The following deals with replacement of the mechatronics unit - that is, the valve body and control unit:
YZNote:
The new mechatronics unit is supplied complete with flashed software and a parameter set matching the vehicle. The adaption values for clutch calibration are in their default settings (predefined value).
After replacing the mechatronics unit a complete basic calibration of the gearbox is necessary, so a basic setting should be carried out.
Position sensors / synchronous body position:
The position sensor calibration is begun by selecting channel 61. Once the end positions have been calibrated (pay attention to readout!), the next calibration follows.
Selecting channel 60 initiates the next calibration - of the synchronous body positions (synchronous points). Only when these two calibrations (channels 61 and 60) have been successfully completed is the basic calibration classified as passed.
Clutch adaption: (clutch safety function, main pressure)
Software version < 0800: Clutch setting with selection of channel 62. The setting is made just low enough so that no torque is transmitted.
Software version >= 0800: A clutch adaption at standstill is not necessary here, though rapid adaption needs to be initiated by selecting channel 67 (sets the adaption values to predefined values).
As generally nothing is known of the history of the new mechatronics unit, the values of the clutch safety function are reset by selecting channel 68.
Also, the values for automatic main pressure adaption should be reset to their default values (predefined values). This is done by selecting channel 65.
The adaption itself is carried out later automatically during driving.
Fitting info:
The fitting of steering wheel paddles is checked and stored by the gearbox control unit. If a new control unit is fitted, it is necessary to select channel 63in order to reset this fitting information to "not recognised". This initiates the procedure for recognition of the steering wheel paddles, and a corresponding entry is made permanently in the fitting information. The same principle applies to detection of the ESP and cruise control variants fitted in the vehicle. This information is reset by selecting channel 69.
Fault memory:
At the very end of the test procedure, if passed successfully, the fault memory should be erased. If failed, its contents should be saved.
Defined adaption test drive:
Recommendation for a test drive and further checks after replacing the mechatronics and successfully performing basic setting.
Preconditions : Gearbox temperature > 30°C < 100° C
J Drive manually in tiptronic off standstill up to in den 6th gear. Drive repeatedly in each of 3rd, 4th ,5th and 6th gears for at least 2 minutes under constant load.
J Engine speed window for all gears 1500 - 3000 rpm.
J Perform 1 sharp braking followed by full-throttle acceleration (to check oil return)
J Manoeuvring with assessment of creepage and starting-off
J Check for leaks
If the test drive cannot be undertaken in the way recommended or for the period recommended, the fast adaptations still outstanding are undertaken automatically and unnoticeably in the subsequent driving cycles.
Summary of actions
1. Channel 61 - Calibrate gearbox tolerances (Engaged calibration)
2. Channel 60 - Calibrate gearbox tolerances with reference to the position of the gear selector (measurement of synchronising point)
3a) Software version < 0800 à Channel 62- Calibrate clutch adaptation whilst stationary
3b) Software version >= 0800 à Channel 67- The values for the clutch adaption are reset.
4) Channel 68 - Reset values for clutch safety function
5. Channel 65 - Reset values for automatic main pressure adaption to defaults
6. Channel 63 - Reset "Steering wheel paddles" fitting info to "not recognised"
7. Channel 69 - Reset "ESP and CCS" fitting info to "not recognised"
8. Interrogate fault memory and erase if test passed
9. Defined test drive
Abbreviations:
CCS - Cruise control system
ESP - Electronic Stability Program
mvbs
Measured value blocks for control unit -J743 (DQ250 - 6Q):
Measured value block 1:
