n.t. 3270a Ba0b - Da0b - Ja0b

8/14/2019 n.t. 3270a Ba0b - Da0b - Ja0b

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8/14/2019 n.t. 3270a Ba0b - Da0b - Ja0b


Contents

Pages

General

Consumables

Parts which mu st always be changed

Oil

Draining

Filling - levelsChecking the converter setting

point

Hyd raulic distributor

Au tomatic transmission (Removal -

Refitting)

Differential outp ut seal

Converter seal

Multifunction switch

Sensors

Computer

Solenoid valves

Wiring diagram

Modular connector

Line pressu re take-off

Gear selector lever

Fault find ing - Introd uction

23-1

23-2

23-2

23-2

23-3

23-4

23-5

23-6

23-8

23-12

23-13

23-14

23-16

23-17

23-19

23-20

23-23

23-24

23-25

23-26

AUTOMATIC TRANSMISSION23

Suspend ed engine moun ting

Diagram

19-1

19-2

ENGINE MOUNTING SYSTEM19

COOLING

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ENGINE MOUNTING SYSTEM

Suspended engine mounting 19

16667R

TIGHTENING TORQUES (in daN.m)

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COOLING

Diagram 19

1 Engine

2 Radiator

3 "Warm" reservoir with degassing following thermostat

4 H eater m atrix

5 Th erm ostat su p port

6 ∅ 3 mm n ozzle

Coolant pum p

Thermostat

Bleed screw

The expansion bott le valve calibration value is 1.2 bar (brown).

16664-1R

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AUTOMATIC TRANSMISSION

General 23

VEHICLE A.T. TYPE ENGINESTEP DOWN

RATIO

FINAL DRIVE

RATIO

D/ L/ BA04 DP0 29 K4M 701 52 / 67 23 / 70

JA04 DP0 30 K4M 701 52 / 67 21 / 73

Automatic transmission identification m ark.

13786R

SPECIFICATIONS

Weight : 70 kg

Mégane vehicles equipped w ith the DP0 automa-

tic transm ission are fitted w ith systems called:

"Shift Lock" and "Lock Up".

The pu rpose of the "Shift Lock" is to proh ibit mo-

vement of the selector lever withou t simultaneou s

pressing of the brake ped al. For repair operations

when the battery i s faulty, refer to the vehicle

handbook.

The "Lock Up " or converter bridging clutch is d es-

igned to connect the automatic transmission di-

rectly to the engine. This connection is made by a

"min i clutch" in the conv erter. The "Lock Up" is

controlled by th e DP0 compu ter.

Gears ratios (epicycloidal gear train):

1st 2nd 3rd 4th REVERSE

2.724 1.499 1 0.71 2.455

TOWING

In all cases, it is pr eferable to tow the vehicle on a

flat-bed trailer or with the front wh eels raised.

How ever, if this is not possible, the vehicle may , in

exceptional circum stances, be towed at a sp eed of

less than 30 mp h (50 km/ h) over a distance limited

to a 30 miles (50 kilometres) maximum.

TOWABLE LOAD

It is compu lsory for the tow ed load to be less than

1,300 kg for a trailer fitted w ith brakes (d river on-

ly).

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Draining 23

Drain plug 2.5

Top-up channel 3.5


DRAINING

It is preferable to drain the automatic transmis-

sion w hile the oil is hot (60°C maximum) to elimi-

nate as many impurities as poss ible .

Draining is by removing p lug (A).

Special features:

The plug has two functions:

- draining via plug (A),

- topping up via the channel (B).

13791R1

PRN2316

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Filling - Levels 23

FILLING

Filling is via h ole (D).

Use a funnel fitted w ith a 15/ 100 filter to pr event

the entry of impu rities.

FILLING PROCEDURE

1 - Place the vehicle on a horizontal surface.

2 - Fill the automatic transmission with 3.5 litres

of new oil.

3 - Run the engine a t idle speed.

4 - Connect the diagnostic equipment and enter

into dialogue with the autom atic transmis-

sion comp uter (enter D14 on the XR25).

5 - Monitor the gearbox oil temperature para-

meter (enter #04 on the XR25).

6 - When a t em per atur e of 60°C ± 1°C is rea-

ched, open the top-up p lug.

7 - Position a receptacle to recover at least 0.1 li-

tres of excess oil and wa it un til the oil flows

drop by drop.

