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Jan 312018
 

Symptom/conditions: Noisy Gearbox

  • The gear grates
Step Operations Test
results
0 Check that the clutch does not drag All OK Problems found Intervention
Check that the clutch does not drag following

P14 – Clutch drag check
Go to
step 2
The clutch drags Overhaul the clutch/flywheel kit and replace and broken components. Go to step 1.
1 After intervening on the clutch kit All OK Problems found Intervention
Check that the problem is no longer present. End of
precedure
The
problem persists
Go to step 2.
2 The
problem persists
All OK Problems found Intervention
The
problem persists
Contact technical assistance for additional information on the problem
 Posted by at 7:46 pm
Jan 312018
 

Symptom/conditions: The car jerks

  • It jerks from a standing start
  • It jerks when changing gear

Preliminary check

If there are other system faults on the vehicle (instrument panel warning lights on referring to : engine control, ABS, VDC…) check the cause of these problems. If this is not the case, proceed with this chart.

Step Operations Test
results
0 Check
oil level
All OK Problems found Intervention
Check
oil level als shown in P2 – Oil level check
Go to
step 1
Level
other than max
Do
P3 – Oil leaks check
1 Check
oil pressure
All OK Problems found Intervention
Check
oil pressure als shown in
P4 – Oil pressure check
Go to
step 2
Press <
40 bar
Do

P5 – Electric pump operation check
2 Check
errors
All OK Problems found Intervention
Check ECU for absence of errors. Specifically check for:
* Clutch position sensor* Errors CAN messages (reception/transmission)
Go to
step 4
Presence of one or more errors included in the list Go to
step 3
3 Check
problems found
All OK Problems found Intervention
Check
problems according

P17 – What to do according to the error on the Selespeed control unit
End of
procedure
The
problem persists
Go to
step 4
4 Bleed the system with Examiner All OK Problems found Intervention
In active diagnosis run two system bleeding cycles through the “clutch bleeding” command Go to
step 5
5 Clutch parameters calibration with Examiner All OK Problems found Intervention
With examiner in active diagnosis, run the calibration of the clutch parameters through ” enable clutch self-calibration “. Go to
step 6
6 Road
test
All OK Problems found Intervention
Check that the fault is no longer present by testing on the road End of
procedure
The
problem persists
Go to
step 6
7 The
problem persists
All OK Problems found Intervention
Check that the problem is not caused by other systems such as the engine, fuel supply ÖÖ. Go to
step 8
There are faults on other car systems. See the
specific charts
8 The
problem persists
All OK Problems found Intervention
Contact technical assistance for additional information on the problem

 

 Posted by at 7:38 pm
Jan 312018
 
  1. Connect the Examiner diagnostics tool
  2. In parameters environment view:
    • Engine revs
    • Clutch disk speed
  3. Make a road test at a steady speed without changing gear (V ” 30 km/h).
  4. While driving watch the two selected parameters
  5. Check that there are no significant fluctuations/ differences on the clutch speed sensor in relation to the engine revs.
 Posted by at 7:33 pm
Jan 312018
 
  1. Set the ignition key to MAR.
  2. Connect the Examiner diagnostics tool and select the “LEVERS STATUS” display in parameters environment.
  3. Make all the selections possible with the buttons on the steering wheel and the gear lever (one at a time) checking the correct status change on Examiner; the list of the selections to be made is the following:
    • Lever Up (+) (forward)
    • Lever Down (-) (backward)
    • RH button Up on steering wheel (+)
    • LH button Down on steering wheel (-)
    • Lever on idle (N)
    • Lever on Reverse (R)
    • Buttons and lever released
  4. If the status displayed is not correct, check the wiring and gearshift buttons/lever.
 Posted by at 7:32 pm
Jan 312018
 

CAN network error:

  • Check:
  • the network sees all the control units (n.b.: pay attention because any control unit connected to the CAN network could cause faults in network operation). If one of the control units does not dialogue, recover/replace that control unit.
  • condition of the connections and continuity of the wiring regarding the CAN line. It is better not to just make a visual analysis of the connection, but to test putting it under mechanical stress (pull the wires, twist them, check that the pins are firm……..); if a fault is found, restore/replace the wiring.

 

Engine speed (from wire):

  • check the correct connection between engine control unit and Selespeed control unit , since this signal is sent by the engine control unit through a special wire. If a fault is found restore/replace the part involved.

 1st/2nd gear range selection solenoid valve:

  • Run the solenoid valve active diagnostics. If the test does not give satisfactory results, pass to the next step
  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.
  • Run the solenoid valve active diagnostics again. If the test does not give satisfactory results replace the solenoid valve and check the functioning.

5th/R gear range selection solenoid valve

  • Run the solenoid valve active diagnostics. If the test does not give satisfactory results, pass to the next step
  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.
  • Run the solenoid valve active diagnostics again. If the test does not give satisfactory results replace the solenoid valve and check the functioning.

 

Clutch solenoid valve current error:

  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.
  • Replace the solenoid valve and check the functioning by making a gear shift.

 

Clutch sensor:

  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.
  • Replace the clutch potentiometer and check the functioning by making a gear shift.

 

Odd or even gears engagement (engagement solenoid valves)

  • Run the solenoid valve active diagnostics. If the test does not give satisfactory results, pass to the next step
  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.
  • Run the solenoid valve active again. If the test does not give satisfactory results replace the solenoid valve and check the functioning.

 

Control unit earth error

  • Check the tightness of the earth connections on the body and on the engine.
  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.

 

Charging relay error*

  • Check the condition of the battery
  • Check the condition of the connections and continuity of the wiring. Make a careful check on the items that supply the power to the control unit (wiring, fuses, relay etc.). If a fault is found, restore/replace the wiring.

