‘The Control Unit - The Key to new generation of automatic gearbox Model Year 1995 «+ Loccup clutch «Stepped planetary gear set + New shift elemen's + Dynamic shift programmes[Introduction oh orth |G _New Components and Operations 5-7 General View of System e - 0 Control UnivFuzzy Logic 1-15 Sensors we. oH BD Actuators ae: 7 Function Diagram 0-38 BD Sett-Diagnosis 4-48 BD _ Mechanicals/ Hydraulics a+ oot Look-up clutch Power tranemission Clutches Power flow @ Final rive e+ 6 @ circuit os. 6s (@ Test Your Knowledge eo - 70 | ~ The Pr me is not a Workshop —_—Please refer to the Service Literature which =r contains all the relevant inspection, adjustment ‘and repair instructions.The 4-speed automatic gearbox (AG 4) for VW and Audi ‘The AG4 95 is a further development of the familar 4-speed automatic gearbox. ‘This Self-Study Programme provides you with Information on the modifications to the AG4 95 gearbox compared to the AG4 89 version. Computer technology has made it possible to design an automatic gearbox which is more ‘convenient and simpier for the driver to use. A lock-up clutcn makes it possibie to minimize torque converter siip. The result is improved fuel ‘economy and thus a cleaner environment for all. Newly designed clutches result in gear changes. ‘which are even more jerk-free and smooth, ‘S9P 17201‘The control unit 68-pin for the automatic gearbox J 217 ssp 17202 ‘The ECO/Sport ewitch on the selector lever thas boon replaced by the floating has beon eliminated ‘= shift point selection based on driver style and Is inserted into the gearbox housing. The information regarding vehicle speed is detected by this induction sensor by means of the puse ‘rotor at the input gear. SSP 17216 Information regarding vehicle speed is required for: + the decision as to which gear should be engaged ‘+ cruise control system ‘+ torque converter sip control ‘The control unit uses the engine speed as a substitute signal. ‘The lock-up clutch is no longer closed. Vehicle speed sender G88 no signal Cruise control system | “no signal”Puloe retor at input goat Electric circuit 20 Signal wire 43. Sereering 65 Outputvoltage SSP 172/16 (Lt. Tae 21ATF temperature sender G 93 is located on the printed conductor at the valve ody in the ATF. The sensor measures the ‘temperature of the automatic transmission fluid. ssp 7218 Use of signal “The ATF temperature sender G 93 is an NTC. resistor, Its resistance drops as the flud temperature rises. Effects of signal fallure No substitute functions exist. ‘Self-dlagnosis "fault message" ATF temperature sender G 93 | “no fault type recognized” a SSP 172/86 2ATE temperature ‘sender G 93 SSP 172/19 Electric circuit 6 ATF temperature signal 67 Supply voltage ‘SSP 172/20 It the ATF temperature reaches the limit of 450°C, the lock-up clutch is closed. The stress on the torque converter is reduced, the ATF cool down. this measure is not adequate, the control unt shifts down a gear. S217 2s‘The engine speed sender G 28 Use of signal Effects of signal fallure Self-diagnosis "fault message" SSP 17285 24 ‘The control unit of the automatic gearbox uses the engine speed signal of the relevant engine ‘management system. + The control unit compares the engine speed and the speed of the car. The control unit recognizes the slip of the lock-up clutch on the basis of the difference in speed. Ifthe slip Is 100 large (difference in speed), the control unt increases the contact pressure of the lock-up ‘clutch and thus reduces the ‘+ The control unit uses the signal of the engine speed sensor as a subsiitute parameter for the signal of the vehicle speed sender. ‘The control unit moves into the back-up mode Engine speed sencer G 78 “speed Information missing”Electric circuit Pe 19 Signal wire J2i7 Engine control unit G28 ssp17202 ‘As the naturally aspirated diesel engine does not need an engine speed sender, a sender is positioned on models with automatic gearbox in the gearbox bell housing. It supplies its signal direct to the AG 4 control unit,The kickdown switch F 8 Use of signal Effects of signal failure Solf-diagnosis ‘fault message" SSP 172/83 is integrated in the throttle bowden cable and detects the accelerator being depressed beyond ‘the full throtte point ‘On the TDI engine the switch is incorporated in the pedal position sensor. AI sem When the switch is operated, the gearbox shifts down immediately into the next lower gear (2.9. from 4th gear to 3rd gat). The control unit takes ‘account of the engine speed. In adcition, the Upshifts occur at higher engine speeds. Ia high power output is required from the engine inthe