / 97253 N
F
R
A
BVA
E N
C
E
7700103423 I
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
Prog. Display
Selector
selec-
lever
tor
Buzzer
S
h
i
Final drive f Control
+
t
L
Rev panel
differential o S 1st counter
c
k
MIL
illumin.
request
Epicyclic Dist.
gear train
Engine
management
throttle α computer
Dist.
Converter
Exchanger
oil flow P/N -
setting D-
AT ECU Gear
Electro- change
hydraulic
distributor
Dist.
oil
Automatic Pump temp.
transmission braking
info.
Electro- Throttle
Kick-
hydraulics potentio- down
meter Electr-
Mechanics info
onics
(engine)
AL4005P
A - TOWING
The transmission is lubricated when the engine is running since this drives the
transmission oil pump. Thus, when towing, the drive wheels must be raised off
the ground. However, the vehicle may be towed with the drive wheels on the
ground under exceptional circumstances and provided that the following
conditions are complied with:
B - DRIVING
Never push the vehicle to try and start it (not possible with automatic
transmission).
Never disconnect:
The centring pin must be used to couple the transmission to the engine.
Remove the centring pin just before coupling the transmission to the engine.
SELECTOR CONTROL
I- SELECTOR LEVER
The selector lever, through the selector shaft (on the transmission), operates the
multifunction switch and the manual valve on the hydraulic distributor.
C
E
RI
AL4007D
A - Upper part
B - Lower part
C - Sleeve stop
D - Control lever
E - Locking plunger for the Shift-Lock function
Ri - Initial setting
The selector lever, located on the central console, has six positions (depending on
application) laid out on an offset or "stepped" grid.
The lever has a mechanical safety device which is unlocked by exerting a radial
action on the lever.
Note: The ignition must be switched on and the brake pedal pressed to
unlock the selector lever from position P. This is the Shift-Lock
function.
Ri
G
AL4028C
C - Sleeve stop
Ri - Initial setting
G - Control return with ball joint
II - PROGRAM SELECTOR
This is located on the central console next to the selector lever and has 3 push
buttons (depending on vehicle).
The driver can therefore inform the ECU of his selection:
• desired program,
• 1st imposed → this is obtained by pressing the "1" button of the selector with
the selector lever in position 2 on the grid.
R
N N
D D
3
2
AL4006C
The driver can select a program by pressing one of the "S" or "¿" program
selector buttons.
AL4008C AL4009C
1 - Filler plug
2 - Transmission housing
3 - Level plug
4 - Drain plug
2
3 AL4010C
• If oil streams out then starts to drip → close the level plug and tighten to 2.4 mdaN.
• If oil drips out or does not flow at all → close the level plug (3),
stop the engine,
add 0.5 litres of oil to the transmission,
repeat the level checking procedure,
the oil level is correct if oil streams out and then starts
to drip,
close the level plug (3) and tighten to 2.4 mdaN
close the filler plug (1) and tighten to 2.4 mdaN
• oil leaks.
Note: An oil check is not included in the PDI nor the first service.
FUNCTIONAL DIAGRAM;
The AL4 automatic transmission is fitted with a standard torque converter which has an
added lock-up device.
I- DESCRIPTION
1- Lock-up piston
2- Double sided friction plate
3- Vibration damper
4- Impeller
5- Turbine
6- Stator
7- Free wheel
8- Oil pump drive
9- Automatic transmission input shaft drive
9 8
Starting
ring
AL4011P
7
1
6
Drive
2 end plate
AL4027C
Converter
5 4
• a stator (6), fitted on the free wheel (7) and located between the impeller and
the turbine,
• a lock-up device operated by the ECU which consists of a piston (1), a friction
plate (2) and a vibration damper (3).
The converter is secured to the engine drive plate (end plate). Its role is to provide
a flexible and automatic link between the engine and the transmission.
• the converter phase where it multiplies the engine torque by up to 2.2 times,
• the coupling phase where it transmits the engine torque with an efficiency of
0.98 (1 if it is locked up).
