1. Welcome to
AfterSalesTraining

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

3. Introduction Your Name Your Dealership
Previous Training Courses or Past Experience
Hobbies and Interests
Did You Ask to Come on This Course
What Do You Hope to Gain From This Course

4. Comfort & Convenience Coffee Breaks Lunch Arrangements Telephones
Messages
Start & Finish Times
Toilets
Smoking Policy
Fire Precautions

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

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

7. 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.

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

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

10. EM – CVT Stepspeed

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

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

13. Operation
Primary Pulley
Secondary Pulley

14. 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

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

16. 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

17. Group One
Torque Flow

18. Torsional Vibration Damper

19. 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

20. Planetary Gear Set

21. 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

22. Forward & Reverse Clutches

23. Clutch Packs

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

25. Forward Clutch Applied

26. 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

27. Reverse Clutch Applied

28. Park/Neutral

29. Primary Pulley

30. Secondary Pulley

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

32. Drive Belt

33. 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

34. Belt Construction

35. Differential & Pinion Shaft

36. Layout

37. Group Two
Hydraulics

38. 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

39. Oil Pump

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

41. 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

42. Hydraulic Control Unit

43. 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

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

45. 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

46. 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

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

48. Sensing Shoe

49. Hydraulic Control System

50. Group Three
External Connections

51. Selector Mechanism

52. Steering Wheel Switches MGF & TF

53. Ratio Control Motor

54. Bi Polar Stepper Motor

55. 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)

56. Oil Cooler Connections

57. 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

58. 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

59. 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

60. Switches & Sensors

61. 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)

62. 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

63. 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

64. 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

65. PWM – Pulse Width Modulation

66. Duty Cycle Increments

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

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

69. Target Engine Speed Map

70. 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)

71. Instrument Pack Display

72. Warning Lamps

73. Fast Set Adaptions F F

74. Gearbox Profile

75. 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

76. Resetting Gearbox Adaptions

77. Resetting Gearbox Adaptions

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

79. 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

80. Water Ingress Into Inhibitor Switch Harness

81. Water Ingress Into GIU Contacts

82. 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

83. 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.

85. 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

87. 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?)

89. 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)

90. 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)

91. 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)