kickdown mode, the air conditioning ‘system is switched off for up to 8 seconds. ‘The kickdown shift point occurs when accelerator pedal is depressed 95% Kickdown switch F 8 “Implauaible signal”ssp 172124 Electric circuit 16 Kickdown signal : ses pre + -/- eo ssp 17275 arThe multifunction switch F 125 Use of signal Effects of signal failure Solf-diagnosis "fault message" SSP 17227 28 Is located in the gearbox housing and is operated by the cable of the selector lever. $8 17228 Depending on the signal regarding the selector lever position supplied by the mutifunction ‘switch, the control unit initiates the following functions: + switches on the reversing lights, ‘+ losks out the starter if@ drive position ie ‘engaged, ‘+ switches the cruise control system on and off, ‘The control unit moves into the back-up mode. Back-up mode ‘The control unit assumes selector lever position “Dt,Electric circuit 18 15 15 15 15 15 Terminal 15 Terminal 31 P,R, Nsignal Mutttunction switch N,D, 3 signal 3,2, 1 signal P,1 signal SSP 172/104 217 vals ss? 17228 nThe brake light switch F Use of signal Effects of signal failure Self-diagnosis "fault message" —# SSP 172/101 30 Is instaled at the pedal bracket. ‘The control unitis supplied with the information brake operated" through this switch. SP 17298 ‘The information of the brake light switch is required for the selector lever lock function. The selector lever cannot be moved out of the P ‘or N position when the car is stationary unless the brake pedal has been operated Ifthe contact is interrupted, the selector lever lock function is no longer performed. Back-up mode ‘The control unit assumes selector lever position o. | ignored in the fault memory.38P 17299 Electric circuit 15 Signal oan I. ssP 172/100 3t‘The solenold valves N88 to N94 are located in the valve body of the gearbox and are operated by the control unit. 2 diferent types of solenoid valves are used. ‘The solenoid valves Neg, N89, NOO, NG? and Nod are YES/NO valves. ‘They open or close an ATF port. + The gears specified by the control unit are engaged by the valves N68, NES and N9O. ‘+ The smoothness of the gearshiftis influenced by the valves N92 and N94, ‘The solenoid valves N91 to N9S are ‘modulation valves ‘These two valves make It possible to set the level of the dutch pressure required. The control Unit specifies the amperage. A low amperage means a high clutch pressure. + The valve N91 controls the clutch pressure for the lock-up clutch. @ ‘+ Tho valve N 93 controls the pressure of the multi-plate clutches and of the multi-plate brakes. noo SSP 1721 ‘The printed conductor ean now be replaced individually. Please use the new special tool 3373 for this operation. Neo Nes No2 Noo NetEffects of signal failure Wa solenoid valve fails, the control unit moves inte the back-up mode. Back-up mode ‘Self-diagnosis “fault message" ‘Solenoid valves NES-ND4 ‘open circult/short clreult to earth” SSP 172/105 Electric elreult 9 Solenoid valve NSO 40 Solenoid valve N94 22 Supply voltage N93 47 Solenoid valve Nt i 54 Solenoid valve N89 | 55 Solenoid valve N88 56 Solenoid valve N92 58 Solenoid valve No3 67 Solenoid valve supply voltage ‘SSP 172832‘The cruise control system ‘When the cruise control system is switched on, the automatic gearbox contro! unit releases the ower supply when the speed of the car rises above 30 kn/h. The car can be driven with the cruise control system in operation in selector lever positions D, 3 and 2. ‘The automatic gearbox control unit interrupts the Bnet supply ihe woioe vw SN A, Nand 1. Solf-diagnosis “fault message" s9P 172/34 Electric circuit 60 Input 61 Output 15 Terminal 15 60 Control unit for cruise control system ‘The powar for the cruise control system is ‘eupplied through the automatic gearbox control 89? 172/82 1s ignored in the faut memory. 213 ssp 17287‘Selector lever lock solenoid N110 is located at the selector lever. ‘SSP 17256 ‘Ths solenoids svtched on wih he lantion ad ing look is overridden by depressing the pase ‘and the selector lever can be moved into a crive position. Solf-diagnosis "fault message" Is ignored in the fault memory. 