N.T. 2628A X066 - X067 THE AUTOMATIC CLUTCH
N.T. 2628AX066 - X067Basic Manual: M.R. 305THE AUTOMATIC CLUTCHis a clutch which is controlled by a computer.77 11 190 785OCTOBER 1996The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.The methods may be modified as a result of changes by the manufacturer in theproduction of the various component units and accessories from which his vehiclesare constructed".CEdition AnglaiseAll copyrights reserved by the Régie Nationale des Usines Renault.Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority of theRégie Nationale des Usines Renault S.A.Régie Nationale des Usines Renault S.A. 1996
ContentsPage20 AUTOMATIC CLUTCHIntroductionRecommendationsSpecial notesLocation on the vehiclePump-hydraulic jack assemblyAccumulatorGear lever sensor (728)Engaged gear sensor (726)Vehicle speed sensor (250)Bonnet switchAccelerator position informationEngine speed sensor (120)Air conditioning information (319)Door switch (180)Computer (730)Operational wiring diagramPump assembly relay (762)Starter relay (232)Buzzer (763)OperationClutch identificationComputer identificationHydraulic fluid levelDischarging the accumulatorProgramming full load and no loadpositionsProgramming the gearsProgramming neutral position forthe solenoid and the jack positionReading clutch wearReading the date of After SalesoperationsEntering the date of After SalesoperationsFault 4920-50
AUTOMATIC CLUTCHIntroductionThe design of the whole vehicle, including theclutch, is continually being improved. The latesttechnological advances have allowed a computercontrolled automatic clutch to be developed.20MAINTENANCE (to be carried out at each visit tothe workshop)Check: the level of the hydraulic fluid (see section"Hydraulic fluid level").The special feature of this clutch is that to performthe clutch - declutch operation, a clutch pedal nolonger needs to be used. the correct operation of the buzzer- start the vehicle,- engage a gear,- open the driver’s door,and the buzzer should sound.The automatic system used in the clutch controlrequires the use of the following components :- an electro-pump and hydraulic jack assemblywhich carries out the clutch - declutch action atthe mechanism control,- a computer to control the assembly,- various sensors, one of which is located in thegear lever knob.- information provided by the injection computer the safety devices preventing the engine fromstarting :- apply the handbrake,- engage a gear,- try to start the engine,the starter should not operate. the safety devices preventing the vehicle frommoving with the bonnet open:- apply the handbrake,- with the engine running: open the bonnet and hold it in positionwith the stay, engage 1st gear (from inside the vehicle), accelerate, the vehicle should not move,the buzzer should sound, to return to normal operation, close thebonnet and select neutral.20-1
AUTOMATIC CLUTCHRecommendations20SPECIAL NOTES FOR REMOVAL-REFITTINGOPERATIONSOperations to be carried out using the XR25 afterthe removal-refitting operations.Apply the handbrake before any operation on thevehicle.Programme the neutral position for the solenoidand the jack position (see section "Programmingneutral position for the solenoid and the jack position"):The connectors for the various components mayonly be disconnected when the ignition is off, theengine has stopped completely and the vehicle isstationary.- each time the pump-jack assembly is removed,- each time a modification is made to the adjustment at the fork.All operations carried out on the automatic clutchmust be carried out by qualified, trained personnel.Programme the full-load and no-load positions(see section "Programming full-load and no-loadpositions") :- when the computer is replaced,- when each operation on the acceleratorcontrol has been carried out (adjustment),- when the injection potentiometer is replaced.All operations carried out in the engine compartment must be carried out with the gear lever inneutral.Pump-jack assemblyProgramme the gears (see section "Programmingthe gears") :- when the computer is replaced,- when the gear lever or gear linkage is removed,- when the gear box is removed,- when the engaged gear sensor is removed.Before carrying out any operation on the pumpjack assembly discharge the accumulator (to dothis see section"Discharging the accumulator").To check the hydraulic fluid level refer to the section "Hydraulic fluid level".Erase the computer memory after every operationon the automatic clutch (see section"Fault finding").When handling the pump-jack assembly, alwayshold it by the motor or the accumulator.Store the date of the After Sales operation in thecomputer after each operation on the automaticclutch (see section "Entering the date of AfterSales operations").The pump-jack assembly supplied by the PartsDepartment is filled with fluid.To prevent leakage of hydraulic fluid duringtransport, the breather plug on the reservoir isblocked by a small rubber ring which should be removed only after the pump-jack assembly hasbeen fitted to the vehicle.20-2
