ALFA 159 TRAINING MATERIAL
Fiat Auto S.p.A.
After Sales Training
Aisin AF40-6
1.9 Multijet 16V
2.4 Multijet 20V
3.2 JTS
ALFA 159 TRAINING MATERIAL
Fiat Auto S.p.A.
After Sales Training
1 AISIN AF40-6 GEARBOX
1.1 Description
The AISIN AF 40-6 gearbox is an automatic, 6-speed gearbox used for the 1.9 JTD 16V
and 2.4 JTD 20V engine versions.
General features
¾ Type: automatic, 6-speed gearbox
¾ Engine: 1.9 JTD 16V and 2.4 JTD 20V
¾ Architecture: 3 clutches, 2 brakes, 1 free wheel, 2 epicyclical trains
¾ Hydraulics: 4 linear solenoids, 2 ON/OFF solenoids
¾ Electronics: built-it Neutral Start Switch and control unit, internal speed sensors and
cabling
NAME AF 40-6
VEHICLE 194
ENGINE VERSIONS 1.9 JTD 16V 2.4 JTD 16V
GEAR RATIO
1 4.148
2 2.370
3 1.556
4 1.155
5 0.859
6 0.686
R 3.394
Idle shaft 0.836
Differential 3.188
BRAKES AND
CLUTCHES
CLUTCHES
C1
1 flange, 6 discs, 6
plates
1 flange, 7
discs, 7 plates
C2
1 flange, 3 discs, 3
plates
1 flange, 4
discs, 4 plates
C3 1 flange, 4 discs, 4 plates
BRAKES
B1 Band type
B2
2 flange, 6 discs, 5
plates
2 flange, 6
discs, 5 plates
One-Way
F1 Roller type
SOLENOIDS
Shift solenoid
2
Linear
6
LINE PRESSURE
[KPa]
IDLING
D 372 – 414
R 575 – 665
STALL
D 1,350 – 1,460
R 1,905 – 2,125
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Gearbox section:
1. Torque converter
2. Transmission gear
3. Transmission gear
4. Differential
5. C1, C2, C3: clutches
6. B1, B2, F1: brakes
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1.2 Functions
Neutral Control
When the vehicle is stopped with the lever in position “D”, the clutches will be
automatically released, and the gearbox will be set to neutral. Thus, the torque
converter will not be stressed; moreover, fewer vibrations will occur, and fuel
consumption will be lowest.
This functions will not be implemented on rough terrain and uphill roads: in the latter
instance, the gearbox will remain engaged, thus ensuring a “hill holder” effect.
Reverse gear control
By moving the lever from “N” to “R”, the reverse gear will not be engaged if the vehicle
speed exceeds 11 r.p.m.
Adaptivity
MODE DESCRIPTION
ADAPTIVE
It is used during normal driving. Both the sports and the economy
modes are automatically selected according to the driving
conditions.
SPORTS
With this mode, the lock-up actuation and gear shifting points are
higher, to achieve a higher engine revs number.
WINTER/LOW GRIP
In case of ice, snow and low grip conditions in general, the vehicle
will be started in the third speed to avoid front wheel slipping.
TIP
By moving the lever from “D” to “+/-“, the driver may choose the
gear shifting point in a sequential fashion. In any case, the control
unit will change the gear automatically to avoid out-of-revs
conditions, or vice versa to avoid jerks when the engine speed is
too low.
HIGH TEMPERATURE
In case of too high gearbox oil temperature, the control unit will
advance lock-up actuation in order to avoid excessive slipping in
the torque converter and, thus, cause the temperature to decrease.
HEATING
In this case, on the contrary, converter slipping will be enhanced in
order to heat the oil.
RISE
The rise will be automatically detected with a control unit algorithm
based on the revs number increase: the gear shifting points will be
increased.
DESCENT
Conversely, the system will, when the vehicle is riding downhill,
make use of a few tricks in order to avoid prolonged use of the
brakes (lock-up, etc.).
FAST ON
This control calculates the driver’s performance requests through
the pressure on the accelerator pedal and regulates, accordingly,
the gear shifting points.
