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M20 AUTOMATED GEARBOX

1. c1sccccsseeeeseeeesaeeess 20 Slowing Gown e Vendo sereno nher nenea ae seria e pantie E EO VE cet E E alee ne ee ee 20 Changing gear with the lever semiautomatic operating MOC 111ccccccseeeeceeeeanceecessaneeeessaaaseeesssaaneseeseas 20 Changing gear in automatic mode auto mode 1 sseeeecccccesesseeeeeeeccesssssueeeceesessaueeseeeeeesesssaeeeeeessessaaasenes 21 Request to putt the gearbox in neutral viscecscessceveccsrsececdescesiavasbewndendiarieeenecareees asic ehebastiebsieeeesiele ives eeeieeedeenes 21 Turning the engine and the system Off ccccssseeseccssaseseeccsnausnecessauusececsaauuseeessaacasecessaaucsecesssaueesssasanenseessaaaes 21 32 SELFADJUSTMENTS ssiecaceeccctesstectexansns E T E 22 CU TOLEO a E AE E A A ee EEE E E eee eee 22 AcCcumUtor denes sSuUrZINg meee enema nC ona a eee ren ER E re ee ee ne eee 23 COLT CTT STA TS NON cae eo sees a eres secon eens a ves a re oad won a meee see ee 23 EG OF TIC NES CIVICE a e E E E E A EEE E EE 24 INCU ACT AOS ENEE PAE N A E A ANE EE A 25 Calculation of the ClUTCHA wear INCOX uo eeecccccssssssesececeeensaueecseeccessaaaseeseeessasauesseeeeeessssauaeseecesssssaucneneeeessssaaagees 26 FOWO TG COMO IIE sirrini gaa sioeeatans E E E EE E 28 4 FUNCTIONAL INTERACTION WITH OTHER SYSTEMS ssssnnaaannunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn 28 4 1 INTERACTION WITH ENGINE CONTROOL cccccccccceceeeseeseeceeceeeeeaeeeeeeeeeeeesseeeeeceeeeeeseeseeeeeeeeeaaa
2. INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Insert the clutch position sensor securing screws and tighten them to the specified torque 0 4 daNm Attach the electrical connection of the clutch position sensor Reassemble the battery holder and the battery 2127E40 GEAR SELECTION POSITION SENSOR OF THE S R ELECTROHYDRAULIC SELECTION GEARBOX Removal Remove the guard under the engine Remove the tube leading from the valve unit to the master cylinder VER f N Detach the electrical connection of the NZ gear selection position potentiometer FI AT 2006 Fiat Auto S p A All rights reserved 46 56 Fiat Auto S 0 A INSTRUCTOR S OUTLINE Parts amp Services a M20 AUTOMATED GEARBOX Training Academy Loosen the screws 1a and remove the gear selection position sensor 1b complete with its O ring Reassembly NOTE The gear selection position sensor should be preloaded during assembly and so the following steps should be taken Turn the engagement pin clockwise to its stroke end Ke uaa gt Position the sensor complete with its O ring as shown on the figure so as to EG engage the pin positioned previously in oy a line with the mark on the sensor A Turn clockwise preload until the Sw gt J o C S locking holes are aligned and then press a the sensor into in place
3. Fiat Auto S p A 6 5 CHANGING GEAR WITH THE VEHICLE IN MOTION Changing gear in manual mode All requests for moving up a gear are made by shifting the lever to the UP position The requests are only accepted if having made the gear change the engine revolutions are sufficient to prevent the engine stalling If the request is accepted by the system once the gear change has been made the display will show the new current gear NOTE the system display shows the gear actually engaged and not the gear requested by the driver If the request is not accepted by the system the display will continue to show the gear engaged before the request was made and will show the ILLEGAL MANOEUVRE message accompanied by an audible signal Similarly the driver may request to change down a gear by shifting the lever to the DOWN position In this case the system will only accept the request if the engine revolutions after the gear change do not exceed the maximum limit allowed for the engine The system also selects the lower gear automatically if the driver maintains the current gear and the engine is about to stall AUTODOWN manoeuvre In the manoeuvres described above the lever is set in the TIP position Changing gear in automatic mode The display will show AUTO above the indication of the gear engaged Even if the mode is automatic to put the vehicle in motion forwards or backwards the driver must request one of the tw
4. change the range of gear selection This operating principle is based on the conversion of the linear motion of the hydraulic piston into longitudinal and rotational movements of the shaft and thus of the parts connected to it ii N FIRAT 1 3 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services Patano O BA M20 AUTOMATED GEARBOX Training Academy How the gear selector works The longitudinal movement of the shaft which corresponds to the gear change within the same range is activated in two simple steps e When EV1 or EV2 is activated the hydraulic piston moves straight in a single direction e EV1 engages odd gears 1 3 5 and EV2 engages even gears R 2 4 6 The motion used to change from one row of gears to another is activated in three steps e the hydraulic brake is activated pressure is applied to EV3 and the drum is blocked e When either of the chambers created by the piston in the hydraulic cylinder is subjected to pressure and moves with linear motion the Key a follows the S shaped profile of the drum in this way the shaft and the selecting needle 2 is forced to perform a longitudinal rotational longitudinal movement which enables both a gear engagement and a gear branch selection to be changed e The row is kept in the right position by a centring sphere 5 which acts on a surface with 4 preshaped channels that correspond to the 4 gear br
5. 16 0 V Rated working voltage VBAT_typ 12 0 V Rated voltage test VBAT_test 13 5 V 0 2 V Overvoltage range 26 0 V lt Vgear_ovlid lt 40 0 V Communication network C CAN 500 kbytes sec Special hardware functions Power latch relay internal TCU woken up by the driver s door opening switch Pin out of control unit 1 Vehicle connector 2 System connector a z re N i Yi ly 100 Je 2006 Fiat Auto S p A All rights reserved 1 6 56 INSTRUCTOR S OUTLINE Parts amp Services Bil Aue oE M20 AUTOMATED GEARBOX Training Academy VEHICLE CONNECTOR CAN H high speed CAN H high speed N A Pw oesoaenon C ope a 10 TCU activation signal key on 15 DESCRIPTION Pump motor control Gearbox speed sensor Power supply for engagement sensor and selection sensor 5V 1 3 Engagement position signal Engagement selection and position sensor earth reference e Seatoxsnsedseno ey aa Power supply for clutch position sensor 5V Owens erat o 10 11 Clutch earth reference Selection position signal 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Input signals For logical operations the system must use the following incoming signals from other systems of the vehicle Specific sen
6. 2127C24 tube from valve unit to clutch master cylinder 2127C35 whole hydraulic unit 2127C45 Clutch master cylinder 1820B38 Coaxial clutch actuator 7 a A I Ja Lo EANN Wy a SS FI AT 2006 Fiat Auto S p A All rights reserved 52 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A Remove the battery Remove the battery holder Connect the battery without putting it in the engine compartment For the bleeding procedure use special pneumatic equipment selecting the relevant cap to be applied to the clutch actuator tank Remove the cap from the clutch actuator oil tank and connect suitable equipment to the tank itself Remove the protective cap and connect the recovery device tube and tank to the bleed valve on the three way connection of the hydraulic coaxial clutch actuator Open the bleed valve on the three way connection of the hydraulic coaxial clutch actuator Open the tap of the equipment s tank slowly Wait for all the air inside the hydraulic clutch disengaging system to flow out and then close the tap of the equipment s tank Close the bleed valve on the three way connection of the hydraulic coaxial clutch actuator and put the protective cap back in place Checking the bleed operation Connect Examiner and carry out the clutch bleed procedure Open the bleed valve on the three way connection
7. Auto S p A All rights reserved 54 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A Loosen the control unit securing screws Assemble the tool N 2000017800 stud bolts plate extractor for removing the control unit as follows Tighten the stud bolts in the control unit locking holes Assemble the reaction plate and fix it to the stud bolts with its nuts Assemble the extractor 3a tighten the screw to detach the control unit 3b from the contact strips of the solenoid valves NOTE Use only the special tool for removing the control unit NEVER use other tools such as screw drivers to pry open and lift the control unit because the operation of the valve unit and the control unit itself could be seriously damaged Remove the complete tool together with the control unit Reassembly FIAT 5 56 2006 Fiat Auto S p A All rights reserved a INSTRUCTOR S OUTLINE Parts amp Services BSH P A M20 AUTOMATED GEARBOX Training Academy NOTE Check that the contact strips of the solenoid valves are positioned correctly To avoid damaging the contact strips of the solenoid valves while assembling the control unit centre it on the stud bolts of the tool N 2000017800 Replace the seal set between the control unit and the valve unit Replace the stud bolts of the tool N 2000017800 in the control unit locking h
8. a 4 a 47 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Insert the screws 1a for securing the gear selection position sensor 1b and tighten them to the specified torque 0 4 daNm Attach the electrical connection of the gear selection sensor Reassemble the tube leading from the valve unit to the master cylinder Reassemble the guard under the engine If the sensor is being replaced With Examiner the following steps should be taken end of line service adjustment 2127C30 ELECTRIC PUMP OF THE S R ELECTROHYDRAULIC SELECTION GEARBOX Removal Put the vehicle on the ramp Remove the guard under the engine Remove the battery Remove the battery holder Remove he elastic dowel on the gearbox side Remove the rigid support on the gearbox side Detach the electrical connection of the electric pump Loosen the screws on the electric pump securing connector side Loosen the two remaining screws 2a and remove the electric pump 2b with its seal 2c NOTE When removing the electric pump pull along the axis with extreme caution without using any tools to prevent all risk of damage 56 2006 Fiat Auto S p A All rights reserved 48 INSTRUCTOR S OUTLINE Parts amp Services Bil Aue oE M20 AUTOMATED GEARBOX T
