70221852 automatic manual transmission

Volkswagon DSG

1. Using the AMT – User interface

2. What is the AMT – Quick product introduction

3. Add-ON specifications and specific maintenance

4. JH1 gearbox specifications and maintenance

5. AMT system power supply and ground architecture

6. AMT connector pin-out

7. AMT anti-start function

8. Oil pressure control function and components

9. Line selection function and components

10. Gear engage function and components

11. Clutch control function and components

12. Complete gear change function

13. Gearshifting decisions and fuzzy logic

14. User interface : gearshifting lever

15. User interface : Instrument cluster & buzzer

16. Intersystem links : CAN, engine speed, Vehicle speed

17. Reverse switch

18. AMT self-teaching procedures

TRM D4F / AMT

Automatic Manual Transmission Troubleshooting

Volkswagon DSG

1 – Using the AMT – User interface

REVERSE

GEAR

NEUTRAL

GEARBOX MODE SELECTION:

AUTOMATIC / MANUAL

MANUAL / AUTOMATIC

CHANGE GEAR

(DOWNSHIFT)

CHANGE GEAR

(UPSHIFT)

A

+

R

N

THE AMT IS CONTROLLED USING A SPECIFIC GEARSHIFTING LEVER

Volkswagon DSG

CHANGE GEAR

(DOWNSHIFT)

CHANGE GEAR

(UPSHIFT)

A

+

R

N

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

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.

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).


Volkswagon DSG

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 ».

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

Volkswagon DSG

2 – What is the AMT – Quick product introduction

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).

Clutch / Clutch housing

Oil tank

Electrical oil pump

Pressure

accumulator

Differential

Gearshifting

mechanism

Valve body

Connector

Volkswagon DSG

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.


1 3 5

2 4 R

N

Changing gears means:

1 – To select a line

2 – To engage a gear

1

2

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.


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


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


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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.


Volkswagon DSG

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

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

A

B

C

1 8

When opening / closing the connector, carefully check the

status of the small locks located on the side.

Volkswagon DSG

7 – AMT Anti-start function (1 / 5)

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.

Volkswagon DSG

7 – AMT Anti-start function (2 / 5)

EF24

30A

BAT+

27

AMT TCU

1

2

28

KEY-ON

SWITCH

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).

76

42

+CRANK

TO STARTER

The cranking request Is

routed to the starter only if

the TCU allows it by setting

Pin #42 to GND

30

87

86

85

AMT ANTI-START RELAY SOCKET

PIN-OUT

To starter

85

30

87

Crank request

And TCU pin #76

To TCU,

Pin 42

To Key-ON

Power supply

69

NO Brake

switch

Braking : +12V

Brakes OFF : 0V

BAT+

Brake

lamps

B.K4

B.K3

CAN-H

CAN-L

45

33

SIM32

ECU

NC Brake

switch A.E4

A.E3

Volkswagon DSG

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

Oil pressure

sensor

Electrical oil

pump

High pressure

line from pump

to valve body

Oil pump

Intermediate

connector

low pressure

return line from

valve body

Pressure

accumulator

Oil pressure control:

Identification and location of components

Electrical oil

Pump GND point

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45

47

49

51

53

55

57

59

61

63

0

1

2

3

4

5

6

7

8

Pressure sensor value(bar) Pump relay Current gear,

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

Initial pressure:

Around 60bars

3rd gear

N

2

1

3

The press.

Accumulator

allows approx. 3

gear changes

N

As soon as the

pressure falls around

50b, the pump relay is

activated

The normal operating pressure is maintained by the TCU between 50 to 60 bars using

the oil pressure sensor and the oil pump relay.

Volkswagon DSG

The line selection function is controlled using:

- The gear selection jack, driven by 2 electrovalves

- The gear selection position sensor.

EF24

30A BAT+

27

AMT TCU

1

2

28

KEY-ON

SWITCH

+5V

GND

Signal

C8

C3

C1

73

51

66

1

2

1

2

9 – Line selection function and components (1/9)

A C B

B4 29

B6 3

SEL1

(EV3)

SEL2

(EV4)

SELECTION

JACK

POSITION

SENSOR

line

Selection

jack

B

C

A

1400

1200

Resistance and

continuity check:

The line selection

position sensor is a

potentiometer

C1

C3

C8

66

51

73

Volkswagon DSG


Line selection function:


Line selection

jack

Line selection

pos. sensor

ENG

POS

SEL-2 CLUTCH

SEL-1 ENG-1

SEL

POS

ENG

JACK

VALVE BODY LAYOUT

SEEN FROM COUPLING FACE

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Line selection

jack

Line selection

pos. sensor

COMMON GND

For all

electrovalves

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ENG

POS

SEL-2 CLUTCH

SEL-1 ENG-1

SEL

POS

ENG

JACK

VALVE BODY LAYOUT


The metal plate holding

the connector

Has to be removed to

reach the valve body


Volkswagon DSG

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


Interaction of the various components

Gear

N

1

2

3

4

5

R

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

Sel

Line

2

1

1

2

2

3

3

WARNING : ALL VALUES ARE MEASURED ON 1 GEARBOX

AND CAN VARY A LOT FROM 1 GEARBOX TO ANOTHER

Volkswagon DSG

The gear engage function is controlled using:

- The gear engage jack, driven by 2 electrovalves

- The gear engage position sensor.

