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Continuously Variable Transmission (Em-CVT) Type Instructor Name Here Electro Mechanical Continuously Variable Transmission (Em-CVT) Type Instructor Name Here

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Introduction Course Code : R105 Course Title : Em-CVT Course Duration : 1 Day

Introduction Course Aim : - To Ensure All Delegates Are Familiar With the Components, Structure and Operation of the Em-CVT Gearbox

Course Objective : - At the End of This Course With the Aid of Support Material, the Delegates Will Be Familiar With the Operation, Location & Functionality of the Em-CVT Gearbox and Interfaces and Be Able to Diagnose the Em-CVT Systems Using the Latest Diagnostic Equipment.

Introduction Course Content : A Detailed Insight into all Em-CVT Components, Their Function & Location. Exercises in Fault Diagnosis Fault Code Retrieval Vehicle Repair Procedures

Continuously Variable Transmission Origins Date Back to 1974 Rubber Drive Belt Construction External to Gearbox Replaced by a Steel Belt Internal to Gearbox Unit

EM – CVT Stepspeed

EM-CVT Advantages Low Engine Revolutions at Constant Vehicle Speeds Improved Emission Control Low Noise, Vibration and Harshness Levels Smooth Acceleration Flexible Mountain Driving

Models Available MGF & MG TF 1.8i K – Series 16 valve Rover 25/MG ZR Rover 45/MG ZS

Operation Primary Pulley Secondary Pulley

Mechanical Layout – Group One Elements Providing Torque Flow Through the Transmission Planetary Gear Set Multiple Clutches Primary Pulley Steel Drive Belt Secondary Pulley Pinion Shaft Differential Unit

Mechanical Layout - Group Two Elements Relate to the Hydraulic System According to Load and Driver Conditions Hydraulic Pump Hydraulic Control Unit

Mechanical Layout – Group Three Elements That Have External Connections From the Transmission Selector Mechanism Speedometer Steering Wheel Switches MGF & TF Only Ratio Control Motor Oil Cooler Connections Park/Neutral Switch

Group One Torque Flow

Torsional Vibration Damper

Torsional Vibration Damper Replaces Torque Converter Used by Conventional Automatic Transmission Engine Power Connected to Input Shaft of the Transmission Via Torsional Damper Splined to Input Shaft of Transmission Bolted to “Drive Plate” on Engine

Planetary Gear Set

Planetary Gear Set Planetary Gear Set Provides Drive Torque in Two Directions – Forward & Reverse Engine Torque Always Enters Transmission Via Planet Carrier Through Input Shaft

Forward & Reverse Clutches

Clutch Packs

Clutches Two Multiplate Clutch Packs - One Forward One Reverse Forward Clutch Operates and Epicyclical Gear Set Operates As One Unit – Forward Drive

Forward Clutch Applied

Clutches Reverse Clutch Operates Annulus of the Planetary Gear Set Is Held Stationary Three Pairs of Planet Gears Driven by Planet Carrier Forcing Sun Wheel to Operate in Opposite Direction – Reverse Drive

Reverse Clutch Applied

Park/Neutral

Primary Pulley

Secondary Pulley

Pulleys Each Pulley Consists of One Fixed Half and One Axially Mobile Half Both Having 11º Angles Distance Between Primary and Secondary Pulleys 155mm

Drive Belt

Drive Belt Van Doorne “Push” Type Belt 24mm Wide Drive Belt Consists of 450 Segments (VT1 CVT Had 350 Segments) Drive Belt Held Together by 24 Steel Bands – 12 Per Side

Belt Construction

Differential & Pinion Shaft

Layout

Group Two Hydraulics

Hydraulic Control System Functions To Match the Belt Tension With Engine Torque to Prevent Belt Slip To Control the Operation of the Forward & Reverse Clutches at Take off and Also Driving To Provide Optimum Ratio for All Driving Conditions

Oil Pump

Oil Pump Oil Pump Housed Within the Transmission Case Pump Shaft Splined and Driven by Planet Carrier Always Runs at Engine Speed

Oil Pump Operates at 40 Bar (588 Psi) Oil Pressure Used for Controlling Both Transmission Hydraulically and for Lubrication Purposes Oil Cooler Stabilises Temperature at 80ºc - 120ºc

