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2003-2015 Volkswagen Touran 4 Door Oil circuit ? hydraulic system User Manual

MY CAR USER MANUAL

Oil circuit ? hydraulic system for Your Volkswagen Touran 4 Door First Generation (2003-2015)

Oil circuit – hydraulic system  
Oil circuit  
The double-clutch gearbox operates with two independent oil circuits using two different oils:  
- Oil circuit for mechanical gearbox  
- Oil circuit for mechatronic module  
Each oil circuit contains an oil which is specifically suitable for to its requirements.  
Mechatronic module  
Oil circuit for mechanical gearbox  
S390_080  
Oil circuit - mechanical gearbox  
Oil circuit - mechatronic module  
The oil supply to the shafts and gears of the  
mechanical gearbox is carried out in the same way as  
for a normal manual gearbox. It will not therefore be  
dealt with in any greater detail here.  
The oil supply for the mechatronic unit is separate  
from the oil circuit for the mechanical gearbox.  
An oil pump delivers the oil at the pressure required  
to enable the hydraulic mechatronic unit components  
to function.  
The oil volume in the mechanical gearbox is 1.7 l.  
The oil volume in the mechatronic unit is 1.1 l.  
For the precise capacities, please refer to the current Workshop Manual,  
"The 7-speed Double-clutch Gearbox 0AM".  
35  
Oil circuit – hydraulic system  
Oil circuit flow chart  
Basic oil circuit  
Filter  
Motor for hydraulic pump V401  
Pressure limiting valve  
Pressure accumulator  
Hydraulic pressure sender  
Non-return valve  
Hydraulic pump  
S390_098  
36  
Hydraulic pump  
The hydraulic pump unit is located in the mechatronic  
module. It consists of a hydraulic pump and an  
electric motor.  
Hydraulic pump  
The motor for the hydraulic pump is a brushless DC  
motor. It is actuated by the mechatronic unit's  
electronic control unit depending on pressure  
requirements. It drives the hydraulic pump via a  
coupling.  
S390_043  
Motor for  
hydraulic pump V401  
lk  
Intake side  
The hydraulic pump operates according to the  
principle of a gear pump. It intakes the hydraulic oil  
and pumps it into the oil circuit at a pressure of  
approx. 70 bar.  
The hydraulic oil is pumped from the intake side to the  
pressure side between the walls of the pump housing  
and the tooth gaps.  
Housing  
S390_071  
Driving gear  
Pressure side  
37  
Oil circuit – hydraulic system  
Motor for hydraulic pump V401  
Torque to the  
Design  
hydraulic pump  
Like conventional, smaller DC electric motors, the  
brushless DC motor also consists of a stator and a  
rotor. Whilst the stator consists of permanent magnets  
and the rotor of electromagnets in the conventional,  
smaller electric motor, the opposite is true in the case  
of the brushless DC motor.  
Rotor with permanent  
magnets  
The rotor consists of 6 permanent magnet pairs and  
the stator of 6 electromagnet pairs.  
Electrical connection  
Electromagnet pole pairs  
How it works  
In the conventional DC motor, commutation (current  
direction change-over) takes place via ring contacts.  
Commutation in the brushless DC motor is carried out  
by the mechatronic unit's electronic control unit and is  
therefore contact-free.  
S390_085  
The stator coils are actuated in such a way that a  
rotating magnetic field occurs in the stator coils.  
The rotor follows this magnetic field and is therefore  
caused to rotate.  
Stator  
Thanks to contact-free commutation, the DC motor  
runs entirely wear-free, with the exception of bearing  
wear.  
Stator  
Rotor  
S390_089  
38  
Electrical actuation  
So that a rotational movement is carried out, the mechatronic unit control unit switches between the possible  
phases in the individual pole pairs within good time. The magnetic field changes.  
The rotor is therefore constantly compelled to turn itself and therefore carries out a rotational movement.  
The schematic shows the design of the circuit using the  