BRAKE ASSISTANCE
On the contrary, the exhaust brake is used in this case to help the
driver in case of deceleration (which is measured, once again,
through the accelerator pedal).
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1.3 Components
Control unit
The B connector is connected to the gearbox cabling, in the pin-to-pin configuration.
The A connector is connected to the front cable:
1
Key switch signal
2
N.C.
3
N.C.
4
K line
5
Steering lock signal
6
CAN L
7
CAN H
8
CAN H
9
Ground
10
N.C.
11
Power supply
12
N.C.
13
Reversing light relay
14
CAN L
15
N.C.
16
N.C.
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Input/output managed by the control unit
The interface with the automatic transmission system manages the information through
the following serial lines:
C-CAN (information, data)
K line (diagnosis)
SIGNAL
I/O
TYPE OF
TRANSMISSION
Key status
I
CAN
System failure warning light
O
CAN
Max. gearbox oil temperature warning light
O
CAN
Gear ON display
O
CAN
Gear selection
I
CAN
System diagnosis
I/O
K
Vehicle speed
I
CAN
Brake pedal pressed for recovery (brake light
contact)
I
CAN
Driver’s side front door status
I
CAN
Acoustic indicator actuation
O
CAN
Start enable to NBS
O
on/ off @GND
Reversing light control
O
on/ off @+15
Engine water temperature
I
CAN
Engine torque variation request
O
CAN
MIL warning light ignition request
O
CAN
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Cabling
The cabling is located inside the gearbox and is connected, inside the valve body, to
the following items:
¾ speed sensors;
¾ oil temperature sensor;
¾ solenoids.
Cabling pin-out
The cabling is connected to the gearbox control unit by means of a pin-to-pin connector
made by Aisin.
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You can easily see the difference compared with the AISIN 5-speed gearbox fitted to
the 2.2 petrol engine version:
AISIN 6-speed cabling
Solenoid valve pack
The purpose of the solenoid valve pack is to supply, through solenoids actuated by the
control unit signals, the hydraulic pressure generated by the oil pump to the brakes,
clutches and lock-ups. Moroever, part of the oil is reserved for component lubrication.
NSW built
into the
control unit
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1
Control unit
2
Torque converter
3
Solenoid valve pack
4
Brakes/clutches
5
Oil radiator
6
Oil pump
7
Epicyclical gears
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Solenoids
Linear solenoids: four linear
solenoids are provided, which
control, in a linear fashion, the
hydraulic pressure of almost all the
brakes/clutches
ON/OFF solenoids: two ON/OFF
solenoids are provided, which
control the “B2” brake for the
exhaust brake in the first gear
SLT linear solenoid: it controls, in
a linear fashion, the line pressure
depending on the throttle signal
and the engine torque
SLU linear solenoid: it controls, in
a linear fashion, the lock-up
pressure with regard to:
throttle signal
engine revs
gearbox input speed
gearbox output speed
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Sensors
Lever position sensor (NSW)
The position sensor is of the Hall-effect type and is built into the body of the control unit.
It informs the control unit of the gear lever position
Linear characteristic of the position sensor
Oil temperature sensor
The oil temperature sensor is a NTC and is built into the cabling.
NCA
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Features:
Temperature Resistance
10 °C 5.62-7.31 (kΩ)
25 °C 3.5 (kΩ)
110 °C 0.22-0.27 (kΩ)
Input/output speed sensors
1.input
2.output
The input speed sensor measures the rotation speed input to the gears, i.e. the
converter turbine speed.
The output speed sensor measures the rotation speed of the gear that conveys the
motion to the differential.
1.4 Tests
Stall test
The purpose of the stall test is to check correct operation, mainly of the gearbox and the
torque converter.
It is carried out with the gear lever in positions “D” or “R”.
The test procedure is as follows:
¾ lock the four wheels and engage the handbrake;
¾ press the brake pedal fully down with your left foot;
¾ position the gear lever to “D”, press the accelerator pedal fully down, then verify the
maximum revs number reached;
¾ move the gear lever to “R”, then check again the maximum revs number.
The standard value is 2,730 r.p.m.