Hydraulic Control Unit

Hydraulic Control Unit Controls the Pulleys and Clutches Primary Pressure Supplied to Primary Pulley to Control Ratio for All Driving Conditions Secondary Pressure Supplied to Secondary Pulley to Ensure That There Is Always Adequate Clamping Force Selection of Correct Clutch – Forward or Reverse

Hydraulic Control Unit Contents Primary Valve Secondary Valve Accumulator Valve Throttle Valve Pilot Valve Clutch Valve Safety Valve Cooler/Lock up Valve Manual Valve

Valve Body Inputs Input Generator Inputted Through Drive Mode Selector Lever Manual Valve Engine Speed Engine Pitot Chamber Engine Pitot Pressure Primary Pulley Speed Primary Pitot Chamber Primary Pitot Pressure Transmission Ratio Primary Pulley Position Sensing Shoe Throttle Angle Throttle Potentiometer Ratio Control Motor

Primary Valve 1 2 3 A Secondary Pressure B Primary Pitot Pressure C Primary Pressure D Return to Sump 1 Ratio Control Motor 2 Cap 3 Valve

Secondary Valve 2 1 A Secondary Pressure B Throttle Pressure C Clutch Pressure D Engine Pitot Pressure 1 Sensing Shoe 2 Valve 1

Sensing Shoe

Hydraulic Control System

Group Three External Connections

Selector Mechanism

Steering Wheel Switches MGF & TF

Ratio Control Motor

Bi Polar Stepper Motor

Ratio Control Motor Connector A . Ratio control motor connection B . Harness connection B Ratio control motor, phase 2B (digital signal) K Not used H Ratio control motor, phase 2A (digital signal) L Not used M Not used D Not used E Ratio control motor, phase 1A (digital signal) F Ratio control motor, phase 1B (digital signal)

Oil Cooler Connections

MGF 1.Oil Cooler 2.Brake Switch 3.Instrument Pack 4.Steering Wheel Switches 5.ECM 6.Gearbox Interface Unit (GIU) 7.Transmission 8.Selector Cable 9.Oil Cooler Feed/return Pipes 10.Gear Selector Lever

Rover 25 1.Brake Switch 2.Instrument Pack 3.Gear Selector Lever 4.Gearbox Interface Unit (GIU) 5.Selector Cable 6.Em-CVT Stepspeed Transmission 7.ECM 8.Oil Cooler Feed/return Pipes 9.Oil Cooler

Rover 45 1.Gearbox Interface Unit (GIU) 2.Brake Switch 3.ECM 4.Instrument Pack 5.Gear Selector Lever 6.Selector Cable 7.Em-CVT Stepspeed Transmission 8.Oil Cooler Feed/return Pipes 9.Oil Cooler

Switches & Sensors

Em-CVT Control A= Hardwired; B= Serial link; J= Diagnostic ISO9141 K Line 1. Engine Control Module (ECM) 2. Instrument pack 3. Brake switch 4. Road speed transducer 5. Gearbox differential speed sensor 6. Park/Neutral switch 7. EM-CVT Stepspeed gearbox 8. Ratio control motor 9. Steering wheel switches (MGF & TF Only) 10. P R N D S LED module 11. P R N D switch 12. Manual/Sport switch 13. Sport +/- switch 14. Shift lock solenoid (if fitted) 15. Diagnostic socket 16. Gearbox Interface Unit (GIU)

GIU Location MG F & TF – LH Side of Boot Rover 25/MG ZR – Centre Console Below Heater Box Rover 45 – Bottom of RH ‘A’ Post

GIU Functions Convert Inputs From Selector Switches Into a Serial Data Stream for ECM Drive Transmission Display LED’s Convert Signal From ECM to Control Ratio Control Motor

GIU Signals Gear Lever ± Switch Status PRND Switch Status Sports/Manual Switch Status Steering Wheel ± Switch Status Gear Lever ± Switch Status Fault Status Brake Pedal Switch Status

PWM – Pulse Width Modulation

Duty Cycle Increments

Power Down Sequence Ignition Off Motor Requested to Retract 428 Half Steps Motor Extended 130 Full Steps

