Technical Note 3882A: Fault Finding Sequential Gearbox

Technical Note 3882A
Sub-section concerned: 21B
FAULT FINDING
SEQUENTIAL GEARBOX
VIAG N°.: 04
77 11 332 742 Edition 6 - MAY 2011 Edition Anglaise

"The repair procedures given by the manufacturer in this document are based on the All rights reserved by RENAULT s.a.s.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The procedures may be modified as a result of changes introduced by the reference numbering system is forbidden without the prior written authority of
manufacturer in the production of the various component units and accessories from RENAULT s.a.s.
which his vehicles are constructed."
© Renault s.a.s. 2011

Transmission
Contents
Page
21B SEQUENTIAL GEARBOX

Introduction 21B-1
Fault finding log 21B-6
System operation 21B-8
Allocation of computer tracks 21B-15
Replacement of components 21B-17
Configurations and programming 21B-22
Fault summary table 21B-23
Interpretation of faults 21B-24
Conformity check 21B-65
Status summary table 21B-67
Parameter summary table 21B-68
Interpretation of statuses 21B-69
Dealing with command modes 21B-75
Customer complaints 21B-77
Fault finding chart 21B-79
SEQUENTIAL121B
GEARBOX
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VDIAG N°.: 04 Fault finding – Introduction 21B
1. SCOPE OF THIS DOCUMENT
This document presents the fault finding procedure applicable to all computers with the following specifications:
Vehicle(s): TRAFIC for G9U730 engines Name of computer: Magnetti Marelli

Function concerned: Sequential gearbox Program N°:
Vdiag N°: 04
2. PRE-REQUISITES FOR FAULT FINDING
Documentation type:
Fault finding procedures (this manual):

– Assisted fault finding (integrated into the diagnostic tool), Dialogys.
Wiring Diagrams:
– Visu-Schéma (CD-ROM), paper version.
Diagnostic tools type:
– CLIP
Special tooling required:
Special tooling required

Multimeter
Ele. 1589 Sequential gearbox bornier
Ele. 1681 Test probe kit
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3. REMINDERS
Procedure
To run fault finding on the vehicle computers, switch on the ignition.
Fault
Faults are declared present or stored (depending on whether they appeared in a certain context and have
disappeared since, or whether they remain present but are not diagnosed within the current context).
The present or stored status of the fault should be taken into consideration when the diagnostic tool is used after
the + after ignition feed has been connected (without any of the system components being activated).
For a present fault, apply the procedure described in the Interpretation of faults section.
For a stored fault, note the faults displayed and apply the Notes section.
If the fault is confirmed when the instructions are applied, the fault is present. Deal with the fault.
If the fault is not confirmed, check:

– the electrical lines which correspond to the fault,
– the connectors for these lines (for oxidation, bent pins, etc.),
– the resistance of the component detected as faulty,
– the condition of the wires (melted or cut insulation, wear).
Or use the fault finding procedure to check the circuit of the component concerned.
Conformity check
The aim of the conformity check is to check data that does not produce a fault on the diagnostic tool because the
data is inconsistent. Therefore, this stage is used to:
– run fault finding on faults that do not have a fault display, and which may correspond to a customer complaint,
– check that the system is operating correctly and that there is no risk of a fault recurring after repairs.
This section gives the fault finding procedures for statuses and parameters and the conditions for checking them.
If a status is not behaving normally or a parameter is outside the permitted tolerance values, consult the
corresponding fault finding page.
Customer complaints - Fault finding chart
If the diagnostic tool check is in order, but the customer complaint is still present, the fault should be dealt with by
Customer complaints.
A summary of the overall procedure to follow is provided on the following page in the
form of a flow chart.
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4. FAULT FINDING PROCEDURE
Check the battery charge and the

condition of the fuses
Print the system fault finding log

(available on CLIP or in the MR or
NT)
Connect CLIP
no
Dialogue with the
computer? See ALP n° 1
yes
Read faults
no
Faults
present Conformity check
yes
no
Dealing with present faults The cause is Fault
still present solved
Dealing with stored faults
Use fault finding charts (ALPs)
no
The cause is Fault
still present solved no
The cause is still Fault
present solved
yes
Contact Techline with the

completed fault finding log
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4. FAULT FINDING PROCEDURE (continued)
Wiring check
Fault finding problems

Disconnecting the connectors and/or handling the wiring harness may temporarily remove, the cause of a fault.
Electrical voltage, resistance and insulation measurements are generally correct, especially if the fault is not
present when the analysis is made (stored fault).
Visual inspection
Look for damage under the bonnet and in the passenger compartment.
Carefully check the fuses, insulators and wiring harness routing.
Look for signs of oxidation.
Tactile inspection
While manipulating the wiring harness, use the diagnostic tool to note any change in fault status from stored
to present.
Make sure that the connectors are properly locked.
Apply light pressure to the connectors.
Twist the wiring harness.
If there is a change in status, try to locate the source of the fault.
Inspection of each component

Disconnect the connectors and check the appearance of the clips and tabs, as well as their crimping (no
crimping on the insulating section).
Make sure that the clips and tabs are properly locked in the sockets.
Check that no clips or tabs have been dislodged during connection.
Check the clip contact pressure using an appropriate model of tab.
Resistance check
Check the continuity of entire lines, then section by section.
Look for a short circuit to earth, to + 12 V or to another wire.
If a fault is detected, repair or replace the wiring harness.
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5. FAULT FINDING LOG
WARNING
Any fault on a complex system requires a full fault finding procedure with the appropriate tools.
The FAULT FINDING LOG, which should be completed during the procedure, enables you to
keep track of the procedure which is carried out. It is an essential item when discussing the fault
IMPORTANT! with the manufacturer.
IT IS MANDATORY TO FILL OUT A FAULT FINDING LOG FOR EACH FAULT FINDING PROCEDURE.
You will always be asked for this log:

– when requesting technical assistance from Techline,
– for approval requests when replacing parts for which approval is mandatory,
– which must be attached to monitored parts for which reimbursement is requested. It is therefore used to decide
whether a reimbursement will be made under warranty and leads to improved analysis of the removed parts.
6. SAFETY INSTRUCTIONS
Safety rules must be observed during any work on a component to prevent any damage or injury:
– make sure that the battery is properly charged to avoid damaging the computers with a low load,
– use the appropriate tools.
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FAULT FINDING LOG
System: Automatic or sequential gearbox
Page 1/2
List of monitored parts: Computer
● Administrative identification
Date 2 0
Log completed by
VIN
Engine
Diagnostic tool CLIP
Update version
● Customer complaint
681 No gear change 622 Noise 679 No drive
680 Slipping 675 Warning light comes on 682 Loss of power
683 Jolts or engine 684 "3H" 685 Erratic gear change

jerking
Other Your comments:
● Conditions under which the customer complaint occurs
005 While driving 004 Intermittently 008 When decelerating
007 When accelerating 009 Sudden fault 010 Gradual deterioration
Other Your comments:
● Documentation used in fault finding
Fault finding procedure used
Type of diagnostic manual: Repair Manual Technical Note Assisted fault finding
Fault Finding Manual N°:
Wiring diagram used
Wiring Diagram Technical Note N°:
Other documentation
Title and/or part number:
FD 12
Fault finding log
page to print or photocopy - page to print or photocopy - page to print or photocopy

FAULT FINDING LOG
System: Automatic or sequential gearbox
Page 2/2
● Identification of the computer and system parts replaced

Part 1 part no.
Part 2 part no.
Part 3 part no.
Part 4 part no.
Part 5 part no.
To be read with the diagnostic tool (Identification screen):
Computer part no.
Supplier no.
Program no.
Software version
Calibration n°
VDIAG
● Faults found with the diagnostic tool
Fault N° Present Stored Fault name Specification
● Conditions under which fault occurs

Status or Parameter N° Parameter name Value Unit
● System-specific information
Description:
● Additional information
Gearbox No.
If an automatic gearbox, which mode (auto/semi-

auto)?
Which gear changes are faulty?
Gearbox oil level check results
"Add-on" oil level check results
Oil appearance
Oil leak? No Seeping Dripping

Location of the leak
Type of noise (metallic, rubbing, etc.)
Is the buzzer active? Yes No

What factors led you to replace the computer?
What other parts were replaced?
Other defective functions?
Your comments:
FD 12
Fault finding log
page to print or photocopy - page to print or photocopy - page to print or photocopy

SEQUENTIAL GEARBOX
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VDIAG N°.: 04 Fault finding – System operation 21B
Having already converted the JH gearbox to sequential for the Twingo and Clio, Renault has now converted
the PK6 for the Trafic and Master. The converted PK6 is known as the PA6
The electro-hydraulic system attached to the gearbox comprises two actuators, one for gear selection and changing,
the other for operating the clutch, and a hydraulic power unit which supplies power to the actuators.
The assembly is linked to the sequential gearbox computer, which itself is linked to the engine management
computer by a multiplex line connection. The gear lever is used to select gears: in automatic mode, gear changes
are controlled by the computer which uses auto-adaptive shift patterns; in manual mode, the driver moves a lever,
which via the computer, changes the gears.
When the gear is changed, the sequential gearbox computer controls the engine management computer and the
torque in such a way as to reduce bucking, leaving the driver free to leave his foot on the accelerator pedal.
The automatic mode used by the sequential gearbox is based on the design of the DP0 automatic gearbox which
uses shift patterns which adapt automatically to the driving style and road conditions.
The gear change is determined by a set of gear change graphs as a function of the accelerator pedal position and
the vehicle speed.
The sequential gearbox is a manual gearbox with a electro-hydraulic control.
Description of user operation:
The interface between the driver and the sequential gearbox system inside the passenger compartment comprises:
– a gear lever (mechanical section and internal electronic section),
– a display,
– a TRACTION CONTROL (snow mode) button,
– a LOAD mode button,
– a buzzer.
Using this interface, the driver can:

– request gear changes (up or down),
– request a specific gear change (into neutral or reverse),
– change between manual and automatic mode,
– activate and deactivate the traction control mode,
– activate and deactivate the load mode.
Description of passenger compartment control:
Description of gear lever positions:

– S: Standby this is the only stable gear lever position. After the driver shifts the gear lever up or down, it
returns each time to the S position.
– R: Reverse: moving the lever to this position enables the driver to select reverse. Given the lever position
of the reverse function, it is possible, if the movement is too slow, for the sequential gearbox computer to
detect an N signal and hence select neutral before reverse.
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Description of gear lever positions (continued):
– N: Neutral: moving the lever to this position enables the driver to select neutral.
– A/M: AUTO/MANUAL: moving the lever to this position enables the driver to select either manual (or
semiautomatic) mode or automatic mode. If AUTO mode is selected, moving the lever will enable the driver
to select manual mode, if manual mode is selected; moving the lever will enable the driver to select
automatic mode.
– +: moving the gear lever towards this position enables the driver to shift up. If AUTO mode is selected, this
action will also enable the driver to exit automatic mode.
– -: moving the gear lever towards this position will enable the driver to shift down. If AUTO mode is selected,
this action will also enable the driver to exit automatic mode.
Description of the TRACTION CONTROL button:
This is a one touch button. Pressing this button once allows the driver to select or deselect the TRACTION
CONTROL mode.
Description of the LOAD button:
This is a one touch button. Pressing this button once allows the driver to select or deselect the LOAD mode.
Description of the display:
This display is specifically for the PA6 sequential gearbox. It displays 6 types of information for the driver:
– indication of the gear selected: 1, 2, 3, 4, 5, 6, N or R,
– the symbol displaying AUTO (A) mode: this symbol lights up when auto mode is selected.
– the TRACTION CONTROL indicator light: this lights up when the TRACTION CONTROL mode is selected.
– the LOAD mode indicator light: this lights up when the LOAD mode is selected.
– the depress brake pedal symbol: this symbol lights up when a driver action requires the brake pedal to be
depressed if the driver is not depressing the brake pedal. This symbol only lights up when there is an error
(driver actions without depressing the brake pedal = symbol lighting up),
– the sequential gearbox fault warning light: this lights up when the sequential gearbox computer detects a
fault on the sequential gearbox system.
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General information about the operation:
Reminder: creeping is only possible in first or reverse gears; it makes parking manoeuvres easier: if the
brake pedal or the handbrake is released, the vehicle moves forward by itself, without the driver having to
accelerate. Creeping is not possible in second gear.
Operation in MANUAL mode:
Manual mode allows the driver to select gears by moving the gear lever. However, in manual mode, the driver is not
completely free to do what he/she likes. This is why this mode is also called sequential mode because the driver is
assisted by the sequential gearbox computer in the following instances:
– when driving, shifting the lever towards the + position may result in engine underspeed. As a result, the
sequential gearbox computer forbids the driver's request,
– when driving, shifting the lever towards the - position may result in engine overspeed. As a result, the
sequential gearbox computer forbids the driver's request,
– when driving, as the overspeed threshold is approached, the computer automatically selects a higher gear,
– when driving, as the underspeed threshold is approached, the computer automatically selects a lower gear,
– when driving, if the vehicle speed reduces too quickly (brakes applied), the sequential gearbox computer can
order a downshift.
– when driving, the selection of N is only accepted by the sequential gearbox computer if the driver's foot is on
the brake pedal,
– when driving, selection of reverse is prohibited,
– when the vehicle is slowing and approaching 0 mph, the sequential gearbox computer engages 1st gear
automatically.
In manual mode, the driver decides when to change gears by:

– moving the gear lever towards +, which enables a higher gear to be selected,
– moving the gear lever towards -, which enables a lower gear to be selected,
– moving the gear lever to N, which enables neutral to be selected,
– moving the gear lever to R, which enables reverse to be selected.
Operation in AUTO mode:
Automatic mode frees the driver from having to worry about changing gear: instead, the sequential gearbox
computer determines when best to change gear in relation to the different vehicle parameters (speed, acceleration,
position of accelerator pedal etc.).
The main characteristics of automatic mode are as follows:

– AUTO mode is only operational and accessible when the engine is running.
– AUTO mode is preselected when the engine is started.
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Operation in AUTO mode (continued):
The AUTO mode entry conditions are as follows:

– Moving the gear lever to the left (towards A/M) when manual mode is selected, when a forward gear is
engaged and AUTO mode was selected.
– TRACTION CONTROL mode deselected by pressing the TRACTION CONTROL button.
– Engine started.
To exit the AUTO mode when driving and in normal operation (no faults), the following conditions must apply:
– Movement of the gear lever to the left (deselecting automatic mode using the lever).
– Movement of gear lever towards + (except when engaging R towards 1 or N towards X).
– Movement of the gear lever towards - (except when changing from N to X or when reverse gear is engaged).
– Engine switched off.
– Ignition switched off or + Accessories active.
– TRACTION CONTROL mode selected by pressing the TRACTION CONTROL button.
Operation of the TRACTION CONTROL mode:
The TRACTION CONTROL button imposes a special TRACTION CONTROL strategy which affects the middle levels
(pulling away programming, gear change management) and the high levels (LAA). The TRACTION CONTROL mode
does not impose pulling away in 2nd gear; pulling away is in 1st gear with special clutch management.
The main characteristics of the TRACTION CONTROL mode are as follows:

– The TRACTION CONTROL mode imposes AUTO mode: if the driver presses the TRACTION CONTROL
when manual mode is selected, the sequential gearbox switches to AUTO mode and TRACTION
CONTROL mode.
– There is no TRACTION CONTROL mode in manual mode; TRACTION CONTROL mode is only active in
AUTO mode.
– When the TRACTION CONTROL button is pressed while TRACTION CONTROL mode is active,
TRACTION CONTROL mode is deselected, but AUTO mode remains active.
– TRACTION CONTROL mode is only operational and accessible after the engine is started.
– The mode is not stored in the memory when the ignition is switched off; the driver must reselect snow mode
each time the engine is started.
The conditions for exiting TRACTION CONTROL mode are as follows:

– TRACTION CONTROL button pressed.
– Ignition switched off and + Accessories reactivated.
– Select manual mode (move lever towards A/M).
– Movement of the gear lever towards + (except when engaging R towards 1 or N towards X).
– Movement of the gear lever towards - (except when engaging R towards 1 or N towards X).
When driving, if the lever is moved towards + or -, TRACTION CONTROL mode is deselected (return to MANUAL
mode) and the request is accepted.
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Operation of the LOAD MODE:
– The LOAD MODE is activated when the driver presses the LOAD button.
– LOAD MODE is only accessible after the engine is started.
– The mode is not stored in the memory when the ignition is switched off; the driver must reselect LOAD
MODE each time the engine is started.
– If LOAD MODE is selected, the load indicator light comes on. However, if the computer detects a load even
though the button has not been pressed, the load indicator light will not come on.
– LOAD MODE is independent of the other driving modes: LOAD MODE is active in manual mode, AUTO
mode and TRACTION CONTROL mode.
– LOAD MODE is independent of all other driver actions (+, -, N, R, A/M).
Conditions for exiting LOAD MODE are as follows:

– Ignition switched off or + Accessories active.
– Load button pressed.
Buzzer operation:
The buzzer operates in the following cases:
– Safety risk: the buzzer sounds when one of the front doors is opened, if the following conditions are met:
– the engine is running,
– a gear is engaged,
– the driver is not applying the brakes.
– The buzzer cuts out if one of the following conditions is confirmed:

– the engine is stopped,
– the driver applies the brakes,
– the driver closes the door(s).
– Driver warning when push-starting vehicle:

– The buzzer will sound to inform the driver that moving the lever to select a gear will enable the engine to
start. The buzzer will sound when the vehicle has reached the speed that will allow the engine to start.
– When the computer detects that the clutch is overheating.
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Lever operation:
– When the vehicle is stationary, the engine switched off and the key at + after ignition feed position, gear
changes are possible.
– Each time the lever is moved, it returns to the S position automatically.
– When the vehicle is stationary, the engine switched off and the key at + after ignition feed position, lever
movements will only be considered if the driver depresses the brake pedal. In this case, all gears are
available. The number of gear changes possible is unlimited.
– When the vehicle is stationary and the engine is running, lever movements will only be considered if the
driver depresses the brake pedal. In this configuration, only gears N, 1, 2 and R are available.
– Position N only allows neutral to be engaged if the driver depresses the brake pedal.
– Position R enables reverse to be engaged. Reverse gear will only be engaged if the vehicle has stopped or
has nearly stopped and if the driver depresses the brake pedal. Engaging reverse when driving is prevented
by the sequential gearbox computer.
Operation of the display:
AUTO repeater:
– AUTO (A) symbol lit: it lights up when AUTO mode is selected.
– Instrument panel display: the display shows A and the gear engaged.
– Symbol goes out: it goes out when AUTO mode is deselected.
TRACTION CONTROL MODE repeater:

– TRACTION CONTROL MODE symbol lit (*): it is lit when the TRACTION CONTROL MODE is selected and
accepted by the computer (pressing the TRACTION CONTROL MODE requires the switch to AUTO mode,
hence the display A + *).
– Instrument panel display: the display shows * + A + the gear engaged. the display is controlled in the same
way as in AUTO mode.
– TRACTION CONTROL MODE goes out: the symbol goes out when TRACTION CONTROL mode is
deselected.
LOAD MODE repeater:

– The LOAD MODE symbol lit: it is lit when LOAD MODE is selected and accepted by the computer.
– Instrument panel display: the display shows C + the gear engaged + A if AUTO mode is active or A + * if
TRACTION CONTROL MODE is active.
– LOAD MODE goes out: the symbol goes out when LOAD MODE is deselected.
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Display programming when gears cannot be engaged:
– When a request would lead to engine overspeed or underspeed: the requested gear flashes then initial gear
reappears. Flashing ends after a delay.
– When there is a mechanical fault (gearbox blockage etc.): application of the retry (1) program by the
computer. During the attempt: the requested gear flashes; then the gear engaged is displayed on the
instrument panel at the end of the attempt. This program cannot be applied to neutral because the N position
cannot flash on the instrument panel; it remains lit.
(1) RETRY: If there is a mechanical fault engaging a gear (lower or higher), the computer will detect this and
will attempt to re-engage twice more; if this does not work, the requested gear will flash on the instrument
panel display and the gearbox will return to the gear used prior to this request.
Depress brake pedal repeater:
This indicator is used when, during normal operation, it is necessary to depress the brake pedal and the driver has
not done so. The indicator asks the driver to depress the brake pedal in order for his request to be accepted.
Consequently: the symbol only lights up if there is a fault (driver action without brake pedal depressed = symbol
lights up) and only if depressing the brake pedal allows the driver's request to be accepted.
– Depress brake pedal symbol lit:

– request to change gear when stopped without the brake pedal depressed,
– request to start engine with gear engaged without brake pedal depressed,
– request to select N when driving without brake pedal depressed,
– request to select AUTO, with the vehicle stationary, the engine running and 2nd gear engaged,
– request to select TRACTION CONTROL MODE, with the vehicle stationary, the engine running and 2nd gear
engaged.
– Depress brake pedal symbol goes out:

– The symbol goes out if the driver depresses the brake pedal or after an adjustable delay.
Note:
If, while the symbol is lit, the driver depresses the brake pedal, the symbol will go out and the display will return to
its previous status (the lever request is not registered).
In the event that the driver makes a request causing the gear requested to flash and the symbol to be displayed at
the same time, they will be synchronised and last for the same time.
Fault warning light:
This warning light comes on when a fault is detected by the sequential gearbox computer.
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VDIAG N°.: 04 Fault finding – Allocation of computer tracks 21B
52-TRACK CONNECTOR
Computer
Allocation
track
1 Power earth 1
2 Power earth 2
3 Selection solenoid valve 2 control
4 to 25 Not used
26 + lever switch feed
27 + battery feed
28 + after ignition feed
29 Selection solenoid valve 1 control
30 Not used
31 Pump assembly relay
32 Engagement solenoid valve 1 control
33 Multiplex line L
34 Not used
35 Not used
36 Vehicle speed
37 Not used
38 Gearbox input speed sensor signal
39 Engagement position sensor signal
40 Oil pressure sensor signal
41 Reversing lights relay
42 Not used
43 Clutch solenoid valve control
44 Engagement solenoid valve 2 control
45 Multiplex line H
46 Not used
47 Not used
48 Engine speed
49 Diagnostic line K
50 Speed sensor earth
51 Selector lever position sensor signal
52 Clutch position sensor signal
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VDIAG N°.: 04 Fault finding – Allocation of computer tracks 21B
28-TRACK CONNECTOR
Computer
Allocation
track
53 to 64 Not used
65 Lever switches earth
66 Sensor earth (except clutch position sensor)
67 Lever switch Stb (standby)
68 Lever switch feed -
69 Brake contact closed
70 Load contact
71 Traction control mode contact
72 Not used
73 5 V supply to sensors
74 Lever switch N (neutral)
75 Not used
76 Starter key switch + signal
77 Not used
78 Front door switches
79 Not used
80 Not used
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VDIAG N°.: 04 Fault finding – Replacement of components 21B
COMPUTER (RE)PROGRAMMING OPERATIONS
The system can be (re)programmed via the diagnostic socket using the RENAULT CLIP diagnostic tool (Consult
Technical Note 3585A and follow the instructions provided by the diagnostic tool).
WARNING
– Switch on the diagnostic tool (mains or cigarette lighter supply).
– Connect a battery charger.
– Switch off all electrical consumers (lights, interior lights, air conditioning, radio/CD, etc.).
– Put the gearbox in neutral.
Before any computer (re)programming
In the old computer, note the clutch replacement date (Read new clutch fitting date) in the Computer
identification screen.
After any computer (re)programming
A) Switch on the ignition.

