Get Gearbox management system Guide for Volkswagen Touran 4 Door First Generation (2003-2015)

Gearbox management system

Overview of the system

Mechatronic unit for

direct shift gearbox J743

Sensors

Gearbox input

speed sender G182

Gearbox input speed sender 1 G632

Gearbox input speed sender 2 G612

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Clutch travel sender 1 G617

Clutch travel sender 2 G618

Gear selector movement sensor 1 G487

Gear selector movement sensor 2 G488

Gear selector movement sensor 3 G489

Gear selector movement sensor 4 G490

Gearbox hydraulic pressure sender G270

Temperature sender in control unit G510

Tiptronic switch in steering wheel E389

Diagnostic connector

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CAN

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Selector lever E313

Dash panel insert J285

Actuators

Motor for hydraulic pump V401

Valve 3 in gear train half 1 N435

Valve 3 in gear train half 2 N439

Valve 4 in gear train half 1 N436

Valve 4 in gear train half 2 N440

Valve 1 in gear train half 1 N433

Valve 2 in gear train half 1 N434

Valve 1 in gear train half 2 N437

Valve 2 in gear train half 2 N438

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Gearbox management system

Sensors

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Clutch travel sender 1 G617,

clutch travel sender 2 G618

The clutch travel senders are located in the

mechatronic unit above the clutch actuators.

For this reason, contact-free sensor technology is used

to record clutch travel.

The double clutch control system requires reliable and

precise recording of the current clutch actuation

status.

Contact-free position recording increases the

reliability of the sensor functions. Measured value

falsification caused by wear and vibrations is

avoided.

G617/G618

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Signal use

Effects of signal failure

The control unit requires these signals to control the

clutch actuators.

If clutch travel sender 1 G617 fails, gearbox path 1 is

shut off. Gears 1, 3, 5 and 7 can no longer be

engaged.

If clutch travel sender 2 G618 fails, gears 2, 4, 6 and

R can no longer be engaged.

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Clutch travel sender

Design

How it works

A clutch travel sender consists of:

An alternating voltage is applied to the primary coil.

As a result of this, a magnetic field is built up around

the iron core. If the clutch is actuated, the clutch

actuator piston moves through the magnetic field

with the permanent magnet. Due to the permenant

magnet's movement, a voltage is induced in the

secondary evaluation coils. The level of the voltage

induced in the left and right evaluation coils is

dependent on the position of the permanent magnet.

Via the level of the voltage in the left and right

evaluation coils, the sensor electronics detect the

position of the permanent magnet and therefore

the position of the clutch actuator piston.

● An iron core, around which the primary coil is

wound

● Two secondary evaluation coils

● A permanent magnet, which is located on the

clutch actuator piston, and

● The sensor electronics

Iron core

Applied alternating voltage

Primary coil

Secondary

evaluation coil

Permanent magnet

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Sensor electronics

Clutch actuator piston

Evaluation voltage

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Gearbox management system

Gearbox input speed sender G182

The gearbox input speed sender is inserted into the

gearbox housing.

The gearbox input speed is identical to the engine

speed.

It is the only sensor located outside of the mechatronic

unit.

The sender operates according to the Hall principle.

It electronically scans the starter ring gear and

thereby records the gearbox input speed.

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G182

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Signal use

Effects of signal failure

The control unit requires the gearbox input speed

signal to control the clutches and to calculate slip.

To do this, it compares the signals from the gearbox

input speed sender G182 before the clutches with the

signals from senders G612 and G632, which transmit

speed signals from the drive shafts.

In the event of signal failure, the control unit uses

the engine speed signal as a substitute signal.

It obtains this signal from the engine control unit

via the CAN bus.

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Gearbox input speed sender 1 G632 and

gearbox input speed sender 2 G612

Both senders are housed in the mechatronic unit.

● Sender G632 scans an impulse wheel, which is

located on drive shaft 1.

● Sender G612 scans a gear on drive shaft 2.

From this signal, the control unit calculates the

speed of drive shaft 2.

From this signal, the control unit calculates the

speed of drive shaft 1.

Both senders are Hall senders.

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G632

G612

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Signal use

Effects of signal failure

The speed signals from drive shafts 1 and 2 are used

by the control unit to control the clutch and to

calculate clutch slip.

If sender G632 fails, gear train half 1 is shut off.

The vehicle can then only be driven in gears 2, 4, 6

and R.

If sender G612 fails, gear train half 2 is shut off.

