TRM D4F / AMT Automatic Manual Transmission Troubleshooting

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Using the AMT User interface What is the AMT Quick product introduction Add-ON specifications and specific maintenance JH1 gearbox specifications and maintenance AMT system power supply and ground architecture AMT connector pin-out AMT anti-start function Oil pressure control function and components Line selection function and components Gear engage function and components Clutch control function and components Complete gear change function Gearshifting decisions and fuzzy logic User interface : gearshifting lever User interface : Instrument cluster & buzzer Intersystem links : CAN, engine speed, Vehicle speed Reverse switch AMT self-teaching procedures

Volkswagon DSG

CHANGE GEAR (UPSHIFT)

+
GEARBOX MODE SELECTION: AUTOMATIC / MANUAL MANUAL / AUTOMATIC

A
R

NEUTRAL

REVERSE GEAR CHANGE GEAR (DOWNSHIFT)

THE AMT IS CONTROLLED USING A SPECIFIC GEARSHIFTING LEVER

1 Using the AMT User interface

Volkswagon DSG

IN MANUAL MODE, THE DRIVER IS ONLY DECIDING WHEN TO CHANGE GEARS USING THE GEARSHIFTING LEVER.
THE GEARBOX THEN AUTOMATICALLY DRIVES THE ACTUAL GEARSHIFTING MECHANISM AND THE CLUTCH.

CHANGE GEAR (UPSHIFT)

THERE IS NO CLUTCH PEDAL

THE FOLLOWING RESTRICTIONS APPLY: 1- IT IS POSSIBLE TO STOP THE ENGINE WITH A GEAR ENGAGED (TO PARK IN A SLOPE FOR INSTANCE). WHEN THIS HAPPENS, THE DRIVER NEEDS TO PRESS THE BRAKE TO BE ALLOWED TO RESTART THE ENGINE. 2 THE GEARBOX WILL AUTOMATICALLY DOWNSHIFT TO PREVENT STALLING OR UPSHIFT TO PREVENT ENGINE OVERSPEED. 3 THE GEARBOX WILL ACCEPT TO CHANGE GEARS UNLESS IT MAY LEAD TO ONE OF THE PREVIOUSLY MENTIONED CASES (STALLING / OVERSPEED).

+
A R

CHANGE GEAR (DOWNSHIFT)

IN MANUAL MODE, THE DRIVER IS DECIDING WHEN TO CHANGE GEARS SIMPLY BY PUSHING THE GEARSHIFTING LEVER TOWARDS FRONT (UPSHIFT) OR REAR (DOWN SHIFT). THE SMALL DISPLAY UNIT INTEGRATED TO THE INSTRUMENT CLUSTER INDICATES THE CURRENTLY ENGAGED GEAR

1 Using the AMT User interface

Volkswagon DSG

IN AUTOMATIC MODE, THE GEARBOX DECIDES WHEN TO CHANGE GEARS TAKING INTO ACCOUNT THE DRIVING CONDITIONS AND THE DRIVER DRIVING STYLE.
THE FOLLOWING RESTRICTIONS APPLY: 1- THERE IS NO P (PARK) FUNCTION, BUT IT IS POSSIBLE TO STOP THE ENGINE WITH A GEAR ENGAGED (TO PARK IN A SLOPE FOR INSTANCE). WHEN THIS HAPPENS, THE DRIVER NEEDS TO PRESS THE BRAKE TO BE ALLOWED TO RESTART THE ENGINE. 2 THE AMT REMAINS A MANUAL GEARBOX, INCLUDING A CLUTCH INSTEAD OF A TORQUE CONVERTER. THE CLUTCH TEMPERATURE IS MONITORED AND IN CASE THE CURRENT OPERATING CONDITIONS MAY LEAD IT TO OVERHEATING, THEN THE DRIVER IS WARNED BY A BUZZER.

+
A R N

Examples of buzzer activation conditions: - Stopping with the car in D, using the parking break. - Long-lasting in a slope, playing on the accelerator to maintain the car stationary
IN AUTOMATIC MODE, THE GEARBOX IS DECIDING WHEN TO CHANGE GEARS EXACTLY LIKE AN AUTOMATIC TRANSMISSION GEARBOX. DURING THIS OPERATING MODE, THE SMALL DISPLAY UNIT INTEGRATED TO THE INSTRUMENT CLUSTER INDICATES ONLY D , R , OR N .

1 Using the AMT User interface

Volkswagon DSG

Oil tank

Pressure accumulator

Clutch / Clutch housing

Electrical oil pump

Connector

Differential Valve body

Gearshifting mechanism

Basically the AMT is a MANUAL TRANSMISSION, including a clutch and all the standard internal features of a manual transmission, but for which the clutch and the gearshifting organs are operated by an electro-hydraulic add-on (often called ROBOT). The objective of this product is to mix the features of a manual transmission (5 gears, reasonable price, reliability) with the confort of an automatic transmission (automatic shifting mode, automatic handling of the clutch).

