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ZF Citroen 4HP20 Automatic Transmission Technical Manual – PDF DOWNLOAD
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Description
ZF Citroen 4HP20 Automatic Transmission Technical Manual – PDF DOWNLOAD
FILE DETAILS:
ZF Citroen 4HP20 Automatic Transmission Technical Manual – PDF DOWNLOAD
Language : English
Pages : 250
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
ZF Citroen 4HP20 Automatic Transmission Technical Manual – PDF DOWNLOAD
INTRODUCTION:
• Totally electronically managed transverse automatic transmission.
• Four forward gears and one reverse gear.
• Auto-adaptive ECU used for managing the converter, gear changes and specific
programs.
• The maximum torque capacity is 330 mN.
• Sealed transmission with reduced maintenance.
• This transmission is aimed at the powerful engines fitted to the top of the range
CITROËN vehicles: mono volume, H and M2 segments.
PRESENTATION
Transmission architecture
• Hydraulic torque converter with lock-up device.
• Primary shaft.
• Two “Simpson 2” type epicyclic gear trains.
• Multidisc clutches / brakes (no belt brakes).
• Step down torque in central position.
• Differential with sealed outputs.
Control
This is provided by:
• the hydraulic unit,
• the ECU,
• the control cable.
Points of note
• Lock-up of 2nd, 3rd and 4th gears with controlled slip.
• Electronic management of all regulation and gear changing functions.
• Multiple programs: auto-adaptive (DSP) – Sport-Snow.
• Gears and programs displayed on dashboard.
TABLE OF CONTENTS:
ZF Citroen 4HP20 Automatic Transmission Technical Manual – PDF DOWNLOAD
I - INTRODUCTION .............................................................................................................................................. 7 II - PRESENTATION ............................................................................................................................................ 9 III - DESCRIPTION ............................................................................................................................................ 10 IV - IDENTIFICATION OF THE COMPONENTS OF THE AUTOMATIC TRANSMISSION .......................................................................................... 11 A - AUTOMATIC TRANSMISSION ................................................................................................................................ 11 B - ECU .................................................................................................................................................. 12 .......................................................................................................................................................... 18 I - SELECTOR LEVER ........................................................................................................................................ 19 .......................................................................................................................................................... 20 II - PROGRAM SELECTOR .................................................................................................................................... 21 III - DISPLAY ON CONTROL PANEL ........................................................................................................................... 22 I - LUBRICATION CIRCUIT ................................................................................................................................... 25 II - OIL GRADE ........................................................................................................................................... 26 III - PERIPHERAL COMPONENTS ............................................................................................................................... 26 A - WATER/OIL HEAT EXCHANGER .......................................................................................................................... 26 ...................................................................................................................................................... 26 B - DIPSTICK ......................................................................................................................................... 27 C - FILTER ............................................................................................................................................ 27 D - SUMP ............................................................................................................................................. 28 1 - Description ................................................................................................................................... 28 2 - Operating principle ........................................................................................................................... 28 a - Cold transmission ......................................................................................................................... 28 b - Warm transmission ........................................................................................................................ 29 IV - CHECKING THE OIL LEVEL .............................................................................................................................. 30 V - DRAINING - REFILLING THE TRANSMISSION ................................................................................................................ 32 A - DRAINING DURING SERVICING ......................................................................................................................... 32 B - FILLING ........................................................................................................................................... 32 I - DESCRIPTION ........................................................................................................................................... 35 II - SPECIFICATIONS ....................................................................................................................................... 36 III - LOCK-UP DEVICE ..................................................................................................................................... 37 A - PRESENTATION ...................................................................................................................................... 37 B - OPERATING PRINCIPLE ............................................................................................................................... 38 I - DESCRIPTION ........................................................................................................................................... 41 II - FUNCTION ............................................................................................................................................ 43 III - PARK LOCK SYSTEM ................................................................................................................................... 44 I - INTRODUCTION .......................................................................................................................................... 47 II - THE EPICYCLIC GEAR TRAIN ............................................................................................................................ 49 A - PRESENTATION ...................................................................................................................................... 49 B - DESCRIPTION ...................................................................................................................................... 51 III - BRAKES AND CLUTCHES ................................................................................................................................ 52 IV - OBTAINING THE GEARS ................................................................................................................................. 56 A - OPERATING DIAGRAM OF THE AUTOMATIC TRANSMISSION ................................................................................................... 56 B - REVERSE GEAR ..................................................................................................................................... 57 C - 1ST GEAR ......................................................................................................................................... 58 D - 2ND GEAR ......................................................................................................................................... 59 E - 3RD GEAR ......................................................................................................................................... 60 F - 4TH GEAR ......................................................................................................................................... 61 G - DEMONSTRATION .................................................................................................................................... 62 H - SUMMARY ........................................................................................................................................... 64 V - COMPLETE OVERVIEW OF THE AUTOMATIC TRANSMISSION ...................................................................................................... 