gearbox RENAULT TWINGO 2009 2.G Sequential Transmission Workshop Manual

2Transmission
V2 MR-413-X44-21B000$TOC.mif
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"The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from
which his vehicles are constructed."
V2
All rights reserved by Renault s.a.s.
Edition Anglaise
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
Renault s.a.s.
© Renault s.a.s. 2008
SEQUENTIAL GEARBOX
Vdiag No: 04
Fault finding - Introduction 21B - 2
Fault finding - Fault finding log 21B - 7
Fault finding - System operation 21B - 8
Fault finding - Replacement of components 21B - 13
Fault finding - Configurations and programming 21B - 21
Fault finding - Fault summary table 21B - 22
Fault finding - Interpretation of faults 21B - 24
Fault finding - Conformity check 21B - 78
Fault finding - Status summary table 21B - 79
Fault finding - Interpretation of statuses 21B - 80
Fault finding - Parameter summary table 21B - 105
Fault finding - Interpretation of parameters 21B - 106
Fault finding - Command summary table 21B - 120
Fault finding - Interpretation of commands 21B - 121
Diagnostic - Fault finding chart 21B - 126

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Fault finding - Introduction
1. SCOPE OF THIS DOCUMENT
This document presents the fault finding procedure applicable to all computers with the following specifications:
2. PREREQUISITES FOR FAULT FINDING
Documentation type
Fault finding procedures (this manual):
–Assisted fault finding (integrated into the diagnostic tool), Dialogys.
Wiring Diagrams:
–Visu-Schéma (CD-ROM), paper.
Type of diagnostic tools
–CLIP
Special tooling required
3. REMINDERS
Procedure
To run fault finding on the vehicle computers, switch on the ignition.Vehicle(s): New Twingo
Function concerned: Sequential gearboxName of computer: Sequential gearbox
Vdiag No: 04
Special tooling required
Multimeter
Elé. 1589 Sequential gearbox bornier
Elé. 1590 Injection bornier
Elé. 1681 Test probe kit
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Fault finding - Introduction21B
Faults
Faults are declared as either present or stored (depending on whether they appeared in a certain context and have
disappeared since, or whether they remain present but have not been diagnosed within the current context).
The present or stored status of faults should be taken into consideration when the diagnostic tool is switched on
after the + after ignition feed (without any system components being active).
For a present fault, apply the procedure described in the Interpretation of faults section.
For a stored fault, note the faults displayed and apply the instructions in the Notes section.
If the fault is confirmed when the instructions in the Notes section are applied, the fault is present. Deal with the fault
If the fault is not confirmed, check:
–the electrical lines which correspond to the fault,
–the connectors on these lines (corrosion, bent pins, etc.),
–the resistance of the component detected as faulty,
–the condition of the wires (melted or split insulation, wear).
Conformity check
The aim of the conformity check is to check data that does not produce a fault on the diagnostic tool because the
data is inconsistent. Therefore, this stage is used to:
–carry out fault finding on faults that do not have a fault display, and which may correspond to a customer
complaint.
–check that the system is operating correctly and that there is no risk of a fault recurring after repairs.
This section gives the fault finding procedures for statuses and parameters and the conditions for checking them.
If a status is not behaving normally or a parameter is outside the permitted tolerance values, consult the
corresponding fault finding page.
Customer complaints - Fault finding chart
If the test with the diagnostic tool is OK but the customer complaint is still present, the fault should be processed by
customer complaint.
A summary of the overall procedure to follow is provided on the following page
in the form of a flow chart.

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4. FAULT FINDING PROCEDURE
Perform a pre-diagnostic on
the system.
Print the system fault finding log
(available on CLIP and in the MR
or Technical Note).
Connect CLIP.
no
Dialogue with
computer?
yes
Read the faults
no
Faults
present
yes
Deal with present faults
Deal with stored faults
no
The cause is
still presentFault
solved
yes
See ALP no. 1
Conformity check
no
The cause is
still presentFault
solved
Use fault finding charts (ALPs)
no
The cause is
still presentFault
solved
Contact the Techline with the
completed fault finding log.

