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23A Automatic Gearbox

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AUTOMATIC GEARBOX GeneralDP0 Identification engraving on the automatic gearbox.

23A

The vehicle only has drive when the engine is running. It is therefore impossible to start the engine of a vehicle with an automatic gearbox by pushing the vehicle. II - TOWING The vehicle should preferably be towed in all cases on a tow truck or with the front wheels raised. Nonetheless, if this is impossible, in exceptional circumstances, the vehicle may be towed at low speed (maximum 12 mph (20 km/h) over a maximum distance of 18 miles (30 km) (lever in N position). WARNING Towing weight (towing a caravan, boat, etc.): - the load being towed must be less than or equal to 950 kg for a DP0 gearbox. - failure to comply with this maximum load will, on a 7% gradient, result in the maximum engine oil and automatic gearbox oil temperature being exceeded, causing damage to the engine.

13786

I - SPECIFICATIONS Weight: 70 kg. Vehicles fitted with the DP0 automatic gearboxes use systems called Shift lock and Lock up . The purpose of the Shift lock function is to prevent the gear selector lever from being moved without the brake pedal being simultaneously depressed. Note: For repair operations when the battery is faulty, refer to the notice on board the vehicle. The purpose of Lock up or converter bypass is to connect the automatic gearbox directly to the engine. This function is performed by a mini clutch located on the converter. Lock up is controlled by the automatic gearbox. As the automatic gearbox is lubricated under pressure, lubrication is only provided when the engine is running. Consequently, and to avoid serious damage, it is essential to comply with the following instructions: - never allow the vehicle to coast with the ignition switched off (i.e. when going down a hill); the damage that this may cause cannot be stressed highly enough, - never push the vehicle (i.e.: to get to a petrol station, unless the precautions in the Towing section have been taken).

23A-1

AUTOMATIC GEARBOX RatiosDP0

23AStep-down Final drive

Vehicle

Engine

Gearboxes Automatic

Gearbox sufx

CMOC CMOU

K4M 761 F4R 771

DP0 DP0

047 049

52 : 67 52 : 67

21 : 73 21 : 73

23A-2

AUTOMATIC GEARBOX ConsumablesDP0

23A

Description Grease MOLYKOTE BR2 LOCTITE FRENBLOC

Component concerned Centring tool

Brake calliper mounting bolt

23A-3

AUTOMATIC GEARBOX Parts to be replaced systematicallyDP0 The following parts must be replaced after being removed: - self-locking nuts, - the seals, - rubber seals, - converter bolts.

23A

23A-4

AUTOMATIC GEARBOX OilDP0 The DP0 automatic gearbox is greased for life and does not require any maintenance: It is only necessary to top up the level in the event of a slight leak. I - OIL SPECIFIED: ELF RENAULT MATIC D3 SYN (can be ordered from ELF) DEXRON III standard II - CAPACITY IN LITRES Total volume: 6 litres.

23A

23A-5

AUTOMATIC GEARBOX Drain the automatic gearbox oil.DP0 SPECIAL FEATURES Tightening torquesm drain plug top up spillway 2.5 daNm 3.5 daNm

23A

It is preferable to change the automatic gearbox oil when it is warm (60C maximum), in order to remove as many impurities as possible. Put the vehicle on a lift. Remove the engine undertray.

1 22316

1

The plug has two functions: - the drain plug (2.5 daNm)(1), - the top up spillway (3.5 daNm)(2).

103406

Drain the oil by removing the plug (1). Note: As a precaution, it is recommended that the volume of oil collected during the oil change (total or partial) be measured to nd out the volume of oil which must be replaced, to prevent lling to the wrong level.