2 What is the AMT Quick product introduction

Volkswagon DSG

1
2

N
1

Changing gears means: 1 To select a line 2 To engage a gear

Two hydraulic actuators controlled by a Transmission Control Unit are used to produce the vertical (selection) and rotational (engage) movements of the gearshifting mechanism. On the AMT, these actuators are hydraulic jacks driven by electrovalves.

2 What is the AMT Quick product introduction

Volkswagon DSG

The complete robot includes 3 actuation jacks (2 which are used to control the gearshifting mechanism and 1 which is used to control the clutch) and 5 electrovalves. The oil pressure in the circuit is controlled using an electrical pump, a pressure sensor and an accumulator.

2 What is the AMT Quick product introduction

Volkswagon DSG

As the clutch mechanism itself includes a return spring, it is actuated using a single electrovalve. The clutch return is obtained using the spring

2 What is the AMT Quick product introduction

Volkswagon DSG

The 2 gearshifting actuators require 2 electrovalves to insure back and forth movements

2 What is the AMT Quick product introduction

Volkswagon DSG

The system is operated under an oil pressure which has to be maintained between 55 to 70 bars. This is obtained using an electrical oil pump driven by the TCU through a relay, a pressure sensor, and a pressure accumulator which allows 3 complete gearshiftings when completely filled.

2 What is the AMT Quick product introduction

Volkswagon DSG

8 A

B
C

When opening / closing the connector, carefully check the status of the small locks located on the side.

The AMT connector is located on top of the gearbox. It is attached to a metal plate screwed to the valve body.

Volkswagon DSG

6 - AMT connector pin-out and identification (3/3)

The AMT is a manual transmission, thus it DOES NOT INCLUDE ANY PARK FUNCTION On the other hand, like all manual transmissions, it is possible to park the car with a gear engaged, by simply stopping the engine with brakes ON without going back to Neutral.

When the car has been stopped with a gear engaged, it is impossible to restart the engine, unless the brakes are depressed. This safety feature is called the ANTI-START function. When the vehicle cannot start AND the engine does not rotate, the first thing to check apart from the battery is this function.

7 AMT Anti-start function (1 / 5)

Volkswagon DSG

27 28

EF24 30A

BAT+ KEY-ON SWITCH

Crank request And TCU pin #76

+CRANK 76
To starter

30 87 86 30

The cranking request Is routed to the starter only if the TCU allows it by setting Pin #42 to GND

85

85 42

87
To Key-ON Power supply To TCU, Pin 42

BAT+ 45 33 1 2 69 CAN-H CAN-L B.K4 B.K3

TO STARTER
AMT ANTI-START RELAY SOCKET PIN-OUT

NC Brake switch A.E4

AMT TCU
Braking : +12V Brakes OFF : 0V

SIM32 ECU

A.E3 NO Brake switch Brake lamps

The anti-start function is implemented using a specific relay which routes the cranking request from the KEY-ON switch to the starter ONLY if the current AMT operating conditions are acceptable (i.e. if no gear is engaged).

7 AMT Anti-start function (2 / 5)

Volkswagon DSG

Oil pump Intermediate connector

Oil pressure sensor

low pressure return line from valve body High pressure line from pump to valve body

Pressure accumulator

Electrical oil Pump GND point

Electrical oil pump

Oil pressure control: Identification and location of components

8 Oil pressure control function and components (2/7)

Volkswagon DSG

63 61 59 57 55

Initial pressure: Around 60bars

8 7 6 5 4

53 51 49 47 45

3rd gear
The press. Accumulator allows approx. 3 gear changes

3 2 1 N
As soon as the pressure falls around 50b, the pump relay is activated

3 2 1 0

Pressure sensor value(bar)

Pump relay

Current gear,

The normal operating pressure is maintained by the TCU between 50 to 60 bars using the oil pressure sensor and the oil pump relay.

8 Oil pressure control function : typical operation (3/7)

Volkswagon DSG

SEL1 (EV3) line Selection jack 1 2 B4 29 27

EF24 30A

BAT+

SEL2 (EV4) 1 2 B6 3

28

SELECTION JACK POSITION SENSOR

KEY-ON SWITCH
+5V Signal GND C8 C3 C1 73 51 1

B B

66

AMT TCU

C1 C3 C8

66 51 73 Resistance and continuity check: The line selection position sensor is a potentiometer

1200

1400

C A

The line selection function is controlled using:

- The gear selection jack, driven by 2 electrovalves - The gear selection position sensor.