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Fault finding - Introduction21B
4. FAULT FINDING PROCEDURE (CONTINUED)
Wiring check
Fault finding problems
Disconnecting the connectors and/or manipulating the wiring harness may temporarily remove the cause of a
fault.
Electrical measurements of voltage, resistance and insulation are generally correct, especially if the fault is not
present when the analysis is made (stored fault).
Visual inspection of the connection
●Check that the connector is connected correctly and that the male and female parts of the connection are
correctly coupled.
Visual inspection of the area around the connection
●Check the condition of the mounting (pin, strap, adhesive tape, etc.), that the connectors are attached to the
vehicle.
●Check that there is no damage to the wiring trim (sheath, foam, adhesive tape, etc.) near the wiring.
●Check that there is no damage to the electrical wires at the connector outputs, in particular on the insulating
material (wear, cuts, burns, etc.).
Disconnect the connector to continue the checks.
Visual inspection of the plastic casing
●Check that there is no mechanical damage (casing crushed, cracked, broken, etc.), in particular to the fragile
components (lever, lock, openings, etc.).
●Check that there is no heat damage (casing melted, darker, deformed, etc.).
●Check that there are no stains (grease, mud, liquid, etc.).
Visual inspection of the metal contacts
(The female contact is called CLIP. The male contact is called TAB.)
●Check that there are no bent contacts (the contact is not inserted correctly and can come out of the back of the
connector). The spring contact of the connector when pulling the wire slightly.
●Check that there is no damage (folded tabs, clips open too wide, blackened or melted contact, etc.).
●Check that there is no oxidation on the metal contacts. Note:
Carry out each requested check visually. Do not remove a connector if it is not required.
Note:
Repeated connections and disconnections alter the functionality of the connectors and increase the risk of poor
electrical contact. Limit the number of connections/disconnections as much as possible.
Note:
The check is carried out on the 2 parts of the connection. There may be two types of connections:
–Connector / Connector
–Connector / Device

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Fault finding - Introduction21B
Visual inspection of the sealing
(Only for watertight connectors)
●Check for the seal on the connection (between the 2 parts of the connection).
●Check the seal at the back of the connectors:
–For unit joints (1 for each wire), check that the unit joints are present on each electrical wire and that they
are correctly positioned in the opening (level with the housing). Check that plugs are present on openings
which are not used.
–For a grommet seal (one seal which covers the entire internal surface of the connector), check that the
seal is present.
–For gel seals, check for gel in all of the openings without removing the excess or any protruding sections
(it does not matter if there is gel on the contacts).
–For hotmelt sealing (heat-shrink sheath with glue), check that the sheath has contracted correctly on the
rear of the connectors and electrical wires, and that the hardened glue comes out of the side of the wire.
●Check that there is no damage to any of the seals (cuts, burns, significant deformation, etc.).
If a fault is detected, repair or replace the wiring (see Technical Note 6015A, Repairing electrical wiring, Wiring:
Precautions for repair).

