B1BBMDK1 - 206 TU3JP ENGINE AL4 AUTOMATIC GEARBOX EMISSION CONTROL L4 TU5JP4 ENGINE AL4 AUTOMATIC GEARBOX EMISSION CONTROL L4

PRESENTATION AL4 AUTOADAPTIVE AUTOMATIC GEARBOX

1 - IDENTIFICATION

The automatic gearbox is identified by a self-adhesive label (A) or an engraving (B) :

- (1) unit reference
- (2) serial number

1 - 1 - DATA

engine code | KFW | NFU
--- | --- | ---
special features | 175/65R14T | 175/65R14H
unit reference | 20TP61 | 20TP49
type of gearbox | AL4

1 - 2 - DRIVE SHAFTS

engine code | KFW | NFU
--- | --- | ---
special features | 175/65R14T tyres | 175/65R14H tyres
gearbox type | AL4 autoadaptive automatic gearbox | AL4 autoadaptive automatic gearbox
unit reference left hand drive shaft | 8LN57 | 8LN21
unit reference right hand drive shaft | 8LN58 | 8LN22
wheel side seal | RZ17.5 | RZ17.5
final drive side seal | JB2A | JB2A

2 - DESCRIPTION

The autoactive gearbox has 4 forward gears and reverse gear with electronic selection and a Lock-up device (converter locking) in all gears 4 - 3 - 2 .

Two switches close to the gear lever allow the driver to choose one of the following three driving programmes :

- selection of the normal programme ; the normal programme is the default selection
- the Sport programme allows more dynamic driving and favours high performance and acceleration
- the Snow programme gives extra grip when pulling away and driving on slippery surfaces

The additional switch allows 1st gear to be selected when the gear lever is in position 2 .

3 - SPECIAL FEATURES

The gearbox is sealed for life and no longer requires draining when the drive shafts are changed .

The gearbox is lubricated for life, and the gauze does not require replacing during the life of the vehicle .

WARNING : this new gearbox uses a synthetic oil (available from Parts Division) which is identical to that used in the 4HP20 (ESSO LT 71141) gearbox .

The gearbox is filled through the plug near the multifunction switch .

WARNING : the plug located under the gearbox has a double function: drain plug and level plug .

As with vehicles fitted with the 4HP20 gearbox, it is not necessary to add oil when being towed .

IMPERATIVE : as the engine and gearbox ECUs communicate with each other, it is essential to read the memories of the two ECUs after an incident affecting either system .

Before removing the gearbox, a request for assistance must be made to the Technical Helpline Team .

3 - 1 - DRAINING AND TOPPING UP THE OIL

ESSO LT 71141 gearbox oil :

- oil capacity (after draining and refilling) : 3 litre(s)
- servicing frequency - check of level : every 60 000 km

The gearbox is filled through the plug near the multifunction switch .

WARNING : the drain plug located under the gearbox has a double function : draining and topping up the oil .

(3) Gearbox casing .

(4) Level plug .

(5) Drain plug .

4 - COMPOSITION

4 - 1 - GEAR SELECTION LEVER

Gear selection is by a lever, via a cable located on the central console in the passenger compartment .

The gear selection lever is guided by an offset shift gate .

Possible gear lever positions P - R - N - D - 3 - 2 .

The engine can only be started in positions P and N .

4 - 2 - MULTI-FUNCTION SWITCH

The multifunction switch provides the following functions :

- cut-off of supply to the starter excitation relay when the gear lever is not in position P or N
- supply to the reversing lights, when the gear lever is in position R
- indication of the gear lever position to the gearbox ECU

WARNING : the instrument panel display is controlled by the gearbox ECU according to the information from the multifunction switch .

The multifunction switch is adjusted using an ohmmeter: in position N, the reading should be 0 ohms between the 2 pins coming from the switch (the direction of rotation of the switch is not important) .

NOTE : do not use a warning bulb for this adjustment (risk of damaging the ECU) .

5 - SERVICING THE GEARBOX

5 - 1 - DOWNLOADING

This operation is to be performed in the following cases :

- updating the gearbox ECU
- adapting the gearbox ECU to a change in the engine ECU

The downloading operation must be followed by the following actions :

- accelerator pedal learning
- configuration
- road test

IMPERATIVE : each update of the automatic gearbox ECU must be accompanied by an update of the engine ECU .

To perform a downloading operation : Follow the diagnostic equipment procedure .

5 - 2 - ACCELERATOR PEDAL LEARNING

This operation is to be performed in the following cases :

- replace the switch
- replacement of the automatic gearbox
- update by downloading
- accelerator cable adjustment

To carry out the pedal learning : Follow the diagnostic equipment procedure .

5 - 3 - CONFIGURATION

This operation is to be performed in the following cases :

- replace the switch
- down-loading of the control unit

A new or newly loaded ECU is always configured with the two following options :

- locking of Shift-Lock gear lever in P
- output OBD (emission control standards)

The ECU configuration operation consists of suppressing diagnosis of options which the vehicle does not have : Follow the diagnostic equipment procedure .

5 - 4 - DEFAULT MODE

When the gearbox malfunctions, there are two possible configurations depending on the seriousness of the fault .

Gearbox in downgraded mode with a replacement programme (default values are taken by substitution) :

- gearbox in downgraded mode with a safety programme (hydraulic 3rd)

WARNING : in safety mode, a jolt is felt when making the P/N, N/R and N/D changes .

5 - 5 - CHECKING USING THE DIAGNOSTIC EQUIPMENT

Read the fault codes or faults (Engine - Automatic gearbox) .

No fault codes found :

- measure the parameters
- carry out the actuators test
- carry out a road test

Fault codes present :

- make the necessary repairs
- clear the fault codes
- carry out a road test to confirm the repair

5 - 6 - CONTROL UNIT REPLACEMENT

IMPERATIVE : changing the ECU during the warranty period must be subject to prior agreement .