Self-Study Programme 221 Electronic manual gearbox.pdf

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Service.
Self-Study Programme 221
Electronic Manual Gearbox
Design and Function
Taking the Lupo as the basis, Volkswagen has
developed the world's first 3 L car that will also
go into volume production.
Designing a vehicle which covers 100 km on 3
litres of fuel involved a great deal of detail work.
Factors influencing fuel consumption - such as
aerodynamics, rolling resistance, engine con-
cept, gearbox tuning and kerb weight - have
been revised systematically.
The goal was achieved by using new technolo-
gies, weight-saving materials and new produc-
tion processes.
However, the driver also plays a key role with
regard to fuel economy.
A great many drivers are not aware of this fact,
though.
The new electronic manual gearbox eliminates
gear shift errors. Gear shifts are executed auto-
matically and in such a way as to optimise fuel
consumption.
The advantages of an electronic manual
gearbox over an automatic gearbox are
lower weight and higher efficiency.
221_001
New
Important
Note
The Self-Study Programme
is not a Workshop Manual.
Please always refer to the relevant Service Literature
for all inspection, adjustment and repair instructions.
2
Table of contents
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The electronic manual gearbox . . . . . . . . . . . . . . . . . . . 4
Mechanicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
The selector lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System representation . . . . . . . . . . . . . . . . . . . . . . . . . . .10
The hydraulic clucth control . . . . . . . . . . . . . . . . . . . . . .12
The selector gate selection . . . . . . . . . . . . . . . . . . . . . . . 14
The gear selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
The pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
The hydraulic pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
The clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 25
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
The sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
The actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
The gearbox control unit. . . . . . . . . . . . . . . . . . . . . . . . 44
The stop/start function . . . . . . . . . . . . . . . . . . . . . . . . . 46
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
The self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3
General information
The electronic manual gearbox
comprises three main elements:
The electronics comprise:
-
-
-
-
-
the electronic selector lever
the electronic accelerator pedal
the gearbox control unit
the electro-hydraulic valves
the potentiometer and the micro-switches
The hydraulics comprise:
- the hydraulic unit with hydraulic pump and
pressure accumulator
- the clutch slave cylinder
- the selector lever
- the pressure valves
The mechanicals comprise:
- manual gearbox 085
- the selector shaft and the lever mechanism of
the selector lever
4
In the electronic manual gearbox,
movements of the gear lever are registered by a potentiometer
and four micro-switches and signalled to the control unit.
The actual gear change is initiated by the gearbox control unit
and executed via hydraulic valves and selector levers.
Manual gearbox
Hydraulic unit
Hydraulic pump
Press. accumulator
Clutch slave cylin-
der
selector lever
Selector lever
Control unit
Lever mechanism
on selector lever
Potentiometer on
selector lever
Potentiometers and
micro-switches in selec-
tor lever housing
221_003
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