9 Line selection function and components (1/9)

Volkswagon DSG

Line selection jack

Line selection pos. sensor

SEL POS

SEL-2

CLUTCH

ENG POS

ENG JACK

SEL-1

ENG-1

VALVE BODY LAYOUT SEEN FROM COUPLING FACE

Line selection function: Identification and location of components

9 Line selection function and components (2/9)

Volkswagon DSG

Line selection pos. sensor

COMMON GND For all electrovalves Line selection jack

Line selection function: Identification and location of components

9 Line selection function and components (3/9)

Volkswagon DSG

The metal plate holding the connector Has to be removed to reach the valve body

SEL POS

SEL-2

CLUTCH

ENG POS

ENG JACK

SEL-1

ENG-1

VALVE BODY LAYOUT SEEN FROM COUPLING FACE

Line selection function: Identification and location of components

9 Line selection function and components (4/9)

Volkswagon DSG

Sel Line

Gear

Jack Travel (mm)

12.4 6.1 6.1 12.4 12.4 19.1 19.0

SEL pos. Sensor value (volts)

2.8 1.5 1.5 2.8 2.8 4.3 4.3

2 1 1 2 2 3 3

N 1 2 3 4 5 R

WARNING : ALL VALUES ARE MEASURED ON 1 GEARBOX AND CAN VARY A LOT FROM 1 GEARBOX TO ANOTHER

Line selection function: Interaction of the various components

9 Line selection function and components-Typical operation (5/9)

Volkswagon DSG

ENG1 (EV1) Gear Engage jack

EF24 30A
B5 32 27

BAT+

1
2

ENG2 (EV2) 1 2 B3 44

28 KEY-ON SWITCH +5V Signal GND C8 C2 C1 66 39 73 1 2

ENGAGE JACK POSITION SENSOR

AMT TCU

B 1000 1200 C A

C8 C2 C1

73 39 66 Resistance and continuity check: The gear engage position sensor is a potentiometer

The gear engage function is controlled using:

- The gear engage jack, driven by 2 electrovalves - The gear engage position sensor.

10 Gear engage function and components (1/10)

Volkswagon DSG

Gear engage jack

ENG2 EV2
SEL POS

Gear engage pos. sensor

ENG POS ENG JACK

SEL-2

CLUTCH

SEL-1

ENG-1

VALVE BODY LAYOUT SEEN FROM COUPLING FACE

Gear engage function: Identification and location of components

10 Gear engage function and components (2/10)

Volkswagon DSG

COMMON GND For all electrovalves

Gear engage jack

Gear engage pos. Sensor connector

Gear engage pos. sensor

Gear engage function: Identification and location of components

10 Gear engage function and components (3/10)

Volkswagon DSG

COMMON GND For all electrovalves

ENG2 - EV

Gear engage function: Identification and location of components : Engage electrovalve #2

10 Gear engage function and components (4/10)

Volkswagon DSG

The metal plate holding the connector Has to be removed to reach the valve body

SEL POS

SEL-2

CLUTCH

ENG POS

ENG JACK

SEL-1

ENG-1

VALVE BODY LAYOUT SEEN FROM COUPLING FACE

Gear engage function: Identification and location of components : Engage electrovalve #1

10 Gear engage function and components (5/10)

Volkswagon DSG

Eng Line

Gear

Jack Travel (mm)

11.7 5.2 18.2 5.4 18.2 5.2 18.9

ENG pos. Sensor value (volts)

2.7 1.3 4.1 1.3 4.1 1.3 4.2

2 3 1 3 1 3 1

N 1 2 3 4 5 R

WARNING : ALL VALUES ARE MEASURED ON 1 GEARBOX AND CAN VARY A LOT FROM 1 GEARBOX TO ANOTHER

Gear engage function: Checking the gear engage position sensor voltage

10 Gear engage function and components-Typical operation (6/10)

Volkswagon DSG

CLUTCH (EV0) Clutch actuation jack 1 2 B2 43 27

EF24 30A

BAT+

BAT+ Braking : +12V Brakes OFF : 0V 69 CLUTCH JACK POSITION SENSOR Brake switch +5V Signal GND Primary Speed sensor 1 2 C8 C4 73 52 Brake lamps

C1
C7 C6

66
38 50

1 2

AMT TCU

NB : twisted Pair wiring ! B 1300 1100 C A C8 C4 C1 73 52 66 Resistance and continuity check: The clutch position sensor is a potentiometer

The clutch operation function is controlled using:

- The clutch actuation jack, driven by 1 electrovalve - The clutch position sensor.

11 Clutch operation function and components (1/8)

Volkswagon DSG

33 Prim. speed TDC 45 48 38

Engine speed information (CAN)

B.K3 B.K4

Engine speed information (point-to-point)

A.B2 C.A4 C.B4

Clutch OPEN AMT TCU

50

EMS ECU

Primary shaft speed sensor Prim. speed TDC

Engine speed (TDC) sensor

ENGINE
GEARBOX

Kiss point

CLUTCH

Prim. speed

TDC Resistance and continuity check: The resistance of the primary shaft speed sensor is approx:

Clutch CLOSED

460 Ohms

The clutch position is checked using the clutch jack position sensor, but also redundant checks between the engine speed (supplied by CAN and through a point-to-point link), the primary shaft speed sensor and the vehicle speed.