23A-6

AUTOMATIC GEARBOX Filling and topping upDP0

23A

Essential equipment Diagnostic tool I - FILLING

1

13792

Position a container to collect at least 0.1 litre of excess oil and wait until the oil flows out drop by drop. Close the filler cap. III - LEVEL CHECKING PROCEDURE OUTSIDE FILLING OPERATIONS Note: The level must be checked following the method described below: Park the vehicle on level ground. Fill the automatic gearbox with 0.5 litres of new oil. Run the engine at idling speed. Connect the Diagnostic tool ( CLIP ). Establish dialogue with the automatic transmission computer, Monitor the transmission oil temperature parameter. Once a temperature of 60C +/- 1 is reached, open the level-setting plug. If the oil does not flow out or the quantity collected is below 0.1 litre: stop the engine, add 0.5 litre, let the automatic gearbox to cool to 50C, then carry out the following operations. Run the engine at idling speed. Connect the Diagnostic tool ( CLIP ). Establish dialogue with the automatic transmission computer,

103407

Fill through the hole (1). Use a funnel with a 15/100 filter to prevent impurities from entering the system. II - FILLING PROCEDURE Park the vehicle on level ground. Fill the automatic gearbox with 3.5 litres of new oil. Run the engine at idling speed. Connect the Diagnostic tool ( CLIP ). Establish dialogue with the automatic transmission computer, Monitor the transmission oil temperature parameter. Once a temperature of 60C +/- 1 is reached, open the level-setting plug.

23A-7

AUTOMATIC GEARBOX Filling and topping upDP0 Monitor the transmission oil temperature parameter. Once a temperature of 60C +/- 1 is reached, open the level-setting plug. Note: When the oil is replaced, the electronic oil ageing counter must be reset (inside the computer). Enter the oil change date using the CF074 Enter gearbox oil change date command on the Diagnostic tool ( CLIP ).

23A

23A-8

AUTOMATIC GEARBOX Checking the setting point of the converterDP0

23A

Essential equipment Diagnostic tool Put the vehicle on a two-post lift. Lift the vehicle until the wheels are raised off the ground by a few centimetres. Connect the Diagnostic tool ( CLIP ). Establish dialogue with the automatic transmission computer, Monitor the automatic gearbox oil temperature parameter. The check should be done at an oil temperature of between 60C and 80C. Start the engine and put the lever in D. Monitor the engine speed parameter: Establish dialogue with the computer. Accelerate fully keeping the brakes applied. The front wheels should not rotate. WARNING - The full load position must not be held for more than 5 seconds. Beyond this, there is a high risk of destroying the converter or the automatic gearbox. - Once the measurement has been taken, release the accelerator and keep the brakes on until the engine speed stabilises to idle speed (there is a risk of damaging the automatic gearbox if this is not complied with).

K4M The engine speed should stabilise at 2700 rpm +/150.

F4R The engine speed should stabilise2500 rpm.

A setting point outside the tolerance requires the converter to be replaced. Note: A setting point which is too low may be linked to a lack of engine power.

23A-9

AUTOMATIC GEARBOX Hydraulic distributorDP0 Essential special tooling Bvi. 1462 Ball plate adjusting screw Essential equipment Diagnostic tool

23A

Drain the automatic gearbox using the plug (1). Remove: - the wheels, - the air intake duct.

4Tightening torquesm distributor bolts mounting 0.75 daNm

ball detent plate bracket mounting bolt (12) ball detent plate mounting bolt cover mounting bolts rechargeable battery reinforcement mounting bolts plate

0.9 daNm 0.8 daNm 1 daNm 4 daNm 2.1 daNm101821

2

3

Disconnect the electrical harness:

REMOVAL Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery. Remove the engine undertray.

- from the battery (2), - from the battery tray (3), - from the injection computer (4). Remove: - the battery, - the computer, - the battery mounting.

1

13792

23A-10

AUTOMATIC GEARBOX Hydraulic distributorDP0

23A

6 5

103412

13788

Remove the electrical harness (5) on the side reinforcement. Remove: - the bolts (6) on the side reinforcement plate, - the side reinforcement.

Remove the seven mounting bolts on the hydraulic distributor. Disconnect the solenoid valve connectors. Remove the hydraulic distributor.

REFITTING

7

14783

Remove the four retaining bolts (7) on the hydraulic distributor cover (be careful as oil may run out).

13789

Fit the distributor and centre it using bolts (4) and (5). Refit the other bolts. Tighten to torque and in the correct order the distributor mounting bolts (0.75 daNm).

23A-11

AUTOMATIC GEARBOX Hydraulic distributorDP0 ADJUSTING THE BALL DETENT PLATE

23A

10

112318

Remove the bolt (8). Position the ball detent plate by placing the roller (9) in the hollow (11) of the sector (10) corresponding to the 1st gear selected position.14782

Hold the multifunction lever switch in the end position (1st selected) using a plastic clip and a bolt in the mechanism housing.