B) The engine coolant temperature must be below 50°C for the following steps to proceed correctly.
C) Enter the VIN using command VP001 Enter VIN.
Check the entry in the Computer identification screen.
Repeat procedure C if unsuccessful.
D) Clear all programming using commands:
– RZ001 Stored fault(s),
– RZ002 Programming,
– RZ008 Initial closed position of clutch.
E) Carry out automatic programming of the clutch end of travel using command VP017 Program clutch closed
position.
In the Function test check the programming:
– ET064 Clutch position programming = DONE.
Repeat procedure E if unsuccessful.
F) Use command AC007 Hydraulic unit pump rehabilitation.
G) Program the gears using command VP008 Programming selection/engagement ranges.
Wait for the procedure to end.
Exit fault finding mode and switch off the ignition.
Wait 1 minute and then re-establish dialogue with the computer.
– ET061 Gear programming = CORRECT.
Repeat procedure G if unsuccessful.
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COMPUTER (RE)PROGRAMMING OPERATIONS (continued)
H) Brake and engage all gears, checking that they are recognised on the display.
I) Put the gearbox in neutral.
Start the engine.
Wait 10 seconds without changing gear (to program the clutch biting point).
– ET062 Program biting point = DONE.
– ET063 Solenoid valve zero point programming = DONE.
Repeat procedure I if unsuccessful.
J) Check that the coolant temperature is above 80°C and that PR095 Clutch temperature is below 180°C.
Repeat starting at half-load 5 or 6 times to program the clutch progressivity.
– ET065 Progressivity programming = COMPLETED.
Repeat procedure J if unsuccessful.
K) Enter the clutch replacement date using command VP013 Enter new clutch fitting date.
Check the entry using Read new clutch fitting date in the Computer identification screen.
Repeat procedure K if unsuccessful.
L) Enter the last After-Sales operation date using command VP009 Enter last After-Sales operation date.
Check the entry using Read last After-Sales operation date in the Computer identification screen
Repeat procedure L if unsuccessful.
M) Exit fault finding mode and switch off the ignition.
N) Check the faults and clear the computer fault memory (some faults are stored when the command modes
are used) or deal with the present faults.
O) Carry out a road test followed by another check with the diagnostic tool.
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ANY PART REPLACEMENT REQUIRES THE COMPULSORY REMOVAL OF THE WHOLE SEQUENTIAL
SYSTEM AND THE IMPLEMENTATION OF THE FOLLOWING PROGRAMMING AND CONFIGURATION
PROCEDURES:
A) Switch on the ignition and check that the engine coolant temperature is below 50°C in order for the following
steps to proceed correctly.
B) Clear the computer fault memory using command:
– RZ001 Stored fault(s).
C) Bleed the clutch circuit (see the bleeding procedure in Repair methods for the sequential gearbox).
Special tooling required: A 60 cc medical-type syringe, or one from hardener kit part no. 77 01 421 080.
D) Bleed the clutch slave cylinder using command AC025 Bleed clutch slave cylinder hydraulic circuit.
Repeat procedure D if unsuccessful.
E) Bleed the hydraulic pressure unit using command AC011 Bleed hydraulic pressure unit.
F) Bleed the clutch hydraulic circuit using command AC009 Clutch circuit phase 2 bleed.
Wait for the procedure to end (this should take 8 minutes).
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BVR
G) Before all the programming is cleared using the following commands, the engine coolant temperature must
be below 50°C for the following steps to proceed correctly:
– RZ002 Programming,
– RZ003 Program biting point,
– RZ008 Initial closed position of clutch.
– Exit fault finding mode and switch off the ignition.
H) Carry out automatic programming of the clutch end of travel using command VP017 Program clutch closed
position.
Repeat procedure H if unsuccessful.
I) Program the gears using command VP008 Programming selection/engagement ranges.
Wait for the procedure to end
– ET061 Gear programming = CORRECT.
Repeat procedure I if unsuccessful.
J) Brake and engage all gears, checking that they are recognised on the display.
K) Put the gearbox in neutral.
Start the engine.
– ET062 Program biting point = DONE.
– ET063 Solenoid valve zero point programming = DONE.
Repeat procedure K if unsuccessful.
L) Check that the coolant temperature is above 80°C and that PR095 Clutch temperature is below 180°C.
Repeat starting at half-load 5 or 6 times to program the clutch progressivity.
– ET065 Progressivity programming = COMPLETED.
Repeat procedure L if unsuccessful.
M) Exit fault finding mode and switch off the ignition.
BVR X7083 04 3.0
21B-20
SEQUENTIAL GEARBOX
BVR
N) Only use this configuration if the clutch has been replaced, otherwise go straight to step O.
Enter the clutch replacement date using command VP013 Enter new clutch fitting date.
Check the entry using Read new clutch fitting date in the Computer identification screen.
Repeat procedure N if unsuccessful.
O) Enter the last After-Sales operation date using command VP009 Enter last After-Sales operation date.
Check the entry using Read last After-Sales operation date in the Computer identification screen.
Repeat procedure O if unsuccessful.
P) Exit fault finding mode and switch off the ignition.
Q) Check the faults and clear the computer fault memory (some faults are stored when the command modes
are used) or deal with the present faults.
R) Carry out a road test followed by another check with the diagnostic tool.
BVR X7083 04 3.0
21B-21
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Configuration and Programming 21B
SETTINGS
VP001: Enter VIN.

This command allows the vehicle identification number to be entered into the computer
manually. Use this command each time the computer is replaced or (re)programmed.
VP008: Programming selection/engagement ranges.
This command enables the gears to be programmed.
Use this command each time parts are replaced; see Replacement of components.
Note:
When replacing or (re)programming a computer, use command AC007 Hydraulic unit pump rehabilitation
before running parameter VP008.
VP009: Enter last After-Sales operation date.

Use this command for each workshop operation on the sequential gearbox.
Select command VP009 on the diagnostic tool.
Enter the service date using the tool's keypad.
VP013: Enter new clutch fitting date.
This command should be used when the clutch is replaced.
Select command VP013 on the diagnostic tool.
Enter the service date using the tool's keypad.
VP014: Enter initial closed position of clutch.
This command enables the value of the initial closed position of the clutch to be re-entered
into a new or reprogrammed computer in order to keep a consistent record of the clutch
wear.
Use this command each time the computer is replaced or reprogrammed.
VP017: Program clutch closed position.
This command is used to automatically program the clutch end of travel.
BVR X7083 04 3.0
21B-22
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Fault summary table 21B
Tool fault Diagnostic tool title
DF002 Computer
DF005 Oil pressure sensor circuit
DF039 Engine speed signal
DF046 Idling setpoint multiplex signal
DF048 Vehicle speed signal
DF057 Gearbox input speed sensor circuit
DF062 Multiplex line fault
DF065 Pump relay circuit
DF066 Starter relay circuit
DF067 Lever position switch circuit
DF068 Clutch position sensor circuit
DF069 Selection position sensor circuit
DF070 Engagement position sensor circuit
DF071 Clutch solenoid valve circuit
DF072 Engagement solenoid valve 1 circuit
DF073 Engagement solenoid valve 2 circuit
DF074 Selection solenoid valve 1 circuit
DF075 Selection solenoid valve 2 circuit
DF076 Clutch control
DF077 Gearbox servo control
DF078 Hydraulic servo control
DF080 Battery voltage
DF082 Brake lights switch circuit
DF107 Engine speed multiplex signal
DF108 Effective average torque multiplex signal
DF144 Coolant temperature multiplex signal
DF145 Pedal position multiplex signal
DF146 Torque no reduction multiplex signal
DF148 Secondary brake contact multiplex signal
DF152 General total multiple signal
DF153 Reversing lights control
DF183 No UCH multiplex signal
DF184 No instrument panel multiplex signal
DF186 No injection multiplex signal
DF188 System operation
DF189 Gear programming
DF190 Clutch position programming
BVR X7083 04 3.0
21B-23
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Interpretation of faults 21B
COMPUTER
DF002 1.DEF : internal electronic fault
PRESENT 2.DEF : main relay fault (integral to computer)
NOTES None.
Check the condition and position of the sequential gearbox fuses in the engine compartment and in the passenger
compartment.
Check the condition and the connection of the computer's 52-track connector.
Repair if necessary.
Check for + before ignition feed on track 27 and of + after ignition feed on track 28 on the computer's 52-track
connector.
Check the insulation, continuity and absence of interference resistance on the following connections:
Chassis earths Tracks 1 and 2 of the computer's 52-track connector
Clear the computer fault memory and exit fault finding.

Switch off the ignition.
Switch on the ignition again and carry out a new check using the diagnostic tool.
If the fault is still present, contact Techline.
Clear the computer fault memory.

AFTER REPAIR
Carry out a road test followed by another check with the diagnostic tool.
BVRPA6_V04_DF002P BVR X7083 04 3.0
21B-24
SEQUENTIAL GEARBOX
BVR
OIL PRESSURE SENSOR CIRCUIT
DF005 CO.0 : open circuit or short circuit to earth
PRESENT CC.1 : short circuit to + 12 V
1.DEF : consistency
NOTES None.
CO.0
NOTES None.
CC.1
Check the condition and positioning of the 30A pump fuse in the engine compartment.
Check the connections of the sensor connector and computer connectors.

Check the continuity and insulation of the connections between:
Sensor connector track A Track 66 of the computer connector
Sensor connector track B Track 73 of the computer connector
Sensor connector track C Track 40 of the computer connector
If the connection is faulty:
Disconnect the intermediate black 24-track connector positioned on the hydraulic unit; check the condition of its
connections.
Sensor connector track A Track C1 of the intermediate connector
Sensor connector track B Track C8 of the intermediate connector
Sensor connector track C Track C5 of the intermediate connector
Also check the insulation between these connections.
Computer connector track 66 Track C1 of the intermediate connector
If the fault is still present, replace the oil pressure sensor on the sequential gearbox.

AFTER REPAIR
BVRPA6_V04_DF005P BVR X7083 04 3.0
21B-25
SEQUENTIAL GEARBOX
BVR
DF005
CONTINUED
1.DEF NOTES None.
Check the level of oil with the accumulator discharged, see the interpretation of command AC081 Discharge
pressure accumulator.
Check the condition and positioning of the 30A pump fuse in the engine compartment. Repair if necessary.
Use command AC012 Hydraulic pump relay with the diagnostic tool and check that the pump unit is working. If
the pump is not working, perform the necessary repairs.
If the fault is still present, replace the oil pressure sensor.
Switch off the ignition.

Switch on the ignition again and carry out a new check using the diagnostic tool.
Replace the pump unit if the fault reappears.