9. mes om E E ne e 7 2 2 COMPONENTS OF THE ELECTROHYDRAULIC KIT cccccecccccceeeeeaeeeeeeeeeeeeseaeeeeeceeeeeeseeaeeeeseeeeeeeeaaas 8 POWE 6 eee a nee Tee E ore EE ee eee eee ee eee 9 OOO VA SM sesrsece tree chp sscn EE E EE E EE E ERE 10 UTC ACE MO EENEI AIE IESE AE E S ET IAEA S A EEE A TT 11 Mechanical unit gear selector siiiciisscsivesennssiaucinsssenrinesinecessiinaessedanaiuserteuiusesiwaviarsiweniasseonersadeseietieansseiaacuas 13 How the gear selector WOKS itesisstnosssssicsnisericrsespiative resident staduncssbeadureissiunenblaentismdmenisarsdonsmimaiuinidientacsiosers 14 PECON CONT O CON eE N E E EEE 14 ECCO CONTOU or E E E E E 15 O S OI i a E E EE E EE E A EEE A EEE E A EE 18 ED SINS o e E E EE EAE EE A EE ENA E E EAA E E E E 18 CSET NCO OLE EEE AEA A E A EA AA E EAE ETE 18 OPERATING COGI tot ar E e A E dev isesessuty san 19 ao rS TEN OPERA TON srrarne eene E E E E E S ES 19 Pressurization of the hydraulic CIPCUIE ccccsceccccseeeceseseccsaueeecsuseessaaeeessaueeeesaeseessaauneessaueessaaasessaneeeessanasenes 19 Turning on starting the vehicle ccccccssseececccnseeeeccssauseeccsaussesessaausecessaaaseeessaauanesssauasecssnaausesessssaansssessaaaes 19 Operation with the engine Off cccccsssseeeseccccccssseceseccessnsauessseeeceesssaueeseeeesesssaaeseeecessessasesueeeeeessuuasaaseeecesssssaaaees 19 FI U ee a E E E A E E A A E E O 19 Automatic engagement of the clutch downhill with the accelerator pedal rel ASE
10. of the hydraulic coaxial clutch actuator Open the tap of the equipment s tank slowly Wait for all the air inside the hydraulic clutch disengaging system to flow out and then close the tap of the equipment s tank NOTE The bleed check should be carried out in the following cases once when the clutch fluid is being replaced three times at the end of operations 2127023 2127C24 2127035 2127C45 four times during operation 1820B38 Close the bleed valve on the three way connection of the hydraulic coaxial clutch actuator and put the protective cap back in place Remove the clutch bleed equipment Disconnect Examiner Reconnect the battery holder and the battery 2127E10 ELECTRONIC CONTROL UNIT OF THE S R ELECTROHYDRAULIC SELECTION GEARBOX FI AT m 53 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services Piai auio HH M20 AUTOMATED GEARBOX Training Academy Removal Remove the guard under the engine Remove the battery and the battery holder Loosen the screws 1a and put the bracket complete with the spark plug preheating unit 1b to one side Detach the electrical connections of the control unit NOTE During the removal operations cover the pins of the control unit connectors so as to protect them against accidental contacts and prevent electrostatic discharge and mechanical damage FI AT 2006 Fiat
11. oil delivery tube to the valve unit Loosen the screws 2a and remove the complete hydraulic unit 2b Loosen the connection 1a of the rigid tube leading from the valve unit to the master cylinder and the screw 1b securing the supporting bracket Loosen the screws 2a and remove the complete master cylinder 2b Reassembly Put the master cylinder back in place and tighten its screws to the specified torque Torque 1 daNm Tighten the connection of the rigid tube from the valve unit to the master cylinder and the intermediate bracket securing screw Put the complete hydraulic unit back in place and tighten the screws to the specified torque Tighten the screw on the intermediate bracket for securing the rigid oil delivery tube to the valve unit Tighten the connection of the oil delivery tube to the valve unit on the valve unit side Tighten the dual shank screw securing the bracket supporting the hydraulic unit Put the ground cable back in place and secure it using its nut Attach the electrical connection of the clutch position sensor Attach the electrical connection of the gear engagement position sensor Attach the electrical connection of the gear selection position potentiometer 2006 Fiat Auto S p A All rights reserved 42 56 INSTRUCTOR S OUTLINE Parts amp Services fiat Ao e PA M20 AUTOMATED GEARBOX Training Academy Connect the tube from the master c
12. ramp Remove the guard under the engine Remove the battery Remove the battery holder Removal the rigid tube for delivering oil to the master cylinder Remove the return tube to the tank Detach the electrical connection of the clutch position sensor Move the spring 1a back and disconnect the tube from the master cylinder with the three way connection 1b on the master cylinder side NOTE Collect the oil that flows out in a suitable container FI AT 2006 Fiat Auto S p A All rights reserved 50 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A Loosen the screws 1a and move the spark plug control unit supporting bracket 1b Loosen the screws 2a and remove the complete master cylinder 2b NOTE The oil tank cannot be separated from the master cylinder and is therefore not managed in Spare parts Reassembly Put the complete master cylinder back in place and fix it using the relevant screws with the specified torque 1 daNm Replace the spark plug control unit supporting bracket and secure it to the chassis using the relevant screws Connect the tube from the master cylinder with the three way connection and fix it with its retaining springs Attach the electrical connection of the clutch position sensor Reassemble the return tube to the tank Reassemble the rigid tube for delivering oil to th
13. the vehicle is at the end of the pick up phase during this manoeuvre the system will satisfy the request Automatic engagement of the clutch downhill with the accelerator pedal released If the vehicle with a gear engaged the accelerator pedal released and the engine started gains speed as it is going downhill having reached a preset speed it automatically engages the clutch to slow the vehicle s engine down If during this phase the driver presses the accelerator pedal the control of the torque transmitted by the clutch returns under the driver s direct control This automatic engagement of the clutch is interrupted if the vehicle is moving in the opposite direction to the gear engaged Slowing down the vehicle When slowing down for example with a gear engaged and accelerator pedal released the system automatically disengages the clutch so that the engine does not stall when it approaches its minimum revolution level The gear is disengaged in this way at an engine speed that depends on the level of deceleration and the controls operated by the driver whether the brake is pressed or not During the slowing down phase if the gear engaged is higher than 2nd the vehicles moves down through the gears When the vehicle stops the 1 gear is engaged automatically Changing gear with the lever Semiautomatic operating mode With the vehicle moving and the clutch fully engaged an UP or Down shift request made by the driver using th
14. to start the engine simply repeat the manoeuvre with the brake pedal pressed or simply press the brake pedal without moving the key from the START position With the brake pedal pressed e The engine starts and the system automatically puts the gearbox in N As well as indicating the current operating mode and the logic available with the key in 15 the instrument panel shows neutral N Once the engine has been started and until the lever is set in the N position with the brake pedal pressed the system will warn the driver of the inconsistency between the gear engaged neutral N and the position of the lever by means of an audible signal Starting the vehicle when stationary Once started the vehicle is considered to be in motion at a speed V 0 km h gearbox in neutral N and selecting lever in N or TIP R The driver should choose whether to start moving forwards or backwards The instrument panel shows the neutral gear N as well as the operating mode and the logic Irrespective of the mode Auto Manual and operating logic Eco Normal chosen to engage the first or second gear the driver must press the brake pedal and move the lever to TIP if he decides to pick up in 1st gear or still with the brake pedal pressed request 1st gear by moving the lever towards TIP if he has not returned the lever to N following the warning described previously it should be borne in mind that when the gearbox is in N the p
15. 40 C to 110 C in activity Working voltage Minimum working voltage VBAT_min 6 0 V Maximum working voltage VBAT_max 16 0 V Rated working voltage VBAT_typ 12 0 V Rated voltage test VBAT test 13 5 V 0 2 V Overvoltage range 26 0 V lt VBAT_ovid lt 40 0 V Communication network C CAN 500 kbytes sec Special hardware functions Power latch relay internal TCU wake up by driver s door opening switch 7 4 GENERAL SYSTEM FEATURES Technical characteristics e Line pressure between 36 5 and 46 bars e Working temperature of between 30 C and 105 C e Starting allowed down to a temperature of 30 C e Capacity of the pump gt 0 81 I min at 45 bars 3 450 rpm and oil at 60 C e The volume of the accumulator is 250 cm3 preloaded to 24 bars at 20 C FI AT 2006 Fiat Auto S p A All rights reserved 38 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A 8 PROCEDURES The procedures for repairing the M20 AMT system are listed below 2127040 HYDRAULIC CONTROL UNIT OF THE S R ELECTROHYDRAULIC SELECTION GEARBOX Removal Put the vehicle on the ramp Remove the guard below the engine Depressurizing the system Detach the electrical connection of the electronic control unit Connect Examiner and carry out the depressurizing procedure Remove the battery and the battery holde
16. Clutch bleeding Self adjustment of clutch valve current Self adjustment of grid FI AT z 2006 Fiat Auto S p A All rights reserved 24 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A If the procedure is not completed successfully one of the codes indicated in the table below will be shown to indicate the actual causes of the fault the corresponding error is indicated in the control unit diagnostics Description of self adjustment error codes Value Hex Comment 00 Self adjustment not yet performed 01 Plausibility error in selecting F Reverse 02 Plausibility error in selecting 1st 2nd 03 Plausibility error in selecting 3rd 4th 04 Plausibility error in selecting 5th 05 Plausibility error in selecting NEUTRAL 06 Plausibility error in engaging 1st 07 Plausibility error in engaging 2nd 08 Plausibility error in engaging 3rd 09 Plausibility error in engaging 4th OA Plausibility error in engaging 5th 0B Plausibility error in engaging 6th OC Plausibility error in engaging Reverse OD Manoeuvre aborted due to invalid general conditions OE Insufficient clutch stroke OF Self adjustment OK The procedure should always be carried out under the following conditions battery voltage within specified range key set to start hydraulic pressure above threshold If any of the previous conditions are not respected the procedure ends with a self a