8 172/88 Electric circuit 29 Output SSP 172/35 35Starter Inhibitor and reversing light relay J 226 Is a combination relay and is integrated in the electiical centre. ‘+ It prevents the engine being started wnen a ‘drive position Is engaged. ‘+ The reversing lights are switched on when . reverse gear is engaged Se yes ‘The relay supplies the signal for this purpose from the multifunction switch F 125. ‘Self-diagnosis ‘fault message" Is ignored in the fault memory. & SSP 17289 Eloetrie circult 60 Terminal 15 11 P.Nsignal 18 P,R,Nsignal 18 P,1 signal F125 Multifunction switch MI6/17 Reversing lights B/SO Starter 36Selector lever display, for Tha ange of the sletr ovr postions of he ‘Transporter T¢ and vehicle rabapexter cote: be easy is Yerstone tr epecticmametsonty — fastuceetmesmcer ri ‘the position of the selector lever at that moment, S8P 17282 ‘Solf-diagnosis "fault message" Ifa faut is stored in the fault memory which is Rot covered by a substitute function, all the display lights of the ranges in the selector lever ‘spiay come on, Electric circult SSP 172/102 37Components B/S0 Starter (terminal 50) D/O Ignition/starter switch (terminal 50) FE Brake light switch Fe Kickdown switch F125 Multifunction switch G28 Engine speed sender G38 Gearbox speed sender GB Vehicle speed sender Geo ——_—Thvottle valve potentiometer G93 ATF temperature sender 4226 ‘Starter inhibitor and reversing light relay a Engine control unit 4217 Automatic gearbox control unit 19 Bubb for selector lever scale MAG/M17 Bulbs for reversing fights MSIM10 Bulbs for brake and taillights N88 Solenoid valve 1 Nad ‘Solenoid valve 2 Noo Solenoid valve 3 NOt Solenoid valve 4 Naz Solenoid valve 5 N93 Solenoid valve 6 Nos Solenoid valve 7 Selector lever lock solencid Colour coding Input signal Output signal Positive EarthThe self-diagnosis ‘The fautt reader V.A.G 1551 “The following functions are possible in data transfer by selecting “Address word 02 Gearbox electronics" (01 = Interrogating control unit version 02- Interrogating fault memory (04- Starting basic setting 05 - Erasing fault memory 06 - Ending output 08- Reading measured valve block 40 moritors the signals of the sensors, the ‘operation of the actuators electrically and parforms a self-test of the control unit. fa fault occurs, substitute functions are readied and fault descriptions stored in the non-volatile memory of the control unit. The faults are thus retained even if the battery Is disconnected and if ‘the connector of the control unit is unplugged. When fauits are stored, the control unit stinguishes between static and sporadic faults. Ha faut eccurs only once within several driving ‘oycles, it is stored as a sporadic fault If the fault {sino longer recognized over a distance of about 1000 km, itis automatically erased in the fault memory. If the fault continues to exist within the drive ‘cycles stored in the control unit, itis stored in the control unit as a static fault. SSP 172/83Function 01 - interrogating control unit version Part number of Gearbox designation 01M EPROM control unit indicates ear with transverse programme mounted engine with lock-up status clutch Y Y ' 01MS27733 BB ‘AG 4 Gearbox 01M 2029 Ceaeg on000, ws 00000 t t Is not required at Workshop code present Function 02 - Interrogating fault memory rs identtied by a colour are ‘The sensors/actuator monitored by the self-diagnosis. SSP 172/40Function 04 - Basic setting After performing certain repairs to the gearbox Display group number 00 ‘and to the engine, itis necessary to erase the values which the control unit has learned" (adapted). For example, after replacing the throttle valve ‘control unit. ‘The following readout appears in the display: Basie setting started ‘Please refer to the current Workshop Manual for the exact procedure of when and how to perform the basic gattingcan be tested in the measured value block. Function 08 - Reading measured value block The signals of the components shown in colour‘The pages which follow provide you with Information on modifications in the mechanical and hydraulic components of the AG4 95 gearbox compared to the AG £9 version. ‘The lock-up clutch permits a direct mechanical transmission of the power between engine and ‘gearbox without a torque converter. The torque ‘converter slip is eliminated and this is reflected in better fuel economy. ‘The muti-plato elutchos K1 and K3 are now balanced in respect of the centrifugal force. This enables the gearshifts to be performed smoothly and softy with a uniform quality SSP 172193, ‘The step-shaped design of the tong planetary (gears produces more favourable gear ratios, The {ear step from 3rd gear to 4th gear is significantly smaller. SSP 17207 ‘The gear step is the name given to the differance inthe ratio between the gears,The lock-up clutch is located in the housing ofthe torque converter. ‘lt creates a mechanical link between engine and be operatod irrespective ofthe gear engaged. Torque convertor sip is eliminated by locking up © the torque converter and approximately 100% of ‘engine power can be transmitted mechanically. SSP 172/49 Forque converter slip is the difference in speed entesn te Input engine speed and te speed at the output of the torque converter. 