AFTER REPAIR
BVR X7083 04 3.0
21B-26
SEQUENTIAL GEARBOX
BVR
ENGINE SPEED SIGNAL (wire connection)
DF039 1.DEF : consistency
STORED 2.DEF : no signal
Conditions for applying the fault finding procedure to stored faults:

NOTES
The fault is declared present after the engine starts.
Check the injection system and deal with any faults.
Check the connection and condition of the 52-track sequential gearbox computer connectors and the injection
computer black 32-track connector A.
Check the insulation, continuity and absence of interference resistance on the following connection:
Sequential gearbox computer track 48 Track B2 of black connector A of the injection
computer

AFTER REPAIR
BVRPA6_V04_DF039M BVR X7083 04 3.0
21B-27
SEQUENTIAL GEARBOX
BVR
IDLING SETPOINT MULTIPLEX SIGNAL
DF046 1.DEF : incorrect parameter
STORED

The fault is declared present after:
NOTES The computer fault memory has been cleared.
The ignition has been switched off and on again.
Starting the engine.
Carry out the multiplex network test.

Check the injection system.

AFTER REPAIR
BVRPA6_V04_DF046M BVR X7083 04 3.0
21B-28
SEQUENTIAL GEARBOX
BVR
VEHICLE SPEED SIGNAL
Special notes:
The fault can only be cleared from the memory using the diagnostic tool after a
road test where the vehicle speed signal is detected by the computer.
NOTES
The fault is declared present after a road test.
Check that the gearbox input speed sensor and the engine speed sensor are operating correctly.
Check the mechanical condition of the clutch.
Check that the speedometer is working correctly when driving.

Check the connection and condition of the sequential gearbox and ABS computer connectors.
Check the insulation, continuity and the absence of interference resistance on the following connection:
Sequential gearbox computer track 36 Track 14, instrument panel black connector
Apply the After repair procedure to clear this fault.
A road test must be performed along with another check using the diagnostic
AFTER REPAIR
tool to clear the vehicle speed signal fault.
BVRPA6_V04_DF048M BVR X7083 04 3.0
21B-29
SEQUENTIAL GEARBOX
BVR
GEARBOX INPUT SPEED SENSOR CIRCUIT
Special notes:
The fault can only be cleared from the memory using the diagnostic tool after a
road test where the vehicle speed signal is detected by the computer.
NOTES
The fault is declared present following a road test at a speed above 6 mph (10 km/h)).
1.DEF NOTES None.
Check that the engine speed sensor is operating correctly and check by performing a road test that the
speedometer is operating.
Check the mechanical condition of the clutch.
AFTER REPAIR
tool to clear the gearbox input speed sensor fault.
BVRPA6_V04_DF057M BVR X7083 04 3.0
21B-30
SEQUENTIAL GEARBOX
BVR
DF057
CONTINUED
2.DEF NOTES None.
Check the condition and connection of the gearbox input speed sensor connector. Repair if necessary.
Check that the sensor is correctly fitted on the gearbox.
Check the speedometer is operating correctly.

Check the connection and condition of the 52-track sequential gearbox computer connector.

Sensor connector track 1 Track 38 of the computer connector
Disconnect the 24-track intermediate connector positioned on the hydraulic unit; check the condition of its
connections.
Sensor connector track 1 Track C7 of the intermediate connector
Sensor connector track 2 Track C6 of the intermediate connector
If the fault is still present, replace the engine speed sensor on the sequential gearbox.
AFTER REPAIR
tool to clear the gearbox input speed sensor fault.
BVR X7083 04 3.0
21B-31
SEQUENTIAL GEARBOX
BVR
MULTIPLEX LINE FAULT
DF062 1.DEF : CAN connection fault
PRESENT

The fault is declared present after:
NOTES
the computer fault memory is cleared, the ignition is switched off and on again and the
engine is started.

AFTER REPAIR
BVRPA6_V04_DF062P BVR X7083 04 3.0
21B-32
SEQUENTIAL GEARBOX
BVR
PUMP RELAY CIRCUIT
DF065 CC.0 : short circuit to earth
PRESENT CO.1 : open circuit or short circuit to + 12 volts
1.DEF : pump motor permanent control or open circuit
Priorities in dealing with a number of faults:

NOTES
First, deal with fault DF005 Oil pressure sensor circuit.
CC.0
NOTES None.
CO.1
Check for the presence and conformity of the relay in the engine fuse box.
Check the connections and condition of the computer and pump relay connectors.
Check for + before ignition feed between tracks 2 and 3 of the relay. Repair if necessary.
Relay connector track 1 Track 31 of the computer connector
If the fault is still present, replace the pump relay.
1.DEF NOTES None.
Check that the PR018 hydraulic pressure when the ignition is switched on is between 40 bar and 50 bar otherwise
apply the fault finding procedure for DF005.
If the checks described in DF005 are correct and PR018 shows a pressure value lower than the one given
previously following the pump motor starting up, replace the pressure sensor.
Ensure that the pump motor is not seized.

Disconnect the relay and check there is no continuity between tracks 3 and 5 of the relay. Replace the relay if
necessary (relay is glued).
Check that there is insulation to + 12 V between track 5 of the relay and track B of the pump motor. Repair if
necessary.
Check for the absence of + 12 V on track 1 of the relay.
Check for insulation to + 12 V between track 31 of the computer connector and track 1 of the relay mounting.
If the checks are in order, the computer is continuously supplying the pump motor.
Replace the sequential gearbox computer.

AFTER REPAIR
BVRPA6_V04_DF065P BVR X7083 04 3.0
21B-33
SEQUENTIAL GEARBOX
BVR
STARTER RELAY CIRCUIT
DF066 CC.1 : short circuit to + 12 V
PRESENT CO : open circuit
NOTES None.
CO.0
NOTES None.
CC.1
Check the presence and conformity of the relay in the engine fuse box.
Check the connection and condition of the computer and starter relay connections.
Check for + after ignition feed on track 1 on the relay connector and the vehicle earth.
If the checks are correct, check the earth connection via the computer on the relay connector between tracks 1
(+ 12 V) and 2 (earth) with command AC013 Starter relay using the diagnostic tool.
If the voltage is correct, replace the starter relay.
If the voltage is incorrect, contact Techline.

AFTER REPAIR
BVRPA6_V04_DF066P BVR X7083 04 3.0
21B-34
SEQUENTIAL GEARBOX
BVR
LEVER POSITION SWITCH CIRCUIT
NOTES None.
CC.0
NOTES None.
CO.1
Check the connection and condition of the lever switch and computer connectors.
Switch connector track A1 Track 74 of the computer connector
Switch connector track B2 Track 67 of the computer connector
Switch connector track B3 Track 68 of the computer connector
Also check the insulation between these 5 connections. Repair if necessary.
Apply the fault finding procedure associated with statuses: ET043, ET044, ET045 and ET046 in the interpretation
of statuses fault finding procedure.

AFTER REPAIR
BVRPA6_V04_DF067P BVR X7083 04 3.0
21B-35
SEQUENTIAL GEARBOX
BVR
CLUTCH POSITION SENSOR CIRCUIT
1.DEF : consistency
NOTES None.
CC.0
NOTES None.
CO.1
Check the connection and condition of the computer and sensor connections.
connections.
Also check the insulation between these connections. Repair if necessary.
Also check the insulation between these connections. Repair if necessary.
Check the condition of the hydraulic control (leak, etc.).

If the fault is still present, replace the clutch position sensor.

AFTER REPAIR
BVRPA6_V04_DF068P BVR X7083 04 3.0
21B-36
SEQUENTIAL GEARBOX
BVR
DF068
CONTINUED
1.DEF NOTES None.
Check the condition and fitting of the clutch position sensor (potentiometer mounting and mechanism, etc.).
Also check the insulation between these 3 connections.
With the engine running, check using the diagnostic tool that PR006 = PR014.
If the checks show no faults, replace the clutch position sensor.
If the fault is still present, check that the clutch is not overheating.

AFTER REPAIR
BVR X7083 04 3.0
21B-37
SEQUENTIAL GEARBOX
BVR
SELECTION POSITION SENSOR CIRCUIT
NOTES None.
connections.
Remove the selection position sensor and check the wear of the potentiometer-cylinder mechanical connection.
If the checks show no faults, replace the selection position sensor.

AFTER REPAIR
BVRPA6_V04_DF069P BVR X7083 04 3.0
21B-38
SEQUENTIAL GEARBOX
BVR
ENGAGEMENT POSITION SENSOR CIRCUIT
DF070 CC.0 : Short circuit to earth
PRESENT CO.1 : Open circuit or short circuit to + 12 V
NOTES None.
connections.
Remove the engagement position sensor and check the wear of the mechanical cylinder-potentiometer
connection.
If the checks show no faults, replace the engagement position sensor.

AFTER REPAIR
BVRPA6_V04_DF070P BVR X7083 04 3.0
21B-39
SEQUENTIAL GEARBOX
BVR
CLUTCH SOLENOID VALVE CIRCUIT
DF071
PRESENT CC.0 : short circuit to earth
OR CC.1 : short circuit to + 12 V
STORED CO : open circuit

NOTES A fault is declared present after engaging all gears, with the brake pedal depressed and
the engine stopped.
Check the connections and condition of the computer and solenoid valve connections.
Sensor connector track 2 Earth terminal on the hydraulic unit
connections.
Check and ensure the continuity and insulation of the connection between:
Computer connector track 43 Track B2 of the intermediate connector
Solenoid valve connector track 1 Track B2 of the intermediate connector
If the checks reveal no faults, replace the clutch solenoid valve.

AFTER REPAIR
BVRPA6_V04_DF071 BVR X7083 04 3.0
21B-40
SEQUENTIAL GEARBOX
BVR
ENGAGEMENT SOLENOID VALVE 1 CIRCUIT
DF072
PRESENT CC.0 : short circuit to earth
OR CC.1 : short circuit to + 12 V

the engine stopped.
Solenoid valve connector track 1 Track 32 of the computer connector
Solenoid valve connector track 2 Earth terminal on the hydraulic unit
Disconnect the 24-track intermediate connector positioned on the hydraulic unit and check the condition of its
connection.
If the checks are correct, replace engagement solenoid valve 1.

AFTER REPAIR
BVRPA6_V04_DF072 BVR X7083 04 3.0
21B-41
SEQUENTIAL GEARBOX
BVR
ENGAGEMENT SOLENOID VALVE 2 CIRCUIT
DF073
OR CC.0 : short circuit to earth

the engine stopped.
connections.
If the checks are correct, replace engagement solenoid valve 2.

AFTER REPAIR
BVRPA6_V04_DF073 BVR X7083 04 3.0
21B-42
SEQUENTIAL GEARBOX
BVR
SELECTION SOLENOID VALVE 1 CIRCUIT
STORED CO.0 : open circuit or short circuit to earth

If DF077 is present with DF074 stored, first apply the fault processing procedure below.
NOTES If only DF074 is stored, apply the fault finding procedure below, if the fault is present
following engagement of all the gears, with the brake pedal depressed and the engine
stopped.
connections.
If the checks are correct, replace selection solenoid valve 1.

AFTER REPAIR
BVRPA6_V04_DF074M BVR X7083 04 3.0
21B-43
SEQUENTIAL GEARBOX
BVR
SELECTION SOLENOID VALVE 2 CIRCUIT
STORED CO.0 : open circuit or short circuit to earth

If DF077 is present with DF075 stored, first apply the fault processing procedure below.
NOTES If only DF075 is stored, apply the fault finding procedure below, if the fault is present
following engagement of all the gears, with the brake pedal depressed and the engine
stopped.
connections.
If the checks are correct, replace selection solenoid valve 2.