10 9 8 12

14785

Position the ball detent plate bracket mounting bolt (12) but do not tighten it.13788-1

Position the tool (Bvi. 1462) in place and fit the bolt (8). Screw the tool in fully whilst holding the ball detent plate. Tighten to torque the ball detent plate bracket mounting bolt (12) (0.9 daNm). Remove the tool (Bvi. 1462). Remove the ball detent plate mounting bolt (8).

23A-12

AUTOMATIC GEARBOX Hydraulic distributorDP0 Tighten to torque the ball detent plate mounting bolt (0.8 daNm). When replacing the oil distributor, the auto-adaptives must be reset using command RZ005: Erase auto-adaptives and the oil age counter of the automatic gearbox computer must be reset using the Diagnostic tool, use command CF074: Enter date of gearbox oil change . After using command RZ005, it is important to carry out a test drive performing all gear changes, both up and down, several times in order to store the new values. Tighten to torque: - the cover mounting bolts (1 daNm), - the rechargeable battery (4 daNm), - the reinforcement plate mounting bolts (2.1 daNm). To refit, proceed in the reverse order of removal. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

23A

23A-13

AUTOMATIC GEARBOX Gearbox: Removing / RefittingDP0 Essential special tooling Rou. 604-01 Tav. 476 Mot. 1453 Hub locking tool Ball joint extractor Multiple-adjusting engine mounting support with retaining straps Inertia wheel centring tool for automatic transmission converter Essential equipment Jack

23A

Special notes for vehicles fitted with a driver's airbag WARNING Observe the following instructions to avoid damaging the rotary switch beneath the steering wheel: - Before the steering column and the steering rack are uncoupled, the steering wheel must be immobilised with the wheels straight for the duration of the operation using a steering wheel locking tool. - If there is any doubt about the correct alignment of the rotary switch, it is necessary to remove the steering wheel to apply the centring method ( Controls - signalsSection). In this case, only qualied personnel who have received training may carry out the operation.

Bvi. 1531

Tightening torquesm wheel bolts brake calliper column bolts track rod end nut track rod end nut engine tie-bar on the sub-frame gearbox edge bolt and starter motor suspension mounting nut on the gearbox track rod end nut converter mounting nut on the drive plate modular connector mounting bolts engine speed sensor mounting bolts engine tie-bar bolts on the K Engine engine tie-bar bolts on the F Engine suspension mounting nut on the rubber pad 11 daNm 0.7 daNm 3.7 daNm 6.2 daNm 10.5 daNm 4.4 daNm 4.4 daNm 6.2 daNm 3.7 daNm 2 daNm

REMOVAL Put the vehicle on a two-post lift. Remove the engine covers.

101821

1 daNm 10.5 daNm 18 daNm 18 daNm

Disconnect the battery. Remove: - the air intake duct, - the battery, - the battery tray, - the injection computer and its mounting, - the air intake pipe, - the wiring harness mountings.

23A-14

AUTOMATIC GEARBOX Gearbox: Removing / RefittingDP0

23A

K4M

2

3

4

1103753

Remove the engine speed sensor.103409

Remove: - the multifunction switch cable ball joint (1) using the tool, - the wiring harness (2) for the multifunction switch cable by removing the sleeve stop, - the wiring harness mountings. Disconnect: - the engine speed sensor, - the connector (3) by removing the connector slide. Remove the mounting bolts (4) from the modular connector support plate. WARNING Protect the connector by sliding it into a waterproof plastic bag.

F4R

103420

Remove the engine speed sensor.

Fit the hose clamps. Disconnect the radiator. Unclip the gearbox wiring harness.

23A-15

AUTOMATIC GEARBOX Gearbox: Removing / RefittingDP0

23A

I -LEFT-HAND SIDE OF THE VEHICLE

5

103423

Remove: - the two bolts (5) from the starter, - the engine undertray. Drain the gearbox. Remove: - the wheels, - the wheel arch liners, Disconnect: - the ABS system sensor wiring, - the xenon headlight adjustment sensor wiring harnesses (if fitted). Note: The xenon headlight adjustment sensor is tted onto the left-hand lower wishbone. - the track rod end using the tool (Tav. 476), Remove: - the hub nut using the tool (Rou. 604-01),

102129

- the anti-roll bar ball joint using the tool (Tav. 476), - the lower ball joint. Remove the stub-axle carrier from the driveshaft. Remove the left-hand driveshaft.