AUTOMATIC CLUTCHSpecial notes20CONNECTING A CAR RADIOThe pump assembly causes interference which may cause problems with the reception of certain radiofrequencies. To remedy this, when fitting a radio as an After Sales operation, the radio housing should beconnected to earth. Certain radios have a special terminal for this purpose (see example below).94911SREMOVAL OF AND/OR REPAIRS TO THE GEAR BOXTo remove the gearbox, you must first remove the pump-jack assembly, its mounting and the engaged gearsensor.Before repairing a JB type gear box, the engaged gear sensor must be removed.This sensor is replaced once the refitting operations have been completed.ATTENTION :Whenever any work is carried out on the gearbox or the gear selector linkage, and before turning over theengine, check the consistency of the information given by the engaged gear sensor in #01. This sensor isfragile, its deterioration could result in serious damage to the gearbox, to the extent of it being irreparable.20-3
AUTOMATIC CLUTCHLocation on the 9319BatteryInjection computerReversing light switchReversing lightDriver’s door switchFront courtesy lightDiagnostic socketStarter relayFuel pump relayVehicle speed sensorFuse boxAccessories boardAir conditioning control panel438Bonnet switch597Engine fuse box724Pump assembly725Solenoid valve726Engaged gear sensor727Clutch position sensor728Gear lever sensor730Computer762Pump assembly c connections----Electrical connectionsNote : Not all components are shown in the above diagram; see page 20-6.20-4
AUTOMATIC CLUTCHPump-hydraulic jack assemblyDESCRIPTIONThe pump and hydraulic jack assembly cannot beseparated.It comprises (see following page):Ian electro-pump assembly (724) comprising:1 a connector2 a pressure accumulator3 an electric motor4 a hydraulic pump5 a solenoid valve (725)6 a pressostat (835)7 a hydraulic unit (integrating the hydraulic circuits, a pressure release valve and anon-return valve)8 a reservoir and a filterIIand a HYDRAULIC JACK, comprising :9 a jack (slave cylinder)10 a clutch position sensor (727)HYDRAULIC DIAGRAMDI200720-520
AUTOMATIC CLUTCHPump-hydraulic jack assembly20DI2008DI200920-6
AUTOMATIC CLUTCHPump-hydraulic jack assemblyI PUMP ASSEMBLY1 - 5 track connectorTrack A: before ignition motor feedTrack B : PressostatTrack C: PressostatTrack D: Solenoid valveTrack E : Solenoid valveTerminal for motor electrical earth2 - AccumulatorThe accumulator permits intermittentoperation of the pump motor.When the accumulator is full, the clutchmay operate through 4 or 5 cycles beforethe accumulator requires refilling.3 - MotorThe electric motor drives the hydraulicpump.The computer operates the motor depending on:- the information from the pressostat,- after ignition informationFeed voltage: 13.5 VAverage current: 7 AMotor current when cold: 25 AResistance : 1 Ω4 - PumpThis is driven by the electric motor.It is of an axial type with 5 pistons.It generates the hydraulic pressure required to supply the jack and fill the accumulator.20-720
AUTOMATIC CLUTCHPump-hydraulic jack assembly5 - Solenoid valve (725)This is controlled by the computer.The solenoid valve determines the position of the clutch by altering the flow.The valve has 4 main positions :- hydraulic supply to the jack (increase in pressure),- hydraulic isolation of the jack (maintenance of pressure),- return to reservoir (decrease in pressure),- defect mode position (fluid passes through a restrictor to returnto the reservoir. This restrictor allows the fluid to leave the jackslowly, allowing the clutch to engage progressively).Feed voltage: 12 VCurrent: 0.9 AResistance: 6 ΩDI201020-820
AUTOMATIC CLUTCHPump-hydraulic jack assembly206 - Pressostat (835)The change in state of the pressostat depends on the hydraulic pressure:- Opens at 41 bars.- Closes at 31 bars.This information allows the operation of the hydraulic pump to be controlled.DI2011Ignition switched onPressostat closed (P 31 bars)Pump fedyesPressostatopens before50 seconds(P 41 bars)noPump fed for 2 secondsPump feed cutA20-9Fault detectedDefect mode
AUTOMATIC CLUTCHPump-hydraulic jack assemblyAJack decreases the pressureyesPressostatclosed(P 31 bars)noPump fed for 3.6 secondsnoPressostatopen(P 41 bars)yesPump feed cutPump fed for 3.6 secondsnoPressostatopen(P 41 bars)yesFault detectedDefect mode20-10Pump feed cut20
AUTOMATIC CLUTCHPump-hydraulic jack assembly7 - Pressure release valveThis protects the various componentsfrom excess pressure.This valve opens at 70 bars (the operatingpressure of the system is 41 bars).8 - ReservoirThis contains the hydraulic fluid.Its size is such that it is able to cope withthe variations in level due to :- the position of the jack,- the fill level of the accumulator,- clutch wear.To check the level refer to the section"Hydraulic fluid level".20-1120