AFTER REPAIR
BVRPA6_V04_DF075M BVR X7083 04 3.0
21B-44
SEQUENTIAL GEARBOX
BVR
CLUTCH CONTROL
DF076 1.DEF : clutch overheating
STORED 2.DEF : position inconsistency between master cylinder and slave cylinder
3.DEF : clutch inconsistency when changing gear

If faults DF076, DF039 and DF107 are all present, deal with faults DF039 and DF107
first.

NOTES
Apply the fault finding procedure below if the fault is present or stored.
Special notes:
This fault occurs following excessive use of the clutch (prolonged holding on slopes,
PR095 > 248°C). When PR095 > 248°C, the buzzer sounds.
1.DEF NOTES None.
Check that the clutch is not slipping by performing a road test, driving with a low load and then up or down an
incline.
If the clutch is slipping:
– pull away several times with a low load and check the development of the PR096 Clutch progressivity.
If the fault is still present, replace the clutch.
2.DEF NOTES None.
Check the fluid level and the clutch control circuit sealing.
Repair if necessary (see MR 377, section 2 or 3 or Technical Note 3803A for the vehicle concerned).
3.DEF NOTES None.
Check the hydraulic and mechanical condition (leaks, discharge, sticking) of the clutch control circuit.
Check the condition of the clutch solenoid valve.
Repair if necessary (see MR 377, section 2 or 3 or Technical Note 3803A for the vehicle concerned).

AFTER REPAIR
BVRPA6_V04_DF076M BVR X7083 04 3.0
21B-45
SEQUENTIAL GEARBOX
BVR
GEARBOX SERVO CONTROL
DF077 1.DEF : automatic mode fault
PRESENT 2.DEF : mechanical fault
OR 3.DEF : gear selection impossible
STORED 4.DEF : loss of engaged gear
5.DEF : automatic transmission malfunction when changing gears.

If faults DF077 and DF076 (2.DEF, 3.DEF) are stored, deal with fault DF076 first.

NOTES Apply the fault finding procedure below if the fault is present or stored.
Special notes:
This fault occurs following excessive use of the clutch (prolonged holding on slopes,
PR095 Clutch temperature > 248°C). When PR095 > 248°C, the buzzer sounds.
1.DEF NOTES None.
If there is a fault linked to the injection, deal with the engine injection fault finding part.
If there are no faults in the engine, this fault is only due to forward movement with significant skidding on a slippery
road followed by a return to tyre adhesion.
Clear the fault and carry out a road test.
2.DEF Special notes:

3.DEF NOTES Improper use of lever when the vehicle is stationary may
4.DEF lead to this fault.

AFTER REPAIR
BVRPA6_V04_DF077 BVR X7083 04 3.0
21B-46
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04
Fault finding – Interpretation of faults 21B
DF077
CONTINUED 1
Check that there are no faults on a selection or engagement sensor and repair if necessary.
Check that the selection control lever is correctly clipped onto the hydraulic unit. Repair if necessary.
Check that there is no water in the gearbox oil. Repair if necessary.
If the fault is still present, carry out the following tests:
Test 1:
Engine stopped, ignition on (+ after ignition), gearbox in Neutral, engage 1st gear, engage 2nd gear, return to
Neutral and check that:
– the value of PR018 Hydraulic pressure changes to about 50 bar.
– ET054 Pump relay control is inactive.
This status must not change for 120 seconds.
If the result is correct, move on to Test 2.

If not, replace engagement solenoid valves 1 and 2 and selection solenoid valves 1 and 2 (see MR 408,
Mechanical, 21B, Sequential gearbox, Solenoid valves: Removal - Refitting).
Test 2:
Engine stopped, ignition on (+ after ignition), gearbox in Neutral, engage 1st gear, engage 2nd gear, return to
Neutral and check that:
– the value of PR018 changes to about 50 bar.
– ET054 is inactive.
Perform a minimum of 2 gear changes and check that ET054 remains inactive.

Otherwise, replace the pressure accumulator (see MR 408, Mechanical, 21B, Sequential gearbox, Pressure
accumulator: Removal - Refitting).
Test 3:
With the engine running and the brake pedal depressed, check ET056 Clutch solenoid valve control and
ET054.
Engage 1st gear and check that:
– ET056 is active and
– ET054 is inactive.
These statuses must not change for 40 seconds.

If not, replace the clutch solenoid valve (see MR 408, Mechanical, 21B, Sequential gearbox, Solenoid valves:
Removal - Refitting).

AFTER REPAIR
BVR X7083 04 3.0
21B-47
SEQUENTIAL GEARBOX
BVR
DF077
CONTINUED 2
Test 4:
With the engine running and the brake pedal depressed, engage 1st gear and wait for 3 minutes.
The engine must not stall during the test.
If the engine stalls, replace the clutch master cylinder kit (part no. 309300676R).
If the fault is still present, replace the electro-hydraulic actuator (see MR 408, Mechanical, 21B, Sequential
gearbox, Actuator module: Removal - Refitting).

Follow the programming procedure described in Replacement of components.

AFTER REPAIR
BVR X7083 04 3.0
21B-48
SEQUENTIAL GEARBOX
BVR
DF077
CONTINUED 3
5.DEF NOTES None.
Step 1
Switch on the ignition, connect the diagnostic tool, engage 1st gear and display the value for parameter PR017
“Engagement position”.
Engage neutral, wait 15 seconds and check the value for parameter PR017 "Engagement position".
1 If the value changes: move on to step 3.
2 If the value does not change, check that the connectors for the engagement position sensor, computer and
intermediate connector are correctly connected and check the value for parameter PR017 Engagement
position. If the value changes after an operation on the engagement position sensor and computer connectors,
repair the connector, otherwise replace the wiring (see Technical Note 6015A, Repairing electrical wiring,
wiring: Precautions for repair).
Repeat the procedure and if the value still does not change: move on to step 2.
Step 2

–57AF between components 1055 and 119,
–57AD between components 1055 and 119,
–51FA between components 1055 and 119.
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace it.
Remove the engagement position sensor and check the wear of the mechanical cylinder-potentiometer connection
(excessive play, mechanical connection broken or sticking).
If the checks are correct, replace the engagement position sensor (see Technical Note 3803A, Special notes the
Trafic fitted with a sequential gearbox, Engaging sensor: Removal-Refitting).
Step 3
Perform step 1 for each gear ratio (1st, 2nd, 3rd, 4th, 5th and 6th).
3 If the values for the engagement position sensor are different from the value in neutral, move on
to step 4.
4 If an inconsistency in the engagement position sensor value appears during these checks, check the wear of the
mechanical cylinder-potentiometer connection (excessive play, mechanical connection broken or sticking).
If the checks are correct, replace the engagement position sensor (see Technical Note 3803A, Special notes the
Trafic fitted with a sequential gearbox, Engagement sensor: Removal - Refitting).

AFTER REPAIR
BVR X7083 04 3.0
21B-49
SEQUENTIAL GEARBOX
BVR
DF077
CONTINUED 4
Step 4
With the engine warm, perform step 1 for each gear ratio (1st, 2nd, 3rd, 4th, 5th and 6th).
1 If an inconsistency in the engagement position sensor value appears during these checks, check the wear of the
mechanical cylinder-potentiometer connection (excessive play, mechanical connection broken or sticking). If the
checks are correct, replace the engagement position sensor (see Technical Note 3803A, Special notes the
Trafic fitted with a sequential gearbox, Engaging sensor: Removal-Refitting).
2 If the values for the engagement position sensor are different from the value in neutral, move on
to step 5.
Step 5
Start the engine, engage 1st gear and wait 15 seconds. Engage neutral and display the value for parameter PR017
"Engagement position", wait 15 seconds and check that the value does not change.
3 Switch off the engine and wait 15 seconds, if it is impossible to push the vehicle, the engagement solenoid valve
is definitely the cause or the engagement position sensor (see Technical Note 3803A, Special notes on the
Trafic fitted with a sequential gearbox, Engagement sensor: Removal - Refitting) and (see MR408
Mechanical, 21B, Solenoid valves: Removal - Refitting).
4 If it possible to push the vehicle: move on to step 6
Step 6
Start the engine, engage 2nd and wait 15 seconds. Engage neutral and display the value for parameter PR017
"Engagement position", wait 15 seconds and check that the value does not change.
Switch off the engine and wait 15 seconds, if it is impossible to push the vehicle, the engagement solenoid valve
is definitely the cause or the engagement position sensor (see Technical Note 3803A, Special notes on the
Trafic fitted with a sequential gearbox, Engagement sensor: Removal - Refitting) and (see MR 408,
Mechanical, 21B, Solenoid valves: Removal - Refitting).

AFTER REPAIR
BVR X7083 04 3.0
21B-50
SEQUENTIAL GEARBOX
BVR
HYDRAULIC SERVO CONTROL
DF078 1.DEF : pressure too low
PRESENT 2.DEF : pump fault
OR 3.DEF : slow pressure loss
STORED 4.DEF : pressure accumulator fault
5.DEF : rapid pressure loss

Apply the interpretation of the other faults first.
NOTES
The fault is declared present during a road test.
Special notes:
1.DEF NOTES Improper use of lever when the vehicle is stationary may
lead to this fault.
Check PR018 Hydraulic pressure, using the diagnostic tool, to make sure that the pump starts at 40 bar
and stops at 50 bar.
Pressure level below a pressure threshold. Fault linked to a lack of oil (internal or external leak) or to a pump failure.
Repair or replace if necessary.
2.DEF NOTES None.
Case of excessive pump operation:

– Internal or external leak in the circuit. For an external leak, locate the leak and repair if necessary. For an internal
leak, replace the hydraulic unit.
– Accumulator diaphragm porous or punctured: replace the accumulator.

AFTER REPAIR
BVRPA6_V04_DF078 BVR X7083 04 3.0
21B-51
SEQUENTIAL GEARBOX
BVR
DF078
CONTINUED
3.DEF
NOTES None.
5.DEF
– Slight internal leak: replace the clutch solenoid valve. If the fault is still present, replace the hydraulic unit.
– Slight external leak: repair or replace the faulty component.
4.DEF NOTES None.
Accumulator diaphragm porous or punctured: replace the accumulator.

AFTER REPAIR
BVR X7083 04 3.0
21B-52
SEQUENTIAL GEARBOX
BVR
BATTERY VOLTAGE
DF080 1.DEF : supply voltage too low
PRESENT 2.DEF : loss of computer supply voltage
NOTES None.
Check that the sequential gearbox supply fuse is correctly positioned and in good condition in the engine
compartment connection unit.
Measure the battery voltage and check the charge circuit. Repair if necessary.
Ensure that the battery and its connections are in good condition (condition and tightness of the terminals).
Check the engine earths on the vehicle. Repair if necessary.
Check the connection and condition of the computer connections.

AFTER REPAIR
BVRPA6_V04_DF080P
BVR X7083 04 3.0
21B-53
SEQUENTIAL GEARBOX
BVR
BRAKE LIGHTS SWITCH CIRCUIT
DF082 CO : open circuit
PRESENT 1.DEF : inconsistent data
NOTES None.
Check for the presence, condition and correct positioning of the brake light fuse in the passenger compartment
fuse box.
Check that the brake lights switch connector is correctly connected, check the condition of the connections as well
as that of the computer. Repair if necessary.
Check that the brake light switch on the pedal is correctly fitted and adjusted.
With the pedal depressed, check the continuity between tracks A3 and B1 of the switch. Replace the switch if
necessary.
With the pedal released, check that there is no continuity between tracks A3 and B1 of the switch. Replace the
switch if necessary.
If the fault is still present, check the continuity of the connection between:
Switch track A3 Track 69 of the computer 28-track connector
Also check the insulation to earth.