1. Brake light switch (Brake for pressed/no readout for not pressed)
2. Brake test switch (Brake for pressed/no readout for not pressed)
3. Shift lock status (PN active/inactive)
4. Speed (0... 255 km/h).
PN - Selector lever at P (Park) or N (Neutral - no gear engaged)
Measured value block 2:
1. Selector lever position (P, R, N, D, S, TT, PL, MI, ZS, ER)
2. Plausibility checked selector lever position (P, R, N, D, S, TT, ER)
3. Error byte from selector lever (0 - inactive
1 - active)
4. Engaged gear (Gear: P, R, N, D
Tiptronic: 1, 2, 3, 4, 5, 6)
Inactive - means in measured value block 2 - fault-free
P - Park
R - Reverse
N - Neutral
D - Drive (normal)
S - Drive (sport)
TT - Tiptronic mode
PL - Plus (Upshift in Tiptronic mode)
MI - Minus (Downshift in Tiptronic mode)
IN - Intermediate (selector lever between two gears)
ER - ERROR
Measured value block 3:
1. Selector lever position (P, R, N, D, S, TT, PL, MI, ZS, ER)
2. Plausibility checked selector lever position (P, R, N, D, S, TT, ER)
3. Tiptronic Up on steering wheel (pressed/unpressed)
4. Tiptronic Down on steering wheel (pressed/unpressed)
Measured value block 4:
1. Selector lever position (P, R, N, D, S, TT, PL, MI, ZS, ER)
2. Direction of travel Forward,
Reverse,
Not recognised)
3. Output speed 1 (0... 4080 rpm)
4. Output speed 2 (0... 4080 rpm)
Measured value block 5:
1. Selector lever position (P, R, N, D, S, TT, PL, MI, ZS, ER)
2. Start enable (pressed/unpressed)
3. Supply voltage 1 (0... 25.5 V)
4. Supply voltage 2 (0... 25.5 V)
Measured value block 6:
1. Selector lever position (P, R, N, D, S, TT, PL, MI, ZS, ER)
2. Valve current clutch valve 1 (0... 1,530 A)
3. Duty cycle safety valve 1 (0... 100%)
4. Main pressure valve current (0... 1,530 A)
Measured value block 7:
1. Selector lever position (P, R, N, D, S, TT, PL, MI, ZS, ER)
2. Valve current clutch valve 2 (0... 1,530 A)
3. Duty cycle safety valve 2 (0... 100%)
4. Main pressure valve current (0... 1,530 A)
Measured value block 8:
1. Input speed (0... 8160 rpm)
2. Input shaft speed 1 (0... 8160 rpm)
3. Input shaft speed 2 (0... 8160 rpm)
4. Output speed (0... 4080 rpm)
Measured value block 9:
1. Engine speed (0... 8160 rpm)
2. Input speed (0... 8160 rpm)
3. Output speed (0... 4080 rpm)
4. Output speed from CAN (0... 4080 rpm)
Measured value block 10:
1. Accelerator pedal angle (0... 100%)
2. Kickdown switch (pressed/not pressed - when unpressed no readout)
3. Engine torque (-100... 410 Nm)
4. Engine torque loss (-50... 205 Nm)
Measured value block 11:
1. Input shaft speed 1 (0... 8160 Nm)
2. Specified clutch torque K1 (-600... 600 Nm)
3. Valve current clutch valve 1 (0... 1,530 A)
4. Actual pressure clutch 1 (-327,68... 327.67 bar)
Measured value block 12:
1. Input shaft speed 2 (0... 8160 Nm)
2. Specified clutch torque K2 (-600... 600 Nm)
3. Valve current clutch valve 2 (0... 1,530 A)
4. Actual pressure clutch 2 (-327,68... 327.67 bar)
Measured value block 13:
1. Specified current clutch valve 1 (0... 1,530 A)
2. Duty cycle safety valve 1 (0... 100%)
3. Duty cycle gear actuator valve 1 (0... 100%)
4. Duty cycle gear actuator valve 2 (0... 100%)
Measured value block 14:
1. Specified current clutch valve 2 (0... 1,530 A)
2. Duty cycle safety valve 2 (0... 100%)
3. Duty cycle gear actuator valve 3 (0... 100%)
4. Duty cycle gear actuator valve 4 (0... 100%)