II - CONVERTER LOCK-UP
A - GENERAL
Lock-up is available on 2nd, 3rd and 4th gears (and 1st gear in rare cases).
The ECU controls the two possible states of the lock-up using a set of
memorised laws.
5 b
4
3
2 - Converter locked up
I- DESCRIPTION
To provide the four forward gears and one reverse gear, the AL4 automatic
transmission has a SIMPSON type epicyclic gear train.
This consists of two simple epicyclic gear trains connected together.
There are:
F1 F2 F3
E1 C2
S2
E2
C1 P2
S1
P1
PS1
Primary pinion of
the step down gear
Movement input
housing PS2
AL4014D
Secondary pinion of
the step down gear
P2
C2
PS1
P1
PS2
C1
AL4015P
Primary pinion of
the step down gear
II - OPERATING PRINCIPLE
1st gear
F1 F2 F3
E1
C1 C2
E2
PS1 PS2
PP des Lock-up
P1 P2
AL4016D
Primary
PP des = Primary step down pinion
2nd gear
F1 F2 F3
E1
C1 C2
E2
PS1 PS2
PP des Lock-up
P1 P2
AL4017D
Primary
PP des = Primary step down pinion
3rd gear
F1 F2 F3
E1
C1 C2
E2
PS1 PS2
PP des Lock-up
P1 P2
AL4018D
Primary
PP des = Primary step down pinion
4th gear
F1 F2 F3
E1
C1 C2
E2
PS1 PS2
PP des Lock-up
P1 P2
AL4019D
Primary
PP des = Primary step down pinion
Reverse
F1 F2 F3
E1
C1 C2
E2
PS1 PS2
PP des Lock-up
P1 P2
AL4020D
Primary
PP des = Primary step down pinion
ECU
The ECU of the AL4 transmission is an autoadaptive and upgradable with a 56 track
Flash Eprom.
I- ECU FUNCTIONS
The ECU has 10 gear changing laws allowing the operation of the
transmission to be altered to the driver's style of driving, to the chosen
program and to the internal and external conditions.
B - PROGRAMS
The ECU manages three programs: autoadaptive, Sport and Snow (upon
driver's request).
C - AUTO-ADAPTIVENESS
The ECU has an autoadaptive program which allows it to chose the law which
will be the best suited to the following conditions from the ten laws listed
above:
• driver's style of driving → 3 laws = "economic", Medium", "Sport ",
• road profile and vehicle load → 3 laws = "slight incline" (or "braking 1"),
"sharp incline" (or "braking 2"), "decline",
• temperature,
• selected program.
F - CHANGE DOWN
The ECU is totally responsible for changing down the gears as a function of
engine load, vehicle speed and driving conditions. The ECU authorises a
double change down (from 4th to 2nd and 3rd to 1st) or forces a single change
down.
H - KICKDOWN
The kickdown order is given by the automatic transmission ECU after the
accelerator pedal is pressed down fully and depending on vehicle speed.
The ECU works out the value of line pressure with closed loop feedback. The
reference value is a function of the turbine torque to overcome.
When the ECU decides to change a gear, it must operate the various
electrovalves involved in a precise order and in accordance with timers which
are a function notably of the engine load and vehicle speed. This provides a
good overlap between the receiver which is emptying and the one which is
filling up.
M - TORQUE REDUCTION
This function is used to attenuate the dragging effect of the transmission when
it is being driven through the engine management computer (idle reference
speed).
• Incorrect operations:
- on the automatic transmission: change from N → D or N → R prohibited if N
above threshold. The change is authorised if N below threshold or after a
timer.
P - SHIFT-LOCK FUNCTION
This function locks the selector lever in position P when the ignition is switched
on. The lever is unlocked by pressing the brake pedal.
The ECU informs the driver of the position of the selector lever and the choice
of program using the display on the control panel.