17. EPEAT MANOEUVRE 1st 2nd 3rd 4th 5th 6th Repeating the manoeuvre means returning the lever to the position corresponding to the gear actually engaged the lever simply has to be returned to the position it was in before the gear change was requested and the same request has to be made with the brake pedal pressed in this way the system will accept the gear change In addition the TIP position central stable position between UP and DOWN corresponds to the first gear if the request is made with the lever in NEUTRAL and the brake pedal pressed or with the gear lever in REVERSE and reverse gear engaged 6 4 SYSTEM BEHAVIOUR WITH THE ENGINE RUNNING AND OR THE VEHICLE IN MOTION Start up 50 When the vehicle has been turned off with the gearbox in N the engine may be started irrespective of whether the brake pedal is pressed or not As well as indicating the current operating mode and the logic available with the key in 15 the instrument panel shows neutral N when the engine is started When the vehicle has been stopped with the gearbox in any gear OTHER THAN N Without the brake pedal pressed a F 7 i a x IAT a 31 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A e The system warns the driver by showing the PRESS BRAKE message on the display and does not allow the engine to be started
18. ER The information will concern e The functional status of the drive vehicle system gear display fault LED buzzer e A gear change completed message following requests made by the driver only when the vehicle is almost stationary while the vehicle is being parked e A continuous audiovisual signal from the buzzer and the fault LED associated with the specific message when a system fault that reduces the safety level is detected e A indication on the display informing the driver of the gear engaged e A warning when the engine is turned off by the driver key off with the gearbox in neutral when the vehicle could move on its own when this happens the audiovisual signal the letter N blinking on the display will last for at least 4 s e An audiovisual signal display to indicate that the system has automatically put the gearbox in neutral e A clutch overheated signal only during pick up a specific warning appears on the reprogrammable multifunction display and an audible signal is emitted by the buzzer e The audiovisual signal display when after a failed engine starting manoeuvre the gearbox is put in neutral a F 7 1 IAT E 29 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A NOTE A request for a gear change cannot always be accepted by the system e g with brake peda
19. INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A M20 AUTOMATED GEARBOX INSTRUCTOR S OUTLINE Parts amp Services otal gt be M20 AUTOMATED GEARBOX Training Academy DOCUMENT CHANGES UPDATES Description of change 2006 Fiat Auto S p A All rights reserved The distribution and copying of this document in whole or in part by any means is Strictly prohibited The drafting of this document will not entail specific liability for unintentional errors or omissions The information given in this document are subject to continual updates Fiat Auto S p A declines all liability for any consequences of the use of information that is not up to date This publication is to be used exclusively for teaching purposes For complete and up to date technical information written for servicing purposes see the service manual and the service information for the model of vehicle concerned alani i i fl i ty d H i 2006 Fiat Auto S p A All rights reserved 2 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A CONTENTS Pe peer ere mre ner mn Ne ne eS oe en a eR een ae naan emer an eee Some 5 T ANTRODUC HON crre mete nese eet nee ner er ne ee ee ee eee 5 12 CENNERA ee E een ee eee eee ere 5 2 MCRAE GC VER Go sade asters andreas seem isedectast S EE 7 ZI LAYOUFOF GEARBOX Camm nein
20. OFF and the engine and vehicle speeds drop to zero The electric pump of the system is also powered to apply pressure to the unit when the pressure reaches the minimum value about 36 5 bars When the driver turns the starter key to the unstable cranking position the AMT control unit e If the gearbox is set to N allows the engine to be started e fthe gearbox is not in N only allows the engine to be started if the brake pedal is pressed Turning on starting the vehicle This is done by turning the starter key the engine is started by activating the starter switch directly from the engine control unit once the AMT control unit has given its consent There is an emergency starting system if the battery cannot start the engine but the system is correctly pressurized the vehicle can be pushed with the clutch released and when a sufficient speed is reached the gear selecting lever is used to engage a gear the system engages the gear best suited to the speed of the vehicle so as to start the engine the driver must make sure the vehicle is moving quickly enough to start the engine when he requests to engage a gear Operation with the engine off For safety reasons any request to change gear from the lever including neutral is only accepted if the driver keeps the brake pedal pressed All available gears may be engaged with the engine off and the electric devices running Pick up The gears that may be engaged
21. OOS sessen a is E deve EREE EEEE EEE 33 Changing gear in automati TA OOS sesse iais nin EEEE AEAEE EE EEEE EEE EEE 33 E O NORMAL LOOC reer eee EA ee mn eS ee In Re oR er een ee a oe eee 34 6 6 REQUESTING NEUTRAL WITH THE VEHICLE IN MOTION cccccssssssseeeeeeeeeeeeeeeseeesseeeeaeeeeeeeeeeeees 34 6 7 REQUESTING REVERSE GEAR WITH THE VEHICLE IN MOTION cccccccccceeeeeeeseeeeeeseseeeeeeeeeeeees 35 CO TEN ARETY DEVICE Sarr ana tee ent nee teen net eee nee eee ee eee eee 36 T GCHARAGCGTERISIIC DATA Weeeermetnntere ane N emt Nn eee mire aon mnentC NNT nM eteer ym Onan rn ain mn mtn ene eye nn eo eR rnin Mme nent Nett er 37 Tei Got A RA TOS eee ene een eee eee ee A ee eee eee ee ee ee eee ere ee 37 Po IID AINA LIS FRU PAIN Serer sere ps oes E E N S 38 7 3 AUTOMATED GEARBOX CONTROL UNIT ccccccceccsssssseeeeececeeeeeeceeeeeseseaaeeeeeseessceeeeeeeseessseaaeaeaeeeeesesess 38 TAOGENERALSYOTEM FEATURES penne ee E ee een eee 38 OG cc crea ec peo ce A E 39 2006 Fiat Auto S p A All rights reserved 4 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A 1 BRIEFING 1 1 INTRODUCTION The automated transmission system AMT Automated Manual Transmission for the M20 gearbox was designed with the same objective as the previous versions in mind that is to enhance the performance of the components of the manual mechanical transmission the system frees the dri
22. Power unit B Oil tank C Assembly drawing of high pressure oil pump motor 1 Low pressure oil return tube 2 High pressure oil tube 3 Accumulator The system works with a line pressure ranging from 36 5 to 46 bars under normal conditions In Recovery mode the system will perform to its best at a pressure of 75 bars The electric pump is turned on when the pressure drops below 36 5 bars and off when the pressure in the circuit reaches 46 bars INSTRUCTOR S OUTLINE Parts amp Services Liata Soe M20 AUTOMATED GEARBOX Training Academy Technical features e Line pressure of between 36 5 and 46 bars e Working temperature of between 30 C and 105 C e Starting possible down to a temperature of 30 C e The capacity of the pump is gt 0 81 I min at 45 bars 3 450 rpm and oil at 60 C e The volume of the accumulator is 250 cm preloaded to 24 bars at 20 C Solenoid valve unit This system performs the following functions e Controls and manages the position of the clutch e Controls and manages the selection and engagement of gears The components used to activate these control functions are 1 Proportional flow valve for controlling the clutch EVO Proportional pressure valve for engaging even gears R 2 4 6 EV2 Proportional pressure valve for engaging odd gears 1 3 5 EV1 On Off valve for selecting the range EV3 Line pressure sensor 0 70 bars Hall effect sensor for the e
23. REPEAT MANOEUVRE message In any case all requests to engage reverse gear below a speed of 5 km h without the brake pressed result in neutral N being engaged and the PRESS BRAKE AND REPEAT MANOEUVRE message being displayed In any case when the lever is shifted to R at any speed and left in this position without pressing the brake the system will engage neutral as soon as the vehicle has come to a standstill 6 8 SYSTEM SAFETY DEVICES A VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED typically 1st 2nd or R If the brake and or accelerator pedal is pressed and then the driver s door is opened the system maintains the current gear The instrument panel will continue to display the mode the logic and the current gear no audible signal will be emitted B VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED typically 1st 2nd or R If neither the brake pedal nor the accelerator pedal is pressed and the driver s door is opened the system engages N after a time of about 1 5 s The instrument panel will continue to display the mode the logic and N As the lever may be in TIP or R the change to N activated by the system creates an inconsistency between the position of the lever and the gear engaged in the gearbox the manoeuvre will therefore be accompanied by an inconsistent audible signal the buzzer is activated in all cases of automatic engagement of N C VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED typically 1st 2nd