14828R

13792S

8 - Close the top-up p lug .

PROCEDURE FOR CHECKING THE LEVEL OTHER

THAN DURING FILLING OPERATIONS

It is ESSENTIAL to follow the p rocedu re described

below to check the level:

1 - Position the vehicle on a horizontal surface.

2 - Fill the automatic transmission with 0.5 litres

of fresh oil.

3 - Run the engine at idle speed. Carry out ope-

rations 4, 5 and 6 described above.

If the oil does not flow ou t or if the quantity reco-

vered is less than 0.1 litres, stop th e engine, add

0.5 litres, allow the tran smission to cool to 50°C

then repeat operations 3-4-5-6.

IMPORTAN T: When the oil is changed, the elec-

tronic oil age counter (inside the computer) must

be rese t to zero. Enter the date of draining using

the command "Entry of date of l ast after sales

service operation" (G74* on the XR25).

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OPTIMA OR CLIP XR25

Enter into d ialogue w ith the compu ter.Enter


Checking the converter setting point 23

Place the vehicle on a tw o post lift.

Lift the vehicle until the wheels are a few centimetres above the ground .

Connect the diagnostic equipment.

IMPORTANT: wh en the m easurem ent has been taken, release the accelerator and keep the brakes appli ed

until the engine speed has stabilised at idle (there is a risk of da mage to the au tomatic transm ission if this in-

struction is not followed ).

The engine speed shou ld stabilise at: 2800 ± 150 rpm

If the setting point does not fall within th e tolerances, the converter m ust be changed.

COMMENT: If the setting po int is too low , this could be due to a lack of eng ine power.

WARNING: Full-load mu st not be maintained for more than 5 seconds . If this period is exceeded , there is a si -

gnif icant risk of destruction of the converter or au tomatic transmission.

OPTIMA OR CLIP XR25

Enter into dialogue with the autom atic transm ission

computer.

Set th e ISO selector to S8

Enter the DP0 transmission code

then

# 0 6

D 1 4 # 0 4

Monitor the gearbox oil temperature parameter.

The check must be carried ou t at an oil temp eratur e of between 60°C an d 80°C.

Start the engine, position the lever at D.

Monitor the engine speed parameter.

Accelerate fully with the brakes app lied. The front w heels should n ot turn .

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Hydraulic distributor 23REFITTING

Offer up the hydraulic distributor and reconnect

the solenoid valve connectors.

Refit the hyd rau lic distributor mou nting bolts asindicated below:

- Position the distributor pre-centring it using

bolts ( 4 ) and ( 5 ).

- Fit the other bolts.

- Tighten the bolts to a torque of 0.75 daN.m in

the ord er 1 - 2 - 3 - 4 - 5 - 6 - 7.

13789R

ADJUSTING THE PLUNGER SHAFT

Retain the m ultifunction switch lever in the ex-

treme p osition (1st imposed ) using a plastic clip

and a screw in th e mechanical section hou sing.

Remove bolt (C).

PRN2318

Position the plun ger shaft by placing the roller (A)

in the groove of sector (B) wh ich correspon ds to

1st imp osed.

13788R

Fit tool B.Vi. 1462 in p lace of bolt (C). Screw thetool in fully wh ile sup por ting the plunger shaft.

Tighten bolt (D) to the specified torque.

Remove the tool then refit bolt (C) and tighten it

to the specified torqu e.

If the tran smission oil is changed , reset the au to-

adap tive values to zero using the command

"Erasing of autoad aptive values" (G80** on the

XR25) and to reset the autom atic transmission

compu ter oil age coun ter to zero, enter comman d

"Entry of date of last after sales service opera -

tion" (G74* on the XR25).

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Automatic transmission (Removal - Refitting) 23ESSENTIAL SPECIAL TOOLS

Mot. 1040 -01 Sub-frame support trolley

B. Vi. 1531 Engine flywheel locating d evice

T. Av. 476 Tool for extracting ball joints

ESSENTIAL EQUIPMENT

Engine supp ort equipment

Comp onent jack

TIGHTENING TORQUES (en daN.m)

Brake caliper gu ide bolt 3

Lower ball joint nu t 6

Shock absorber base bolt 17Engine tie-bar bolt 6.2

Gearbox surround and starter bolt 4

Suspend ed mou nting to gearbox nut 4.4

Wheel bolts 9

Steering ball joint nut 4

Converter to drive plate

mounting nut 2.1

Inertia flywh eel to converter

mounting nut 2.1

Modu lar connector sup port bolt 2

SPECIAL FEATURES OF VEHICLES FITTED WITH A

DRIVER’S AIR BAG

NOTE: do n ot move the orange ring du ring this

operation. This ring m ay break on rem oval or

refitting. If this shou ld hap pen , do not replace thecontrol cable as the absence of this part d oes not

comprom ise the operation of the system.