66 A - PARTS LIST ....................................................................................................................................... 67 I - FUNCTIONS ............................................................................................................................................. 69 ..................................................................................................................................................... 69 II - OIL PUMP ............................................................................................................................................ 70 III - THE HYDRAULIC UNIT ................................................................................................................................. 71 A - ROLE .............................................................................................................................................. 71 ...................................................................................................................................................... 71 B - COMPOSITION ...................................................................................................................................... 72 .................................................................................................................................................. 72 C - DESCRIPTION ...................................................................................................................................... 73 1 - External appearance ........................................................................................................................... 73 2 - Internal components .......................................................................................................................... 74 3 - Harness ...................................................................................................................................... 76 D - FUNCTION OF THE VARIOUS ELEMENTS ................................................................................................................. 77 1 - Selector slide valve WS ....................................................................................................................... 77 2 - Main pressure valve SYS.DR - V ................................................................................................................ 77 3 - Pressure reduction valve DR.RED - V ........................................................................................................... 77 4 - Clutch slide valves KV ........................................................................................................................ 77 5 - Holding slide valves HV ...................................................................................................................... 78 6 - Gear control valve SV ......................................................................................................................... 78 7 - Safety valve SIV .............................................................................................................................. 78 8 - Converter pressure valve WD - V ............................................................................................................... 78 .................................................................................................................................................. 78 9 - Converter clutch valve WK - V ................................................................................................................ 79 a - Introduction .............................................................................................................................. 80 b - Operation ................................................................................................................................ 81 c - Functions of the EDS ...................................................................................................................... 82 d - Actuator connections ..................................................................................................................... 83 e - Actuator identification ................................................................................................................... 83 E - SUMMARY OF OPERATED ELEMENTS ..................................................................................................................... 84 F - LAYOUT OF THE HYDRAULIC UNIT ..................................................................................................................... 85 G - OPERATION ........................................................................................................................................ 87 1 - Gear changes .................................................................................................................................. 87 a - Parking position ......................................................................................................................... 89 b - Reverse gear ............................................................................................................................. 91 c - Neutral .................................................................................................................................. 93 d - Position D - 1st gear .................................................................................................................... 95 e - Position D - 2nd gear .................................................................................................................... 97 f - Position Drive - 3rd gear ................................................................................................................ 99 g - Position Drive - 4th gear ................................................................................................................101 h - Position D - 3rd emergency/Reverse emergency .............................................................................................105 2 - Controlling the main line pressure ...........................................................................................................109 a - 16 bar position ...........................................................................................................................109 b - 7 bar position ............................................................................................................................109 c - Role of DR.RED-V ..........................................................................................................................109 3 - Controlling the lock-up ......................................................................................................................111 a - "Open" position ...........................................................................................................................111 b - Controlled - closed position .............................................................................................................113 I - PROGRAM SELECTOR ......................................................................................................................................115 II - AUTOMATIC TRANSMISSION INPUT AND OUTPUT SPEED SENSORS ...............................................................................................117 A - ROLE ..............................................................................................................................................117 B - DESCRIPTION ......................................................................................................................................118 C - OPERATION ........................................................................................................................................119 1 - Turbine speed sensor ..........................................................................................................................119 2 - Vehicle speed sensor ..........................................................................................................................119 III - OIL TEMPERATURE PROBE ..............................................................................................................................120 A - ROLE ..............................................................................................................................................120 B - OPERATION .........................................................................................................................................120 IV - BRAKING INFORMATION .................................................................................................................................121 V - LOGICAL INFORMATION SUPPLIED BY THE EMC ...............................................................................................................121 A - THROTTLE POTENTIOMETER SIGNAL FOR AUTOMATIC TRANSMISSION .........................................................................................122 B - ENGINE TORQUE SIGNAL FOR AUTOMATIC TRANSMISSION ...................................................................................................122 1 - Calculating the engine torque .................................................................................................................122 