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Fault finding - Fault finding log
5. FAULT FINDING LOG
You will always be asked for this log:
●when requesting technical assistance from Techline,
●for approval requests when replacing parts for which approval is mandatory,
●to be attached to monitored parts for which reimbursement is requested. The log is needed for warranty
reimbursement, and enables better analysis of the parts removed.
6. SAFETY INSTRUCTIONS
Safety rules must be observed during any work on a component to prevent any damage or injury:
Make sure the battery is properly charged to avoid damaging the computers if there is a low charge.
Use the appropriate tools. IMPORTANTIMPORTANT
Any fault on a complex system requires thorough fault finding with the appropriate tools. The
FAULT FINDING LOG, which should be completed during the procedure, enables you to keep
track of the procedure which is carried out. It is an essential document when consulting the
manufacturer.
IT IS THEREFORE MANDATORY TO FILL OUT A FAULT FINDING LOG EACH TIME FAULT FINDING
IS CARRIED OUT.
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SEQUENTIAL GEARBOX
Fault finding - System operation
1. Sequential gearbox functions
The electrohydraulic system attached to the gearbox comprises two actuators, one for gear selection and changing,
the other for operating the clutch, and a hydraulic power unit which supplies power to the actuators.
The assembly is linked to the sequential gearbox computer, which itself is linked to the engine management
computer by a multiplex line connection. The gear lever is used to select gears: in automatic mode, gear changes
are controlled by the computer which uses auto-adaptive shift patterns; in manual mode, the driver moves a lever
which, via the computer, change the gears.
When the gear is changed, the sequential gearbox computer controls the engine management computer and the
torque in such a way as to reduce bucking, leaving the driver free to leave his foot on the accelerator pedal.
Description of user operation:
The interface between the driver and the sequential gearbox system inside the passenger compartment comprises:
–a gear lever (mechanical section and internal electronic section),
–a display,
–a buzzer.
Using this interface, the driver can:
–request gear changes (up or down),
–request a specific gear change (into neutral or reverse),
–switch between manual and automatic mode,
Description of passenger compartment control:
Description of gear lever positions:
–“S”: Standby: this is the only stable gear lever position. Each time the driver presses the lever, it returns to the S
position.
–“R”: Reverse: moving the lever to this position enables the driver to select reverse gear. Given the lever position
of the reverse function, if the movement is too slow, the sequential gearbox computer can read the N signal and
hence neutral is selected before reverse.
–“N”: Neutral: moving the lever to this position enables the driver to select neutral.
–“A/M”: AUTO/MANUAL: moving the lever to this position enables the driver to select either the manual mode (or
semi-automatic) or automatic mode. If AUTO mode is selected, moving the lever will enable the driver to select
manual mode, if manual mode is selected; moving the lever will enable the driver to select automatic mode. The automatic mode used by the sequential gearbox is based on the design of the DP0 automatic gearbox which
uses
shift patterns that adapt automatically to the driving style and road conditions.
The gear change is determined by a set of gear change graphs as a function of the accelerator pedal position and
the vehicle speed.
The sequential gearbox is a conventional manual gearbox with an electrohydraulic control.
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Description of gear lever positions (continued):
–"+": moving the gear lever towards this position enables the driver to shift up,
–“-”: moving the gear lever towards this position will enable the driver to shift down.
Description of the display:
This display is specifically for the sequential gearbox. It displays 4 types of information for the driver:
–displays the gear selected: 1, 2, 3, 4, 5, N or R,
–the pictogram displaying AUTO mode: this pictogram lights up when AUTO mode is selected,
–the “depress brake pedal” symbol: this symbol lights up when a driver action requires the brake pedal to be
depressed if the driver is not depressing the brake pedal. This symbol only lights up when there is an error (driver
actions without depressing the brake pedal = symbol lighting up),
–the sequential gearbox fault warning light: this lights up when the sequential gearbox computer detects a fault on
the sequential gearbox system.
General information about the operation:
Operation in MANUAL mode:
Manual mode allows the driver to select gears by moving the gear lever. However, in manual mode, the driver is not
completely free to do what he/she likes. This is why this mode is also called semiautomatic mode because the driver
is still assisted by the sequential gearbox computer in the following instances:
–when driving, shifting the lever towards the “+” position may result in underspeed. As a result, the sequential
gearbox computer forbids the driver's request,
–when driving, shifting the lever towards the “-” position may result in engine overspeed. As a result, the sequential
gearbox computer forbids the driver's request,
–when driving, as the overspeed threshold is approached, the computer automatically selects a higher gear,
–when driving, as the underspeed threshold is approached, the computer automatically selects a lower gear,
–when driving, if the vehicle speed reduces too quickly (brakes applied), the sequential gearbox computer can
order a downshift. Reminder:
Creep is only possible in first or reverse gears; it makes parking manoeuvres easier: if the brake pedal or
the handbrake is released, the vehicle moves forward by itself, without the driver having to accelerate.
Creeping is not possible in second gear.

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Operation in MANUAL mode (continued):
–when driving, the selection of “N” is only accepted by the sequential gearbox computer if the driver's foot
is on the brake pedal,
–when driving, selection of reverse gear is prohibited,
–when the vehicle is slowing down and the speed is approaching 0 mph, the sequential gearbox computer
automatically selects 1
st gear.
In manual mode, the driver decides when to change gears by:
–moving the gear lever towards “+” which enables a higher gear to be selected,
–moving the gear lever towards “-” which enables a lower gear to be selected,
–moving the gear lever to “N” which enables neutral to be selected,
–moving the gear lever to “R” which enables reverse gear to be selected.
Operation in AUTO mode:
Automatic mode frees the driver from having to worry about changing gear: instead, the sequential gearbox
computer determines when best to change gear in relation to the different vehicle parameters (speed, acceleration,
position of accelerator pedal etc.,).
The main characteristics of automatic mode are as follows:
–AUTO mode only functions when the engine is running.
–AUTO mode is preselected when the engine is started.
The AUTO mode entry conditions are as follows:
–Moving the gear lever to the left (towards A/M) when manual mode is selected, when a forward gear is
engaged and AUTO mode was selected.
–Engine started.
To exit AUTO mode when driving and under normal operating conditions (no faults), the following exit conditions
must be met:
–Movement of the gear lever to the left (deselecting automatic mode using the lever).
–Movement of gear lever towards “+” (except when changing from R to 1 or N to “X”).
–Movement of the gear lever towards “-” (except when changing from N to “X” or when reverse gear is
engaged).
Buzzer operation:
The buzzer operates in the following cases:
–Safety risk: the buzzer sounds when one of the front doors is opened, if the following conditions are met:
–the engine is running,
–a gear is engaged,
–the driver is not applying the brakes.
–The buzzer will cut out if one of the following conditions is confirmed:
–the engine is not running,
–the driver applies the brakes,
–the driver closes the door(s).
–Driver warning when push-starting vehicle:
–The buzzer will sound to inform the driver that moving the lever to select a gear will enable the engine to
start. The buzzer will sound when the vehicle has reached the speed that will allow the engine to start.
–When the computer detects that the clutch is overheating.