Measured value block 15:
1. Travel measurement gear actuator 1-3 (0... 1023)
2. Travel measurement gear actuator 2-4 (0... 1023)
3. Travel measurement gear actuator 5-N (0... 1023)
4. Travel measurement gear actuator 6-R (0... 1023)
Measured value block 16:
1. Travel gear actuator 1-3 (-12,7... 12.8mm)
2. Travel gear actuator 2-4 (-12,7... 12.8mm)
3. Travel gear actuator 5-N (-12,7... 12.8mm)
4. Travel gear actuator 6-R (-12,7... 12.8mm)
Measured value block 17:
1. Synchronous travel 3rd gear: (-12,7... 12.8mm)
2. Synchronous travel 2nd gear: (-12,7... 12.8mm)
3. Vacant
4. Synchronous travel R gear: (-12,7... 12.8mm)
Measured value block 18:
1. Synchronous travel 1st gear: (-12,7... 12.8mm)
2. Synchronous travel 4th gear: (-12,7... 12.8mm)
3. Synchronous travel 5th gear: (-12,7... 12.8mm)
4. Synchronous travel 6th gear: (-12,7... 12.8mm)
Measured value block 19:
1. Temperature standard (-250... 250 °C)
2. Temperature reserve (-250... 250 °C)
3. Temperature clutch (-250... 250 °C)
4. Empty gas info (no empty gas/empty gas - means idle)
Measured value block 30:
1. Lower adapted clutch pressure K1 (0... 1,275 A)
2. Lower adapted clutch pressure K1 from microslip adaption (0... 1,275 A)
3. Upper adapted clutch pressure K1 from microslip adaption (0... 1,275 A)
4. Upper adapted clutch pressure K1 from macroslip adaption (0... 1,275 A)
Measured value block 31:
1. Lower adapted clutch pressure K2 (0... 1,275 A)
2. Lower adapted clutch pressure K2 from microslip adaption (0... 1,275 A)
3. Upper adapted clutch pressure K2 from microslip adaption (0... 1,275 A)
4. Upper adapted clutch pressure K2 from macroslip adaption (0... 1,275 A)
Measured value block 32:
1. Current lower pressure point clutch 1 from current-to-pressure adaption (0... 1,275 A)
2. Current upper pressure point clutch 1 from current-to-pressure adaption (0... 1,275 A)
3. Current lower pressure point clutch 2 from current-to-pressure adaption (0... 1,275 A)
4. Current upper pressure point clutch 2 from current-to-pressure adaption (0... 1,275 A)
Measured value block 33:
1. Main pressure adaption readings: Success counter to K1 (0... 65535)
2. Main pressure adaption readings: Abort counter to K1 (0... 65535)
3. Main pressure adaption readings: Success counter to K2 (0... 65535)
4. Main pressure adaption readings: Abort counter to K2 (0... 65535)
Measured value block 40:
1. Flash checksum (0... 255)
2. Vacant
3. Vacant
4. Vacant
Measured value block 41:
1. Parameter set designation
2. Vacant
3. Vacant
4. Vacant
Measured value block 42:
1. Mantissa of software parameter 1 (0... 255)
2. Mantissa of software parameter 2 (0... 255)
3. Mantissa of software parameter 3 (0... 255)
4. Mantissa of software parameter 4 (0... 255)
Measured value block 43:
1. Mantissa of software parameter 5 (0... 255)
2. Mantissa of software parameter 6 (0... 255)
3. Mantissa of software parameter 7 (0... 255)
4. Mantissa of software parameter 8 (0... 255)
Measured value block 44:
1. Mantissa of software parameter 9 (0... 255)
2. Mantissa of software parameter 10 (0... 255)
3. Vacant
4. Vacant
Measured value block 45:
1. Exponent of software parameter 1 (0... 255)
2. Exponent of software parameter 2 (0... 255)
3. Exponent of software parameter 3 (0... 255)
4. Exponent of software parameter 4 (0... 255)
Measured value block 46:
1. Exponent of software parameter 5 (0... 255)
2. Exponent of software parameter 6 (0... 255)
3. Exponent of software parameter 7 (0... 255)
4. Exponent of software parameter 8 (0... 255)
Measured value block 47:
1. Exponent of software parameter 9 (0... 255)
2. Exponent of software parameter 10 (0... 255)
3. Vacant
4. Vacant
Measured value block 48:
1. Software designation DQ250
2. Vacant
3. Vacant
4. Vacant
Measured value block 49:
1. Minimum voltage at UH1
2. Maximum voltage at UH1
3. Minimum voltage at UH2
4. Maximum voltage at UH2
UH1 -
UH2 -
Measured value block 50:
1. Selector lever part number
Characters 1 to 12 (part number)
16 (programmability 0 or 1)
18 to 19 (program version)
21 to 22 (data level)
All other characters are blanks
2. Vacant
3. Vacant
4. Vacant
Measured value block 51:
1. Display of internal error ID no. 0 (0... 65535)
2. Display of internal error ID no. 1 (0... 65535)
3. Display of internal error ID no. 2 (0... 65535)
4. Display of internal error ID no. 3 (0... 65535)
Measured value block 52:
1. Display of internal error ID no. 4 (0... 65535)
2. Display of internal error ID no. 5 (0... 65535)
3. Display of internal error ID no. 6 (0... 65535)
4. Display of internal error ID no. 7 (0... 65535)
Measured value block 53:
1. Display of internal error ID no. 8 (0... 65535)
2. Display of internal error ID no. 9 (0... 65535)
3. Display of internal error ID no. 10 (0... 65535)
4. Display of internal error ID no. 11 (0... 65535)
Data for basic calibration (MVB 60- MVB 68):
Measured value block 60:
1. Status gear actuator adaption (Synchronous: 0-1-2-3-4-5-6-7-8-9-10-11-12-13
engaged: 129-130-131-132-133-134-135-136-137-138-139-140-141)
2. Sub-status gear actuator adaption (Synchronous: 0-1-2-3
engaged: 128-129-130-131-132-133-134-135-136-137)
3. Gear actuator index (0 = GS_13
1 = GA_24
2 = GA_5N
3 = GA_6R)
4. Gear actuator side (0 = neutral
1 = side A (negative travels: 3-2-N-R)
2 = side B (positive travels: 1-4-5-6))
Measured value block 61:
1. Status gear actuator adaption (Synchronous: 0-1-2-3-4-5-6-7-8-9-10-11-12-13
engaged: 129-130-131-132-133-134-135-136-137-138-139-140-141)
2. Sub-status gear actuator adaption (Synchronous: 0-1-2-3
engaged: 128-129-130-131-132-133-134-135-136-137)
3. Gear actuator index (0 = GS_13
1 = GA_24
2 = GA_5N
3 = GA_6R)
4. Gear actuator side (0 = neutral
1 = side A (negative travels: 3-2-N-R)
2 = side B (positive travels: 1-4-5-6))
Measured value block 62:
1. Status at standstill for shaft 1: (0 = OFF
1 = EMPTY
2 = ENGAGE
3 = REFERENCE
4 = START VALUE
5 = RAMP
6 = CONTROL
7 = DONE
8 = CALCULATION
16 = MVB_INACTIVE
17 = MVB_WAIT
18 = MVB_RESULT
19 = MVB_ABORT_TESTER
32 = MVB_EMERGENCYRUNNING
33 = MVB_N_ENGINE
34 = MVB_ENGINE_NOK
35 = MVB_TEMPERATURE
36 = MVB_BRAKE
37 = MVB_ACCELERATORPEDAL
38 = MVB_V_VEH
39 = MVB_SELECTORLEVER
40 = MVB_M_ENGINE_LOSS
41 = MVB_M_ENGINE_MAX
64 = MVB_SYSTEM
65 = MVB_CLUTCH_NOK
66 = MVB_SIG_UNSTABLE
67 = MVB_DMMOT_CONTROL)
2. Status at standstill for shaft 2: (0 = OFF
1 = EMPTY
2 = ENGAGE
3 = REFERENCE
4 = START VALUE
5 = RAMP
6 = CONTROL
7 = DONE
8 = CALCULATION
16 = MVB_INACTIVE
17 = MVB_WAIT
18 = MVB_RESULT
19 = MVB_ABORT_TESTER
32 = MVB_EMERGENCYRUNNING
33 = MVB_N_ENGINE
34 = MVB_ENGINE_NOK
35 = MVB_TEMPERATURE
36 = MVB_BRAKE
37 = MVB_ACCELERATORPEDAL
38 = MVB_V_VEH