11 Clutch operation function and components (2/8)

Volkswagon DSG

Clutch fork

Clutch activation jack Position sensor

Clutch bearing

Clutch activation jack

Clutch operation function: Identification and location of components

11 Clutch operation function and components (3/8)

Volkswagon DSG

Primary shaft speed sensor

Clutch operation function: Identification and location of components

11 Clutch operation function and components (4/8)

Volkswagon DSG

The metal plate holding the connector Has to be removed to reach the valve body

SEL POS

SEL-2

CLUTCH

ENG POS

ENG JACK

SEL-1

ENG-1

VALVE BODY LAYOUT SEEN FROM COUPLING FACE

Clutch operation function: Identification and location of components

11 Clutch operation function and components (5/8)

Volkswagon DSG

Instrument cluster
Acc. Ped. sensor 1 2 3 4 5 6 TDC sensor B.H3 A B C.A4 C.B4 A.F4 A.H3 A.H2 A.G2 A.F2 A.F3 A.B4 A.B2

Diag. Conn.
7

Diag - K Engine speed signal

49 48

B.K4
B.K3

CAN-H CAN-L

45
33

Vehicle speed signal

36 69

1 2

A.E4 A.E3 A B1

+KEY-ON

AMT TCU

SIM32 ECU

B2

VEH. SPEED SENSOR

16 Intersystem links : CAN, vehicle speed, engine speed (1/5)

Volkswagon DSG

Intersystem links: Identification and location of components : Vehicle speed sensor

16 Intersystem links : CAN, vehicle speed, engine speed (2/5)

Volkswagon DSG

Intersystem links: Identification and location of components : Engine speed / TDC sensor

16 Intersystem links : CAN, vehicle speed, engine speed (3/5)

Volkswagon DSG

BAT+

REVERSE SWITCH

REVERSE LAMPS

The reverse switch is attached to the gearbox, between to the 5th gear cover and the left driveshaft differential output. It is automatically switched ON as soon as the reverse gear is engaged. IT IS NOT LINKED WITH ANY ECU / TCU AND THUS CANNOT BE DIAGNOSED USING PDT

17 The reverse switch (1/1)

Volkswagon DSG

EF25 40A

31 SPECIAL FUNCTIONS PUMP UNLOCK A8 Oil pump Intermed. connector

LOCK
PUMP ACTIVATION REQUEST

AMT TCU

ALL AMT TCUs are delivered with the oil pump de-activated. Thus, the first operation to perform with DDT when a new TCU is installed in a car, the pump must consist of UNLOCKING the pump using the appropriate SPECIAL FUNCTION

18 AMT special procedures: Pump unlocking (1/1)

Volkswagon DSG

Engage line 5mm Selection line 5mm 12mm 19mm

12mm

19mm

The second mandatory operation to be performed on ALL BRAND NEW TCUs or every time a TCU is associated to a new gearbox (i.e. when exchanging TCUs or gearboxes between cars) is to request the TCU to perform the gearshifting grid self teaching

18 AMT special procedures: Self-teaching the grid (1/3)

Volkswagon DSG

1 Check environmental condition

Parameter label Acceptable range Comments

Engine RPM
Key-ON Water temp Parking brake

0
ON < 60C OFF

The grid teaching can only be performed engine OFF

The grid-teaching cannot be started in power-latch Engine must be cold Flat ground, parking brake not active

Gear displayed
SEL pos ENG pos ENG 5-R

N
10.5 to 15mm 9.0 to 14.0 mm NOT 100

The gearbox must be in NEUTRAL

TRUE Neutral TRUE Neutral TCU check

2 Reset ALL the self-teached values

GRID TEACHING INITIAL CLUTCH CLOSED POSITION CLUTCH KISS POINT

Before performing the AMT grid teachings, the environmental conditions and preliminary operations listed above must be realised

18 AMT special procedures: Self-teaching the grid (2/3)

Volkswagon DSG

3 Launch the grid self teaching procedure (normal duration : 90s)

19mm ENG POS 12mm 05mm

19mm

SEL POS

12mm 05mm

90s

4 Switch the vehicle OFF and wait for the end of the power latch (min:10s) 5 Switch the vehicle ON without starting the engine, depress the brake pedal and check that all gears can be selected
5 4 3 2 1 N R

The grid self teaching procedure itself does not resuire any human process. It is even possible to switch OFF the key during this procedure

18 AMT special procedures: Self-teaching the grid (3/3)

Volkswagon DSG