example of a wound coil.  
Mechatronic unit  
Supply voltage  
control unit  
Wound coil  
S390_086  
Legend  
1st phase – positively switched  
2nd phase – negatively switched  
3rd phase - open  
39  
Oil circuit – hydraulic system  
Gearbox hydraulic pressure sender  
G270 and pressure limiting valve  
Hydraulic pressure sender  
Pressure limiting valve  
The hydraulic pump pumps the hydraulic oil through  
the filter towards the pressure limiting valve, the  
pressure accumulator and the hydraulic pressure  
sender.  
When the hydraulic oil pressure at the pressure  
limiting valve and the hydraulic pressure sender  
reaches approx. 70 bar, the control unit switches the  
electric motor and therefore the hydraulic pump off.  
The bypass ensures that the system functions if the  
filter channel is clogged.  
S390_100  
lk  
Pressure accumulator  
Pressure accumulator  
The pressure accumulator is designed as a gas  
pressure accumulator.  
It provides the hydraulic system with oil pressure  
when the hydraulic pump is switched off.  
Its storage volume is 0.2 litres.  
S390_096  
40  
Oil circuit flow chart  
Working pressure  
Return  
Controlled working pressure  
Clutch safety valve  
KS  
=
KS  
KS  
Clutch actuator K1  
Clutch actuator K2  
Gear selector 1 - 3  
Gear selector 5 - 7  
Gear selector 4 - 2  
Gear selector 6 - R  
S390_048  
Legend  
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  
The clutch safety valves enable the clutches to be drained and therefore opened in the event of a fault.  
41  
Oil circuit – hydraulic system  
Task and function of the solenoid valves in  
the oil circuit  
Gear train half pressure control solenoid valves  
The gear train half pressure control solenoid valves  
control the oil pressure for gear train halves 1 and 2.  
If a fault is detected in a gear train half, the pressure  
control solenoid valve can shut off the corresponding  
gear train half.  
lk  
Gear train half 2  
pressure control  
valve  
Gear train half 1  
pressure control  
valve  
S390_101  
Gear selector solenoid valves  
The gear selector solenoid valves control the volume  
of oil to the gear selectors. Each gear selector shifts  
2 gears. If no gear is engaged, the gear selectors are  
held in the neutral position via oil pressure.  
In selector lever position "P" and when the ignition is  
switched off, 1st gear and reverse gear are engaged.  
Gears 6/R  
Gears 2/4  
Gears 5/7  
Gears 1/3  
S390_102  
Clutch actuator solenoid valves  
The clutch actuator solenoid valves control the volume  
of oil to the clutch actuators. The clutch actuators  
actuate clutches K1 and K2.  
When not supplied with current, the solenoid valves  
and the clutches are open.  
K1  
K2  
S390_103  
42  
Shifting the gears  
As in the case of conventional manual gearboxes,  
the gears are shifted using selector forks.  
Each selector fork shifts two gears.  
The selector forks are mounted on both sides in the  
gearbox housing.  
Selector fork  
gears 5/7  
Selector fork  
gears 6/R  
Selector fork  
gears 1/3  
Selector fork  
gears 2/4  
S390_058  
43  
Oil circuit – hydraulic system  
Shifting the gears  
Gear selector  
gears 5 and 7  
Gear selector  
gears 6 and R  
When changing gears, the selector forks are moved  
via the gear selectors integrated into the mechatronic  
unit.  
Gear selectors and selector forks  
The gear selector piston is connected to the selector  
fork. To change gears, oil pressure is applied to the  
gear selector piston, thereby moving it. When it  
moves, it also moves the selector fork and the sliding  
sleeve. The sliding sleeve actuates the synchronising  
hub and the gear is engaged.  
Gear selector  
gears 1 and 3  
Gear selector  
gears 2 and 4  
S390_107  
Gear selector  
movement sensor  
Gear selector cylinder  
Gear selector piston  
Permanent magnet  
Sliding sleeve  
Selector fork  
Synchronising hub  
S390_056  
Via the permanent magnet and the gear selector movement sensor, the mechatronic unit detects the new position  