7

6

103412

23A-16

AUTOMATIC GEARBOX Gearbox: Removing / RefittingDP0 Remove: - the clip (7) from the gearbox computer wiring harness, - the side reinforcement (6)

23A

- the track rod end using the tool (Tav. 476), - the anti-roll bar ball joint using the tool (Tav. 476), - the lower ball joint.

8

9

103413

103418

Open the retaining bracket (8) on the gearbox computer wiring harness. Disconnect the gearbox computer connector (9). II - RIGHT-HAND SIDE OF THE VEHICLE

Remove the relay bearing bracket. Remove the stub-axle carrier from the driveshaft. Remove the right-hand driveshaft. Attach the cooling radiator assembly to the upper cross member using rope.

102129

Remove: - the hub nut using the tool (Rou. 604-01), Remove the side reinforcement.

101212

23A-17

AUTOMATIC GEARBOX Gearbox: Removing / RefittingDP0

23A

F4R

102009

Remove the radiator lower cross member.

K4M

11

10103421

Remove: - the exhaust mounting nuts (10), - the engine tie-bar.

10

103749

Remove: - the exhaust mounting nuts. - the engine tie-bar.

11103418

Remove: - the lower engine/manifold bracket, - the starter mounting bolt (11),

23A-18

AUTOMATIC GEARBOX Gearbox: Removing / RefittingDP0 - the starter motor, - the three nuts on the converter. Note: The nuts on the converter can be accessed by removing the starter motor. Rotate the crankshaft clockwise to access the three drive plate / converter connecting nuts and remove them.

23A

Fit the Jack tool beneath the gearbox. Remove: - the lower gearbox edge bolts, - the studs, - the automatic gearbox,

1213790

103423

Attach the converter with a piece of string to stop it being knocked out of place.

Remove the upper studs (12) around the edge of the gearbox. Strap the bonnet down.

REFITTING WARNING - Do not re-use the converter mounting nuts or the inertia ywheel nuts if they have been removed: always use new nuts. - Check for the presence of the centring rings.

13 14102449

Open the cover (13). Remove the cover (14). Fit the tool (Mot. 1453). Remove the gearbox support pad.

23A-19

AUTOMATIC GEARBOX Gearbox: Removing / RefittingDP0

23A

- the engine tie-bar bolts on the K Engine (10.5 daNm), - the engine tie-bar bolts on the F Engine (18 daNm), - the suspension mounting nut on the rubber pad (18 daNm). Fill the automatic gearbox and check the level (Section Automatic gearbox, Filling and topping up, page 23A-7). When the oil is replaced, the auto-adaptives must be reset using command RZ005: Clear autoadaptives and the automatic gearbox oil ageing counter must be reset using command CF074: Enter date of gearbox oil change . After using command RZ005, it is important to carry out a test drive performing all gear changes, both up and down, several times in order to store the new values.16361

WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

Refit the flywheel nuts on the converter using the tool (Bvi. 1531). To refit, proceed in the reverse order to removal. WARNING Check that the centring pins are present. When refitting the automatic gearbox to the engine, make sure that the converter is perfectly positioned on the axis of the input shaft (the end of the studs is level with the gasket face). Tighten to torque: - the wheel bolts (11 daNm), - the brake calliper column bolts (0.7 daNm), - the track rod end nut (3.7 daNm), - the track rod end nut (6.2 daNm), - the engine tie-bar on the sub-frame (10.5 daNm), - the gearbox edge bolt and starter motor (4.4 daNm), - the suspension mounting nut on the gearbox (4.4 daNm), - the track rod end nut (6.2 daNm), - the converter mounting nut on the drive plate (3.7 daNm), - the modular connector mounting bolts (2 daNm), - the engine speed sensor mounting bolts (1 daNm),

23A-20

AUTOMATIC GEARBOX Starter plateDP0 Essential special tooling K4M Mot.1677 Mot. 582-01 Flywheel locking tool (F engines) Flywheel locking tool (K engines) Essential equipment Diagnostic tool

23A

1

1

Tightening torquesm drive plate bolts drive plate bolts 4.5 daNm + 50 +/- 5 5.5 daNm

1 1

This operation can be performed after the automatic gearbox has been removed.