24. aaeess 28 4 7 INTERACTION WITH CRUISE CONTROL creiser inaenea aE a E E EEE ENEE TEE 28 4 INTERAC HON WITA ce ten psec E E E E E EEEE E E E E 28 4 4 INTERACTION WITH ESP ASR MSR aa000aannnnnn000annnnnnooornnnnrnrnoosnnnnnreronnnnnrerrrosnnnnrrreronnnrrrerrrsnnnnrrerrrennnne 28 5 SAFETY DEVICES AND FUNCTIONS IN CASE OF A BREAKDOWN ccccccccsssseeseeeeeeeeseenenenneeeeeenes 28 51 INCORRECT MANOEUVRES serere eraa E A EEE EE EOE 29 5 2 AUDIOVISUAL INFORMATION FOR THE DRIVER c cccccccccccceeeeeeeeeeceeeeeeseaeeeeeeeeeeeessaeeeeseesesaaas 29 6 MULTISTABLE LEVER INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A OKEY ON CD ernieren irene Ap EARE r i de AEEA EAE ROER EO r E Rag 31 6 4 SYSTEM BEHAVIOUR WITH THE ENGINE RUNNING AND OR THE VEHICLE IN MOTION 31 ID 0 PFE ESEA A AAEE AOE E S AOE AE A E A A AIA E E TA 31 Starting the vehicle when stationary ccccccccccccsseeceeecccesessseusesecesssssessseeccesessaseeeeeecessessasaeseecessssssaeeeeeecessnsas 32 Changing gear With the vehicle IN MOTION ccccccccsseeeeseecccecnsssueeseeceesesaaueeseeeesssssueusseseesssssaaaesseeeessasaaaaeeseeees 32 TNC E E e siesta cae tee ih gate noah a der A E E phe nl os uptin E E see ayy cudnt ace cient E E E eh 32 6 5 CHANGING GEAR WITH THE VEHICLE IN MOTION cccccccccccecssseeeeeseeeecceeeeceeeeseesesaaaeeessseeeeeeeeeeeess 33 Changing gear If Manual M
25. actuator e the clutch release control The electrohydraulic unit is controlled by four solenoid valves supplied with the necessary hydraulic power by a electric pump and an accumulator Having identified the driver s requirements from the position of the lever an electronic control unit 1 controls the gear change autonomously by directly controlling the clutch gearbox and motor torque during the gear change the engine is under the control of the gearbox The combined action of the gearbox and the engine considerably increases the system s performance and frees the driver from having to synchronize the movements of the clutch and accelerator during the gear change which may be performed without him removing his foot from the accelerator This prevents incorrect requests for a gear change and prevents the engine from stalling or reaching excessively high revolutions In terms of driving assistance the system also ensures that first gear is immediately available when the vehicle stops and automatically changes down through the gears when the vehicle decelerates suddenly The indication of the gear engaged is shown on a display on the electronic dashboard as are indications of faults or critical driving conditions for the vehicle or for the components of the transmission the latter are signalled by a series of warning or system fault messages together with the general fault or transmission fault LEDs INSTRUCTOR S OUTLINE Parts
26. amp Services Bil Aue oE M20 AUTOMATED GEARBOX Training Academy 2 CHARACTERISTICS 2 1 LAYOUT OF GEARBOX The electrohydraulic unit is assembled on the M20 gearbox as shown in the pictures below jie ial Y T ja i 4 i i jl li a 3 ji T 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services Liata Soe M20 AUTOMATED GEARBOX Training Academy 2 2 COMPONENTS OF THE ELECTROHYDRAULIC KIT The electrohydraulic kit is a single unit made up of three main parts e the power unit made up of a electric pump accumulator and hydraulic tank 1 e the solenoid valve unit that converts hydraulic energy into mechanical energy by means of the interface between the engaging pistons and the drive shaft 2 e the mechanical gear control unit that interfaces directly with the gearbox by means of the opening on the box itself 3 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services Bil Ae een M20 AUTOMATED GEARBOX Training Academy Power unit The power unit supplies hydraulic energy for driving both the engagement and selection of gears and the clutch cylinder it is made up of an electric pump C and an oil tank B there is also a semi rigid high pressure tube that connects the accumulator to the solenoid valve unit and a flexible low pressure tube made of preformed rubber which connects the valve unit to the tank A
27. anches i jl FIA 2006 Fiat Auto S p A All rights reserved 14 56 INSTRUCTOR S OUTLINE Parts amp Services Bl Aue ent M20 AUTOMATED GEARBOX Training Academy Electronic control unit The control unit of the system is assembly directly on the solenoid valve unit of the gearbox the engine cable is connected to the control unit by means of a connector On the control unit there is a label bearing its identification data spare part number software version software calibration A complete view of the identification label is shown below L E B m A Manufacturer s drawing number B Date C Bar code with manufacturer s information D Working voltage E Type of EPROM assembled E welded Z Socket base M Masked F Flash F Marelli code on bar code G Suppliers code H Name of application Software version and calibration L Supplier s registration number M Manufacturer s logo N Type approval code O Marelli code P Production block Q Year of production A i i K FIAT 1 5 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Technical Characteristics Type CFC300F01 Connector 28 pin Working ambient temperature 40 C to 110 C operating Working voltage Minimum working voltage Veat_min 6 0 V Maximum working voltage VBAT_max
28. chamber 3 fills up with DOT4 oil with oil pressure gt 0 bar from EVO in Chamber 1 the piston moves towards the right INpota passes into chamber 2 and OUTpot4 into chamber 3 no more oil enters from INpota while from OUT porta there is sufficient thrust to shift the CSC of the clutch The movement of the clutch is therefore proportional to the movement of the piston inside the cylinder Everything is handled directly by the AMT control unit via the solenoid valve EVO i T i 2006 Fiat Auto S p A All rights reserved 12 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A Mechanical unit gear selector The gear selector is used to choose the most suitable gear and thus handles both gear engagement and selection it is made up as follows 1 Control shaft Gear control needle S shaped cam A WwW N Latch 5 Selection centring sphere The selector consists of a control shaft 1 which includes a dual selecting needle 2 The latter is capable of selecting gears in the same range and in different ranges The device called the latch 4 only performs a rotary movement which is what is required to change selection from a lower range to a higher one and vice versa the drum with the double S slot 3 under the thrust of the oil provides a rotation resulting from a longitudinal movement of the selecting needle This forces the needle to
29. clutch If the system is turned off with the gearbox in neutral the buzzer must signal the risk of leaving the vehicle off without a gear engaged IRT m 1 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A 3 2 SELF ADJUSTMENTS The self adjustments reset the system so that it ensures correct operation and are as follows Clutch bleeding Accumulator depressurizing Clutch self adjustment End of line service self adjustment New actuators Clutch wear index calculation Statistical data deletion Control unit rewriting Clutch bleeding The procedure should always be carried out following the guidelines listed here below When it has to be performed when filling after completely emptying to repair the hydraulic KIT e having repaired the hydraulic KIT after replacing hydraulic components valves pump pressure sensor delivery tube e during general servicing of hydraulic KIT Why it has to be performed e The aim of this routine is to eliminate any air present in the hydraulic circuit after replacing the components listed above by executing 15 clutch opening closing cycles with the oil pump running Equipment required Examiner SMART Plus NOTES The procedure takes about 1 min The Power latch phase lasts about 15 s Having activated the procedure you will hear when the clutch s
30. ction with the ABS 4 4 INTERACTION WITH ESP ASR MSR When the ASR is active the system inhibits the SPRINT start During the activation of the ASR or the ESP the system inhibits the AUTO UP SHIFT manoeuvre 5 SAFETY DEVICES AND FUNCTIONS IN CASE OF A BREAKDOWN p 2006 Fiat Auto S p A All rights reserved 28 5 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A Strategies that handle incorrect manoeuvres prevent potentially dangerous operating conditions for the transmission vehicle 5 1 INCORRECT MANOEUVRES e Engagement of reverse gear not accepted with the vehicle in motion over 3 5 km h e Gear change with vehicle in motion and clutch engaged the driver s request is not accepted if it may generate an excessively high or low number of engine revolutions e Gear change with the vehicle at a standstill and with the engine started only the gears enabled for pick up 1st 2nd and Reverse are accepted e Engine turned off using key with vehicle in motion the system should handle the gearbox until all the speeds monitored engine gearbox input and output are zero e Engine starting disabled if a gear is engaged and the brake pedal is not pressed e Engine starting with gear engaged this can only be done when the vehicle is at a standstill with the accelerator pedal released brake pedal pressed and no faults e The system should put the gearbox in ne
31. d makes driving less tiring especially in town e t ensures comfortable or sporty gear changes through its advanced control logic slave e There is no clutch pedal inside the vehicle and the gear lever is replaced by Up Down Neutral Reverse controls on a specially designed joystick on the central tunnel e t provides automatic gear control in AUTO mode selected by the driver on the basis of two different logic modes ECO NORMAL The automated gearbox has two operating modes e SEMIAUTOMATIC MODE MANUAL the driver controls gear changes using the joystick on the tunnel e AUTOMATIC MODE AUTO the electronic system decides when to change gears on the basis of two strategies the first for comfortable driving NORMAL and the second for reducing fuel consumption to a minimum ECO INSTRUCTOR S OUTLINE Parts amp Services Piai auio HH M20 AUTOMATED GEARBOX Training Academy Assembly drawing with the main components of the automated gearbox system 1 TCU Transmission Control Unit 2 Electrohydraulic unit with electric pump 3 Gear display and signal board 4 ECO switch 5 Brake pedal with dual switch 6 Lever for selecting gears and Auto mode 7 Accelerator pedal Drive by Wire The slave system is made up of an electrohydraulic unit 2 assembled directly on the gearbox which controls the following gearbox movements by means of two actuators e the gear selecting and engaging movement dual effect