45The lock-up clutch In the torque converter Torque converter ——_Lock-up dutch wih torsion camper > e¢€¢ 9 5? 172/60 ‘The torque convertor is welded and filled with ATF. ‘The torsion damper at the lock-up clutch reduces the torsional vibrations of the engine. ‘Torsion damper SSP 17261 ‘The torque converter has been cut open to provide a better illustration, 46Components of the lock-up clutch SSP 172/82 “The lock-up clutch is connected to the turbine wheel ‘SSP 17283 7Operating principle of the lock-up clutch | Modulation valves ltr the ATF pressure steplessly 3 ATF ports are pressurized altemately with oll Pressure to open and close the lock-up clutch. ‘The 3-port principle with the modulation valve N01 makes it possible to specifically increase and reduce the pressure when closing and ‘opening the lock-up clutch. This ensures comfortable, jerk-free closing. ‘The lock-up clutch Is open ‘The ATF fows through port A and B. Port Cis closed. The oll flowing out of port B passes to the planetary gear where it lubricates the components. 8 ‘The lock-up clutch is operated by the modulation valve N91 in the valve body. The control unit ‘Specifies the moment at which the lock-up clutch loses or opens, Its mainly closed when driving in 3rd and 4th gear in order to lock up the torque converter. SSP 172155 SSP 172/56‘The-lock-up clutch closes ATF is fed through port Cto close the lock-up clutch, Port A is opened. As a resut, the of pressure on the rear of the lock-up ctch is higher than on the front. The friction lining moves against the torque converter housing and creates 8 postive connection from the engine to the gearbox. The planetary gear is now lubriated through ports C and B. The lock-up clutch is opened ‘The ATF is now again supplied through port A. Port Cis closed. As a result, the pressure at the {ont of the lock-up clutch is increased. The lock- up clutch opens. ‘The lubricating oil is again supplied through ports AandB. Rear of lock-up clutch Friction lining ‘Torque converter SSP 172/89 SSP 172/60 49Hydraulic power flow - the lock-up clutch Is open ‘SSP 172/60 80Mechanical power flow - the lock-up clutch Is closed SSP 172/61 stThe centrifugal force-pressure The operation of the clutches K1 balance clutches K1 and K3 and K3 has been modified. This Increases the smoothness of the gearshift. SSP 17274 Clutch open The spring elds ine ech open io matter the, 85° 17206Clutch closes, ATF is forced under pressure into the chamber upstream of the piston in order to close the clutch. The ATF pressure compresses the spring and at the same time the plates of the cuutch, ‘The power is transrritted through the plates of the clutch. SSP 17205 ‘Clutch opens The space upstream of the piston is mado pressureless in order to open the clutch. ‘The force of the spring pushes the piston back into ts initial position. The clutch opens. SSP 17287 538“The clutches and brakes are operated by the control urit through the solenoid valves in the valve body in line withthe drive position engaged. SSP 172162(Clutches K1, K2 and K3 pass the power to the Planetary gear set. ‘+ Brake BZ holds the large sun wheel tight ‘+ K2 crives the large sun whee! + KX crives the small sun wheel + K3 chives the planet cartier ‘+ Brake B1 holds the planet cartier tight Planet carrier ‘The gear step from Srd to 4th gears improved by modifying the long planetary gears. The long planetary gears are stepped. SSP 172163, 65S=S= I SS? 172/85 56 fs Tie Na AS Ver ceHydraulic, selector lever position SSP 172768 Small sunwhe@ Planet carrier san cana eee Soa eae See ee oe! Transmission ratio of tst gear = 2.71 2nd gear hydraulic SSP 172167, Largo sunwhool Small aun whoo! — Pump whoot Frbine wheal (> clutch Kt (solenoid valve N88) (_y drives the smail sun wheel (= Brake B2 (solenoid vaive N €9) (holds the large sun whee! ‘Transmission rato of 2nd gear = 1 oT3rd gear hydraulic SSP 172/69 uo vet Pane Ce Cee ena av nea Spon (} Clutch k3 (solenoid vaive N90) Planet carrier 3rd gear with lock-up clutch ‘As tho emall sun wheel and the planet carrier ‘re driven, the entire planetary gear set rotates. ‘Transmission ratio of 3rd gear = 1.00 s9 17269 ‘Torque converter housing Look-up clutch (modulation valve N 91) > Remaining power transmission is identical with the hydraulic power flow ‘Transmission ratio of 3rd gear = 1.00 direct gear4th gear Turbine whee! Purp whos! Bz Zz] K3 $sP172/70 upaiwel a Pump whee! ‘Turbine whee! | Brake B2 holds the large