AFTER REPAIR
BVRPA6_V04_DF082P BVR X7083 04 3.0
21B-54
SEQUENTIAL GEARBOX
BVR
DF107 MULTIPLEX SIGNALS
DF144
DF145
DF146
STORED

If faults DF107, DF108, DF144, DF145, DF146 and DF062 are present, deal with
DF062 Multiplex line fault first.
NOTES
The fault is declared present after the computer fault memory has been cleared, the
ignition has been switched on and off again and the engine has been started.
Check injection system for DF107 Engine speed multiplex signal. If no fault appears, apply procedure for DF025
Flywheel signal sensor circuit described in the Technical Note dealing with this type of injection system.
For DF108 Effective average torque multiplex signal and DF146 Torque no reduction multiplex signal check
the injection system.
Check injection system for DF144 Coolant temperature multiplex signal. If no fault appears, apply procedure for
DF004 Coolant temperature sensor circuit described in the Technical Note dealing with this type of injection
system.
Check injection system for DF145 Pedal position multiplex signal. If no fault appears, apply procedure for DF125
Pedal potentiometer track 1 circuit and DF126 Pedal potentiometer track 2 circuit described in the Technical
Note dealing with this type of injection system.
Check injection system for DF146 Torque no reduction multiplex signal.

AFTER REPAIR
BVRPA6_V04_DF107M/BVRPA6_V04_DF108M/BVRPA6_V04_DF144M/
BVRPA6_V04_DF145M/BVRPA6_V04_DF146M BVR X7083 04 3.0
21B-55
SEQUENTIAL GEARBOX
BVR
SECONDARY BRAKE CONTACT MULTIPLEX SIGNAL
STORED 2.DEF : consistency

If faults DF148 and DF062 are both present, deal with DF062 Multiplex line fault first.
NOTES
fuse box.
Check that the brake light switch connector is correctly connected, check the condition of the connections as well
as those of the computer. Repair if necessary.
Check the adjustment of the brake light switch on the pedals.
With the pedal depressed, check the continuity between tracks A3 and B1 of the switch. Replace the switch if
necessary.
With the pedal released, check the continuity between tracks A1 and B3 on the switch. Replace the switch if
necessary.
With the pedal depressed, check there is no continuity between tracks A1 and B3 on the switch. Replace the switch
if necessary.
Check the insulation and continuity on the connection between:

Switch track B3 Injection computer connector
If the fault is still present, apply the injection system fault finding procedure.

AFTER REPAIR
BVRPA6_V04_DF148M BVR X7083 04 3.0
21B-56
SEQUENTIAL GEARBOX
BVR
DISTANCE COVERED MULTIPLEX SIGNAL
STORED

NOTES The fault is declared present after the computer fault memory has been cleared, the

AFTER REPAIR
BVRPA6_V04_DF152M BVR X7083 04 3.0
21B-57
SEQUENTIAL GEARBOX
BVR
REVERSING LIGHTS CONTROL
DF153
OR CC.0 : short circuit to earth

NOTES The fault is declared present after command AC094 Reversing lights is run using the
diagnostic tool.
Check for the presence and conformity of the relay in the engine fuse box.
Check the wiring on the reversing lights relay mounting connections and the 52-track computer connector.
Check for + after ignition feed between tracks 1 and 3 of the relay and the vehicle earth. Repair if necessary.
(+ 12 V) and 2 (earth) with command AC094 Reversing lights using the diagnostic tool.
If the voltage is correct, replace the reversing lights relay.

AFTER REPAIR
BVRPA6_V04_DF153 BVR X7083 04 3.0
21B-58
SEQUENTIAL GEARBOX
BVR
NO UCH MULTIPLEX SIGNAL
DF183
STORED


AFTER REPAIR
BVRPA6_V04_DF183M BVR X7083 04 3.0
21B-59
SEQUENTIAL GEARBOX
BVR
NO INSTRUMENT PANEL MULTIPLEX SIGNAL
STORED


AFTER REPAIR
BVRPA6_V04_DF184M BVR X7083 04 3.0
21B-60
SEQUENTIAL GEARBOX
BVR
NO INJECTION MULTIPLEX SIGNAL
STORED

If faults DF186 and DF062 are both present, deal with DF062 CAN fault first.
NOTES

AFTER REPAIR
BVRPA6_V04_DF186M BVR X7083 04 3.0
21B-61
SEQUENTIAL GEARBOX
BVR
SYSTEM OPERATION
DF188
STORED

Apply the interpretation of the other faults first.
NOTES
The fault is declared present after a road test.
This fault appears following an electronic and mechanical inconsistency on the sequential system.
Deal with the other faults first.
Clear the computer fault memory. Switch off the ignition.

AFTER REPAIR
BVRPA6_V04_DF188M BVR X7083 04 3.0
21B-62
SEQUENTIAL GEARBOX
BVR
GEAR PROGRAMMING
DF189
PRESENT
Special notes:
NOTES
The gearbox grid values are not correct and not stored in the computer.
Switch on the ignition.

Program the gears using command VP008 Programming selection/engagement ranges.
– ET061 Gears programming = DONE.
Brake and engage all gears, checking that they are recognised on the display.
If the procedure is unsuccessful, run command AC024 Actuator sequential control and repair if necessary.
If no fault is detected, there is an internal mechanical gearbox fault.


AFTER REPAIR
BVRPA6_V04_DF189P BVR X7083 04 3.0
21B-63
SEQUENTIAL GEARBOX
BVR
CLUTCH POSITION PROGRAMMING
DF190
PRESENT
Special notes:
NOTES
The clutch position programming values are not correct and not stored in the computer.
Run command VP017 Clutch closed programming using the diagnostic tool.

AFTER REPAIR
BVRPA6_V04_DF190P BVR X7083 04 3.0
21B-64
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Conformity check 21B
NOTES Only carry out a conformity check after a complete check with the diagnostic tool.
Parameter or Status
Order Function Display and Notes Fault finding
Check or Action
In the event of a fault,

Diagnostic tool apply the fault finding
1 BVR
dialogue procedure detailed on
ALP 1.
STB status lever in rest In the event of a fault,

AUTO mode ET012: AUTO MODE
position consult the interpretation
2 lever position
A status lever held in of statuses: ET043, ET044,
contact detection ET029: AUTO MODE
AUTO position ET045, ET046
Lever contact
ET043:
N° 0
Lever contact Closed or open In the event of a fault,

ET044:
Lever position N° 1 contact status consult the interpretation
3
contact detection Lever contact confirmed according to of statuses: ET043, ET044,
ET045: position of gear lever. ET045, ET046
N° 2
Lever contact
ET046:
N° 3

at 20°C and above: 40
Hydraulic Hydraulic consult the interpretation
4 PR018: to 50 bar
pressure pressure of DF005 Oil pressure
at -30°C: 35 to 42 bar
sensor circuit.

Clutch Clutch from 1000 to 14000
5 PR096: consult the interpretation
progressivity progressivity Initial value: 7500
of DF071 and DF076.
Accelerator Accelerator 16 < pedal position Consult the injection fault

6 PR022:
pedal position pedal position < 255 finding procedure
BVRPA6_V04_CCONF BVR X7083 04 3.0
21B-65
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Conformity check 21B
NOTES Only carry out a conformity check after a complete check with the diagnostic tool.
Parameter or Status
Order Function Display and Notes Fault finding
Check or Action

apply the
6.3 % < Clutch position
7 Clutch position PR015: Clutch position interpretation of DF068
< 90 %
Clutch position sensor
circuit.

Selection apply the
40 % < selection
8 position lever at PR016: Selection position interpretation of DF069
position < 60 %
N Selection position
sensor circuit.

apply the
Engagement Engagement 41 % < Engagement
9 PR017: interpretation of DF070
position at N position position < 63 %
Engagement position
sensor circuit.
Brake pedal not Released status

10 depressed ET018: Brake pedal confirmed, brake pedal In the event of a fault,
detection not depressed consult the
Depressed status interpretation of status
Depressed brake ET018 Brake pedal.
11 ET018: Brake pedal confirmed, depressed
pedal detection
brake pedal
TRACTION In the event of a fault

TRACTION Contact status ACTIVE
CONTROL consult interpretation
CONTROL or INACTIVE confirmed
12 ET130: MODE of status ET130
mode selector with button pressed or
SELECTOR Traction control mode
detection released
SWITCH selector contact.
In the event of a fault

VEHICLE LOAD Contact status ACTIVE
VEHICLE LOAD consult interpretation
MODE or INACTIVE confirmed
13 mode selector ET160: of status ET160
SELECTOR with button pressed or
detection Vehicle load mode
CONTACT released
selector contact.
BVR X7083 04 3.0
21B-66
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Status summary table 21B
SEQUENTIAL GEARBOX STATUS SUMMARY TABLE
Tool status Diagnostic tool title
ET003 Brake light switch (opening)

ET004 Brake light switch (closure)
ET012 Gear selector position
ET013 Gear engaged
ET018 Brake pedal
ET027 Driver's door open
ET028 Handbrake
ET030 Accelerator pedal position
ET043 Lever contact N° 0
ET047 Detection of brake pedal positions
ET048 Driver's door statuses detection
ET050 Operating mode recognition
ET051 Pedal position detection: Full Load
ET052 Pedal position detection: No Load
ET053 Vehicle speed signal detection
ET054 Pump relay control
ET056 Clutch solenoid valve control
ET057 Engagement solenoid valve 1 control
ET058 Engagement solenoid valve 2 control
ET059 Selection solenoid valve 1 control
ET060 Selection solenoid valve 2 control
ET061 Gear programming
ET062 Biting point programming
ET063 Solenoid valve zero point programming
ET064 Clutch position programming
ET065 Progressivity programming
ET066 Reversing lights control
ET086 Downshift request
ET129 Traction control mode detection
ET130 Traction control mode selector switch
ET160 Vehicle load mode selector contact
BVR X7083 04 3.0
21B-67
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Parameter summary table 21B
SEQUENTIAL GEARBOX PARAMETERS SUMMARY TABLE
Tool
Diagnostic tool title
parameter
PR001 Coolant temperature

PR005 Gearbox output speed
PR006 Engine speed
PR008 Computer feed voltage
PR014 Gearbox input speed
PR015 Clutch position
PR016 Selection position
PR017 Engagement position
PR018 Hydraulic pressure
PR022 Accelerator pedal position
PR095 Clutch temperature
PR096 Clutch progressivity
PR105 Vehicle speed
PR106 Effective engine torque
PR107 No reduction engine torque
PR147 Initial closed position of new clutch
PR148 Closed position of clutch
PR152 Anticipated engine torque
PR153 Slow torque setpoint
PR154 Rapid torque setpoint
BVR X7083 04 3.0
21B-68
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Interpretation of statuses 21B
BRAKE PEDAL
ET018
Special notes:
NOTES Carry out the checks only if the depressed and released statuses are not consistent
with the pedal position.
Released STATUS, brake pedal depressed.
If brake lights operate:

– Check and ensure the continuity of the connection between track A3 of the brake light switch connector and
track 69 of the computer connector.
If the brake lights do not operate:
– Check the brake light lighting relay,
– Check the condition, fitting and adjustment of the brake light switch and brake light fuse.
– Remove the brake pedal switch and check that it is operating correctly:
Continuity between tracks Insulation between tracks
Switch engaged (Brake pedal

A1 and B3 A3 and B1
released)
Switch released (Brake pedal

A3 and B1 A1 and B3
depressed)
– Replace the switch if necessary.