32. djustment KO and its error The procedure may also be aborted for the following reasons error on engagement selection and clutch sensors error on engagement selection and clutch actuators error on actuator drivers error on sensor actuator ECU power supply New actuators The procedure should be carried out following the guidelines indicated here below When it should be performed e After replacing the hydraulic KIT e After replacing the clutch selection and or engagement solenoid valve Why it should be performed e The purpose of the routine is to force the solenoid valve losses to the values of new solenoid valves FI AT 25 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Equipment required Examiner SMART Plus NOTES The procedure takes about 5s The Power latch lasts for about 15 s The procedure should be activated with the engine OFF and the key set to ON To save the values to the ECU the key should be removed and the power latch terminated Calculation of the clutch wear index This procedure enables the AMT gearbox control unit to calculate the clutch wear index with the aid of the engine control unit which saturates the desired percentage of the accelerator pedal via SW and provides the corresponding engine torque The clutch wear index calculating procedure is r
33. e N blinking for about 4 sec accompanied by an audible signal indicating that the driver has left the vehicle with the gearbox in neutral N F VEHICLE STATIONARY ENGINE RUNNING gear engaged OTHER than neutral N KEY OFF procedure If the engine is stopped no information about the gearbox will be displayed NOTES changes compared to previous systems z No generic fault LED m Acceptance of neutral at all speeds with accelerator released m The contacts for the stable and unstable positions are no longer served by simple switches but are magnetic contacts of the Hall effect sensor type so the continuity of the contact cannot be checked using the multimeter except by using the instrumental diagnosis provided by EXAMINER SMART to analyse the corresponding parameters 7 CHARACTERISTIC DATA 7 1 GEAR RATIOS Transmission ratios P N j i j j H a i 37 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services Fiat auto S p A M20 AUTOMATED GEARBOX Training Academy 7 2 FLUIDS AND LUBRICANTSI Recommended product features Selenia CS Speed Check Hydraulic unit oil 0 505 litres ecK up every ATF DEXRON III eo Check up every 30 000 Km Clutch cylinder oil 38 cc 0 038 litres Replacement every 2 years or 60 000 Km 7 3 AUTOMATED GEARBOX CONTROL UNIT Type CFC300F01 Connector 28 pin Working environment temperature T From
34. e gear control lever causes a gear change The requests will only be accepted by the system if they are compatible with the engine s minimum and maximum revolution limits The activation of the lever normally moves up or down one gear only but under some operating conditions the gear shift may be more than one if requested by the driver by pushing it quickly twice The gear change requested by the driver without releasing the accelerator pedal to move up a gear once accepted by the system will be executed in an automatic sequence of phases that will depend on the driver s behaviour e the engine torque is reduced by means of a command sent by the system to the engine control and the clutch is released at the same time e The clutch is released the new gear is selected and engaged and at the same time as the gear change the engine is controlled in such a way that the engine reaches the same number of revolutions as the clutch will have after the new gear has been engaged e The clutch is regulated and a gradual return is made to the maximum torque that can be supplied by the engine at the new level of revolutions When the system detects that the engine revolutions are synchronized with those of the clutch it releases it completely The three steps described above are managed as a function of Estimated performance requested by the driver Estimate of the transmission temperature A gear change in progress made can be interrup
35. e master cylinder Reassemble the battery holder Reassemble the battery Reassemble the guard under the engine Take the vehicle off the ramp 0010T48 HYDRAULIC UNIT OF THE ELECTROHYDRAULIC SELECTION GEARBOX BLEEDING THE UNIT NOTE This procedure is to be performed if tubes or components of the hydraulic circuit have been removed reassembled The brake pedal should be pressed from the start through the end of the operation Connect the Examiner diagnostic instrument and perform the operations indicated in the specific procedure for bleeding air from the hydraulic unit of the electrohydraulic selection gearbox hm FIAT 1 56 2006 Fiat Auto S p A All rights reserved a Fiat autoSp A _ INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy 0010T6B CLUTCH OIL FOR THE ELECTROHYDRAULIC SELECTION GEARBOX CHECKING THE LEVEL AND TOPPING IT UP NOTE The clutch oil level should be checked with the vehicle on a flat surface and with the engine cold and therefore at a standstill Check that the level is in line with the MIN notch on the tank If the level is below the MIN reference top up and bleed the system 0010T6A HYDRAULIC CLUTCH UNIT OF THE ELECTROHYDRAULIC SELECTION GEARBOX BLEEDING THE UNIT TO BE DONE WHEN ONE OF THE FOLLOWING OPERATIONS IS PERFORMED 2127C23 tube from clutch master cylinder to three way connection
36. ear lever may be moved with or without the brake pedal pressed The system will not engage any gear when the lever is moved so the gear engaged before the lever was moved with the engine running or with the key set to 15 will remain the same FI AT 2006 Fiat Auto S p A All rights reserved 30 INSTRUCTOR S OUTLINE Parts amp Services Bil Aue oE M20 AUTOMATED GEARBOX Training Academy 6 3 KEY ON 15 With the vehicle stationary and the key in the on position key controlled electric devices enabled the instrument panel shows the gear engaged the indication of the operating mode automatic AUTO or manual NO INDICATION ON DISPLAY and the logic economy E or normal NO INDICATION ON DISPLAY the letter E is only displayed in Automatic mode All gears may be engaged using the lever with the brake pedal pressed When the lever is moved without the brake pedal pressed the system will not make some gear of the changes requested The following situations may arise when the lever is moved without the brake pedal pressed FINAL Yellow LED OF LEVER FAULT PRESS BRAKE NEUTRAL N TIP PEDAL AND REPEAT NO NO MANOEUVRE PRESS BRAKE REVERSE TIP PEDAL AND REPEAT NO NO MANOEUVRE PRESS BRAKE REVERSE NEUTRAL PEDAL AND REPEAT NO NO MANOEUVRE PRESS BRAKE MANOEUVRE PRESS BRAKE NEUTRAL N REVERSE PEDAL AND REPEAT NO NO MANOEUVRE PRESS BRAKE 1 2 3 4 5 6 REVERSE PEDAL AND R
37. equired by the AMT control unit in that it saves the characteristic values for each specific clutch in Eeprom taking into consideration the normal wear of the clutch in time C C TORQUE TRANSMITTED P POSITION OF CLUTCH A NEW CLUTCH B WORN CLUTCH D WORKING CURVE Equipment required e Examiner SMART Plus r a mam N 1 l ii z k FIPT i p j im Mi a f I i it W Ja 7 A gt 2006 Fiat Auto S p A All rights reserved 2 56 INSTRUCTOR S OUTLINE Parts amp Services Fiat Auto S p A M20 AUTOMATED GEARBOX Training Academy NOTES Procedure 1 Delete the statistics 2 Repeat the kiss point self learning procedure as described in clutch self adjustment 3 Perform the end of line service self adjustment 4 The clutch wear index will then be self learnt automatically using the procedure followed at the factory The new procedure is used to reset the clutch parameters selectively and thus facilitates a more precise learning procedure N B in view of the availability of this new procedure the old clutch wear index calculation should simply be considered as a back up method Deleting the statistics The procedure should be performed following the guidelines indicated here below When it is to be performed When replacing the clutch assembly When replacing the kit When replacing the gearbox When replacing the lever When replacing the levers on the steering wheel When replac
38. h the mark on the sensor Turn clockwise preload until the locking holes are aligned and then press the sensor back in place FI AT 2006 Fiat Auto S p A All rights reserved 44 56 INSTRUCTOR S OUTLINE Parts amp Services Bil Aue oE M20 AUTOMATED GEARBOX Training Academy Tighten the screws 1a securing the gear engagement position sensor 1b and tighten them to the specified torque 0 4 daNm Attach the electrical connection of the gear engagement position sensor Reassemble the guard under the engine If the sensor is being replaced with Examiner the following steps should be taken enable the end of line service 2127E44 CLUTCH POSITION SENSOR OF THE S R ELECTROHYDRAULIC SELECTION GEARBOX Removal Remove the battery and the battery holder Detach the electrical connection of the clutch position sensor Loosen the screws 2a and remove the clutch position sensor 2b NOTE The clutch position sensor should be preloaded during assembly and so the following steps should be taken Turn the engagement pin clockwise to its stroke end J d Position the sensor as shown on the figure so as to engage the pin set previously in line with the mark on the sensor Turn clockwise preload until the locking holes are aligned and then press the sensor back in place sa Hae 4 56 2006 Fiat Auto S p A All rights reserved
39. he control unit as analogue inputs for safety reasons ECO mode the signal is given by a switch connected directly to the AMT control unit Through the multi function display the system provides the driver with the following indications Display of gear engaged via CAN Selection of AUTO mode via CAN Current mode ECO through the display of the letter E on the display System faults through a dedicated LED being lit via the CAN Audible signal from the buzzer of the instrument panel connected via the CAN it warns the river that there is a critical problem on the vehicle system Q NB while operating in AUTO mode the display shows the current gear FI AT 2006 Fiat Auto S p A All rights reserved 18 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A 3 OPERATING LOGIC 3 1 SYSTEM OPERATION Pressurization of the hydraulic circuit When the pressure drops below the minimum working threshold the hydraulic circuit is pressurized in two different ways When the door on the driver s side is opened the system automatically applies pressure to the hydraulic system to allow a gear to be changed without having to wait for the hydraulic circuit to be filled timing of fixed pump activation With the key set to start the system control unit is powered and will be so until the power key is set to