REMOVAL Position the tool (Mot. 582-01). F4R Remove: - the bolts (1),

103752

1 1 2

- the drive plate, - the (Mot.1677) or (Mot. 582-01) tool.

REFITTING2 1 1 Check that the drive plate is not damaged (warping tolerance 0.2 mm on the external diameter). Fit the drive plate, ensuring it is correctly positioned in relation to the centring pin (2). Note: Apply LOCTITE FRENBLOC to the bolt threads. Tighten the bolts on the drive plate.

103245

Position the tool (Mot.1677) to immobilise the starter motor ring gear.

F4R Angular tighten to torque the drive plate bolts (4.5 daNm + 50 +/- 5) by immobilising the starter motor ring gear using the tool (Mot.1677).

23A-21

AUTOMATIC GEARBOX Starter plateDP0

23A

K4M Angular tighten to torque the drive plate bolts (5.5 daNm) by immobilising the starter motor ring gear using the tool (Mot. 582-01).

To refit, proceed in the reverse order of removal. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Connect the Diagnostic tool for the conformity check.

23A-22

AUTOMATIC GEARBOX Differential output gasketDP0 Essential special tooling Bvi. 1459 Bvi. 1460 Right-hand driveshaft output seal assembly Left-hand driveshaft output seal assembly

23A

Tightening torquesm wheel bolts lower ball joint nut torque reaction mounting bolts on the subframe engine tie-bar bolts to the K engine engine tie-bar bolts to the F engine track rod end nut hub nut 11 daNm 6.2 daNm 10.5 daNm

1

10.5 daNm13791

18 daNm 3.7 daNm 28 daNm

Drain the automatic transmission through plug (1). Remove the faulty differential output seal using a screwdriver or a hook, taking care not to scratch the contact surfaces. WARNING

REMOVAL This operation takes place after the relevant driveshaft is removed (see Workshop Repair Manual 364, Section 2). Put the vehicle on a two-post lift. Remove the battery cover Disconnect the battery. Remove the engine undertray.

Do not drop the spring of the seal into the automatic gearbox.

REFITTING The seal should be fitted using either tool (Bvi. 1459) or tool (Bvi. 1460). Guide the assembly until the tool is touching the automatic gearbox housing. To refit, proceed in the reverse order to removal. Tighten to torque: - the wheel bolts (11 daNm), - the lower ball joint nut (6.2 daNm), - the torque reaction mounting bolts on the subframe (10.5 daNm), - the engine tie-bar bolts to the K engine (10.5 daNm), - the engine tie-bar bolts to the F engine (18 daNm), - the track rod end nut (3.7 daNm), - the hub nut (28 daNm).

23A-23

AUTOMATIC GEARBOX Differential output gasketDP0 Fill the automatic gearbox and check the level (Section Automatic gearbox, Filling and topping up, page 23A-7). WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

23A

23A-24

AUTOMATIC GEARBOX Converter sealDP0 Essential special tooling Mot. 587 Bvi. 1457 Seal extractor Converter assembly lip seal

23A

REMOVAL This operation is performed after the automatic gearbox and converter have been removed. Remove the converter by withdrawing it as far as possible without deviating from the course of the shaft. WARNING The converter contains a large amount of oil which may escape when it is being removed. Using the tool (Mot. 587), remove the seal, taking care not to scratch the contact surfaces.

REFITTING WARNING - Work as cleanly as possible to prevent foreign bodies from entering the system. - Oil all the contact surfaces. Position the new prelubricated seal as far as the stop using the tool (Bvi. 1457). Check that the converter is correctly positioned. To refit, proceed in the reverse order to removal.

23A-25

AUTOMATIC GEARBOX Line pressure tappingDP0 Essential special tooling Bvi. 1215-01 Automatic transmission oil pressure gauge kit

23A

Some fault finding procedures on the automatic gearbox involve taking the line pressure using a pressure gauge. The pressure measurement tapping is located close to the pressure sensor.