AUTOMATIC CLUTCHPump-hydraulic jack assembly20II HYDRAULIC JACK9 - Jack (slave cylinder)The jack receives hydraulic pressure from the pump assembly and controls the clutch fork.The jack may have one of many positions. There are however 3 stable control positions:- Clutch out position (vehicle stationary, no gear engaged).- Slipping position (vehicle stationary, gear engaged during gear changing operation). This positiongives a rapid response time.- Clutch in position (vehicle moving, gear engaged; vehicle stationary, ignition off).The variations in clutch position are compensated for by a grooved adjustment device. This deviceshould be adjusted each time the pump-jack assembly is replaced (see section"Removal-refitting ofthe pump-jack assembly").Clutch wear is compensated for by the automatic clutch system. This wear may be read (see section"Reading clutch wear").DI200910 - Clutch position sensor (727)The sensor (727), which is mechanically connected to the piston, informs the computer of the positionof the clutch. (It cannot be separated from the jack).3 track connector:A : EarthB : Clutch position informationC : 5 Volts20-12
AUTOMATIC CLUTCHPump-hydraulic jack assemblyREMOVAL - REFITTINGREMOVALSpecial notesPut the vehicle on a 2 post lift.Apply the handbrake before any operation on thevehicle.Disconnect the battery.20Remove the air intake pipe and its support.The connectors for the various components mayonly be disconnected when the ignition is off, theengine has stopped completely and the vehicle isstationary.Remove the injection computer after taking off itsprotective plastic cover (A).Before carrying out any operation on the pumpjack assembly discharge the accumulator (to dothis see section"Discharging the accumulator").It is forbidden to :- separate the pump assembly from the jack,- dismantle the various components of the pumpassembly or the jack (assembly is under pressure).11896RDisconnect the pump connector (1).Separate the fork/ jack connection.20-13
AUTOMATIC CLUTCHPump-hydraulic jack assemblyRemove adjusting clip (B) having first marked itsposition (by counting the number of grooves).This will prevent you having to adjust the clutchmechanism (applies only to the reassembly of thesame electro-pump assembly).20Remove the clip and the left wheel arch bolt (thisallows access to the jack mounting nut).Remove the jack mounting nut (7).Remove the jack mounting plate (10).97963R197969-1R1Raise the vehicle.Disconnect the clutch position sensor connector(3).Remove the engine undertray.Lower the vehicle.20-14
AUTOMATIC CLUTCHPump-hydraulic jack assemblyRemove the three pump mounting nuts (4, 5 and6).20To remove the pump assembly mounting, unscrewthe nut on the edge of the gear box (8) and thetwo bolts (9) on the housing.11897R11895RLift the pump and then remove the earthing wireby unscrewing its mounting nut (2).REFITTINGLower the vehicle.To refit the pump assembly mounting , tightenthe nut (8) on the edge of the gearbox to a torque of 4 daN.m. , then tighten the bolts (9) on thehousing to a torque of 4 da N.m.Pull back the jack to allow removal of the cableand the ball joint through the jack pressure ring.Extract the pump-jack assembly (handle the assembly by the motor or the accumulator to avoiddamaging it).Reposition the pump assembly in its housing. Thepump assembly is supplied filled with fluid. Beforefitting it, secure the earthing wire by tighteningits mounting nut.Thread the cable through the jack pressure ring(having first removed the adjustment shim andmemorised its position for new pump-jack assemblies).Refit the three pump assembly mounting bolts (4),(5) and (6). Tighten them to a torque of 2.5daN.m.Remove the rubber ring on the reservoir breather(this prevents leakage of hydraulic fluid duringtransport).To carry out other refitting operations, proceed inreverse order to removal.20-15
AUTOMATIC CLUTCHPump-hydraulic jack assemblyADJUSTING THE CLUTCH MECHANISM20IMPORTANT :(after replacing the pump-jack assembly)After each replacement of the pump-jack assembly it is necessary to :- programme the neutral position for the solenoid valve and the position of the jack (see section "Programming the neutral position for thesolenoid and the jack position "),- enter the date of the After Sales operation (seesection "Entering the date of After Sales operations"),- erase the computer memory (see section "Faultfinding").To adjust the clutch mechanism the adjustingsleeve (10), delivered with the pump-jack assembly, must be used. (It is grey, and has also beensupplied with this documentation).This sleeve is correctly positioned when it touchesthe body of the jack at one end and the steel washer on the cable at the other end (it is necessary topull slowly on the cable in order to position theshim).Position the cable and the ball joint (11) on thefork.Slide the ball-joint (11) until it touches the fork(push against the fork very gently to eliminate anyplay).Press the retaining clips (12) into the adjustmentgroove which is closest to the ball joint (11).Remove the plastic adjustment shim (10) and retain it as a special tool.97966RReconnect the battery20-16