40. ing the pump When replacing the accumulator only When replacing the pump relay When replacing the auto key to be used when replacing the AUTO switch only When replacing the sport key When resetting the statistics Why it should be performed The system will continue to work even if this procedure is not carried out The following counters describe the history of each individual component so when one of the components listed above is replaced the data set associated with it must be reset or restored to their default values The information provided by these counters also enables the number of manoeuvres and faulty conditions the system found itself in when an error was validated to be identified Equipment required Examiner SMART Plus FI AT eee 2 1 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Rewriting the control unit The procedure should be carried out following the guidelines indicated here below When it should be performed The procedure should only be carried out after replacing the TCU Why it should be performed The system will continue to work even if this procedure is not carried out The following procedure enables the history of the system gearbox and kit to be traced by transferring the data from one TCU to another This operation may be performed if the devices required to pe
41. l released or a request to enter Reverse with the vehicle travelling at more than 3 5 km h etc 6 MULTISTABLE LEVER 6 1 DESCRIPTION The gear selecting lever of the automated gearbox system is of the multistable type that is it has three stable and three unstable positions With reference to the drawing below the three stable positions are NEUTRAL N REVERSE R and TIP located between the unstable positions UP and DOWN The unstable positions which are positions that are left by the lever as soon as the pressure applied to it is released are as mentioned previously the positions for shifting up a gear UP down a gear DOWN and entering automatic mode A M the gearbox is returned to manual mode by setting the lever to the A M position again NEUTRAL I i UP Ble TN aw A ro a _AUTO A de opi MANUAL S TIP Se e DOWN i REVERSE 6 2 SYSTEM BEHAVIOUR WITH THE VEHICLE STATIONARY AND THE ENGINE OFF Opening the door When the door is opened with the vehicle stationary the instruments panel is turned on and the vehicle information is displayed the gear engaged is not however displayed The hydraulic pump of the AMT assembly is activated to apply pressure to the circuit and enable the system to be operational when the driver starts the vehicle Behaviour before the key is turned on With the Key Off vehicle stationary with the key controlled electric devices disabled the g
42. le speed close to 0 km h If the driver attempts to engage reverse R gear without pressing the brake pedal and with a vehicle speed of up to about 10 km h the system engages neutral N automatically and the display shows the PRESS BRAKE PEDAL REPEAT MANOEUVRE message an audible signal is also emitted If reverse gear R is engaged again irrespective of whether the brake pedal is pressed or not and with a speed of over 10 km h the system takes no action and the display shows the ILLEGAL MANOEUVRE message an audible signal is also emitted NOTE with the brake pedal pressed reverse gear will only be engaged if the vehicle stops within a time of about 3 seconds Disengagement of reverse gear or engagement of 1st gear The system engages 1 gear when the lever is set in TIP so with the brake pedal pressed and the vehicle speed close to 0 km h the system accepts the gear change If the driver attempts to engage first gear without pressing the brake pedal and with a vehicle speed of up to 10 km h the system automatically engages neutral N and the display shows the PRESS BRAKE PEDAL REPEAT MANOEUVRE message an audible signal is also emitted If the driver attempts to engage first gear with the brake pedal pressed and with a vehicle speed of over 10 km h the system does not change gear and the display shows the ILLEGAL MANOEUVRE message the display continues to show the indication R gear currently e
43. ngaged an audible signal is also emitted Detailed specifications Request for reverse gear at a speed of over 10 km h A if within a time set the vehicle speed reaches a speed at which reverse gear is accepted the request is accepted by the system which engages reverse gear providing the driver does not release the brake pedal B if within the time set and indicated in point A the vehicle soeed remains above 10 km h the request is denied by the system and the driver is warned by the ILLEGAL MANOEUVRE message irrespective of whether the brake is pressed or not the system maintains the initial gear C if within the time set and indicated in point A the vehicle speed remains below 10 km h but above 5 Km h the request WITHOUT THE BRAKE PEDAL PRESSED the request is denied by the system which engages neutral gear N and the driver will be warned by the ILLEGAL MANOEUVRE message DO NOT PRESS BRAKE AND REPEAT MANOEUVRE D If within the time set and mentioned in point A the vehicle speed remains below 5 km h but above the speed at which reverse gear is accepted the request WITHOUT THE BRAKE PEDAL a F 7 1 IAT T 35 56 2006 Fiat Auto S p A All rights reserved _____INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A PRESSED is denied by the system which will engage neutral N and the driver will be warned by the PRESS BRAKE AND
44. ngagement position Hall effect sensor for the selection position CON DO OF FP W ND Earth points for AMT electronic control unit S 2006 Fiat Auto S p A All rights reserved 10 56 Fiat Auto 0 A INSTRUCTOR S OUTLINE Parts amp Services yia M20 AUTOMATED GEARBOX Training Academy A Power unit B Return to tank Clutch actuator 1 Clutch position potentiometer 2 DOT4 oil tank 3 Oil outlet for the clutch actuator CSC inside the gearbox bell housing 4 Inlet for oil from the solenoid valve unit _______INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A The Master Slave system fig A and fig B is made up of a cylinder inside which runs a piston that forms three chambers the first chamber receives the pressurized oil from the hydraulic unit via the solenoid valve EVO the second and third chambers let the DOT4 oil through and according to the thrust received by the oil in the first chamber pressure is applied to the CSC clutch actuator The advantage of using this solution lies in the fact that the same CSC assembled on the gearbox in the manual version may be used Inlet outlet of oil from EVO IN pots Out DOT4 to CSC Piston Chamber 1 Chamber 2 Chamber 3 Clutch closed Clutch open ee Se ae ee Operation at rest with no pressure from EVO in Chamber 1 INpot4 and OUT por are directly linked in chamber 3 7 so
45. nstably into a specific position and is deselected by repeating this operation N B if the lever is faulty the system switches to AUTOMATIC mode Request to put the gearbox in neutral This request has priority over all other gear change requests and is made using the lever only With the engine off as mentioned previously the brake pedal must be kept pressed With the vehicle in motion this request to enter neutral is always accepted Turning the engine and the system off By turning the key of the vehicle to the OFF position the engine is turned off and the system maintains the gear engaged The system is not deactivated until it detects the engine gearbox and vehicle speeds as zero and has saved the functional and diagnostic data to the stable memory of the control unit EEprom The system is turned off at most 5 s after the vehicle was stopped and the engine was turned off If the starter key is turned to the OFF position when the gearbox is in neutral the system warns the driver by means of an audible signal emitted by the buzzer in the instrument panel Information for the driver display and buzzer The system informs the driver by means of a display operation in Manual mode and gear engaged operation in Auto mode ECO mode and current gear system fault buzzer improper use of the vehicle vehicle not safe system fault A couple of examples of incorrect use are listed here below pick up with overheated
46. o available pick up gears 1st or 2nd or Reverse with the brake pedal pressed the system will remain in automatic mode In this mode the system also accepts requests made using the lever both TIP and TIP which keep it in automatic mode AUTOMATIC GEAR PROMPTING strategy in fact having accepted the request made by the driver the system continues to run in a fully automatic way The Kick Down function is also available when the accelerator pedal is pressed suddenly to the end of its stroke the system recognizes the request for maximum torque and thus moves down one two or three gears according to the vehicle s operating conditions FI AT m 33 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A ECO NORMAL Logic If the system is in automatic mode the letter E will also appear on the display when the E key is pressed When the E key is pressed again the Economy logic is disabled the letter E will disappear from the display Normal logic If the system is in manual mode pressing the E N key has no effect no indication will appear on the display 7 If the system is in automatic mode in Economy or Normal logic when the lever is set in A M it enters Manual mode and the AUTO and E indications will disappear from the display m If the system is in manual mode when the lever i
47. olenoid valve and the selespeed pump are activated The procedure is to be carried out under the following conditions engine off brake pedal pressed key set to start clutch position sensor OK clutch actuator OK If any of these conditions are not respected the procedure will end without any error code SN _ i i FI AT K i 2006 Fiat Auto S p A All rights reserved 22 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX LEa WA anh Fiat Auto S p A Accumulator depressurizing The procedure should always be carried out following the guidelines listed here below When it is to be performed e Before repairing the KIT to replace hydraulic components valves pressure sensor delivery tube Why it has to be performed e The aim of the routine is to empty the hydraulic circuit by conveying the oil towards the tank of the KIT to enable the components indicated above to be replaced by executing 15 clutch opening closing cycles with the oil pump deactivated This entails eliminating the pressure inside the hydraulic unit To check the oil level Equipment required Examiner SMART Plus NOTES The procedure takes about 1 min The Power latch phase lasts for about 15 s When the procedure is started you will hear the clutch solenoid valve being activated Check by reading the parameter with Examiner that the pressure in the hydraulic circuit has dropped below