Power Up Sequence Ignition On Motor Requested to Retract 428 Half Steps Motor Extended 10 Full Steps (Pull Away)

Target Engine Speed Map

Manual Drive Mode Gear Speeds Gear Position MPH/1000 Rpm (Kph) 1 4.60 (7.36) 2 7.80 (12.48) 3 10.65 (17.04) 4 14.00 (22.40) 5 17.75 (28.40) 6 23.50 (37.60)

Instrument Pack Display

Warning Lamps

Fast Set Adaptions F F

Gearbox Profile

Resetting Gearbox Adaptions Select 2nd Gear With Engine at Normal Operating Temperature Accelerate to 5000 Rpm Release Throttle & Allow Vehicle to Slow Without Using Brakes Until Engine Idle Speed Is Obtained Repeat Until ‘F’ Stops Flashing Clear All Fault Codes Using T4

Resetting Gearbox Adaptions

Resetting Gearbox Adaptions

Towing the Vehicle Do Not Exceed 30 Mph (50kph) Do Not Exceed 30 Miles (50km) Vehicle Will Not Tow or Push Start

Complaint: Car Defaults to 4th Gear Ratio, Fault Code P0705, P1787 Logged Check: Water Ingress Into Inhibitor Circuit As Per AD165 / 161. Replace Engine Harness If Nec. Inhibitor Switch Corroded? Replace As Nec. Operation of Selector Lever Switches With T4 in Real Time Monitor. Replace Lever Mech. If Nec. Examine GIU Contacts Replace GIU

Water Ingress Into Inhibitor Switch Harness

Water Ingress Into GIU Contacts

Complaint: Car Defaults to Single Ratio Intermittently, Fault Code P1787 Logged. Check: Transmission Oil Level and Condition Check Oil Cooler Function Inhibitor Circuit for Water Ingress Correct Tune Loaded in MEMS (GM Code) Ratio Actuator and GIU Connections Secure

Complaint: Car Defaults to Single Ratio Intermittently, Fault Code P1787 Logged. Check: Resistance of Actuator Circuits 18-30ohms (Check From Pins 5/6 & 7/8 at GIU and Work Back Towards Transmission). Replace Giu If Resistance Checks Ok Replace Transmission (or ZF Service Replace Actuator / Internal Harness) If Resistance NOK Out of Gearbox Connection.

Complaint: Car Will Not Achieve More Than 2000rpm, Stuck in Single Ratio Fault Code P0722 Logged Check: Output Speed Sensor Circuit – Use Test-book in Real Time Monitor (CVT Parameters) to See If Road Speed Signal Ok Check for Debris Across Sensor Pick - up Substitute MEMS ECM if Signal and Wiring Ok

Complaint: Engine Vibrates in D at Idle Check: Engine Idle Speed and Throttle Step Position (23 Steps) Engine Mountings Loose? Check Routing of Selector Cable (25 & 45), Vibrates on Heat-shields. Transmission Oil Level and Condition Ok? Oil Cooler Function (Return Pipe Kinked?)

Other Complaints: Noise – Road Speed Related, - Secondary Gear Whine, Diff Failure Noise – Engine Speed Related, - TV Damper Rattle, CVT Belt or Primary Bearing Failure, Alternator Whine, Engine Belt Whine No Manual Gear Selection – GIU (or Wiring ) Failure, Sport / Manual Switch Failure, Steering Wheel Switch Short Circuit (MGF)

Other Complaints: Loss of Drive in D and R (No Fault Codes) - CVT Belt Broken, Other Internal Damage (Check for Debris in Oil Pan) Engine Jerks Violently When D or R Selected, Many Fault Codes Logged (Engine Related), Cannot Reset Adaptions – MEMS ECM Faulty (R45 5 Cases to Date)

P-F Flashes on Dash Following Other Repairs to MEMS or New Programme Downloaded. Stuck in 1st Ratio – Fast Adaption Procedure Requires Re-set. Use T4 (Vehicle Maintenance) to Initiate New Adaptions. Output Speed / Camshaft Sensor Wiring Wrong Way Around (New Cars or Following Transmission Replacement)