1

103420

Remove the bolt (1) to take the line pressure. Remove the pressure tapping union (466-06) from the kit (Bvi. 1215-01) and place it in position (Workshop Repair Manual 366 Fault finding ).

23A-26

AUTOMATIC GEARBOX Multifunction switchDP0

23A4

Tightening torquesm selector lever nut multifunction mounting bolts switch 1 daNm 1 daNm

2

REMOVAL Set to neutral N .

5 1

3

103409

Disconnect: - the multifunction switch cable ball joint (1), - the control cable from the sleeve stop (2) on the modular connector support. Remove the lever and the two multifunction switch mounting bolts (3). Disconnect the modular connector (4) by releasing the slide mechanism on the connector. Remove the three modular connector support plate mounting bolts (5).

101821

Disconnect the battery. Remove: - the air intake duct, - the battery, - the battery tray, - the injection computer and its mounting, - the air filter unit, - the wiring harness mountings.

6

13785

Remove the two modular connector mounting plate bolts . Remove the green connector (6) on the multifunction switch (12-track).

23A-27

AUTOMATIC GEARBOX Multifunction switchDP0

23A

REFITTING Place the multifunction switch in neutral N . Adjust the multifunction switch. To refit, proceed in the reverse order of removal. Tighten to torque the selector lever nut (1 daNm). Check that the system and gears are working. ADJUSTING THE MULTIFUNCTION SWITCH With the gearbox selector shaft in neutral, place two electric terminals on the pressure control tabs.

103411

Switch the multimeter to the ohmmeter position. Turn the multifunction switch by hand until the switch is closed (resistance at contact terminals: 0 ). Tighten to torque the multifunction switch mounting bolts (1 daNm). WARNING After tightening, the switch must be closed. Check that the system and gears are working. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

23A-28

AUTOMATIC GEARBOX ComputerDP0 The computer is located behind the left-hand wheel arch. REPLACING THE COMPUTER Note:

23A

REMOVAL Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery. Remove the front bumper.

When the automatic gearbox computer is replaced, it is necessar y to enter the age of the automatic gearbox oil stored in the memory of the computer to be replaced in the memory of the new computer. Use the following procedure. Read the oil ageing value from the memory of the computer being replaced using parameter PR133: Oil ageing counter and note down the value. Replace the computer. Call up the oil ageing value in the memory of the new computer using command CF320: Oil ageing counter report .

3

2 1

103415

Disconnect the computer connector. Remove: - the resonator (1), - the four computer mounting nuts (2), - the computer (3).

REFITTING To refit, proceed in the reverse order of removal. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

23A-29

AUTOMATIC GEARBOX Input speed sensorDP0

23A

Tightening torquesm input speed mounting bolt sensor 1 daNm

REMOVAL Remove the engine covers. Disconnect the battery. Note: The speed sensor can be removed without draining or removing the automatic gearbox.

1

103419

Remove the connector (1) from the gearbox connector support plate.

103416

Note: When replacing a sensor, always remove the gearbox connector (Section Automatic gearbox, Gearbox connector, page 23A-35).

213786-1

Remove the input speed sensor (2). WARNING Protect the connector by sliding it into a waterproof plastic bag.

REFITTING To refit, proceed in the reverse order to removal.

23A-30

AUTOMATIC GEARBOX Input speed sensorDP0 Tighten to torque the input speed sensor mounting bolt (1 daNm). WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

23A

23A-31

AUTOMATIC GEARBOX Output speed sensorDP0

23A

Tightening torquesm output speed sensor mounting bolt 1 daNm

REMOVAL Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery. Note: The speed sensor can be removed without draining or removing the automatic gearbox.

2

103420

Remove the output speed sensor (2).

REFITTING To refit, proceed in the reverse order to removal. Tighten to torque the output speed sensor mounting bolt (1 daNm). WARNING103417

1

Connect the battery; carry out the necessary programming (Section Electrical equipment).

Disconnect the connector (1). Remove the engine undertray.