 

Lever switches 0/1/2/3 error

  • Connect the Examiner diagnostics tool and select “LEVER STATUS” in parameters environment.
  • Make all the selections possible with the buttons on the steering wheel and the gear lever (one at a time) checking the correct status change on Examiner; the list of the selections to be made is the following:
  • Lever Up (+) (forward)
  • Lever Down (-) (backward)
  • Lever on idle (N)
  • Lever on Reverse (R)
  • Lever released
  • If the status displayed is not correct, check the connections, the wiring continuity and the gear shift lever.

 

Lever switch error (any of the four, or auto button)

Lever check

  • Connect the Examiner diagnostics tool and select the “LEVERS STATUS” display in parameters environment.
  • Make all the selections possible with the buttons on the steering wheel and the gear lever (one at a time) checking the correct status change on Examiner; the list of the selections to be made is the following:
  • Lever Up (+) (forward)
  • Lever Down (-) (backward)
  • Lever on idle (N)
  • Lever on Reverse (R)
  • Lever released
  • If the status displayed is not correct, check the connections, the wiring continuity and the gear shift lever.

Auto button check

  • Select the state of inputs display (ON/OFF) relating to the auto button.
  • Press and release the automatic operation selection button at the base of the gear shift lever.
  • Check on Examiner that the change of status has taken place.
  • Start the engine and check that when the button is pressed, “AUTO” is shown on the display .
  • If the change of status does not take place (step 4) and/or “AUTO” is not displayed( step 5.), check the button and the wiring

N.B. there have been cases where the auto button remains stuck: this can cause malfunctioning of the lever.

 

Engagement sensor.

When this error is present, the gear change is slower than usual due to the system operating in recovery.

  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.
  • Replace the engagement potentiometer ** and check the correct reading of the position, making a series of gear changes

 

Selection sensor.

When this error is present, the gear change is slower than usual due to the system operating in recovery.

  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.
  • Replace the selection potentiometer and check the correct reading of the position, making a series of gear changes.

 

Clutch disk speed (this signal is read by the sensor that reads the speed of the primary shaft***)

  • Check the condition of the connections and continuity of the wiring. If a fault is found, restore/replace the wiring.
  • Replace the clutch disk speed sensor (see components r/r general procedure) and check the correct reading of the position, making a series of gear changes.

 

Car speed.

Only for Alfa 156 Selespeed:

N.B. The car speed signal is supplied by the Instrument Panel on board to the Selespeed control unit, therefore any signal omission/fault on the panel will also result on the Selespeed System.
Proceed as follows:

  • Check that the car speed signal arrives continually to the Panel on board.
  • If the signal does not arrive continuously:
  • Proceed following the instructions in the Service Handbook
  • If the signal arrives continuously:
  • Check the condition of the connections and continuity of the line wiring, especially between the control units signalled with an error. If a fault is found, restore/replace the wiring

 

Only for Alfa 147 Selespeed:

N.B. If the car speed signal reaches the Selespeed control unit through the CAN line from the ABS control unit, therefore any signal omission/fault on the ABS control unit will also result on the Selespeed System. Proceed as follows:

  • Check whether there are any faults in the ABS control unit and/or the engine control unit that justify the omission of the car speed signal.
  • If no faults are found:
  • Use the EXAMINER diagnostics tool to check for dialogue problems on the CAN line

 

No accelerator pedal information.

The signal is received by the Selespeed control unit through the CAN line:

  • On Examiner select CAN network information and check if there is the presence of control unit error
  • Check the condition of the connections and continuity of the line wiring, especially between the control units signaled with an error. If a fault is found, restore/replace the wiring.

 

Brake switch.

The signal is received by the Selespeed control unit through the CAN line and through a wire:

  1. Check the condition of the brake switch.
    • Bring the ignition key to MAR.
    • Connect the Examiner diagnostics tool and select the inputs status display (ON/OFF) for the switch on the brake pedal.
    • Press the brake pedal and check that the displayed value changes (from released to pressed and vice-versa).
    • If there is no status change check the switch on the brake pedal, its fastening, its position, the condition of the connections and the wiring.
  2. If a fault is found, restore/replace the components/wiring

 

Pump relay error

  • check the condition of the connections and continuity of the wiring. Make a careful check on the items that supply power to the electric pump (fuses, relay etc.). If a fault is found, restore/replace the wiring. There have been cases where the “fastom” housed in the relay holder socket have pulled out.

 

Accumulator oil discharge error:

  • replace the accumulator

 

Start enable relay error

  • The Selespeed control unit supplies the earth for the start relay block; if a short circuit to the battery or an open circuit is diagnosed, the engine cannot start; if instead a short circuit to earth is found the engine can be started without the enable from the Selespeed control unit. In any case the problem arises from the wiring or from systems that enable the start downstream of the Selespeed control unit. Check the condition of the connections and the continuity of the wiring downstream of the Selespeed control unit.

 

Check the condition of the brake switch.

  1. Bring the ignition key to MAR.
  2. Connect the Examiner diagnostics tool and select the inputs status display (ON/OFF) for the switch on the brake pedal.
  3. Press the brake pedal and check that the displayed value changes.
  4. If there is no status change check the switch on the brake pedal, its fastening, its position, the condition of the connections and the wiring.
  • If a fault is found, restore/replace the components/wiring. * This error is connected to a control unit power supply problem and not to the control unit itself
** It is a good practice to insert tool n°1870753001 before removing the hydraulic unit potentiometer
*** This sensor is positioned on the gearbox to the right of the reverse lights sensor
 Posted by at 7:30 pm