The vehicle can then only be driven in gears 1, 3, 5

and 7.

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Gearbox management system

Temperature sender in

control unit G510

The temperature sender is located directly in the

mechatronic unit's electronic control unit.

The sender measures the temperature directly of the

components at risk. As a result, measures to reduce

the oil temperature can be introduced at an early

stage, thereby avoiding excessive heating.

Hot hydraulic oil constantly flows around the control

unit, thereby heating it. Severe heating may impair

the functions of the electronics.

G510

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S390_074

Signal use

Effects of signal failure

The sender's signal is used to check the mechatronic

unit's temperature.

In the event of signal failure, the control unit uses an

internally available substitute value.

At a temperature of 139 °C, engine torque reduction

can be implemented.

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Gearbox hydraulic pressure

sender G270

The hydraulic pressure sender is integrated into

the mechatronic unit's hydraulic oil circuit.

It is designed as a diaphragm pressure sender.

Further information on the hydraulic

pressure sender can be found

in self-study programme 308

"The Direct Shift Gearbox 02E".

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G270

S390_075

Signal use

Effects of signal failure

The control unit uses the signal to control the motor

for the hydraulic pump V401.

In the event that the signal fails, the motor for

hydraulic pump runs continuously.

The hydraulic pressure is determined by the pressure

control valve.

At a hydraulic oil pressure of approx. 60 bar, the

motor is shut off according to the pressure sender

signal, and is switched on again at approx. 40 bar.

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Gearbox management system

Gear selector movement sensors

1 to 4, G487 to G490

The gear selector movement sensors are located

in the mechatronic unit.

On combination with the solenoids on the selector

forks, they generate a signal, from which the control

unit recognises the precise position of the gear

selectors.

G490

gears 6 and R

G489

gears 5 and 7

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G488

gears 1 and 3

G487

gears 2 and 4

Signal use

Effects of signal failure

The control unit requires the precise position of the

gear selectors to control the gear selectors for

changing gears.

If a movement sensor fails, the control unit cannot

detect the position of the corresponding gear selector.

As a result, the control unit is unable to recognise

whether or not a gear is changed via the gear

selector and the selector fork.

To prevent damage to the gearbox, the gearbox path

of the movement sensor which has failed is shut off in

this case.

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Selector lever E313

The selector lever sensor system and the control system for the selector lever lock solenoid are integrated into the

selector lever.

The selector lever positions are detected by Hall sensors, which are integrated into the selector lever sensor system.

The selector lever position signals and the Tiptronic signals are transmitted via the CAN bus to the mechatronic unit

and to the control unit in the dash panel insert.

Signal use

Based on the signals, the control unit detects the

selector lever positions. It uses the signals to

implement the driver's D-R-S or Tiptronic command

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and to control starter release.

Effects of signal failure

If the control unit detects no selector lever position,

both clutches are opened.

Hall sensors for

Tiptronic position

Tiptronic switches in steering to shift

up and down E438 and E439

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The switches are located on the right and left on the

steering wheel. The gears can be shifted up and down

by actuating the switches. The shift signals are

transmitted from the steering column electronics

control unit J527 to the mechatronic unit for direct

shift gearbox J743 via the CAN bus.

Hall senders for detecting the

selector lever position

E439

E438

Signal use

In Tiptronic mode, the gears can also be shifted

up and down using the steering wheel switches.

If the Tiptronic switches on the steering wheel are

actuated in automatic mode, the gearbox control

system switches to Tiptronic mode.

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Tiptronic shifting strategy

If the Tiptronic switches on the steering wheel are

no longer actuated, the gearbox control system

automatically switches back to automatic mode

following the expiry of a timer.

- Automatic upshifting on reaching the maximum

engine speed

- Automatic downshifting on falling below the

minimum engine speed

Effects of signal failure

- Kick-down downshifting

In the event of signal failure, no Tiptronic functions are

possible via the steering wheel switches.

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Gearbox management system

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Actuators

Clutch actuator solenoid valves

Valve 3 in gear train half 1 N435,

valve 3 in gear train half 2 N439

The clutch actuator solenoid valves are located in the

mechatronic unit's hydraulic module.

● Solenoid valve N435 controls the oil volume for

clutch K1

They are actuated by the electronic gearbox control

unit. They are used to control the oil volume for

actuating the clutches.

● Solenoid valve N439 controls the oil volume for

clutch K2

Valve 3 in gear train half 1

N435

Valve 3 in gear train half 2

N439

S390_076

Effects of signal failure

If one of the solenoid valves fails, the corresponding gear train half is shut off.