of the selector fork.  
44  
Gear changes  
As in the case of the direct shift gearbox 02E, the selector forks are actuated hydraulically.  
To change the gears, the mechatronic electronic control unit actuates the corresponding gear selector solenoid  
valve.  
How it works  
Initial position  
Changing to 1st gear is shown here as an example.  
The gear selector piston is held in neutral position "N"  
via the oil pressure controlled by gear selector  
solenoid valve N433 for gears 1 and 3. No gear is  
engaged.  
Valve 4 in gear train half 1 N436 controls the oil  
pressure in gear train half 1.  
Mechatronic unit  
N436  
Pressure control valve  
in gear train half 1  
N433  
gears 1/3  
Gear selector cylinder  
Gear selector piston  
Piston chamber  
Sliding sleeve  
Selector fork  
S390_057  
45  
Oil circuit – hydraulic system  
Changing to 1st gear  
To change to 1st gear, the gear selector valve increases the oil pressure in the left piston chamber. As a result of this,  
the gear selector piston is pushed to the right. As the selector fork and the sliding sleeve are connected to the gear  
selector piston, they also move to the right.  
Due to the sliding sleeve's movement, 1st gear is engaged.  
Mechatronic unit  
N433  
gears 1/3  
Gear selector cylinder  
Gear selector piston  
Piston chamber  
Selector fork  
S390_097  
Sliding sleeve  
46  
Clutch actuators  
Clutches K1 and K2 are actuated hydraulically. To achieve this, the mechatronic unit contains a clutch actuator  
for each clutch.  
A clutch actuator consists of a clutch actuator cylinder and a clutch actuator piston. The clutch actuator piston  
actuates the clutch engaging lever. The clutch actuator piston is equipped with a permanent magnet, which is  
lk  
required by the clutch travel sender to detect the piston position.  
To prevent detection of the piston position from being impaired, the actuator cylinder and the actuator piston  
must not be magnetic.  
Clutch actuator K1  
Clutch actuator cylinder  
Permanent magnet  
Boot  
Clutch actuator piston  
Piston rod  
Dust  
protection  
bellows  
Engaging  
lever  
Support ring  
Guide ring  
Clutch actuator K2  
S390_092  
47  
Oil circuit – hydraulic system  
Clutch operation  
To actuate the clutches, the mechatronic electronic  
control unit actuates the solenoid valve  
How it works  
Actuation of K1 is shown here as an example.  
lk  
● N435 valve 3 in gear train half 1 for clutch K1 and  
● N439 valve 3 in gear train half 2 for clutch K2.  
Clutch not actuated  
The clutch actuator piston is in the resting position.  
The solenoid valve N435 is open in the return flow  
direction. The oil pressure from the gear train half  
pressure control valve N436 flows into the  
mechatronic unit's oil reservoir.  
N435  
Clutch actuator K1 in resting position  
S390_093  
48  
Clutch actuated  
If clutch K1 is to be actuated, the solenoid valve N435  
is actuated by the electronic control unit. When  
actuated, it opens the oil channel to the clutch  
actuator, and oil pressure is built up at the rear of  
the clutch actuator piston. The clutch actuator piston  
moves and thereby actuates the K1 clutch engaging  
lever. Clutch K1 is closed. The control unit receives a  
signal regarding the precise position of the clutch via  
clutch travel sender 1 G167.  
Clutch slip, the speed difference between the gearbox  
input speed and drive shaft speed, is achieved by  
solenoid valve N435 by controlling the oil pressure  
between the clutch actuator and the return flow.  
lk  
N435  
Clutch actuator K1 actuated  
S390_094  
49  

Related Topics

Oil circuit
Hydraulic pump
Motor for hydraulic pump V401
Gearbox hydraulic pressure sender G270 and pressure limiting valve
Oil circuit flow chart
Task and function of the solenoid valves in the oil circuit
Shifting the gears
Gear changes
Clutch actuators
Clutch operation

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