14829-1R

REMOVAL

Place the v ehicle on a two post lift.

Remove the front wheels.

Disconnect:

- the ba tter y,

- the ball joint (1) from the mu ltifunction switch

cable,

- the multifun ction switch cable (2) by releasing

the sheath end.

WARNING

To prevent any risk of destruction of the rotary

switch under the steering w heel, follow the

instructions below:

• Before the steering column and the rack are

uncoupled, it is ESSENTIAL that the steering

wheel is immobil ised with the wheel s straight

using a "steering w heel immobili ser" tool for

the entire duration of the operation.

• If there is any doubt about the correct centring

of the rotary sw itch, the steering w heel must

be removed and the centring procedure

described in section 88 "Air bag" must be

applied.

REMIND ER: in this case, only qualified, trained

personnel must carry out the procedure.

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Automatic transmission (Removal - Refitting) 23Disconnect connector (1) by releasing the

connector slide.

Remove the m odu lar connector sup port p late

mou nting bolt (2).

16370R

IMPORTANT:Protect the connector by s liding i t into a

sealed plastic bag.

13785S

Fit hose clamp s and d isconnect the exchanger.

Remove:

- the wir ing mounting bolts,

- the TDC sensor ,

- the upper gearbox surround bolts,- the right and left mud shields,

- the engine undertray,

- the right and left driveshafts,

- the fasteners securing the power steering pipe

on the automatic transmission.

Disconnect the sp eed sensor connector.

Remove:

- the engine/ gearbox upper s tuds,

- the sta rt er ,

- the exhaust/ gearbox strut,

- the engine tie-bar ,

- the steering shaft yoke,

- the steering unit mounting bolts,

- the horn,

- th e bu mp er.

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Automatic transmission (Removal - Refitting) 23

98755R

Fit the sub-frame sup port tool (Mot. 1410-01).

Secur e the steering unit.

Remove:

- the sub-frame,- the automatic transmission computer and its

sup port (und erneath the battery tray)

- the right-hand scuttle grille (Scénic version),

- the left-hand light un it (Scénic version).

Fit the engine support tool.

13798S

Tilt the engine / automatic transmission assembly

as mu ch as possible.

Fit the compon ent jack.

Remove the gearbox surround bolts and the lower

stud (starter end ).

Uncoup le the autom atic transm ission from the

engine taking care not to unseat the converter.

16637S

Remove the gearbox mounting.

Turn the crankshaft clockwise to gain access to th e

three nuts connecting the drive plate and the

converter and remove them.

Detach the p ower steering p ipe toward s the rear

and secur e it.

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Automatic transmission (Removal - Refitting) 23

REFITTING

DO NOT REUSE THE CONVERTER MOUNTING

NUTS OR THE INERTIA FLYWH EEL MOUN TING

NUTS, IF IT WAS REMOVED. ALWAYS FIT NEWNUTS.

Refit the inertia flywheel on the converter using

tool B. Vi. 1531.

Refitting does not p resent any d ifficulties,

pr oceed in the reverse order to removal.

CHECK THAT THE CENTRING PINS ARE PRESENT

Change the exhaust d ownp ipe seal.

Top u p the oil (refer to th e relevant section).

If the oil is changed , reset the au toada ptive values

to zero using the comm and "Erasing of

autoadaptive values" (G80** on th e XR25) and to

reset the autom atic transm ission comp uter oil age

counter to zero, enter comman d "Entry of date of

last after sales service operation " (G74* on the

XR25).

16361R

Secur e the converter using a p iece of string to

preven t it from becoming unseated.

13790S

Remove the inertia flywheel to change the

converter.