48. oles Insert the stud bolts in the four holes in the control unit support and screw them in loosely Assemble the control unit onto the contact strips of the solenoid valves Loosen and remove the stud bolts fix the control unit by tightening the screws to the specified torque 1 0 daNm Attach the electrical connections of the control unit Replace the bracket complete with the spark plug preheating unit and fix it in position with its screws Reassemble the battery holder and the battery itself Reassemble the guard under the engine 0010T47 HYDRAULIC UNIT FLUID OF THE ELECTROHYDRAULIC SELECTION GEARBOX CHECKING THE LEVEL AND TOPPING UP NOTE The oil level of the automated gearbox is to be checked with the vehicle on a flat surface and the engine cold and therefore at a standstill Apply pressure to the hydraulic circuit of the automated gearbox by opening the door on the drivers side so as to activate the electrohydraulic pump Open the bonnet and check that the level corresponds to the MIN notch on the tank If the level is below the MIN market remove the cap and add the relevant fluid product table until it reaches the MIN notch NOTE The consumption of oil in the electrohydraulic selection gearbox is very low If the level is below the MIN notch the whole circuit should be checked for leaks iy 2006 Fiat Auto S p A All rights reserved 56
49. or R If no action is taken for a time of more than 3 minutes that is neither the brake pedal nor the accelerator pedal has been pressed and the lever is not shifted in any direction e g when the vehicle has stopped at the traffic lights the system automatically selects N The instrument panel will continue to display the mode logic and N As the lever may be in TIP or R the change to N executed by the system can create an inconsistency between the position of the lever and the gear engaged in the gearbox so the manoeuvre will be accompanied by an audible error signal D VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED typically 1st 2nd or R When the brake pedal is pressed and no other action is taken for a time of more than 10 minutes the system automatically selects neutral N The instrument panel will continue to show the mode the logic and N As the lever may be either in TIP or in R the shift to N executed by the system entails an inconsistency between the lever and the gear engaged in the gearbox the manoeuvre will therefore be accompanied by an audible error signal E VEHICLE STATIONARY ENGINE RUNNING change to neutral N KEY OFF procedure i 7 2006 Fiat Auto S p A All rights reserved 36 INSTRUCTOR S OUTLINE Parts amp Services Bil Aue oE M20 AUTOMATED GEARBOX Training Academy If the engine is turned off the instrument panel continues to display the mode the logic and th
50. osition of the lever in TIP corresponds to 1st gear move the lever to TIP and then towards TIP still with the brake pedal pressed if he wants to pick up in second gear when starting on a slippery road surface Changing gear with the vehicle in motion There are two ways of changing gear according to the system operating modes MANUAL No indication on display or AUTOMATIC AUTO Engine started The vehicle starts to move pick up when the accelerator pedal is pressed Once the engine is started the only gears that may be engaged are 1st 2nd or R Gears may only be engaged with the brake pedal pressed NOTE No AUDIBLE SIGNAL is emitted when reverse gear R is engaged NOTE when the gearbox is in N or R the TIP position corresponds to the 1st gear Any TIP request made is not considered by the system as it is not a plausible request When the driver requests a gear change with the vehicle stationary but without pressing the brake pedal the request will be denied by the system which will warn the driver by showing the PRESS BRAKE AND REPEAT MANOEUVRE message on the display and emitting an audible signal the audible signal is turned off when the consistency between the lever position and engaged gear is restored FIRT 2006 Fiat Auto S p A All rights reserved 32 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy
51. r Loosen the screws 1a and move the bracket complete with the spark plug preheating unit 1b to one side Remove the tube leading from the hydraulic unit to the tank i 3 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Move the spring 1a back and detach the tube from the master cylinder with a three way connection 1b on the master cylinder side Detach the electric connection of the gear selection position potentiometer Detach the remaining electrical connection of the control unit Detach the electrical connection of the gear engagement position sensor 2006 Fiat Auto S p A All rights reserved 40 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX LLa WA Juin Fiat Auto S p A Detach the electrical connection of the clutch position sensor Loosen the nut and remove the ground cable Loosen the dual shank screw securing the bracket supporting the hydraulic unit Loosen the connection 1a of the tube supplying oil to the valve unit 1b on the valve unit side a 4 56 2006 Fiat Auto S p A All rights reserved _______INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Loosen the screw of the intermediate bracket securing the rigid
52. raining Academy Reassembly Position the shaft of the pump with the bevels set vertically as shown on the figure Position the shaft of the electric pump with the bevels in a horizontal position as shown on the figure Fit the seal Put the electric pump back in place setting it on the same axis as the support and check that there remains a clearance a 0 3 0 6 mm Insert the side screws for securing the electric pump to its support without tightening them Insert the screw for securing the electric pump on the connector side without tightening it a Os Tighten the side screws 1 for NS securing the electric pump set in 5 position previously to the specified torque 0 6 daNm Tighten the screw on the connector side 2 for securing the electric pump positioned previously to the specified torque 0 6 daNm Attach the electrical connection of the electric pump Reassemble the rigid support on the gearbox side Reassemble the elastic dowel on the gearbox side Reassemble the battery holder Reassemble the battery Reassemble the guard under the engine Take the vehicle off the ramp Fi AT 49 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services otal gt be M20 AUTOMATED GEARBOX Training Academy 2127045 CLUTCH MASTER CYLINDER OF THE S R ELECTROHYDRAULIC SELECTION GEARBOX Removal Put the vehicle on the
53. rform it are working in other words if the TCU to be replaced does not allow the data to be read the procedure will not be carried out successfully As mentioned previously the system will however continue to work If the TCU and any other component subjected to the data set deleting procedure are replaced at the same time the values of the statistical data should be written down before deleting the dataset of the component to be replaced Equipment required Examiner SMART Plus 4 FUNCTIONAL INTERACTION WITH OTHER SYSTEMS 4 1 INTERACTION WITH ENGINE CONTROL During motion the two systems do not interact because the system does not perform any function so there is only an exchange of information and signals over the network When a gear change is in progress the system is the master of the engine control that is the gearbox control system instructs the engine via the CAN as to what engine torque should be applied decrease while the clutch is being released and increase when the gear change has been completed and the clutch is being engaged in addition the engine revolutions are adapted to the gearbox revolutions so as to reduce the stress applied to the clutch to a minimum 4 2 INTERACTION WITH CRUISE CONTROL CC is a system that is not influenced by the presence of the AMT system but can only be deactivated in MANUAL mode and not in AUTO mode 4 3 INTERACTION WITH ABS The system has no functional logic for intera
54. s set to A M Automatic mode will be enabled and the display will show the word AUTO the system also restores the most recently selected logic Eco or Normal saved before Manual mode was enabled 6 6 REQUESTING NEUTRAL WITH THE VEHICLE IN MOTION e f Neutral is requested with the ACCELERATOR PEDAL RELEASED irrespective of whether the BRAKE pedal is pressed or not the system accepts the request and the display shows neutral N as well as the operating mode and logic If the neutral gear N is requested with the ACCELERATOR PEDAL PRESSED irrespective of whether the BRAKE pedal is pressed or not the system denies the request and maintains the current gear in addition as the lever is in a different position from the gear actually engaged in the gearbox the display shows the MANOEUVRE NOT ALLOWED message accompanied by an audible signal Whether the system is in AUTOMATIC or MANUAL mode the return from N neutral is executed by shifting the lever to the stable TIP position THE BRAKE PEDAL DOES NOT HAVE TO BE PRESSED The manoeuvre returns the gearbox to the most suitable gear FI AT T 2006 Fiat Auto S p A All rights reserved 34 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A 6 7 REQUESTING REVERSE GEAR WITH THE VEHICLE IN MOTION Reverse gear may only be engaged under the following conditions Brake pedal pressed 7 Vehic