EF24

30A

BAT+

27

AMT TCU

1

2

28

KEY-ON

SWITCH

+5V

GND

Signal

C8

C2

C1

66

39

73

1

2

1

2

10 – Gear engage function and components (1/10) B

C A

B5 32

B3 44

ENG1

(EV1)

ENG2

(EV2)

ENGAGE

JACK

POSITION

SENSOR

Gear

Engage

jack

B

C

A

1200

1000

Resistance and

continuity check:

The gear engage position

sensor is a potentiometer

C8

C2

C1

73

39

66

Volkswagon DSG

10 – Gear engage function and components (2/10)

Gear engage function:


Gear engage

jack

ENG2 – EV2

Gear engage

pos. sensor

ENG

POS

SEL-2 CLUTCH

SEL-1 ENG-1

SEL

POS

ENG

JACK

VALVE BODY LAYOUT


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Gear engage

jack

Gear engage

pos. sensor

Gear engage

pos. Sensor

connector




COMMON GND

For all

electrovalves

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ENG2 - EV


Identification and location of components : Engage electrovalve #2


COMMON GND

For all

electrovalves

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ENG

POS

SEL-2 CLUTCH

SEL-1 ENG-1

SEL

POS

ENG

JACK

VALVE BODY LAYOUT



Identification and location of components : Engage electrovalve #1


the connector




Volkswagon DSG

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

Gear

N

1

2

3

4

5

R

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

Eng

Line

2

3

1

3

1

3

1

WARNING : ALL VALUES ARE MEASURED ON 1 GEARBOX

AND CAN VARY A LOT FROM 1 GEARBOX TO ANOTHER


Checking the gear engage position sensor voltage

Volkswagon DSG

The clutch operation function is controlled using:

- The clutch actuation jack, driven by 1 electrovalve

- The clutch position sensor.

EF24

30A 27

AMT TCU

1

2

+5V

GND

Signal

C8

C4

C1

73

52

66

1

2

11 – Clutch operation function and components (1/8)

A C B

B2 43

CLUTCH

(EV0)

CLUTCH

JACK

POSITION

SENSOR

Clutch

actuation

jack

B

C

A

1100

1300

38

50

C7

C6

1

2

Primary

Speed

sensor

NB : twisted

Pair wiring !

69 Brake

switch

Braking : +12V

Brakes OFF : 0V

BAT+

BAT+

Brake

lamps

Resistance and

continuity check:

The clutch position

sensor is a potentiometer

C8

C4

C1

73

52

66

Volkswagon DSG

ENGINE GEARBOX

B.K3

B.K4

A.B2

C.A4

C.B4 EMS ECU

AMT TCU

33

45

48

38

50

Engine speed

(TDC) sensor Primary shaft

speed sensor

Engine speed information

(point-to-point)

Engine speed information (CAN)

CLUTCH


Resistance and continuity check:

The resistance of the primary shaft

speed sensor is approx:

460 Ohms

Clutch OPEN

Kiss point

Clutch CLOSED

TDC Prim.

speed

TDC Prim.

speed

TDC Prim.

speed

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.

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Clutch operation function:


Clutch

activation jack

Clutch

activation jack

Position sensor Clutch fork

Clutch bearing

Volkswagon DSG




Primary shaft

speed sensor

Volkswagon DSG


ENG

POS

SEL-2 CLUTCH

SEL-1 ENG-1

SEL

POS

ENG

JACK

VALVE BODY LAYOUT



the connector





Volkswagon DSG

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

AMT TCU

1

2

49

48

45

33

36

69

SIM32 ECU

Engine speed signal

CAN-H

CAN-L

Vehicle speed signal

Diag - K

VEH. SPEED

SENSOR

A

B1

B2

+KEY-ON

C.A4

C.B4

TDC

sensor

Instrument

cluster

A.B4

A.B2

B.K4

B.K3

A

B

B.H3

7

Diag. Conn.

A.F4

A.H3

A.H2

A.G2

A.F2

A.F3

Acc. Ped.

sensor

1

2

3

4

5

6

A.E4

A.E3

Volkswagon DSG


Intersystem links:

Identification and location of components : Vehicle speed sensor

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Intersystem links:

Identification and location of components : Engine speed / TDC sensor


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17 – The reverse switch (1/1)

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

BAT+

REVERSE

SWITCH

REVERSE

LAMPS

Volkswagon DSG

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

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

EF25

40A

31

A8

AMT TCU

Intermed.

connector

Oil pump

PUMP

ACTIVATION

REQUEST

SPECIAL FUNCTIONS

PUMP UNLOCK

LOCK

Volkswagon DSG

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

Engage line

Selection line

5mm

12mm

19mm

1

2

5mm 12mm

4

3

N

R

5

19mm

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

Volkswagon DSG


Before performing the AMT grid teachings, the environmental conditions and

preliminary operations listed above must be realised

Engine RPM

Key-ON

Water temp

Parking brake

Gear displayed

SEL pos

ENG pos

ENG 5-R

0

ON

< 60°C

OFF

N

10.5 to 15mm

9.0 to 14.0 mm

NOT 100

Parameter

label

Acceptable

range

1 – Check environmental condition

Comments

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

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

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The grid self – teaching procedure itself does not resuire any human process. It is

even possible to switch OFF the key during this procedure

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

SEL POS

ENG POS

19mm

12mm

05mm

19mm

12mm

05mm

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

N 1

2 3

4 5

R

90s

70221852 automatic manual transmission

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