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Gear train half pressure control valves

Valve 4 in gear train half 1 N436,

valve 4 in gear train half 2 N440

Both valves are solenoid valves, and are located in

the mechatronic unit's hydraulic module.

Valve 4 in gear train half 1 controls the hydraulic oil

pressure to the gear selectors and to the clutch

actuator in gear train half 1.

Gear train half 1 is used to shift gears 1, 3, 5 and 7.

Valve 4 in gear train half 2 controls the hydraulic oil

pressure to the gear selectors and to the clutch

actuator in gear train half 2.

Valve 4 in gear train half 2

N440

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Valve 4 in gear train half 1

N436

Effects of signal failure

If one of the solenoid valves fails, the corresponding gear train half is shut off, and only the gears assigned to the

other gear train half can be engaged.

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Gearbox management system

Gear selector solenoid valves

Valve 1 in gear train half 1 N433,

valve 2 in gear train half 1 N434,

valve 1 in gear train half 2 N437,

valve 2 in gear train half 2 N438

The gear selector solenoid valves are located in the

mechatronic unit's hydraulic module.

● N433 gears 1 and 3, gear train half 1

● N434 gears 5 and 7, gear train half 1

● N437 gears 4 and 2, gear train half 2

They are used by the gearbox control unit to control

the oil volume to the gear selectors and therefore for

changing gears.

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● N438 gears 6 and R, gear train half 2

Valve 2 in gear train half 1

N434

Valve 2 in gear train half 2

N438

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Valve 1 in gear train half 1

N433

Valve 1 in gear train half 2

N437

Effects of signal failure

If one of the solenoid valves fails, the corresponding gear train half is shut off.

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Motor for hydraulic pump V401

The motor for the hydraulic pump is integrated into

the mechatronic unit's hydraulic module.

It is actuated by the gearbox control unit subject to

requirements.

The control unit shuts the motor off when the hydraulic

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pressure in the system has reached 60 bar, and

switches it on again when the pressure has fallen to

40 bar.

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Motor for

hydraulic pump V401

Effects of signal failure

If the motor cannot be actuated, the hydraulic pressure drops and the clutches open independently due to the

pressure plates' spring force.

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Gearbox management system

Functional diagram

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Components

E313

Selector lever

E438 Tiptronic switch in steering wheel to shift up

E439 Tiptronic switch in steering wheel to shift down

F319

Selector lever locked in position P switch

G182 Gearbox input speed sender

G270 Gearbox hydraulic pressure sender

G487 Gear selector movement sensor 1

G488 Gear selector movement sensor 2

G489 Gear selector movement sensor 3

G490 Gear selector movement sensor 4

G510 Temperature sender in control unit

G612 Gearbox input speed sender 2

G617 Clutch travel sender 1

G618 Clutch travel sender 2

G632 Gearbox input speed sender 1

J119

Multifunction display

J285 Control unit with display in dash panel insert

J453

J519

J527

J533

J681

J743

Multifunction steering wheel control unit

Onboard supply control unit

Steering column electronics control unit

Data bus diagnostic interface

Terminal 15 voltage supply relay 2

Mechatronic unit for direct shift gearbox

N110 Selector lever lock solenoid

N433 Valve 1 in gear train half 1

N434 Valve 2 in gear train half 1

N435 Valve 3 in gear train half 1

N436 Valve 4 in gear train half 1

N437 Valve 1 in gear train half 2

N438 Valve 2 in gear train half 2

N439 Valve 3 in gear train half 2

N440 Valve 4 in gear train half 2

V401 Motor for hydraulic pump

Diagnosis connector

Y6

Selector lever position display

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Input signal

Positive

Output signal

Bi-directional

Ground

CAN data bus

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Gearbox management system

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CAN data bus connection

The schematic shown below symbolically shows the

integration of the mechatronic unit for direct shift

gearbox into the vehicle's CAN data bus structure.

J104

Control unit for ABS with EDL

J527

J533

J587

Steering column electronics control unit

Data bus diagnostic interface

J248 Diesel direct injection system control unit

J285 Control unit with display

in dash panel insert

Selector lever sensor control unit

J623 Engine control unit

J743 Mechatronic unit for direct shift gearbox

J519

Onboard supply control unit

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Diagnostic connector

"Powertrain" CAN data bus

CAN "convenience" data bus

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Gearbox management system for Your Volkswagen Touran 4 Door First Generation (2003-2015)

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