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Differential output seal 23ESSENTIAL SPECIAL TOOLS

B. Vi. 1459 Tool for fitting th e right-hand dr iveshaft seal

B. Vi. 1460 Tool for fitting the left-hand dr iveshaft seal


Brake caliper guid e bolt 3

Lower ball joint nu t 6

Shock absorber base bolt 17

Wheel bolts 9

Steering ball joint nut 4

Drain plug 2.5

To change a d ifferential outp ut seal, the corre-

spond ing driveshaft mu st be removed.

REMOVAL

Place the vehicle on a tw o post lift.

Disconnect the battery.

Drain the au tomatic transmission via plug (A).

Remove the faulty differential output seal using a

screwdr iver or a hook taking care not to scratch

the su rfaces in contact.

Take care not to d rop th e seal spring into th e

automatic transmission.

REFITTING

The seal is fitted u sing tool B. Vi. 1459 or B. Vi.

1460.

Guid e the assembly un til the tool is in contact

w ith the autom atic transm ission casing.

Refit in the reverse ord er to remov al.

TIGHTEN THE SCREWS, NUTS AND BOLTS TO THE

RECOMMENDED TORQUES.

Fill the autom atic transm ission an d check the level

(refer to the relevant section).

13791R1

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Converter seal 23

ESSENTIAL SPECIAL TOOLS

B. Vi. 1457 Tool for fitting the converter seal

Mot. 587 Tool for extracting th e seal

The converter seal can on ly be removed following

removal of the automatic transmission and the

converter (refer to the relevant section).

REMOVAL

Remove the converter keeping a s close as possible

to th e centreline.

Warning : the converter contains a significant

amoun t of oil wh ich m ay leak on removal.

Using Mot. 587, remove the seal taking care not t o

scratch the surfaces in contact.

REFITTING

The operation m ust be carried ou t w ith great

care. Lubricate all surfaces in contact.

Fit the n ew seal (coated with oil ) to its stop u sing

tool B. Vi. 1457.

Check that the converter is fitted correctly.

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Multifunction switch 23


Multifunction switch mounting bolt 1

Lever mounting nu t 1

REMOVAL

Place the sw itch in position N .

Disconnect:

- the mu ltifunction switch cable ball joint (1),

- the multifunction switch cable (2) by releasing

the sheath end.

Remove:

- the lever and the two multifunction switch

mou nting bolts (3),

14829-1R3

Disconnect the mod ular conn ector (1) by releasing

the connector slide.

Remove the th ree modu lar connector sup port

plate m oun ting bolts (2).

Remove the tw o m odu lar connector plate

mou nting bolts then remove the m ultifunction

switch green connector (12-way).

16370R

REFITTING

Place the m ultifunction switch in p osition N .

Reconnect the mu ltifun ction sw itch connector.

13785R

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Multifunction switch 23

SETTING THE MULTIFUNCTION SWITCH

Control level in th e NEUTRAL position:

Fit tw o electrical terminal connectors on th eposition checking tabs.

16371S

Set the multimeter to the ohm meter position.

Rotate the mu ltifun ction switch by hand un til the

setting electrical contact closes (resistance at the

terminals of the contact= 0 Ω).

Tighten the bolts to a torque of 1 daNm.

AFTER TIGHTENING, THE ELECTRICAL CONTACT

SHOULD BE CLOSED.

TIGHTEN THE SCREWS, NUTS AND BOLTS TO THE

RECOMMENDED TORQUES.

Check that the geas operate and change correctly.

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Sensors 23

The removal of:

- the speed sensors,

- the line pressure sensor,

- the exchanger flow control solenoid valve,

is carried ou t without draining and w ithout

removal of the automatic transmission.

TIGHTENING TORQUES (en daN.m)

Input speed sensor mounting

bolt 1

Outp ut speed sensor mounting

bolt 1

Exchanger flow control solenoid valve bolt 1

Line p ressure sensor bolt 0.8

13786-1R

Special feature of REMOVAL:

If a sensor is changed, always rem ove the mod ular

connector (see section "Autom atic transm ission

remova l/ refitting").

IMPORTANT:

Protect the connector by sliding it into a sealed

plastic bag.

1 Input sp eed sensor

2 Outp ut speed sensor

3 Exchanger flow control solenoid valve

4 Line p ressure sensor

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Computer 23

LOCATION OF THE COMPUTER

The comp uter is located und erneath the battery

tray.

16764S

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Solenoid valves 23

The solenoid valves are removed following

removal of the hyd raulic distributor (refer to the

relevant section).