23A-32

AUTOMATIC GEARBOX Flow regulation solenoid valveDP0

23A

Tightening torquesm radiator ow control solenoid valve mounting bolt 1 daNm

2

REMOVAL Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery. Note: The radiator ow control solenoid valve can be removed without draining or removing the automatic gearbox.13786-1

1

Remove: - the two solenoid valve bolts (1), - radiator flow control solenoid valve (2).

REFITTING To refit, proceed in the reverse order to removal. Tighten to torque the radiator flow control solenoid valve mounting bolt (1 daNm). WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

103434

23A-33

AUTOMATIC GEARBOX Solenoid valvesDP0

23A

WARNING Work as cleanly as possible to prevent foreign bodies from entering the system.

REMOVAL

2

1

3

4

5

6

7

813787

(1) (2) (3) (4) (5) (6) (7) (8) Note:

Modulating solenoid valve Lock up solenoid valve (converter lock-up) Sequence solenoid valve 4 Sequence solenoid valve 3 Sequence solenoid valve 1 Sequence solenoid valve 2 Sequence solenoid valve 6 Sequence solenoid valve 5

This operation can be performed after the hydraulic distributor has been removed.

23A-34

AUTOMATIC GEARBOX Gearbox connectorDP0 Connector numbering

23A

1 3 5

2 4

1

2

313785

4 5

(1) (2) (3) (4) (5)

Green connector (multifunction switch) Yellow connector (electrohydraulic interface) Green connector (line pressure)

103248

REMOVALYellow connector (turbine speed) Blue connector (radiator ow control solenoid valve) Put the vehicle on a two-post lift. Remove the engine covers. Select neutral N Note: These connectors may be removed separately from the gearbox connector when certain components are replaced.

101821

Disconnect the battery. Remove: - the air intake duct, - the battery,

23A-35

AUTOMATIC GEARBOX Gearbox connectorDP0 - the battery tray, - the injection computer and its mounting, - the air filter unit, - the wiring harness mountings.

23A

REFITTING To refit, proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

7

8

9

6

103409

Disconnect: - the ball joint (6) from the multifunction switch cable, - the wiring harness (7) from the multifunction switch cable by loosening the sleeve stop, - the unit connector (8) by releasing the slide valve on the connector. Remove: - the three mounting bolts (9) from the unit connector support plate, - the two unit connector mounting bolts, - the connector in the colour that appears on the gearbox connector. Follow the five wiring harnesses connected to the gearbox connector. Remove the five wiring harnesses. These wiring harnesses are either connected to components directly or via a connector. If they are connected to a component directly, the component should also be removed.

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23A- 1 AUTOMATIC GEARBOX General DP0 23A Identification engraving on the automatic gearbox. I - SPECIFICATIONS Weight: 70 kg. Vehicles fitted with the DP0 automatic gearboxes use systems called « Shift lock » and « Lock up ». The purpose of the « Shift lock » function is to prevent the gear selector lever from being moved without the brake pedal being simultaneously depressed. The purpose of « Lock up » or converter bypass is to connect the automatic gearbox directly to the engine. This function is performed by a « mini clutch » located on the converter. « Lock up » is controlled by the automatic gearbox. As the automatic gearbox is lubricated under pressure, lubrication is only provided when the engine is running. Consequently, and to avoid serious damage, it is essential to comply with the following instructions: - never allow the vehicle to coast with the ignition swit- ched off (i.e. when going down a hill); the damage that this may cause cannot be stressed highly enough, - never push the vehicle (i.e.: to get to a petrol station, unless the precautions in the « Towing » section have been taken). The vehicle only has drive when the engine is running. It is therefore impossible to start the engine of a vehicle with an automatic gearbox by pushing the vehicle. II - TOWING The vehicle should preferably be towed in all cases on a tow truck or with the front wheels raised. Nonetheless, if this is impossible, in exceptional cir- cumstances, the vehicle may be towed at low speed (maximum 12 mph (20 km/h) over a maximum distan- ce of 18 miles (30 km) (lever in N position). 13786 Note: For repair operations when the battery is faulty, refer to the notice on board the vehicle. WARNING Towing weight (towing a caravan, boat, etc.): - the load being towed must be less than or equal to 950 kg for a DP0 gearbox. - failure to comply with this maximum load will, on a 7% gradient, result in the maximum engine oil and automatic gearbox oil temperature being excee- ded, causing damage to the engine.
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