sun wheel (sclenoid The planetary gear set orbits around the large L valve N89) sun wheel Clutch K3 drives the planet carrier (solenoid Tranerission ratio of ath gear = 0.74 valve N30) 4th gear with lock-up clutch SSP i727 Lookup clutch Large sun whest Planet cartor [Torque converter housing Look-up elutch (modulaton valve N81) [=F emaining power transmission is identical Transmission rato of sth gear « 0.74 withthe hycraulic power flow 59Reverse gear Pump whee! ‘Turbine wheel [> Brake 81 holds the planet carrier tight (solenoid vaive Nez |__, Clutch k2 is closed by the selector lever and the large sun wheel driven. Transmission ratio of reverse = 2.88‘The power Is transmitted from the planetary ‘gear through the axles to the wheels. Final crive for models with transverse-mounted engine ‘+ Golf gearbox designation 01M ‘+ Passat gearbox designation 01M Planetary gear ‘Torque converter Drive pinion Differential Bevel gear SOP 172/75Final drive for models with north-south engine ‘+ Audi gearbox designation 01N SOP 172/86 Final drive for commercial vericies with transverse-mounted engine + T4 goarbox designation 01° + Sharan gearbox designation 099 SSP 17276We have selected a greatly simplified illustration in order to make the ATF circuit easier to understand. SSP 1727 MERE Section sie [EEE aivery sice HEE oistrivution‘Suction side > Oil sump | Suetion filter i vawe body I> Housing labyrinth Pump suction side Delivery side [-— Delivery side [> Housing labyrinth -—— Valve body L__» Pressure valve Distribution [—— Pressure valve |» Solenoid valves [Slide valve SSP 172/781, Which components on the AGS 95 have been modified or are new compared to the AGs 897 FeEEBBBB ‘The control unit The lock-up clutch ‘The multcplate clutches Kt and KS ‘The goarbox speed sender G28 ‘The planetary gear set ‘The modulation valve N 91 2. A shift point selection based on driver's style and driving situation and a shift programme based on driving resistance have beon integrated In the control unit of the AG4 95. Which ‘component has it been possible to eliminate as a result? a) @ ic] ‘The vehicle speed sender G68 ‘The engine speed sender G28 ‘The ECO/SPORT switch 3, The AGS 95 has a new sensor. What Is It called and which functions are performed on the basis of its signal? [A] Gearbox speed sender G38 [B) —Muttfunction switen F 125 [E] Reduction in engine torque during the gearshift [2] Control of the multi-plate clutches during the gearshift4. the ATF reaches a temperature of 180 °C, the control unit initiates measures to reduce the ATF temperature, Which measures does the control unit adopt? a) The control unit moves into tha back-up mode B] Thetocc-up cutchie closed [EC] The contro! unit shifts into the next lower gear 8. Which information is supplied to the control unit by the multifunction switch F 125 and what are the functions which are then initiated? [A] Switching on and off of the eruise control system Locking of the starter when a drive position is engaged Selector lever position ‘Switching on of the reversing ights 8 ee 6. What are the advantages which a torque converter with integrated lock-up clutch offers ‘compared to a torque converter without a lock-up clutch? [R] The ock-up cluten permits mechanical power transmission between engine and gearbox ‘The torque converter slip is eliminated and appronimately 100% of engine power can be [B) transmitted a7. Which valve In the valve body controls the lock-up clutch? [A] The control valve N88 [B] The solenoid vaive N91 (E] The solenoid valve N93 8. f the throttle valve control unit is replaced, itis then necessary to perform a basic setting. How Is this basic setting performed? [A] After the ignition is switched on, the control unit automatically performs a basic setting Reference should be made to the Workshop Manual for the exact procedure for performin (B] the basic setting i 9. The solenoid valves N91 and N93 are modulation valves. What tasks do they perform? [A] Solenoid valve N91 controls the clutch pressure of the lock-up clutch TE] Sotencia vaive Not conirois the pressure for ctutch Kt [E] Solenoid valve NSB controls the pressure for clutch K3 2) Solencid valve NS controls the pressure of the multi-plate clutches and of the muit-piate B10. What task does the starter inhibitor and reversing light relay J 226 perform? [A] It operates the selector lever lock solenoid N 110 [BJ] Itprevents the engine being started when a crive position is engaged [C] When reverse gearis engaged, the reversing lights are ewitched on by this relay.qi 4 1 @ Sao aw Saag aaa Seao8 SaoGlorious outlooks SSP 172/106