13787R

1 EVM Modulating solenoid valve

2 EVLU LOCK UP solenoid valve (converter

bridging clutch)

3 EVS4 Sequence solenoid valve






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Wiring diagram 23

16379G

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Wiring diagram 23

16379D

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Wiring diagram 23PARTS LIST

Component or

Unit No.

Description

104 Ignition switch

119 Automatic transmission computer

120 Injection computer

160 Brake switch

209 Monostalk

225 Diagnostic socket

247 Instrument panel

419 AC control unit

597 Engine compartment fuse box

721 ABS e lectronic control unit + ABS hydraulic assembly block

755 Poor grip control

756 Air b ag /p reten sioners el ectronic contro l un it

780 Turbine or vehicle speed sensor (automatic transmission)

969 Gear selector lever locking motor

971 D P0 automatic transmission module

1016 Passenger compartment fuse box

R34 Engine/ Dashboard

R35 Pedal assembly/ Dashboard

R36 ABS / Dashboard

R254 D ashboard/ Plenum chamber

R255 ABS / Plenum chamber

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Modular connector 23

13785R1

1 GREEN conn ector (mu ltifun ction switch)

2 YELLOW connector (IEH)

3 GREEN conn ector (line p ressure)

4 YELLOW connector (tu rbine sp eed)

5 BLUE conn ector (vehicle speed )

3

6

9

12

1

4

7

10

3

6

9

12

1

4

7

10

TRACK NUMBERING

3 1

3 1

3 1

1

2

3

4

5

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Line pressure take-off 23

13791R2

The oil pressure ta ke-off is located next to the

pressure sensor.

Remove bolt (V) and fit tool Bvi. 466.06.

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Gear selector lever 23

PRN2317

REMOVAL

Turn ring (B) in the direction show n on the

diagram below to remove the cable from th e

sheath end .

DO NOT MOVE THE ORANGE RING ( P ) DURING

THIS OPERATION

13796R

13796R1

Reconnect the cable on the m ultifunction switch

ball joint in position N on the gear selector lever

and on the multifunction switch.

Operate the clip to lock the p osition. Setting is

complete.

NOTE: The orange ring (P) may break on removal

or refitting. If this sh ould happen, DO N OT

REPLACE THE CONTROL CABLE, as the absence of

this part does not compromise the ope ration of

the system.

REFITTING

Refit in the reverse ord er to remov al.

The gear selector cable has a p recise setting.

Press the Slide (T), then secure it in position u sing

the clip.

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Fault finding - Introduction 23

For fault finding methods refer to NT 2998A.

SPECIAL FEATURES

The engine speed , engine torque, load and engine coolant temp erature information, supplied by the petrolengine management comp uter via wire connections, is now tran smitted via a mu ltiplexed connection (CAN

bus on tracks 38 an d 39 of the Autom atic Transmission comp uter).

Thus two new faults are controlled by the Automatic Transm ission computer:

- 11 injection → Automatic Transm ission connections (CAN inform ation)

- 12 engine speed s (transmitted by in jection)

These faults cann ot be a ccessed on the XR25. How ever, general fault finding is available.

REPAIRING THESE NEW FAULTS

- 11 Right injection → Autom atic Transmission connection (CAN information)

Check the continuity and insulation of the following connections:

• between track 38 of the autom atic transm ission computer connector and track 27 of the injection

computer connector,

• between track 39 of the autom atic transm ission computer connector and track 57 of the injection

computer connector.

Check the insu lation between these two connections.

Check the connections at the injection compu ter and autom atic transm ission computer connectors.

- 12 Right engine speed (transmitted by injection)

This fault correspond s to the receipt by the au tomatic transm ission comp uter of a specific code transm it-ted by the engine management comp uter indicating that the engine speed sensor is faulty.

App ly the repair procedu re suggested in th e injection fault find ing section.

CHANGES TO THE PROCEDURE FOR REPAIRING KNOWN FAULTS

- 4 Right Coolant temp erature sensor circuit

- 6 Right Invalid engine torque information

- 7 Left Load poten tiometer circuit (see by injection)

- 19 Right Engine speed sensor circuit

These four faults correspon d to incorrect values received from th e injection computer v ia the CAN connec-

tions.

In this case, apply the rep air procedu re suggested in the injection fault finding section.

CONVERTER SETTING POINT

The setting p oint is 2800±150 rpm.

See NT 2998A for method of checking .

Documents

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