AUTOMATIC CLUTCHAccumulator2011905RREMOVALREFITTINGDischarge the pressure in the accumulator (seesection "Discharging the accumulator").Remove the protective plug of the newaccumulator.Remove the pump-jack assembly (see section"Pump-jack assembly").Check that the surfaces of the accumulator andthe pump assembly connecting parts are clean.Protect eyes with grinding goggles.Position the accumulator and tighten to a torqueof 3.5 0.5 daN.m.Thoroughly clean the part connecting the accumulator with the pump assembly.Stick the safety label on the accumulator (one issupplied with the accumulator).Unscrew the accumulator (1) a half-turn.Refit the pump-jack assembly to the vehicle (seesection "Pump-jack assembly").Wrap a cloth around the lower part of the accumulator (the part mounted on the pump assembly) (this is to catch any hydraulic fluid escapingdue to residual pressure).Refill the reservoir approximately three-quartersfull with Castrol Dot 3 brake fluid.Carefully unscrew the accumulator by hand.20-17
AUTOMATIC CLUTCHAccumulatorCHECKING THAT THE SYSTEM OPERATES CORRECTLYConnect the XR25.Switch the ignition on and then off again (repeatthe operation 10 times, waiting 10 seconds eachtime the ignition is switched off).Switch the ignition on. Connect the automaticclutch computer to the XR25 (enter D26).Fully press down slowly and release the clutch 20times.Check the level of hydraulic fluid (see section "Hydraulic fluid level").Carry out a road test using all the gears.Recheck the hydraulic fluid level.Check that no fault is stored in the automaticclutch computer.Check that there is no leakage at the surfaces ofthe accumulator-pump connection.20-1820
AUTOMATIC CLUTCHGear lever sensor (728)20DESCRIPTIONThere are two switches in the gear lever knob:- a pull switch (switch closes when the gear lever is pulled),- a push switch (switch closes when the gear lever is pushed).A force applied to the gear lever knob by the driver which is greater than a predetermined threshold closesone of the two switches, connecting it to earth.This information tells the computer that the driver wishes to change gear. If there is a fault with the sensor,the information is taken from the signal from the gear engaged sensor.When this sensor is replaced, the gears must be programmed (see section "Programming the gears")3 track connector:A : Push informationB : Pull informationC : Earth20-19
AUTOMATIC CLUTCHGear lever sensor (728)20DI2012KEY1234567SwitchInsulationEarthTo computerLoad ringPush forcePull force20-20
AUTOMATIC CLUTCHGear lever sensor (728)20REMOVALREFITTINGSwitch off the ignition and disconnect the battery.Clean section (A) of the lever using solvent S 56(Part Number 77 01 421 513).Unclip the protective boot.On section (A) of the lever apply a thin bead ofLoctite SCELBLOC (Part Number 77 01 394 072).Disconnect the electrical connection (1).Unclip the reverse gear safety cable (3).Put the gear lever in 4th gear; use a punch to extract the roll pin (2).Extract the upper section of the gear lever. Takecare as this is bonded as well as being secured by aroll pin.97968RReplace the lever. Check the alignment of theholes in the upper and lower sections throughwhich the roll pin is fitted.If any excess adhesive is present, wipe it off usinga cloth.Replace the roll pin (2).97967R20-21
AUTOMATIC CLUTCHGear lever sensor (728)20Refit the reverse gear safety cable (3).ATTENTIONReconnect the electrical connection.The sensor in the gear lever knob is extremelyfragile and should be handled with care.Refit the protective boot.Check that reverse gear engages correctly.IMPORTANTCheck the play X. In 1st and 2nd gears it should be4 mm 0.7.After removing the gear lever, it is necessary to:- programme the gears (see section"Programming the gears"),- erase the computer memory (see section "Faultfinding"),- enter the date of the After Sales operation (seesection "Entering the date of After Salesoperations").DI370920-22
AUTOMATIC CLUTCHEngaged gear sensor (726)20DESCRIPTIONThe sensor comprises:- a linear potentiometer,- a reversing light switchIt is mounted on the gearbox housing.A cam which is part of the selection device actuates the potentiometerfollower. A switch at the end of travel stop feeds the reversing light.5 track connector:ABCDE::::: 5 Volts feedGear engaged informationEarthReversing light switchDI2013Key:FGHI::::Selection finger with camGear controlPotentiometerReversing light switch20-23
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Régie Nationale des Usines Renault S.A. C Régie Nationale des Usines Renault S.A. 1996 N.T. 2628A X066 - X067 THE AUTOMATIC CLUTCH is a clutch which is controlled by a computer. Basic Manual: M.R. 305 77 11 190 785 OCTOBER 1996 Edition Anglaise
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