a - General method ............................................................................................................................122 b - Reminder of simplified advance calculation ...............................................................................................123 c - Calculating the decline in torque due to the advance ......................................................................................123 d - Calculating passive losses ................................................................................................................123 2 - Engine torque signal ..........................................................................................................................124 C - REV COUNTER SIGNAL GENERATED BY THE MP7.0 EMC .....................................................................................................124 VI - SELECTOR LEVER POSITION INFORMATION .................................................................................................................125 ......................................................................................................................................................130 ..................................................................................................................................................132 I - ECU FUNCTIONS ........................................................................................................................................136 A - GEAR CHANGING LAWS ................................................................................................................................136 B - PROGRAMS ..........................................................................................................................................136 C - AUTO-ADAPTIVITY ..................................................................................................................................136 D - GEAR CHANGE UP PREVENTION DUE TO SUDDEN REMOVAL OF FOOT FROM ACCELERATOR ..........................................................................137 E - TORQUE REDUCTION ..................................................................................................................................137 F - IDLE SPEED COMPENSATION ...........................................................................................................................137 G - CHANGE DOWN .......................................................................................................................................137 H - MANAGEMENT OF IMPOSED GEARS .......................................................................................................................137 I - KICKDOWN (K.D) ...................................................................................................................................138 J - CONVERTER OPERATION ...............................................................................................................................138 K - ADAPTATION OF THE GEAR CHANGING PRESSURE ..........................................................................................................138 L - CONTROL PANEL DISPLAY .............................................................................................................................138 M - SAFETY - DIAGNOSTICS ..............................................................................................................................138 N - UPGRADES ..........................................................................................................................................138 II - INPUTS/OUTPUTS ......................................................................................................................................139 III - CONNECTIONS ........................................................................................................................................140 IV - ECU ARCHITECTURE ....................................................................................................................................141 I - GEAR CHANGING LAWS ....................................................................................................................................143 A - NOTES ............................................................................................................................................144 B - INTERPRETING THE CURVES ..........................................................................................................................145 C - KICK-DOWN FUNCTION ................................................................................................................................145 II - HOLD COMMAND ........................................................................................................................................146 III - PROGRAMS AND VARIOUS LAWS ..........................................................................................................................147 IV - DSP FUNCTION (AUTOADAPTIVE CHANGING LAWS) ...........................................................................................................152 A - INTRODUCTION ......................................................................................................................................152 1 - Adaptivity to load (increase gear) ............................................................................................................152 2 - Adaptivity to driver ..........................................................................................................................152 3 - Specific case: going downhill and braking ....................................................................................................153 4 - Other functions ...............................................................................................................................153 B - ADAPTIVE FUNCTION .................................................................................................................................153 1 - Parameters used ...............................................................................................................................153 2 - Description of the function ...................................................................................................................154 a - Principle .................................................................................................................................154 b - Processing parameters ....................................................................................................................155 c - Working out sportivity indices Spx ........................................................................................................155 d - Working out the set of gear changing laws Skx .............................................................................................156 e - Safety function ...........................................................................................................................157 f - Case of "sport" program ..................................................................................................................159 g - Substitution program E-PROG ...............................................................................................................159 h - Short duration function SESP ..............................................................................................................159 C - SPECIFIC FUNCTIONS ................................................................................................................................160 1 - Recognition of vehicle going downhill .........................................................................................................160 2 - Gear change up prevention (HSV) ...............................................................................................................160 a - Aim .......................................................................................................................................160 b - Description ...............................................................................................................................160 3 - Forced gear changes down when braking (ZRS) ...................................................................................................161 a - Aim .......................................................................................................................................161 b - Description ...............................................................................................................................161 4 - Temperature protection functions SKTEMP .......................................................................................................162 a - Specific gear changing laws in the event of high temperature. .............................................................................162 b - Specific function of the lock-up in the event of high temperature .........................................................................163 c - Engine radiator fan control ...............................................................................................................163 5 - Warm up function WARML .......................................................................................................................164 V - ADAPTIVE REGULATION OF LINE PRESSURE .................................................................................................................165 A - AUTOADAPTIVITY TO ENGINE TORQUE ...................................................................................................................165 B - AUTOADAPTIVITY TO GEAR CHANGES ....................................................................................................................165 VI - OPERATING THE LOCK-UP CLUTCH ........................................................................................................................168 A - NEED FOR THE VARIOUS STATES .......................................................................................................................168 B - STRATEGY ..........................................................................................................................................168 VII - SAFETY FUNCTIONS ....................................................................................................................................171 VIII - FUNCTIONS PERFORMED BY THE ENGINE MANAGEMENT COMPUTER (EMC) .......................................................................................172 A - INFORMATION SUPPLIED TO THE EMC FROM THE AUTOMATIC TRANSMISSION ...................................................................................172 1 - Working out the "drive" state or "parking/neutral" state ......................................................................................172 2 - Recognition of change from P/N ( D ............................................................................................................172 3 - Recognition of change from D ( P/N ............................................................................................................172 B - RETARDING THE ADVANCE WHEN CHANGING GEARS ........................................................................................................173 C - AUTOMATIC TRANSMISSION PROTECTION ................................................................................................................174 D - ANTI-STALLING .....................................................................................................................................174 I - CONTROL PANEL DISPLAY .................................................................................................................................175 A - COMMUNICATIONS PROTOCOL ...........................................................................................................................175 B - MEANING OF THE BITS ..............................................................................................................................177 1 - b1, b2, b3, b4 ................................................................................................................................177 2 - b5, b6 .......................................................................................................................................178 3 - b7, b8 ........................................................................................................................................178 II - OPERATION OF REVERSING LIGHTS .......................................................................................................................181 III - STARTING PREVENTION .................................................................................................................................181 IV - SHIFT-LOCK ..........................................................................................................................................182 V - KEY-LOCK .............................................................................................................................................184 .........................................................................................................................................................186 VI - OPERATING THE FANS ..................................................................................................................................187 I - GENERAL ...............................................................................................................................................189 A - AIM ...............................................................................................................................................189 B - RECORDING FAULTS ..................................................................................................................................189 C - CLASSIFYING FAULTS ...............................................................................................................................190 D - DETECTING FAULTS ..................................................................................................................................190 E - DOWNGRADED MODE ..................................................................................................................................191 II - SERIAL COMMUNICATIONS WITH THE ELIT TESTER ..........................................................................................................192 III - DESCRIPTION OF THE DIAGNOSTIC ......................................................................................................................196 A - LIST OF FAULTS ....................................................................................................................................196 I - LAYOUT ................................................................................................................................................199 II - INSTALLATION ........................................................................................................................................200 III - LOCATION ...........................................................................................................................................201 IV - PARTS LIST ..........................................................................................................................................202 I - DOWNLOADING TO THE ECU ................................................................................................................................203 II - INITIALISING THE ECU .................................................................................................................................203 III - TESTING AFTER THE WORK ..............................................................................................................................203 IV - LIST OF AUTHORISED OPERATIONS ON THE 4HP20 TRANSMISSION IN AFTER-SALES DURING THE FIRST YEAR OF WARRANTY* ...........................................204 V - SPECIAL TOOLING ......................................................................................................................................206 I - TRANSMISSION REPAIR PROCEDURE .........................................................................................................................209 A - SPECIFIC CASE ....................................................................................................................................210 B - SEARCHING FOR FAULTS ..............................................................................................................................210 1 - Problems with gear changing quality ...........................................................................................................210 2 - Transmission operating fault(s) ...............................................................................................................211 II - ANALYSE THE RESULTS ..................................................................................................................................211 A - OIL CONDITION .....................................................................................................................................211 B - DIALOGUE IMPOSSIBLE ..............................................................................................................................212 C - DIALOGUE POSSIBLE .................................................................................................................................212 D - VISUAL WARNING IN THE EVENT OF FAULTS .............................................................................................................212 1 - Flashing of the Sport and Snow warning lights - display of last gear selected ................................................................212 2 - Flashing of Sport and Snow warning lights (without gear being displayed) ......................................................................212 E - EMERGENCY AND REPLACEMENT PROGRAM ................................................................................................................213 1 - 4th hydraulic then 3rd hold after starting: P.R.N. possible ...................................................................................213 2 - Oil temperature 120 or 60° C depending on phases ..............................................................................................213 3 - Does not change to Kick-Down ..................................................................................................................213 4 - Gears do not change in position D, the same gear is maintained ...............................................................................214 F - QUICK DIAGNOSTIC ..................................................................................................................................214 1 - Faults relating to the adjustment of the selector control .....................................................................................214 2 - Faults requiring the transmission to be removed and replaced ..................................................................................214 3 - Fault requiring the multifunction switch to be checked on the transmission ...................................................................215 4 - Abnormal noise or vibrations ..................................................................................................................215 5 - Faults relating to the EMC ....................................................................................................................215 III - AUTOMATIC TRANSMISSION OIL LEAKS ...................................................................................................................216 IV - PRESENTATION ........................................................................................................................................218 A - DIAGNOSTIC TOOLING ................................................................................................................................218 1 - ELIT unit: 4125-T .............................................................................................................................218 2 - Terminal box: 4109-T ..........................................................................................................................218 3 - PROXIA station: 4165-T .......................................................................................................................219 4 - LEXIA station: 4171-T .........................................................................................................................219 V - DIAGNOSTIC: AUTOMATIC TRANSMISSION 4HP20 .............................................................................................................220 A - DIAGNOSTIC TOOLING ................................................................................................................................220 1 - ELIT unit: 4125-T .............................................................................................................................220 2 - PROXIA station: 4165-T ........................................................................................................................220 3 - LEXIA station: 4171-T ........................................................................................................................221 4 - Terminal box: 4109-T. Harness: 4187-T .........................................................................................................221 5 - KOSTAL socket control harness and function selector connector: 8010-T (L) ....................................................................222 ......................................................................................................................................................222 B - FAULT FINDING TABLE ..............................................................................................................................223 1 - List of faults ................................................................................................................................223 2 - Fault 1. Engine speed signal .................................................................................................................224 3 - Fault 2. Automatic transmission input speed ..................................................................................................225 4 - Fault 3. Automatic transmission output speed ..................................................................................................225 5 - Fault 4. Multifunction switch ................................................................................................................226 6 - Fault 5. Throttle position signal (load potentiometer through injection ECU) .................................................................227 7 - Fault 6. Automatic transmission oil thermistor ...............................................................................................228 8 - Fault 7. Ignition on supply ..................................................................................................................229 9 - Fault 8. Battery voltage ......................................................................................................................229 C - ELECTRICAL TESTS .................................................................................................................................240 1 - Diagnostic connection .........................................................................................................................240 2 - Reversing lights control ......................................................................................................................240 3 - Starting authorisation .......................................................................................................................241 4 - Gear lever release actuator ...................................................................................................................241 5 - Program selector .............................................................................................................................242 6 - Multifunction switch .........................................................................................................................243 7 - Hydraulic unit ................................................................................................................................244 D - OPERATION ........................................................................................................................................246 1 - Operation of electrovalves and pressure regulators ............................................................................................246 2 - Kickdown ......................................................................................................................................246 E - DOWNLOADING TO THE ECU ...........................................................................................................................247 1 - Updating the ECU by downloading ...............................................................................................................247 2 - Initialising the auto-adaptives ...............................................................................................................247 F - SYMPTOMS OCCURRING DUE TO THE ABSENCE OF A FAULT ON THE DIAGNOSTIC TOOL ..........................................................................248 1 - No dialogue between the ECU and the diagnostic tool ...........................................................................................248 2 - Cannot start engine, lever in position P, N ...................................................................................................248 3 - Cannot release lever from position P by pressing brake pedal ..................................................................................248 4 - Reversing lights do not illuminate with selector lever in position R .........................................................................249 5 - No noticeable effect when selecting sport / snow ..............................................................................................249 6 - No drive, lever in position D, whilst an imposed gear has not been requested previously then no gear changes after returning to position D ....249 V - SPECIFICATIONS - MAINTENANCE ............................................................................................................................. 13 A - INTERVALS - CAPACITIES ................................................................................................................................ 13 B - GEARS ................................................................................................................................................. 13 VIII - MISCELLANEOUS NOTES ................................................................................................................................... 17 VII - LAYOUT OF THE 4HP20 AUTOMATIC TRANSMISSION ............................................................................................................. 16 A - TOWING ................................................................................................................................................ 17 B - LIFTING ........................................................................................................................................... 17 VI - TIGHTENING TORQUES ...................................................................................................................................... 14
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