The ECU may also warn the driver of a transmission problem by flashing the
sport and snow warning lights.
Using the parameters 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 automatic transmission oil needs changing.
S - SAFETY - DIAGNOSTIC
The ECU:
• permanently checks its supplies and that its sensors and actuators are
operating correctly,
• validates and stores operating faults,
• talks with after-sales tools through the K line,
• 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 L4 emmisions level and above).
T - CONFIGURATION - DOWNLOADING
U - OTHER FUNCTIONS
II - OPERATING SUMMARY
3 4 5 7 4 5 9 4 11
1 2
12
33 6 8 10
A B C
36 17 13
13 16
14
14 15 EOBD
15 14
16 13 16
32
19 18
31 34
30 35
28
29 27 26 25 24 23 22 21 20
AL4021P
Load information
A - Petrol engine with double track potentiometer
B - Petrol engine with single track potentiometer
C - Diesel engine
Parts list
REF. DESCRIPTION
1 Accelerator pedal
2 Kickdown function on accelerator cable
3 Double track throttle potentiometer
4 TDC sensor
5 Engine coolant temperature probe
6 Petrol injection ECU
7 Single track throttle potentiometer
8 Petrol injection ECU
9 Potentiometer on injection pump load lever
10 Diesel injection ECU
11 Torque reduction electrovalve
12 Kickdown information
13 Engine load information
14 Engine speed + engine coolant temperature information
15 Engine torque information (provided by injection ECU)
16 Torque reduction request information + idle speed compensation request
information
17 Illumination of EOBD light request information (only on versions with L4
depollution)
18 LED display (control panel)
19 Diagnostic socket
20 Sequence electrovalve
21 Pressure modulating electrovalve
22 Oil flow modulating electrovalve
23 Transmission oil temperature probe
24 Transmission oil pressure sensor
25 Transmission input speed sensor
26 Transmission output speed sensor
27 Multifunction switch
28 Reversing lights
29 Starter motor prevention relay
30 Shift lock actuator
31 Gear lever
32 Program selector (Sport, Snow, Normal, 1st imposed)
33 Brake pedal (braking information)
33 Stop switch
34 Automatic transmission ECU
35 Not in position P reminder buzzer
36 Throttle position information (throttle potentiometer)
INTERFACE MODULE
gearbox water-oil
heat exchanger
1 blue 3 bypass solenoid
valve
gearbox input
2 yellow 3 speed sensor
multifunctional
5 green 12 switch
HYDRAULIC BLOCK
The hydraulic block, supplied by the oil pump at a certain internal pressure (called “line
pressure”) contains the circuits and the hydraulic valves for supplying the brakes, the clutches,
the converter, the lock-up clutch and lubricating elements. The solenoid valves needed for
gearbox operation are housed in a hydraulic accumulator.
• 1 - Hydraulic block
• 2 - EVS4 sequence solenoid valves
• 3 - EVS3 sequence solenoid valves
• 4 - EVS1 sequence solenoid valves
• 5 - EVS2 sequence solenoid valves
• 6 - EVS6 sequence solenoid valves
• 7 - EVS5 sequence solenoid valves
• 8 - Line pressure modulating solenoid valve (EVM1)
• 9 - Lock-up clutch engagement modulating solenoid valve (EVM2)
• 10 - Manual solenoid valve (VM)
AUTO-DIAGNOSTIC
I- FAULT 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 has cooled),
• when the transmission oil is old (oil counter value at calibrated maximum value),
• when there is a break in the serial link between the transmission ECU and the
control panel.
The "SPORT" and "SNOW" warning lights flash if there is a fault on the following
components or information:
• transmission ECU,
• ECU supply,
• oil pressure sensor,
• supply to sequence electrovalves (EVS1 to EV6),
• regulation fault in main hydraulic pressure,
• multifunction switch,
• sequence electrovalves (EVS1 to EV6),
• main pressure modulating electrovalve (pressure EVM),
• converter lock-up modulating electrovalve (lock-up EVM),
• oil flow electrovalve in heat exchanger,
• main hydraulic pressure electrovalve,
• accelerator pedal not programmed,
• input speed and output speed,
• input speed and engine speed,
• output speed and engine speed,
• engine speed information,
• pedal position,
• supply to analogue sensors.
SEQUENTIAL CONTROL
R
S2
1603
N S3
C+
S4
M D
1600 P/N 1630
C-
S5
S6
The electrical statuses of the P, R, N and D positions are taken from the
multifunction switch (1600) located on the sequentially controlled automatic
gearbox. The electrical statuses of the sequential control (1603) are connected
directly to the ECU.
AFTER-SALES OPERATIONS
I- DOWNLOADING
II - CONFIGURATION
The aim of this operation is to tell the automatic transmission ECU that the
transmission oil has just been changed.
This procedure consists of making the transmission ECU memorise the "old oil"
counter should the ECU be replaced without changing the oil.
Note: If the oil counter cannot be read from an old ECU, change the transmission
oil.
The ECU permanently adapts itself to the transmission.Thus, when replacing the
transmission, the ECU or another transmission component, a road test must be
performed choosing a route which allows frequent gear changes and the use of all
gears. All the programs should also be selected.
This test is absolutely essential so that the ECU can adapt itself to the
transmission by comparing reference values with actual values. The difference
recorded is then memorised to allow optimum gear changing quality.
Transmission fitted
Authorised replacements:
• drain and fill oil,
• download/configure ECU,
• program pedal,
• initialise/update "old oil" counter,
• hydraulic distributor cover seal,
• selector shaft seal,
• driveshaft seals,
• seal between closing plate and transmission housing,
• gear selector control,
• heat exchanger and its seals,
• accessible plugs, support brackets and control pins,
• complete hydraulic distributor,
• electrovalves and pressure regulators on hydraulic 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,
• transmission ECU (*).
Note: If the oil in the transmission is burnt, always replace the heat
exchanger.
(*) only after approval.
Transmission removed
Authorised replacements (depending on transmission architecture):
• torque converter,
• inter housing gasket,
• whole transmission (*).
IMPORTANT: When returning a transmission under warranty, return it with its heat
exchanger.
The operating procedures for the various authorised operations are given in the
corresponding after-sales document.
Replacing the whole AL4 transmission or its ECU must be subject to prior
approval.
This approval is given by the Regional Headquarters for France. The point of sale
fills in the "request for replacement approval" (copy enclosed) and sends this duly
completed request to the Regional Headquarters. After being analysed, additional
technical assistance will be proposed in order to complete the diagnostic or
replacement approval will be faxed back to the point of sale on the approval
request.
Conditions
Procedure
X - SPECIAL TOOLING
Box - (C ) 0338-ZT
A B C D E F
G H1 H2 J1 J2 K
L M1 M2 N1 N2 P
AL4026D
A - Drift
B - 2 sockets for removing-refitting converter
C - Right hand driveshaft seal extractor
D - Tool for holding converter
E - Ball joint extractor
F - Tool for fitting converter lip seal
G - Hook for removing lip seal from converter
H1 - Tool for fitting left hand driveshaft seal
H2 - Guide for fitting left hand driveshaft seal
J1 - Tool for fitting right hand differential output seal
J2 - Guide for fitting right hand differential output seal
K - Tool for fitting selector shaft seal
L - Interface harness for checking AL4 automatic transmission
M1 - Screw for setting internal selector control
M2 - Shim for adjusting internal selector control
N1 - Gear changing shaft seal extractor
N2 - Gear changing shaft seal extractor
P - Socket for removing transmission mounting
XI - DIAGNOSTIC TOOLING
• identifying ECUs,
• reading faults,
• erasing faults,
• measuring parameters,
• activating actuators,
• configuring ECUs,
• erasing faults,
• measuring parameters,
• activating actuators,
• configuring ECUs,
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