55. sors of the automated gearbox Clutch revolution sensor the value is read from the primary shaft of the gearbox Position sensor for clutch engagement and selection Single signals coming from other vehicle systems Number of engine revolutions incoming signal from the engine control unit via the C CAN network Brake pedal switch two signals one separate pin 9 of vehicle connector the other via the C CAN network Driver s door opening switch separate Key on stable position and separate starting Signals coming from other systems via the CAN network are Accelerator pedal position e Engine torque vehicle speed engine temperature etc Output signals The reverse light activating signal is no longer managed by a switch set on the gearbox but is activated directly by the AMT control unit on pin 4 of the vehicle connector User interface The user interfaces with the system using the following controls Accelerator pedal via CAN from the engine control node Brake pedal through two signals one separate and the other via C CAN Request for a gear change or mode selection using a specially designed multi stable electromechanical lever with three stable positions NEUTRAL REVERSE and TIP and three unstable positions UP DOWN AUTOMATIC MANUAL by means of 4 signals that convert the electrical signals of the 10 Hall effect sensors located inside the lever itself the signals must be read by t
56. ted at any time by another request from the driver providing it is an acceptable request that is compatible with the minimum and maximum engine revolution limits The actuator control sequences during the change of gear have timeouts that is if the gear ii 2006 Fiat Auto S p A All rights reserved 20 56 INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat Auto S p A change is not made successfully it is repeated once starting from neutral and then the next gear up from the one requested is engaged Changing gear in automatic mode auto mode The automated gearbox has an automatic operating mode very similar to that present on conventional automatic gearboxes The choice of the gear to be engaged is made on the basis of two maps that correlate the position of the accelerator pedal with the vehicle speed The reason why there are two maps is that in AUTOMATIC mode the driver can select by pressing a button on the dashboard management of two modes defined initially as ECO energy saving and NORMAL for sportier driving If the accelerator pedal is released under certain conditions the system does not increase the gear so that the engine slows down Gear changes are made in exactly the same way as in semiautomatic operating mode using the lever and the same control parameters for the gearbox and engine actuators are used Automatic mode is selected by setting the lever u
57. the accumulator preloading threshold about 2 3 Bars The procedure should always be carried out under the following conditions engine off brake pedal pressed key set to start clutch position sensor OK clutch actuator ok If any of the previous conditions are not respected the self adjustment will be aborted and an error message will be displayed on examiner Clutch self adjustment The procedure should always be carried out following the guidelines shown here below When it should be performed When the vehicle reaches the end of the line after replacing the AMT control unit after replacing removing the gearbox after replacing removing the KIT detachment after replacing the clutch Why it should be performed e The purpose of the routine is to quickly recalculate the Kiss point i e the position at which the clutch starts to transmit engine torque Equipment required Examiner SMART Plus FI AT 1 23 56 2006 Fiat Auto S p A All rights reserved _______INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A NOTES The procedure takes about 1 min The Power latch phase lasts for about 15 s The procedure should be performed before starting the engine with the key set to ON and the gearbox in neutral Then the engine can be started A time of 10 s should pass between one activation cycle and the next The activation c
58. utral first and then allow the engine to be started e With the vehicle at a standstill or almost gear change requests are only enabled if the brake pedal is pressed This prevents dangerous situations caused by the gear lever being shifted by passengers in the vehicle or persons from outside the vehicle e g through the window or accidentally by the driver himself when the vehicle is parked on a slope It eliminates the risks of incorrect manoeuvres by the driver under critical conditions e g downhill or by the passengers The gearbox is put automatically in neutral and an audible warning is emitted for the driver e When the oil pressure is not sufficient to manage the clutch e If the driver opens the door to get out of the vehicle with the engine running the pick up with the door open is allowed in that the driver s foot on the brake or accelerator is detected the gearbox is put into neutral 1 5 s after the door is opened e When the driver does not accelerate or brake for at least 3 minutes with the engine running gear engaged and vehicle stationary e With the engine running gear engaged and accelerator released and brake pedal pressed for at least 10 minutes If faults that reduce the System s Safety Level take place the vehicle s functions are limited e g limitation of gears to 1st 2nd Reverse when there is a fault in the revolutions or the engaged gear detecting sensors 5 2 AUDIOVISUAL INFORMATION FOR THE DRIV
59. ver from the obligation of controlling the clutch pedal and the gear lever without depriving him of the pleasure of driving that comes from the direct control of transmission It also improves driving safety through direct control that prevents mistakes made by the driver and incorrect handling of the transmission system providing him with a more advanced vehicle interface The system consists essentially of a mechanical transmission with a single dry plate clutch and synchronized mechanical gearbox driven by a hydraulic slave cylinder As on the previous versions no modifications have been make to the clutch or the gearbox for the installation of the hydraulic actuators used to control the stroke of the clutch and the gear engaging and selecting movements 1 2 GENERAL The AMT system for M20 provides the following features e It improves the performance of the components of the manual mechanical transmission e It frees the driver from the obligation of controlling the clutch pedal and the conventional gear lever e t improves driving safety through a control function that prevents mistakes made by the driver and incorrect handling of the transmission system e t provides the driver with a more advanced vehicle interface e It is a hydraulic gearbox and clutch control system that maintains all the advantages of the dry plate clutch and mechanical gearbox weights strength and reliability low energy consumption e It simplifies use an
60. with the engine started and the vehicle at a standstill for the pick up phase are 1st 2nd and Reverse these gears under these conditions may only be requested by moving the lever To engage the gear for safety reasons the driver must keep the brake pedal pressed To engage Reverse gear in addition to the conditions indicated above the vehicle must also be at a standstill gearbox input revolutions detected 0 The vehicle pick up only occurs if the driver presses the accelerator pedal with the brake pedal released at this point the system gradually engages the clutch to set the vehicle in motion The FI RT 1 9 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A driver can adjust the torque transmitted by the clutch by modulating the position of the accelerator pedal when the accelerator is released the clutch must be gradually released when the minimum threshold of engine revolutions is reached When the system detects that the engine revolutions are synchronized with the clutch revolutions it engages the clutch completely package closure For each of the three gears in which the pick up may be executed a special clutch engagement map is implemented During the pick up phase the driver may only request a gear change when the number of clutch revolutions corresponds to the number of engine revolutions that is
61. ycles should be executed in the same driving cycle The procedure should always be carried out under the following conditions key set to start no request for gear change clutch position sensor OK engagement actuators OK power supply for sensors actuators ECU OK lf any of these conditions are not respected the procedure ends self adjustment KO with an error message End of the line service The procedure should always be carried out following the guidelines here below When it should be performed At end of line where necessary After replacing the gearbox After replacing removing the KIT After replacing any selection or engagement potentiometer After replacing the control unit Why it should be performed e The purpose of the routine is to save the thresholds of the gear change grid Equipment required Examiner SMART Plus NOTES The procedure takes about 5 minutes The procedure should be requested with the engine OFF and the key set to ON The hydraulic pressure should be above the gear change acceptability threshold 36 5 46 bars The battery voltage should be within the preset limits vehicle operating range To save the values to the control unit turn the Key to OFF and terminate the power latch the power latch phase takes about 15 s The procedure entails activating the following functions automatically Fast self adjustment of closed clutch position Clutch stroke test
62. ylinder with a three way connection on the master cylinder side and close its spring Connect the tube from the hydraulic unit to the tank Replace the bracket complete with the spark plug preheating unit into its seat and fix it with its screws Attach the electrical connections of the engine control unit Reassemble the battery holder the battery and the guard below the engine With Examiner the following steps should be taken clutch self adjustment end of line service adjustment new actuator adjustment only when replacing the hydraulic actuator unit Remove the vehicle from the ramp 2127E42 GEAR ENGAGEMENT POSITION SENSOR OF THE S R ELECTROHYDRAULIC SELECTION GEARBOX Removal aV ae Remove the guard under the engine Detach the electrical connection of the gear engagement position sensor 43 7 56 2006 Fiat Auto S p A All rights reserved INSTRUCTOR S OUTLINE Parts amp Services M20 AUTOMATED GEARBOX Training Academy Fiat auto S p A Loosen the screws 1a and remove the gear engagement position sensor 1b complete with its O ring Reassembly NOTE The gear engagement position sensor should be preloaded during assembly and so the following steps should be taken Turn the engagement pin clockwise to its stroke end Position the sensor complete with its O ring as shown on the figure so as to engage the pin set previously in line wit

M20 AUTOMATED GEARBOX

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