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1.5 Procedures
Oil level check
¾ Position the vehicle on a lift.
¾ With the coolant cold, start the engine and move the speed selector
twice from position "P" to position "D" and viceversa with the brake
pedal depressed.
¾ Maintain the selector in each position for 2 seconds.
¾ Adjust the transmission fluid temperature between 80-85°C,
connecting the Examiner, to allow the automatic transmission fluid
cooling circuit thermostat valve to open, then stabilise at a temperature
of 35-45°C.
¾ Remove the automatic transmission fluid level check plug (1a) and
check that fluid emerges from the drain plug hole (1b).
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If no fluid emerges, proceed as follows
¾ Retighten the automatic transmission fluid level check plug.
¾ Remove the automatic transmission fluid filler plug.
¾ Add 0.5 litres of the specified fluid to the filler opening 1.
¾ Automatic transmission Fluid Oil Tutela Gi/Vi 3.320 kg
¾ With the brake pedal depressed, move the gear selector twice
from position "P" to position "D" and viceversa, maintaining the
selector in each position for 2 seconds.
¾ Set the selector to "P" and operate the parking brake (it is advisable to use chocks to
lock the wheels).
¾ Remove the automatic transmission fluid level check plug and check
that fluid emerges from the drain plug hole.
¾ If no fluid emerges, repeat the above operations.
¾ Clean oil traces from the drain hole area and tighten the automatic.
¾ Transmission fluid level check plug to the specified torque.
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¾ Before tightening, check that the o-ring fitted to the plug is undamaged.
¾ Replace the o-ring if it is damaged.
Automatic transmission fluid level check plug: 0.6 -0.8 daNm
¾ Tighten the automatic transmission fluid drain plug to the
recommended torque.
Automatic transmission filler plug: 2.4 -3.6 daNm
¾ Automatic transmission Fluid for 1.9 JTD 16v, 2.4 JTD 20v & 3.2 JTS:
Oil Type : TUTELA GI/VI
Replacing gearbox from spare part department : 2.84 Litres @ 15 deg c
Changing oil during service : 3.89 Litres @ 15 deg c
Total refilling after gearbox opening : 7.14 Litres @ 15° deg c
ALFA 159 TRAINING MATERIAL
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ALFA 159 TRAINING MATERIAL
Fiat Auto S.p.A.
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1.6 GEAR CONTROLS
¾ The request to change gear may take place in the following ways:
¾ - sequential (manual) or automatic via the selector lever
¾ - sequential (manual) via the steering wheel controls (where present).
¾ Selector lever
¾ P = Park
¾ R = Reverse
¾ N = Neutral
¾ D= Drive, automatic forward gear
¾ + = Shift from higher transmission ratio in sequential mode
¾ - = Shift from lower transmission ratio in sequential mode
¾ Manual sequential command from selector lever
¾ The 6 gear changes can be managed sequentially by moving the lever to the right and
raising it in the +
¾ direction engages a higher ratio whilst lowering it in the - direction engages a lower ratio.
¾ Each gear engaged is shown by a number on the instrument panel display.
¾ Automatic command from selector lever
¾ The automatic command D can be selected from the sequential operation in any driving
conditions.
¾ The optimum ratio is selected by the gearbox electronic control unit depending on the
engine speed and load
¾ conditions.
¾ Manual sequential command from steering wheel (where present)
¾ The change can be managed sequentially via the controls on the steering wheel.
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¾ To use the controls of the steering wheel, the gear lever must be in a (manual) sequential
position:
¾ Operating the lever on the steering wheel in the + direction engages a higher ratio
¾ Ooperating the lever on the steering wheel in the +-direction engages a lower ratio
¾ Automatic driving mode selection (where present)
¾ It is possible to select different driving modes by pressing the SPORT/WINTER button on
the gearbox control panel.
¾ The following driving modes are available:
¾ NORMAL: gear changes at low engine speeds, favouring comfort and reduced
consumption
SPORT: gear changes at higher engine speeds, enhancing sporty driving
WINTER: programme for setting off on roads in poor grip conditions.
¾ The selection mode remains in force until the button is pressed again or the engine is
switched off.
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