39 = MVB_SELECTORLEVER
40 = MVB_M_ENGINE_LOSS
41 = MVB_M_ENGINE_MAX
64 = MVB_SYSTEM
65 = MVB_CLUTCH_NOK
66 = MVB_SIG_UNSTABLE
67 = MVB_DMMOT_CONTROL)
3. Lower adapted clutch point for K1 (0... 1,275 A)
4. Lower adapted clutch point for K2 (0... 1,275 A)
Measured value block 63:
1. Fitting info steering wheel paddles (0 = not recognised
1 = recognised)
2. Vacant
3. Vacant
4. Vacant
Measured value block 64:
1. Number of exceedings of permissible centrifugal oil temperature (0... 255)
2. Vacant
3. Vacant
4. Vacant
Measured value block 65:
1. Correction values main pressure adaption: Low pressure on K1 (-327.68... 327.67 bar)
2. Correction values main pressure adaption: High pressure on K1 (-327.68... 327.67 bar)
3. Correction values main pressure adaption: Low pressure on K2 (-327.68... 327.67 bar)
4. Correction values main pressure adaption: High pressure on K2 (-327.68... 327.67 bar)
Measured value block 66:
1. Adapted flags gear actuator 13 (0 = inactive / 1 = active)
2. Adapted flags gear actuator 24 (0 = inactive / 1 = active)
3. Adapted flags gear actuator 5N (0 = inactive / 1 = active)
4. Adapted flags gear actuator 6R (0 = inactive / 1 = active)
Measured value block 67:
1. Clutch adaption values: for K1 (0... 1,275 A)
2. Clutch adaption values: for K2 (0... 1,275 A)
3. Vacant
4. Vacant
Measured value block 68:
1. Clutch adaption values: Lower current point adaption K1 (0... 1,275 A)
2. Clutch adaption values: Lower current point adaption K2 (0... 1,275 A)
3. Vacant
4. Vacant
Control unit identification (MVB 80 - MVB 82):
Measured value block 80:
1. Measured value block 80 as per expanded control unit identification
(manufacturer works number and identifier : hhh-kkk, 7-digit
Date of manufacture : dd.mm.yy, 8-digit
Manufacturer modification status number : 12345678, 8-digit
Manufacturer test status no. : pppp, 4-digit
Manufacturer serial no. : nnnn, 4-digit)
Measured value block 81:
1. Measured value block 81 as per expanded control unit identification
(Chassis number : 17-digit
Module no. or serial no. : 14-digit
Type test number : 7-digit)
Measured value block 82:
1. Measured value block 82 as per expanded control unit identification
(Flash tool code : 1234567890123, 13-digit
Flash date : dd.mm.yy, 8-digit
Hardware module : 3-digit
Hardware sort key : 2-digit
Software module : 3-digit
Software sort key : 2-digit)
Measured value block 125:
1. CAN devices, engine (Engine 0 = no message / Engine 1 = message OK)
2. CAN devices, ABS (ABS 0 = no message / ABS 1 = message OK)
3. CAN devices, dash panel insert (Combi 0 = no message / Combi 1 = message OK)
4. CAN devices, selector lever (Selector lever 0 = no message / Selector lever 1 = message OK)
Measured value block 126:
1. CAN device - data bus diagnostic interface (gateway)
2. CAN device - steering column module
3. Vacant
4. Vacant
Measured value block 225:
1. Number of timeouts, engine (0... 255, multiple of EMC timeout)
2. Number of timeouts, ABS (0... 255, multiple of EMC timeout)
3. Number of timeouts, dash panel insert (0... 255, multiple of EMC timeout)
4. Number of timeouts, selector lever (0... 255, multiple of EMC timeout)
Measured value block 226:
1. Number of timeouts, gateway (0... 255, multiple of EMC timeout)
2. Vacant
3. Vacant
4. Vacant
also check the clutch temp switch g509 form cold start