– Check that there is + after ignition feed on tracks A1 and B1 on the brake light switch connector.

AFTER REPAIR
BVRPA6_V04_ET018 BVR X7083 04 3.0
21B-69
SEQUENTIAL GEARBOX
BVR
ET018
CONTINUED
Pressed STATUS, Brake pedal released.
– Check the condition, fitting and adjustment of the brake light switch and brake light fuse.
– Remove the brake pedal switch and check that it is operating correctly:
Continuity between tracks Insulation between tracks
Switch engaged (Brake pedal

A1 and B3 A3 and B1
released)
Switch released (Brake pedal

A3 and B1 A1 and B3
depressed)
– Replace the switch if necessary.

– Check the insulation to 12 V of the connection between track A3 of the brake light switch connector and track
69 of the computer connector.

AFTER REPAIR
BVR X7083 04 3.0
21B-70
SEQUENTIAL GEARBOX
BVR
LEVER CONTACT N° 0
ET043
ET044 LEVER CONTACT N° 1
NOTES Special notes: None.
MEASURE RESISTANCE ON THE

LEVER POSITION SWITCH STATUSES BLACK 10-TRACK CONNECTOR ON
THE GEAR LEVER END
ET043: OPEN Between tracks A2 and A3 ≈ 1090 Ω.
Lever in rest position ET044: OPEN Between tracks A2 and B2 ≈ 1090 Ω.

ET012: Stand-by confirmed ET045: OPEN Between tracks A2 and A1 ≈ 1090 Ω.
ET046: OPEN Between tracks A2 and B3 ≈ 1090 Ω.
Neutral position maintained ET044: CLOSED Between tracks A2 and B2 ≈ 270 Ω.

ET012: N confirmed ET045: CLOSED Between tracks A2 and A1 ≈ 270 Ω.
R position maintained ET044: OPEN Between tracks A2 and B2 ≈ 1090 Ω.

ET012: R confirmed ET045: CLOSED Between tracks A2 and A1 ≈ 270 Ω.
ET046: CLOSED Between tracks A2 and B3 ≈ 270 Ω.

AFTER REPAIR
BVRPA6_V04_ET043/BVRPA6_V04_ET044/BVRPA6_V04_ET045/BVRPA6_V04_ET046 BVR X7083 04 3.0
21B-71
SEQUENTIAL GEARBOX
BVR
ET043
ET044
ET045
ET046
CONTINUED
NOTES Special notes: None.
MEASURE RESISTANCE ON THE

LEVER POSITION SWITCH STATUSES BLACK 10-TRACK CONNECTOR ON
THE GEAR LEVER END
ET043: CLOSED Between tracks A2 and A3 ≈ 270 Ω.
+ position maintained ET044: CLOSED Between tracks A2 and B2 ≈ 270 Ω.

ET012: UP confirmed ET045: OPEN Between tracks A2 and A1 ≈ 1090 Ω.
- position maintained ET044: CLOSED Between tracks A2 and B2 ≈ 270 Ω.

ET012: DW confirmed ET045: OPEN Between tracks A2 and A1 ≈ 1090 Ω.
ET043: CLOSED Between tracks A2 and A3 ≈ 270 Ω.
- AUTO position maintained ET044: OPEN Between tracks A2 and B2 ≈ 1090 Ω.

ET012: A confirmed ET045: OPEN Between tracks A2 and A1 ≈ 1090 Ω.
UP = Upshifting.
DW = Downshifting.
Replace the gear lever unit if one of the contacts is faulty.

AFTER REPAIR
BVR X7083 04 3.0
21B-72
SEQUENTIAL GEARBOX
BVR
TRACTION CONTROL MODE SELECTOR SWITCH
ET130
Special notes:
Only perform the checks if the active and inactive statuses are not consistent with the
NOTES
position of the button. Status ACTIVE or INACTIVE confirmed with button pressed or
released
STATUS Active
Check the connection and condition of the traction control selector button connections. Repair if necessary.
Check there is no continuity between button tracks A2 and B1 in the released position. If there is continuity,
replace the switch.
Check the continuity and insulation against earth of the connection between:
Button connector Track B1 Track 71 of the computer connector
STATUS Inactive
Check the connection and condition of the traction control selector button connections.
Check the continuity between button tracks A2 and B1 in the pressed position. If there is no continuity, replace
the switch.
Check for earth on Track A2 of the button connector.

AFTER REPAIR
BVRPA6_V04_ET130 BVR X7083 04 3.0
21B-73
SEQUENTIAL GEARBOX
BVR
VEHICLE LOAD MODE SELECTOR CONTACT
ET160
Special notes:
Only perform the checks if the active and inactive statuses are not consistent with the
NOTES
position of the button. Status ACTIVE or INACTIVE confirmed with button pressed or
released
STATUS Active
Check the connection and condition of the vehicle load mode selector button connections. Repair if necessary.
Check there is no continuity between button tracks A3 and A2 in the released position. If there is continuity,
replace the switch.
Check the continuity and insulation against earth of the connection between:
Button connector Track A3 Track 70 of the computer connector
STATUS Inactive
Check the connection and condition of the traction control selector button connections. Repair if necessary.
Check the continuity between button tracks A3 and A2 in the pressed position. If there is no continuity, replace
the switch.
Check for earth on Track A2 of the button connector.

AFTER REPAIR
BVRPA6_V04_ET160 BVR X7083 04 3.0
21B-74
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Dealing with command modes 21B
CLEARING
RZ001: Stored fault(s).

This command is used to clear the stored faults from the computer.
RZ002: Programming.
This command is used to clear the gear programming.
RZ003: Program clutch biting point.
This command is used to clear the clutch biting point programming.
RZ008: Initial closed position of clutch.
This command enables the initial closed position of the clutch to be cleared.
ACTUATORS
AC006: Hydraulic unit pump inhibition.

This command enables inhibition of the hydraulic pump.
AC007: Hydraulic pump rehabilitation.
This command enables the rehabilitation of the hydraulic pump after the computer has been
replaced or after the inhibition of the pump using command AC006.
AC008: Clutch circuit phase 1 bleed.
This command is used to perform the first clutch circuit bleeding phase after an operation
during parts replacement (see Replacement of components).
AC009: Clutch circuit phase 2 bleed.
This command is used to perform the second clutch circuit bleeding phase after an
operation during parts replacement (see Replacement of components).
This command takes 8 minutes.
AC011: Hydraulic pressure unit bleed.
This command is used to bleed the hydraulic pressure unit after an operation during parts
replacement (see Replacement of components).
AC012: Hydraulic pump relay
This command enables the hydraulic pump relay to be operated when checking that the
relay is working (by listening) or testing the supply.
AC013: Starter relay.
This command enables the starter relay to be operated when checking that the relay is
working or testing the supply.
AC014: Clutch solenoid valve
This command enables the clutch solenoid valve to be operated when checking that the
solenoid valve is working or testing the supply.
BVR X7083 04 3.0
21B-75
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Dealing with command modes 21B
ACTUATORS (continued)
AC015: Engagement solenoid valves

This command enables the engagement solenoid valves to be operated when checking that
the solenoid valves are working (by listening) or testing the supply.
AC016: Selection solenoid valves.
This command enables the selection solenoid valves to be operated when checking that the
solenoid valves are working (by listening) or testing the supply
AC017: Display.
This command enables the display integrity to be checked by searching through all the data
available relating to the sequential gearbox.
AC019: Return the gearbox to neutral.
This command returns the gearbox to neutral.
AC024: Actuator sequential command
This command enables all sequential gearbox switches to be operated in order to check that
they are working.
AC025: Clutch slave cylinder hydraulic circuit bleed.
This command is used to perform the first clutch slave cylinder bleeding phase after an
operation during parts replacement (see Replacement of components).
AC028: Reverse engagement.
This command enables reverse to be engaged.
AC081: Discharge accumulator.
This command enables pressure in the hydraulic circuit to be discharged. The handbrake
must be engaged when using this command.
AC094: Reversing lights.
This command allows the reversing light relay to be operated so that the operation and
lighting up of the reversing lights can be checked.
BVR X7083 04 3.0
21B-76
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Customer complaints 21B
Only refer to these customer complaints after performing a full check with the
NOTES
diagnostic tool.
NO DIALOGUE WITH THE DIAGNOSTIC TOOL
NO DIALOGUE WITH THE SEQUENTIAL GEARBOX COMPUTER ALP1
SEQUENTIAL GEARBOX OPERATING FAULTS IMMOBILISING THE VEHICLE
CANNOT SELECT A FORWARD OR REVERSE GEAR WHEN STATIONARY ALP2
IMPOSSIBLE TO SELECT NEUTRAL ALP2
IMPOSSIBLE TO START WITH GEAR ENGAGED, EVEN WITH BRAKE PEDAL

ALP2
DEPRESSED
IMPOSSIBLE TO ENGAGE OR DISENGAGE A GEAR ALP3
ENGINE CAN ONLY BE STARTED IF THE BRAKE PEDAL IS DEPRESSED ALP3
SEMIAUTOMATIC MODE IMPOSSIBLE ALP3
ENGINE STALLS WHEN BRAKE PEDAL IS DEPRESSED ALP3
SEQUENTIAL GEARBOX OPERATING FAULTS NOT IMMOBILISING THE VEHICLE

CANNOT ACCESS AUTOMATIC MODE IF SEMIAUTOMATIC MODE WAS
ALP4
PREVIOUSLY SELECTED
CANNOT ACCESS SEMIAUTOMATIC MODE IF AUTOMATIC MODE WAS
ALP4
PREVIOUSLY SELECTED
AUTOMATIC MODE CANNOT BE SELECTED WHEN STARTING THE ENGINE
ALP4
AGAIN
NO REVERSING LIGHT ALP5
BVR X7083 04 3.0
21B-77
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Customer complaints 21B
SEQUENTIAL GEARBOX OPERATING FAULTS NOT IMMOBILISING THE VEHICLE
NO CREEPING ALP6
BRAKE LIGHTS PERMANENTLY LIT ALP6
FORWARD OR REVERSE GEAR CAN BE SELECTED WITHOUT DEPRESSING THE

ALP6
BRAKE PEDAL
LOSS OF AUTOMATIC MODE ALP7
VEHICLE DOES NOT MOVE FORWARD, ENGINE RUNNING ALP8
INADEQUATE REACTION TO FULL LOAD REQUEST ALP9
CLUTCH CHATTERING ALP10
LOSS OF DISPLAY WHILE DRIVING ALP11
DISPLAY AND WARNING BUZZER FUNCTION ERRATICALLY ALP12
VEHICLE JUMPS WHEN ENGINE IS STARTED ALP13
BVR X7083 04 3.0
21B-78
SEQUENTIAL GEARBOX
BVR
VDIAG N°.: 04 Fault finding – Fault finding Chart 21B
ALP1 No dialogue with the sequential gearbox computer
Special notes:
NOTES
Only consult this customer complaint after a complete check with the diagnostic tool.
Ensure that the diagnostic tool is not causing the fault by trying to establish dialogue with a computer on another
vehicle. If the tool is not causing the fault and dialogue cannot be established with any other computer on the same
vehicle, it may be that a faulty computer is disrupting diagnostic line K.
Proceed by successive disconnections to locate this computer.
Check the battery voltage and carry out the operations necessary to obtain the correct voltage (9.5 V < battery
voltage < 17.5 V).
Check the condition of the sequential gearbox fuses on the passenger compartment fuse board (5 A) and in the
engine fuse box (5 A, 10 A, 30 A).
Check that the computer connector is properly connected and check the condition of its connections.
Check the sequential gearbox earths (quality, rusting, tightness of the earth bolts on top of the hydraulic unit).
Check that the supply to the computer is correct:
– Earth on tracks 1 and 2 of the 52-track connector.
– + before ignition feed on track 27 of the 52-track connector.
– + after ignition feed on track 28 of the 52-track connector.
Ensure that the diagnostic socket is correctly supplied:

– + before ignition feed on track 16.
– + after ignition feed on track 1
– Earth on track 5.
Check the continuity and insulation of the connection between:
Computer connector track 49 track 7 of the diagnostic socket.
If dialogue has still not been established after these checks, contact Techline.
Clear the computer fault memory. Switch off the ignition and wait 20 seconds.
AFTER REPAIR
BVRPA6_V04_ALP01 BVR X7083 04 3.0
21B-79
SEQUENTIAL GEARBOX
BVR
Cannot select a forward or reverse gear when stationary
Impossible to select N
ALP2
Impossible to start engine with gear engaged, even with brake
pedal depressed
Special notes:
NOTES
Check the + after ignition feeds and the earths of the sequential gearbox computer.
Check the condition of the gear lever contacts and that they are working correctly (consult the interpretation of
statuses: ET043, ET044, ET045, ET046). Repair if necessary.
Check for the supply fuse of the brake light switch on the passenger compartment fuse board and its condition.
Check that the brake lights switch connector is correctly connected, check the condition of the connections as well
as that of the computer. Repair if necessary.
With the pedal depressed, check the continuity between tracks A3 and B1 on the switch. Replace the switch if
necessary.
Switch track A3 Track 69 of the computer 28-track connector.
Also check the insulation to earth.
AFTER REPAIR
BVRPA6_V04_ALP02 BVR X7083 04 3.0
21B-80
SEQUENTIAL GEARBOX
BVR
Impossible to engage or disengage a gear
Engine can only be started if brake pedal depressed
ALP 3
Semiautomatic mode not possible
Engine stalls when brake pedal is depressed
Special notes:
NOTES
Check the + after ignition feeds and the earths of the sequential gearbox computer.
Check that the gear lever is not seized or damaged or even broken. Replace the lever if necessary.
Apply the interpretation of ET043, ET044, ET045, ET046.
If the fault is still present, check the multiplex network using the diagnostic tool.
AFTER REPAIR
BVRPA6_V04_ALP03 BVR X7083 04 3.0
21B-81
SEQUENTIAL GEARBOX
BVR
Cannot access automatic mode if semiautomatic mode was
previously selected
Cannot access semiautomatic mode if automatic mode was
ALP4
previously selected
Automatic mode cannot be selected when starting the engine
again
Special notes:
NOTES
Check the condition and correct connection of the gear lever. Repair if necessary.
Apply the interpretation of statuses ET043, ET044, ET045, ET046.
AFTER REPAIR
BVRPA6_V04_ALP04 BVR X7083 04 3.0
21B-82
SEQUENTIAL GEARBOX
BVR
ALP 5 No reversing lights
Special notes:
NOTES Only consult this customer complaint after a complete check with the diagnostic tool.
The display should indicate that R is engaged.
Check the presence and conformity of the relay in the engine fuse box and the bulbs in the rear lights.
Check the wiring on the reversing lights relay mounting connections and the 52-track computer connector.
Check for + after ignition feed on tracks B1 and B3 of the relay and the vehicle earth. Repair if necessary.
Relay connector track B2 Track 41 of the computer connector
(+ 12 V) and 2 (earth) with command AC094 Reversing lights using the diagnostic tool.
If the voltage is correct, replace the reversing lights relay.
Check for + after ignition feed on track 1 of the reverse gear switch connector.
Relay mounting Track B5 Track 32 of the UCH green connector.
AFTER REPAIR
BVRPA6_V04_ALP05 BVR X7083 04 3.0
21B-83
SEQUENTIAL GEARBOX
BVR
No creeping
Brake lights permanently lit
ALP6
Forward or reverse gear can be selected without depressing the
brake pedal
Special notes:
In a case where there is no creeping, if the customer has heard the buzzer whilst
NOTES
driving, it is normal for creeping to be prohibited (clutch overheating). Let the clutch
cool down and check that creeping is once again active. If the fault is still present, apply
the procedure detailed below.
fuse box.
Check that the connectors for the brake light switch and handbrake switch are correctly connected and check the
condition of the wiring as well as that of the computer. Repair if necessary.
With the pedal depressed, check the continuity between tracks A3 and B1 on the switch. Replace the switch if
necessary.
Switch track A3 Track 69 of the computer 28-track connector
Check the condition of the handbrake switch on its support.
AFTER REPAIR
BVRPA6_V04_ALP06 BVR X7083 04 3.0
21B-84
SEQUENTIAL GEARBOX
BVR
ALP7 Loss of automatic mode
Special notes:
NOTES
Level 1 severity injection fault sent by the engine control via the multiplex line connection.
Check the fuel injection using the diagnostic tool.
AFTER REPAIR
BVRPA6_V04_ALP07 BVR X7083 04 3.0
21B-85
SEQUENTIAL GEARBOX
BVR
ALP8 Vehicle does not move forward, engine running
Special notes:
NOTES
Apply the fault finding procedure associated with the multiplex network test.
AFTER REPAIR
BVRPA6_V04_ALP08 BVR X7083 04 3.0
21B-86
SEQUENTIAL GEARBOX
BVR
ALP 9 Inadequate reaction to full load request
Special notes:
NOTES
Carry out a road test and check for a hard point on the accelerator pedal under full load and on consecutive
downshifting.
If the hard point is noticeable on the pedal but not when downshifting, perform another road test with the selector
in automatic mode.
If downshifting is still not working, check, using the diagnostic tool, that PR022 is approximately 255 under full load.
If the value is less than 255, check the operation of the pedals (pedal travel fault or pedal potentiometer damage).
If the fault is still present check the injection system using the diagnostic tool.
AFTER REPAIR
BVRPA6_V04_ALP09 BVR X7083 04 3.0
21B-87
SEQUENTIAL GEARBOX
BVR
ALP 10 Clutch chattering
Special notes:
NOTES
If the clutch chatters on light acceleration after the vehicle has been started and is pulling away in a forwards gear
on the flat, reprogram the clutch progressivity as explained below.
With the engine running, lock the handbrake, engage 1st gear, and let the engine run at idle speed for 10 minutes
(without applying any pressure to the brake pedal or accelerator).
After performing this procedure, start with the engine cold and then with the engine warm to check that there has
been an improvement.
AFTER REPAIR
BVRPA6_V04_ALP10 BVR X7083 04 3.0
21B-88
SEQUENTIAL GEARBOX
BVR
ALP 11 Loss of display while driving
Special notes:
NOTES
Check the sequential gearbox supply fuses.

Check all the earths and that the wiring is not damaged.
AFTER REPAIR
BVRPA6_V04_ALP11 BVR X7083 04 3.0
21B-89
SEQUENTIAL GEARBOX
BVR
ALP 12 Display and warning buzzer operation erratically
Special notes:
NOTES
– The buzzer is active:

– when the front doors are opened,
– if the clutch overheats only while the vehicle is being driven.
– if the sequential gearbox programming has not been carried out.
– The depress brake pedal symbol is active:
– When the engine is running on a gear lever request or if the lever is accidentally shifted to the neutral
position while the vehicle is being driven.
Carry out a road test to recreate the customer complaint.
Carry out the following programming:
– VP008 Program selection/engagement ranges.
– Delete the biting point programming using command:
RZ003 Program biting point.
Shift the gear lever to rest position (Stb).
Start the engine.
Check that the programming has been correctly performed using the following status:
ET062 Program biting point = Done.
Repeat the procedure if unsuccessful.
AFTER REPAIR
BVRPA6_V04_ALP12 BVR X7083 04 3.0
21B-90
SEQUENTIAL GEARBOX
BVR
ALP 13 Vehicle jumps when engine is started
Special notes:
NOTES
If a gear was engaged when there is a request to start the engine check the oil level in the sequential gearbox
circuit.
Check that the brake pedal switch is operating correctly and that the gear lever contacts are in good condition
(consult the interpretation of statuses: ET043, ET044, ET045, ET046).
Ensure that the cylinder and the clutch fork are operating correctly (damage, seizing, part breakage, etc.).
Clear the fault 21B-59t from the computer memory. Switch off the ignition and wait
AFTER REPAIR 20 seconds.
BVRPA6_V04_ALP13 BVR X7083 04 3.0
21B-91

Technical Note 3882A: Fault Finding Sequential Gearbox

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Technical Note 3882A: Fault Finding Sequential Gearbox

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Technical Note 3882A

Sub-section concerned: 21B

77 11 332 742 Edition 6 - MAY 2011 Edition Anglaise

© Renault s.a.s. 2011

21B SEQUENTIAL GEARBOX

Vehicle(s): TRAFIC for G9U730 engines Name of computer: Magnetti Marelli

2. PRE-REQUISITES FOR FAULT FINDING

Fault finding procedures (this manual):

Diagnostic tools type:

Special tooling required:

Special tooling required

BVRPA6_V04_PRELI BVR X7083 04 3.0

To run fault finding on the vehicle computers, switch on the ignition.

If the fault is not confirmed, check:

Customer complaints - Fault finding chart

BVR X7083 04 3.0

Check the battery charge and the

Print the system fault finding log

Dealing with stored faults

Use fault finding charts (ALPs)

Contact Techline with the

BVR X7083 04 3.0

Fault finding problems

Inspection of each component

If a fault is detected, repair or replace the wiring harness.

BVR X7083 04 3.0

You will always be asked for this log:

BVR X7083 04 3.0

List of monitored parts: Computer

Diagnostic tool CLIP

681 No gear change 622 Noise 679 No drive

680 Slipping 675 Warning light comes on 682 Loss of power

683 Jolts or engine 684 "3H" 685 Erratic gear change

Other Your comments:

● Conditions under which the customer complaint occurs

005 While driving 004 Intermittently 008 When decelerating

007 When accelerating 009 Sudden fault 010 Gradual deterioration

Other Your comments:

● Documentation used in fault finding

Fault finding procedure used

Fault Finding Manual N°:

Wiring diagram used

Wiring Diagram Technical Note N°:

Title and/or part number:

page to print or photocopy - page to print or photocopy - page to print or photocopy

● Identification of the computer and system parts replaced

● Conditions under which fault occurs

If an automatic gearbox, which mode (auto/semi-

Gearbox oil level check results

"Add-on" oil level check results

Oil leak? No Seeping Dripping

Type of noise (metallic, rubbing, etc.)

Is the buzzer active? Yes No

Other defective functions?

page to print or photocopy - page to print or photocopy - page to print or photocopy

Description of user operation:

Using this interface, the driver can:

Description of passenger compartment control:

Description of gear lever positions:

BVR X7083 04 3.0

Description of the TRACTION CONTROL button:

Description of the LOAD button:

Description of the display: