Sensodrive Gearbox

TECHNICAL TRAINING
ELECTRONICALLY CONTROLLED
"SENSODRIVE" GEARBOX
DOCUMENT REF N°: 2.4.404 November

2002
QUALITY DEVELOPMENT DIVISION

NOTE TO READERS
This document contains information of a confidential nature.
It is therefore strictly reserved for the use of CITROËN trainers and may
not be distributed to people outside the relevant department s.
A
BROCHURE SUMMARY
SENSODRIVE ELECTRONICALLY CONTROLLED

GEARBOX (MA TYPE)
The aim of this brochure is to present the electronically controlled manual

gearbox known as SENSODRIVE. This MA type gearbox can be used in
automatic or manual mode.
The following subjects will be dealt with in this document:
- Presentation of the gearbox,
- Presentation and operation of the actuators,
- Presentation of the various modes:
. automatic mode,
. manual mode,
. safety mode,
. downgraded mode.
- Presentation of the auto-diagnostic function,
- Maintenance, repair and programming of the sequential manual

gearbox.
ELECTRONICALLY CONTROLLED "SENSODRIVE" GEARBOX

B
CONTENTS
SECTION 1: PRESENTATION ........................................................ 1

I- GENERAL DETAILS............................................................................................1
II - DESCRIPTION...................................................................................................3
III - OPERATION......................................................................................................7
SECTION 2: OPERATING PRINCIPLE .......................................... 21

I- OPERATION IN "AUTOMATIC" MODE ...............................................................21
II - OPERATION IN "SEQUENTIAL" MODE ..............................................................28
III - GEAR CHANGE................................................................................................28
IV - DISPLAY OF FAULTS - OPERATION IN DOWNGRA DED MODES ........................32
SECTION 3: MECHANICAL COMPONENTS .................................. 36

I- DESCRIPTION.................................................................................................36
II - CLUTCH ACTUATOR (1665) ............................................................................37
III - GEARBOX ACTUATOR (1664, 1663)...............................................................43
SECTION 4: SYSTEM COMPONENTS .......................................... 47

I- DIAGRAM........................................................................................................47
II - GEARBOX ECU ...............................................................................................51
III - COMPONENTS LINKED TO THE ECU................................................................56

C
CONTENTS
SECTION 5: DIAGNOSTICS - REPAIRS........................................ 70

I- RECOMMENDATIONS......................................................................................70
II - DIAGNOSTIC TOOL FUNCTIONS ......................................................................75
III - REMOVING / REFITTING PARTS .......................................................................90
IV - EXCHANGING PARTS ......................................................................................92
V- DOWNLOADING THE ECU PROGRAM ..............................................................94
VI - EXCHANGING A SENSODRIVE ECU .................................................................95
VII - CONFIGURING A NEW ECU .............................................................................95
VIII - ROAD TEST.....................................................................................................95
IX - WARRANTY RETURN PROCEDURE...................................................................95
SECTION 6: WIRING DIAGRAM ................................................... 96

I- LAYOUT DIAGRAM..........................................................................................96
II - WIRING DIAGRAM...........................................................................................97
III - LOCATION DIAGRAM ......................................................................................98
IV - PARTS LIST.....................................................................................................99

D

1
Section 1
PRESENTATION
I- GENERAL DETAILS
The MA type sequential gearbox is a manual gearbox in which the following

components are electromechanically operated:
• gear selection and changing,

• clutch control.
The MA type sequential gearbox uses a specific ECU and two electrical
actuators to control the gearbox mechanically (derived from the MA type
gearbox).
The driver changes gear effortlessly - there is no clutch pedal.
The MA type sequential gearbox has 2 operating programs:
• a "sequential" program: the driver decides when to change gear,

• an "automatic" program: the gearbox ECU decides when to change gear.
The engine can only be started when the brake pedal is pressed.
Features of the "sequential" program:
• the driver changes gear using the gear selector or the paddles at the
steering wheel,
• the driver can change down two gears at once,
• in certain operating conditions, the gearbox ECU ignores the driver's
requests (*),
• in certain operating conditions, the gearbox ECU will change a gear (*),
• the driver can select the "automatic" program at any time.
(*) operating safety function: to prevent the engine from stalling and to
protect against excess engine speeds.

2
Section 1
Features of the "automatic" program:
• the ECU adjusts the operation of the gearbox to the road, engine load and
driving style (auto-adaptive program),
• snow mode is selected automatically as soon as wheel slip is detected

(ABS/ESP ECU or gearbox ECU),
• the driver can select the "sequential" program at any time (program
button, gear selector, paddles at the steering wheel),
• if the accelerator pedal is pressed to the floor, the ECU automatically

switches to a KD point (kickdown).
When changing gear:
• the accelerator pedal does not have to be released,
• the engine speed is adjusted by the engine ECU upon an order from the
gearbox ECU.
The sequential gearbox means that the following components are no longer
required:
• the clutch pedal,
• the manual gear lever (no cable, no linkage).
The MA type Sequential Manual Gearbox is a zero maintenance unit.
The gearbox is lubricated for life.

3
Section 1
II - DESCRIPTION
The following components are used to control the gearbox:
• a specific MA type gearbox,
• a specific ECU with "Flash" memory (software can be updated by

downloading),
• a clutch actuator (electric),
• a gearbox actuator (electric),
• a gearbox input speed sensor,
• a short stroke gear selector (electric),
• paddles at the steering wheel,
• a program selector,
• a display (on the control panel) showing the current gear engaged and the
program selected by the driver,
• a specific engine ECU (the engine ECU communicates with the gearbox
ECU).
Advantages of electronic management:
• permanent adaptation of the gear changing thresholds as a function of

driving style, road profile and vehicle load ("automatic" program),
• improvement in gear changing quality (improvement in driving pleasure),
• conservation of an excellent gear changing level throughout the vehicle's
life as the gearbox automatically adjusts itself to compensate for wear,
• reduction in fuel consumption ("automatic" program),
• increase in operating safety ("sequential" program: the ECU can cause a
gear change in certain cases),
• auto-diagnostics and emergency modes (priority is given to vehicle
mobility).
The engine ECU communicates with the gearbox ECU regarding gearbox
and engine operation.

4
Section 1
Advantage of the gearbox ECU and engine ECU communicating with each
other:
• gears can be changed without releasing the accelerator pedal,
• engine speed can be controlled during a gear change,
• mechanical protection of the gearbox and engine is increased,
• driving pleasure is increased,
• operating safety is increased,
• emission control standards are met.
1 - Display on the control panel (LCD).

2 - Snow LED
3 - Auto LED
4 - Alphanumeric display
5 - Gear selector
6 - Program selector
7 - Gear selection grid
8 - RH steering wheel paddle (+)
9 - LH steering wheel paddle (-)
The engine can only be started when the brake pedal is pressed.

5
Section 1
A - VEHICLE IDENTIFICATION
Vehicles can be identified by:
• a liquid crystal display on the control panel,

• the program selector (6),
• the gear selector (5) (simplified selection grid (7)),
• the paddles at the steering wheel (8) (9).
B - DRIVER CONTROLS
Features of the paddles at the steering wheel:
• gears are changed by pulling the paddle,

• the LH paddle (-) is used to change down,
• the RH paddle (+) is used to change up,
• the paddles are incorporated into the switch module at the steering
wheel,
• the paddles cannot be used to engage neutral (N) nor reverse (R).
Features of the gear selector:
• the gear selector is electrically controlled and has a short stroke,

• the central position (a) of the gear selector is the only stable position,
• the (+) position is used to change up,
• the (-) position is used to change down,
• position "N" is used to select neutral,
• position "R" is used to select reverse.
The program selector is used to select the following programs:
• "automatic" program,
• "sequential" program.
The "snow" program is selected automatically when wheel slip is detected

(ABS/ESP ECU or gearbox ECU).

6
Section 1
C - DRIVER'S INFORMATION - USE
Display on the control panel (LCD).

2 - Snow LED
3 - Auto LED
The control panel display shows:
• the active program (auto for "automatic" and nothing for "sequential"),
• the gear engaged (1, 2, 3, 4, 5, R, N).
The program selected is displayed on the control panel by the following

LEDs:
• "sequential" program active: the LED (3) is off,
• "automatic" program active: the LED (3) is on,
• "snow" program active: the LED (2) is on.
Gear changes are possible when the control panel display is active.
The gearbox ECU sends the gear engaged information to the BSI on the
CAN.
The BSI retransmits the gear engaged information to the control panel.

7
Section 1
III - OPERATION
Unlocking the doors - opening the driver's door
Opening the driver's door or unlocking the doors causes:
• a rapid initialisation of the gearbox actuators (clutch actuator, gearbox

actuator),
• activation of the control panel display,
• display of the gear engaged and the active program,
• the clutch to open if "N" is engaged.
Gears 1, 2, N and R can be engaged as soon as the control panel is active.
When the ignition is switched on, the gearbox switches by default to

"automatic" mode.
Actuator initialisation
The gearbox ECU must initialise the actuators (clutch actuator, gearbox
actuator) in the following cases:
• when the battery is disconnected before the control panel is switched off,
• when the battery is disconnected before the gearbox ECU goes to sleep
(4 minutes after the control panel is switched off),
• if the programming operation fails or if the values are not stored in the
gearbox ECU (see corresponding operation).
When the ignition is switched on, when the brake pedal is pressed (*), the
gearbox ECU:
• initialises the position of the clutch fork (movements of the clutch fork),
• initialises the position of the gear lever (movements of the gear lever).
(*) the engine can only be started when the brake pedal is pressed.
Warning: The engine is not authorised to start during the actuator position
initialisation operations.
Note: The time required to initialise the actuator positions varies between 10
seconds and 1 minute.
Note: If the programming operation has not been performed, the initialisation
operations are performed every time an attempt is made to start the
engine.

8
Section 1
Starting the engine - starting safety
This function is used to:
• ensure that the driver is present (by the brake pedal being pressed)
before allowing the vehicle to move off,
• avoid the vehicle from moving off suddenly when a gear is engaged.
Gear engaged (1, 2 or R):
• pressing the brake pedal causes the clutch to open (declutching),

• the engine is authorised to start,
• releasing the brake pedal, before the engine is started, causes the clutch
to close and prevents the engine from being started,
• when the engine is running and a gear engaged, pressing the accelerator
pedal causes the vehicle to move off.
The rate of increase in vehicle speed is controlled by the amount and speed
with which the accelerator pedal is pressed.
Gear "N" engaged:
• the clutch opens when the control panel is switched on,
• the engine can be started when the brake pedal is pressed.
Choice of gearbox operating mode
When the ignition is switched on, the gearbox switches by default to

"automatic" mode.
The driver can select the required program by pressing the program
selector.
The control panel display shows the program selected by the driver.
Engaging a gear:
First gear is engaged by pressing a (+) control (either the gear selector or
the paddle).
The engine speed must be around idle speed.
Note: Reverse gear can only be engaged when the brake pedal is pressed and
the vehicle stationary.
Note: The paddles cannot be used to engage neutral N or reverse R.

9
Section 1
A - OPERATION IN "AUTOMATIC" MODE
1 - General details
Gears are changed from 1st to 5th automatically (without the driver
having to do anything).
Gears can be changed without releasing the accelerator pedal.
Gears are changed as a function of the following parameters:
• position of the accelerator pedal,
• vehicle load and speed,
• road profile (vehicle going downhill, etc),
• driving style.
The ECU adjusts the operation of the gearbox to the road, engine
load and driving style.
Gearbox behaviour is linked to the driver's driving style ranging from

the most gentle to the most sporty.
If the accelerator pedal is pressed to the floor, the ECU

automatically switches to a KD point (kickdown).
The kickdown function is used to:
• delay a change to a higher gear (it occurs at a higher engine

speed),
• change down a gear if the vehicle speed conditions are met.

10
Section 1
2 - Methods of changing gear

a - Methods of changing up a gear
With action by driver Without action by driver

Action on the accelerator pedal and Reduction in vehicle load
vehicle acceleration
(vehicle returns to flat road, etc)
Release of the accelerator pedal after a Gear changes adapted progressively
kickdown to suit driving style
Action on the following components (*): Upon exiting a gearbox ECU upwards
gear change lock function
(+) or (++) gear selector
(+) or (++) paddles
(+) or (-) A single action is performed.

(++) or (--) Two successive actions are performed.
(*) The gearbox ECU automatically selects the "sequential"
program.
b - Methods of maintaining a gear

Accelerator pedal released quickly -
Accelerator pedal released (no load) -
c - Methods of changing down a gear

Accelerator pedal pressed Reduction in vehicle speed
(vehicle going uphill)
Accelerator pedal pressed to floor Increase in vehicle load
(kickdown) (*) (vehicle going uphill)
Action on the brake pedal -
Action on the following components (**): -
(-) or (--) gear selector
(-) or (--) paddles

(*) Change down a gear if the vehicle speed conditions are met.
(**) The gearbox ECU automatically selects the "sequential"
program.

11
Section 1
d - Selecting the "sequential" program
The "sequential" program is selected after the following actions:
• press on the program selector button (6),
• action on one of the (+) or (-) controls (either the gear selector
or the paddles).
An action on a (+) control changes up a gear.
An action on a (-) control changes down a gear.
Note: A command which is incompatible with vehicle or engine

speed is ignored.
e - "Snow" program
The "snow" program is selected automatically when wheel slip is

detected (ABS/ESP ECU or gearbox ECU).
Features:
• 1st gear is prohibited,
• the vehicle moves off in 2nd gear,
• gears are changed less frequently than for the other programs,
• gentler operation (no sudden variation in torque at the wheels),
• there is a forced change down when braking.
The snow program is automatically deactivated when the wheels

stop slipping.

12
Section 1
B - OPERATION IN "SEQUENTIAL" MODE
1 - General details
The driver changes gear using the gear selector or the paddles at the
steering wheel.
2 - Engaging a gear
First gear is engaged by pressing a (+) control (either the gear

selector or the paddle).
The engine speed must be around idle speed.
Note: Reverse gear can only be engaged when the brake pedal is
pressed and the vehicle stationary.
Note: The paddles cannot be used to engage neutral N or reverse R.
3 - Methods of changing gear
The driver can select the required gear using the following controls:
• the gear selector,
• the paddles at the steering wheel.
a - Double gear change
The driver can change up or down 2 gears by operating the (+) or

(-) controls twice in succession (gear selector or paddles).
Between two (+) or (-) commands, the gear lever must pass
through the central position.
Between two (+) or (-) commands, the paddles must be released.
Note: A command which is incompatible with vehicle or engine

speed is ignored.

13
Section 1
b - Methods of changing up a gear
Action on the following components: Maximum engine speed reached, higher gear
selected (*)
(+) or (++) gear selector
(+) or (++) paddles

(*) The "sequential" program remains active.
c - Methods of changing down a gear
Action on the following components: Engine speed not sufficient (engine speed
too low) (*)
(-) or (--) gear selector
(-) or (--) paddles

(*) The "sequential" program remains active.
Note: If the engine speed is too low, the gearbox ECU opens the
clutch to prevent the engine from stalling.
d - Selecting the "automatic" program
The driver can select the "automatic" program when the vehicle is
moving.
e - Engaging gear "N" when the vehicle is moving
The driver can engage gear "N" when the vehicle is moving.
Pressing one of the (+) or (-) controls causes a gear to be

engaged which is compatible with the vehicle speed.

14
Section 1
C - ENGAGING A GEAR - VEHICLE PARKED
The gearbox ECU allows a gear to be engaged when the vehicle is

stationary and the engine off:
• gears 1, 2, N and R can be engaged with the ignition on,
• gears 1, 2, N and R can be engaged as soon as the control panel is

active (number of gear changes authorised: 1).
Note: it is not possible to deselect a gear with the ignition off.
D - SAFETY FUNCTIONS
1 - Starting the engine - starting safety
The engine can be started when the brake pedal is pressed.
2 - Incorrect operations on the controls by the driver
The driver's controls are temporarily deactivated in the following

cases:
• opposing commands between the gear selector and the paddles,
• sustained press on the gear selector,
• sustained press on the paddles,
• sustained actions on the gear selector.
3 - Automatic engaging of gear "N"
The gearbox ECU will engage gear "N" after 3 minutes when the
following conditions are met:
• vehicle stationary,
• engine running,
• gear engaged.
Pressing the accelerator pedal will engage 1st gear if the vehicle has
not been stationary for more than 2 minutes.

15
Section 1
E - CLUTCH PROTECTION FUNCTIONS
The gearbox ECU permanently estimates the temperature of the clutch

friction plate.
When the vehicle is on a hill with a gear engaged, the driver can hold the
vehicle by pressing on the accelerator pedal.
This causes the clutch to heat up progressively.
When the clutch becomes too hot, the gearbox ECU performs a
declutching and clutching sequence, to oscillate the vehicle until the
engine stalls thus warning the driver.
Note: Always use the handbrake to immobilise the vehicle.
F - FAULT DISPLAY
Display on the control panel (LCD).

2 - Snow LED
3 - Auto LED
10 - Flashing display
The "auto" and "snow" LEDs flash simultaneously to indicate an operating

fault.
The alphanumeric display also displays a dash (4).

16
Section 1
G - SUMMARY OF THE CONTROLS
1 - "Automatic" program active
a - Actions on the gear selector
ACTIONS ON THE GEAR SELECTOR
Gear
"+" "-" "N" "R" "++" "--"
engaged
R A + 1 (a) No action A+N No action A+R A+R
N A+1 No action No action A+R M+2 M+N
1 M+2 M+1 A+N A+R M+3 M+1
2 M+3 M+1 A+N A+R M+4 M+1
3 M+4 M+2 A+N A+R M+5 M+1
4 M+5 M+3 A+N A+R M+5 M+2
5 M+5 M + 4 (b) A+N A+R M+5 M+3
M: "Sequential" program
A: "Automatic" program
R: Reverse
N: Neutral
(+) or (-) A single action is performed
(++) or (--) Two successive actions are performed
(a) example 1:
• reverse (R) is engaged,
• a (+) action on the gear selector will engage first gear and the
"automatic" program is maintained.
(b) example 2:
• 5th gear is engaged,
• a (-) action on the gear selector will engage fourth gear if the
"sequential" program is selected.

17
Section 1
b - Actions on the paddles
ACTIONS ON THE PADDLES
Gear engaged "+" "-" "++" "--"
R No action No action A+R A+R
N M+1 No action M+2 M+N
1 M+2 No action M+3 M+1
2 M+3 M+1 M+4 M+1
3 M+4 M+2 M+5 M+1
4 M+5 M+3 M+5 M+2
5 No action M+4 M+5 M+3
M: "Sequential" program.
A: "Automatic" program.
R: Reverse.
N: Neutral.
c - Actions on the program selector
GEAR ENGAGED ACTIONS ON THE PROGRAM SELECTOR
R M+R
N M+N
1 M+1
2 M+2
3 M+3
4 M+4
5 M+5
R: Reverse.
N: Neutral.

18
Section 1
2 - "Sequential" program active
a - Actions on the gear selector
ACTIONS ON THE GEAR SELECTOR
Gear
"+" "-" "N" "R" "++" "--"
engaged
R M+1 No action M+N No action M+R M+R
N M+1 No action No action M+R M+2 M+N
1 M+2 No action M+N M+R M+3 M+1
2 M+3 M+1 M+N M+R M+4 M+1
3 M+4 M+2 M+N M+R M+5 M+1
4 M+5 M+3 M+N M+R M+5 M+2
5 No action M+4 M+N M+R M+5 M+3
R: Reverse.
N: Neutral.
b - Actions on the paddles
ACTION ON THE PADDLES
Gear engaged "+" "-" "++" "--"
R No action No action M+R M+R
N M+1 No action M+2 M+N
1 M+2 No action M+3 M+1
2 M+3 M+1 M+4 M+1
3 M+4 M+2 M+5 M+1
4 M+5 M+3 M+5 M+2
5 No action M+4 M+5 M+3
R: Reverse
N: Neutral
(+) or (-) A single action is performed
(++) or (--) Two successive actions are performed

19
Section 1
c - Actions on the program selector
ACTIONS ON THE PROGRAM

GEAR ENGAGED
SELECTOR
R A+R
N A+N
1 A+1
2 A+2
3 A+3
4 A+4
5 A+5
R: Reverse
N: Neutral

20
Section 1

21
Section 2
OPERATING PRINCIPLE
I- OPERATION IN "AUTOMATIC" MODE
A - GENERAL DETAILS: GEAR CHANGING LAWS
The operating point of the gearbox is defined by the following

information:
• throttle position,
• vehicle load and speed.
Whilst operating, the decision to change gear is taken by the ECU from a
set of curves called the "gear changing laws".
Each gear changing law includes:
• the gear changing thresholds (upwards and downwards changes),

• the kickdown points.

22
Section 2
B - GEAR CHANGING CURVES
Example of gear changing law.

X - Vehicle speed
Y - Accelerator pedal position (%)
A - 2nd gear to 1st gear changing curve
B - 1st gear to 2nd gear changing curve
C - 3rd gear to 2nd gear changing curve
D - 2nd gear to 3rd gear changing curve
E - 4th gear to 3rd gear changing curve
F - 3rd gear to 4th gear changing curve
G - Point example 1
H - Point example 2
KD - Kickdown points
The gear change is obtained when the operating point crosses the curve
(rising or falling speed).
Note: The gear changing thresholds are different for upwards and
downwards gear changes to prevent repeated gear changes.
In all cases, the gear changing laws are used to obtain maximum vehicle
performance, upon the actions of the driver.
If the accelerator pedal is pressed to the floor, the ECU automatically
switches to a KD point (kickdown).
Example 1: vehicle speed increasing:
• the accelerator pedal is pressed to 80% of its travel,
• the vehicle is in 3rd gear,
• a higher gear will be selected if the vehicle speed reaches 60 mph
(100 kph).
Example 2: vehicle speed decreasing:
• the accelerator pedal is pressed to 80% of its travel,
• the vehicle is in 4th gear,
23
Section 2
• a lower gear will be selected if the vehicle speed falls below 45 mph
(72 kph).

24
Section 2
C - GEAR CHANGING AUTO-ADAPTIVITY
The ECU adjusts the operation of the gearbox to the road, engine load
and driving style.
Whilst operating, the decision to change gear is taken by the ECU from a
set of curves called the "gear changing laws".
The ECU uses 9 gear changing laws:
• 6 auto-adaptive laws (reference laws),
• 1 law specific to the "snow" program,
• 1 warming up law for cold starting,
• 1 law specific to the downgraded modes.
J - "Driver" laws
K - "Vehicle load" laws
L1 - Economy law
L1-2 - Intermediate law: economy - medium
L2 - Medium
L2-3 - Intermediate law: medium - sport
L3 - Sport law
L4 - Braking law 1
L4-5 - Intermediate law: braking 1 - braking 2
L5 - Braking law 2
L6 - Downhill
L7 - Snow

25
Section 2
The auto-adaptive laws are the following:

• economy law (reduced fuel consumption is promoted),
• medium law (behaviour is a bit more sporty than for economy law),
• sport law (sporty driving),
• braking law 1 (law suited to low vehicle loads and gentle slopes),
• braking law 2 (law suited to high vehicle loads and steep slopes),
• downhill law (law suited to downhill, use of the engine brake).
Laws L1 - L7 are stored in the ECU memory (reference laws).
Laws L1-2, L2-3, L4-5 and L5-6 are calculated dynamically by the
gearbox ECU from the reference laws.
The ECU alters the gear changes as a function of the following:
• driving style,
• road profile: surface adherence, uneven road,
• engine: load, speed, temperature.
The main information taken into account is as follows:
• throttle position,
• rate of change of throttle position,
• average throttle position,
• variation in gearbox output speed,
• vehicle acceleration (engine torque),
• vehicle speed.
To adjust the behaviour of the gearbox to suit the driver's demands:
• the ECU selects the most suitable reference law from the "driver"
laws,
• the ECU selects the most suitable reference law from the "vehicle
load" laws,
• from the selected laws, the gearbox ECU then calculates a more
suitable intermediate law and selects it.
The choice is made from the average values and the last few minutes of
operation.
The choice can be corrected temporarily (see "temporary rise in
sportiness").
The ECU uses an infinite number of gear changing laws.
The gearbox ECU causes a gear change after the gear to be engaged is
validated.
Gears 1 to 5 are selected in sequence automatically, without any driver
intervention.
Note: For details on using the "automatic" program, refer to the section:
Main functions: MA type sequentially controlled manual gearbox.

26
Section 2
D - SPECIFIC LAWS
1 - Warming up law
This operating law is activated when the engine is cold.
The warming up law:
• is activated for a preset time which depends on each engine

• is deactivated at the end of the timer
2 - Snow law
The snow program is automatically selected if the wheels are

slipping.
Vehicle with ESP
• the ESP ECU informs the gearbox ECU that the wheels are
slipping,
• the gearbox ECU automatically selects the "snow" law,
Vehicle with ABS:

• the ABS ECU informs the gearbox ECU of the speed of the 4
wheels,
• the gearbox ECU then determines whether the wheels are slipping
from the wheel speeds and selects the "snow" law if necessary.
As soon as the wheels stop slipping, the ECU reverts to the law which
was active before the wheels started slipping.
Features:
• 1st gear is prohibited. The gear selection lever is in the central

position,
• the vehicle moves off in 2nd gear,

• gears are changed less frequently than for the other programs,
• a kickdown position will only cause a gear change down if the
vehicle speed is below 10 mph (15 kph),
• gentler operation (no sudden variation in torque at the wheels),
• there is a forced change down when braking.

27
Section 2
E - OTHER AUTO-ADAPTIVE FUNCTIONS
1 - Prohibition of upward gear changes (accelerator pedal released

quickly)
This function prevents a higher gear being selected incorrectly when

the accelerator pedal is released quickly (engine braking whilst
decelerating).
This function is active when the vehicle is in a cornering situation

(detected from the wheel speed information).
Note: This function is also active when the vehicle is going downhill
when the accelerator pedal is released.
2 - Temporary rise in sportiness
This function is active when the accelerator pedal is pressed quickly

in the "automatic" program.
The ECU temporarily switches to a more sporty operating law to

promote acceleration.
Note: When the accelerator pedal is released, the ECU immediately

reverts to the law in use prior to the temporary rise in sportiness.
3 - Gear lock when changing law
In certain conditions, the current gear engaged is locked when the

ECU changes operating law.
The gear is released in the following conditions:
• foot removed from the accelerator pedal,
• vehicle accelerates after a programmed timer.
4 - Change down when braking
Change down during braking is auto-adaptive.
Note: A change down can be forced in certain driving conditions

(depending on the law used).
In certain cases, the gearbox ECU can cause a triple change

down to promote engine braking.

28
Section 2
II - OPERATION IN "SEQUENTIAL" MODE
Features of the "sequential" program:
• the driver changes gear using the gear selector or the paddles at the
steering wheel,
• the driver can change down two gears at once,
• in certain operating conditions, the gearbox ECU ignores the driver's

requests (*),
• in certain operating conditions, the gearbox ECU will change a gear (*),
• the driver can select the "automatic" program at any time.
(*) operating safety function: to prevent the engine from stalling and to
protect against excess engine speeds.
The gearbox ECU causes a gear change after the driver's demand is
validated.
For details on using the "sequential" program, refer to the section: Main
functions: MA type sequentially controlled manual gearbox.
III - GEAR CHANGE
Gears are changed using the following information:
• the position of the accelerator pedal,
• the gear to be engaged.
During a gear change, the gearbox ECU:
• controls the engine torque and speed via the engine ECU in order to
change the gear,
• controls the actuators simultaneously (clutch actuator, gearbox

actuator).

29
Section 2
A - GEAR CHANGING SEQUENCE
M - Example: upward gear change.

P - Example: downward gear change, vehicle accelerating.
t - Time.
N - Gear N.
N+1 - Gear N+1 (higher gear).
N-1 - Gear N-1 (lower gear).
a - Engine speed before gear change.
b - Clutched state (clutch closed).
c - Declutched state (clutch open).
d - Engine speed after gear change.
Q - Start of gear change.
R - Clutch opening phase.
S - Engine speed regulation phase by gearbox ECU.
U - Clutch closing phase.
V - End of gear change.
The driver perceives the gear change during phases R, S and U.
The phases are the same for both programs (AUTO and SEQUENTIAL).

30
Section 2
B - GENERAL GEAR CHANGING PRINCIPLE

A gear change is a sequence of successive phases.
Sequence of operations:
OPERATING PHASE ECU ACTIONS DURING A GEAR CHANGING PHASE

(Q) The gearbox ECU sends the following information to the engine ECU
on the CAN:
- gear change in progress information
- change in compressor status prohibited information (to prevent
any disturbance during the gear change)
The clutch is closed (b)
The driver's request is ignored (accelerator pedal)
The gearbox ECU sends the gear engaged information to the BSI so
that this can be displayed on the control panel
(R) The gearbox ECU causes the clutch to open progressively
Whilst the clutch is opening, the gearbox ECU sends the value of
the maximum torque allowed by the gearbox (maximum torque
allowed by the gearbox information) to the engine ECU
The value of maximum torque allowed by the gearbox is permanently
adjusted by the gearbox ECU as a function of clutch opening
Upon an order from the gearbox ECU, the engine ECU reduces the
engine torque until a torque value of 0 Nm is reached at the end of
phase R
(S) To prevent the engine from racing (the clutch is open (c)), the
gearbox ECU sends the following information to the engine ECU:
- request to regulate the engine speed
- the engine speed setting
During this phase, the gearbox ECU controls the engine ECU with an
engine speed setting
The engine speed setting is permanently adjusted so as to obtain
the engine speed corresponding to the gear to be engaged
progressively (d)
The gearbox ECU controls the gearbox actuator to perform the gear
change
(U) The gearbox actuator has engaged the requested gear
The gearbox ECU causes the clutch to close progressively
Whilst the clutch is closing, the gearbox ECU sends the value of the
maximum torque allowed by the gearbox (maximum torque allowed
by the gearbox information) to the engine ECU
The value of maximum torque allowed by the gearbox is permanently
adjusted by the gearbox ECU as a function of clutch closing
Upon an order from the gearbox ECU, the engine ECU progressively
increases the engine torque until a torque value corresponding to
the driver's demand (accelerator pedal) is reached
The engine speed is adjusted to the vehicle speed and the gear
engaged
(V) The gear change is complete
The clutch is closed
The driver's request is no longer ignored (accelerator pedal)

31
Section 2
C - UPWARD GEAR CHANGE (M)

The gearbox ECU controls the engine ECU to obtain an engine speed
suited to the gear engaged N+1 and the vehicle speed.
The gearbox ECU causes a reduction in engine speed (d).
D - DOWNWARD GEAR CHANGE - (P)
The gearbox ECU controls the engine ECU to obtain an engine speed
suited to the gear engaged N-1 and the vehicle speed.
The gearbox ECU causes an increase in engine speed (d).
E - CLUTCH CLOSING PHASE
The gearbox ECU can modify the speed at which the clutch closes (U).
The ECU can use 3 clutch closing speeds, from the slowest (the most
comfortable) to the fastest (the most sporty).
The clutch closing speed at the end of the gear change depends on the
driver's driving style.
F - DOUBLE GEAR CHANGE
When the "sequential" program active, the driver can request another
gear change during phase S.
The gearbox ECU authorises another gear to be engaged for as long as
the synchronisation phase of the previous gear has not started.
If the synchronisation phase has started, the gear change continues
through to phase V.
G - GEAR CHANGING PROBLEMS
It may be difficult to engage a gear in certain cases.
In this case, the gearbox ECU tries to change gear a further two times.
When the vehicle is stationary, the ECU opens and closes the clutch to
help the gear to engage.
The corresponding gear is deactivated after three failed consecutive
attempts.
A fault is stored in the gearbox ECU memory.
H - AUTO-ADAPTIVITY
The gearbox ECU takes the age of the gearbox into account.
When operating, the ECU causes the following to be programmed
automatically on a regular basis:
• the position of the clutch biting point,
• the position of the start of synchronisation point (synchro).

32
Section 2
IV - DISPLAY OF FAULTS - OPERATION IN DOWNGRADED MODES
A - DISPLAY OF FAULTS
The "auto" and "snow" LEDs flash simultaneously to indicate an operating

fault.
The alphanumeric display also displays a dash (4).
B - OPERATION IN DOWNGRADED MODES
FAULT NOTED EFFECT
Incomplete programming fault The gearbox ECU initialises the actuators when the
ignition is switched on and when the brake pedal is
pressed
The time required to initialise the actuator positions

varies between 10 seconds and 1 minute
The engine cannot be started during the actuator

position initialisation operations
Gearbox fault The gear jumps out:
- flashing of "auto" and "snow" LEDs: yes
- faulty gear prohibited
- another gear selected
The gear cannot be engaged (after 3 attempts):
- faulty gear prohibited
- another gear selected
The gear cannot be disengaged:
- maintaining of the gear engaged whilst driving
- gear engaged: 3, 4 or 5. When the vehicle stops, the

gearbox ECU declutches (impossible to drive)
- gear engaged: R, 1, 2: driving is authorised

33
Section 2
FAULT NOTED EFFECT
ECU supply fault Flashing of "auto" and "snow" LEDs: yes
No gearbox operation
Clutch actuator motor signal fault - Flashing of "auto" and "snow" LEDs: yes
incorrect current
Maintaining of the gear engaged whilst driving
When the vehicle stops, the gearbox ECU engages gear

"N"
Driving impossible
ECU fault - output stage Flashing of "auto" and "snow" LEDs: yes
ECU fault - RAM The actuators are no longer controlled (gearbox

actuator, clutch actuator)
ECU fault - ROM Driving impossible
Position sensor supply fault - Flashing of "auto" and "snow" LEDs: yes
clutch actuator / gear changing
Driving with reduced comfort
actuator
Position sensor supply fault -

selection actuator
Position signal fault - selection Flashing of "auto" and "snow" LEDs: yes
actuator
Driving with reduced comfort
Position signal fault - gear changing The ECU tries to control the actuator in an open loop
actuator
The gear change is possible in an open loop:
- the gearbox ECU automatically selects the

"sequential" program
- limited gear changes
- loss of comfort
- no double nor triple gear changes
The gear change is impossible in an open loop:
- when the vehicle stops, the gearbox ECU engages

gear "N"
- driving impossible

34
Section 2
FAULT NOTED EFFECT

Position signal fault - clutch Flashing of "auto" and "snow" LEDs: yes
actuator The ECU tries to control the actuator in an open loop
The clutch can be opened and closed in an open loop:
- the gearbox ECU automatically selects the
"sequential" program
- limited gear changes
- loss of comfort
The clutch cannot be opened and closed in an open
loop:
- when the vehicle stops, the gearbox ECU engages
gear "N"
- driving impossible
Gear selector signal fault Gear selector deactivated
Flashing of the "auto" and "snow" LEDs: yes, only after
having selected the "auto" program
Gears "N" and "R" can be selected using the paddles
The gearbox ECU selects the "automatic" program if the
paddles and gear selector cannot be used
Paddle signal fault Paddles deactivated
Flashing of the "auto" and "snow" LEDs: yes, only after
having selected the "auto" program
The gearbox ECU selects the "automatic" program if the
paddles and gear selector cannot be used
Input speed signal fault Flashing of "auto" and "snow" LEDs: no
The gearbox ECU takes the wheel speed into account
Loss of comfort and increase in gear changing time
ECU fault - powerlatch Flashing of "auto" and "snow" LEDs: no
The ECU remains active and the battery may be
discharged
Disconnecting the battery during the powerlatch
causes a fault to be stored
Gear changing actuator motor Flashing of "auto" and "snow" LEDs: yes
signal fault Maintaining of the gear engaged whilst driving
Selection actuator motor signal When the vehicle stops, the gearbox ECU opens the
fault clutch
Driving impossible
Clutch fault Flashing of "auto" and "snow" LEDs: no
Reduction in the number of gear changes

35
Section 2

36
Section 3
MECHANICAL COMPONENTS
I- DESCRIPTION
1 - Gearbox input speed sensor

2 - Clutch housing
3 - Gearbox actuator
4 - 5th gear housing
5 - Gearbox ECU
6 - Clutch actuator
7 - Clutch fork
8 - Push rod
9 - Clutch actuator support
The metal support (9) supports:
• the gearbox ECU (5),
• the clutch actuator (6).
The support (9) is mounted on the gearbox by means of 4 bolts.
The clutch actuator is mounted on the support (9) by means of 3 bolts.
The gearbox ECU is mounted on the support (9) by means of rubber

spacers.

37
Section 3
II - CLUTCH ACTUATOR (1665)
A - ROLE
The clutch actuator is used to:
• open and close the clutch,
• adjust the clutch for wear.
B - DESCRIPTION
6 - Clutch actuator
10 - Push rod
11 - Linkage
12 - Clutch wear adjustment system
13 - Force compensating spring
14 - Toothed segment
15 - Electric motor with integrated position sensors (2 sensors)

38
Section 3
The clutch actuator with an aluminium housing incorporates:
• an electric motor with integrated position sensors (15) (2 sensors),
• a force transfer and return system,
• a force compensating spring,
• a clutch wear adjustment system,
• a clutch thrust bearing tensioning system.
Clutch type: pushed.
The clutch actuator is used to obtain two stable mechanical positions:
• clutch open: clutch in declutched position,
• clutch closed: clutch in clutched position.
The clutch is controlled with the following phases:
• opening of the clutch: declutching phase,
• closing of the clutch: clutching phase.

39
Section 3
C - OPERATION
Simplified diagram of the clutch actuator.

A - Clutch closed
B - Clutch open
C - Clutch wear adjustment
a - Clutch thrust bearing
7 - Clutch fork
10 - Push rod
11 - Linkage
12 - Clutch wear adjustment system
12a - Sleeve
12b - Locking system
12c - Piston
12d - Clutch thrust bearing tensioning system
13 - Force compensating spring
14 - Toothed segment
15 - Electric motor
15a - Position sensor (Hall effect sensor)
15b - Phonic wheel (magnetic field)
15c - Electric motor collector
The electric motor (15) is controlled electrically by the gearbox ECU.
The electric motor is not energised by the gearbox ECU to maintain the
clutch in the open or closed position.
To control the clutch, the gearbox ECU uses the two position sensors
(15a).
The sensors are located opposite a magnetic phonic wheel linked to the
rotor of the electric motor.

40
Section 3
The sensors supply the gearbox ECU with a square signal when the
electric motor rotates.

41
Section 3
1 - Opening of the clutch (B)
Sequence of operations:
• the gearbox ECU supplies the electric motor (15),
• the electric motor (15) drives the toothed segment (14),
• the wear adjustment system is locked (the locking system (12b)

immobilises parts (12a) and (12c)),
• the rotation of the toothed segment causes the linkage (11) to

move,
• the clutch fork (7) causes the clutch thrust bearing to move which
then opens the clutch,
• at the end of travel of the toothed wheel (14), the force

compensation spring (13) assists the electric motor (15).
When the clutch is open (declutched position), the electric motor is

no longer energised.
The declutching travel is identical regardless of clutch wear

(approximately 20 mm).
2 - Closing of the clutch (A)
The gearbox ECU inverts the supply to the electric motor (15).
The toothed segment (14) returns to its initial position.
When the clutch is in the clutched position, the fork no longer exerts
a force on the wear adjustment system (12).
The wear adjustment system (12b) is released and becomes

compressible.

42
Section 3
3 - Clutch wear adjustment (C)

The wear adjustment system is automatically locked when the
toothed wheel (14) is driven by the electric motor (15).
Clutch closed (clutched): the wear adjustment system is unlocked.
The spring (12d) can exert a force on the clutch thrust bearing.
Clutch plate wear is compensated for by the compression of the
wear adjustment system (12).
When the clutch plate is worn:
• the clutch mechanism pushes the fork and push rod back,
• the clutch fork moves towards the push rod (10),
• the spring (12d) is compressed. The wear adjustment system is
shortened.
The length of the wear adjustment system is:
• at a maximum when the clutch is new,
• at a minimum when the clutch is worn.
Note: the wear adjustment system cannot be repaired.
4 - Feature of the electric motor control
The clutch actuator is controlled by the gearbox ECU via a control
stage incorporated into the ECU.
The control stage of the gearbox ECU is used to:
• control the electric motor in both directions of rotation
• vary the rotational speed of the electric motor
• measure the electric current absorbed by the electric motor.
Two position sensors incorporated into the electric motor allow the
gearbox ECU to:
• measure the movement of the clutch fork
• measure the movement speed of the clutch fork.
To operate, the gearbox ECU must memorise:
• the total travel of the clutch fork
• the clutch biting point.
These values are memorised after a programming procedure which is
activated by a diagnostic tool.
Refer to the procedure: repairing the MA type sequential manual
gearbox.
The clutch opening and closing speeds are determined by the
gearbox ECU as a function of driver demands.

43
Section 3
III - GEARBOX ACTUATOR (1664, 1663)
A - ROLE
The gearbox actuator engages each gear using translation and rotational
movements of the gear changing lever.
To perform the required movements, the gearbox actuator incorporates:
• two electric motors with integrated position sensors,
• a ramp system, used to select and engage a gear simultaneously (to
save time).
B - DESCRIPTION
16 - Gear changing lever
17 - Electric motor, gear changing actuator
18 - Electric motor, gear selection actuator
The gearbox actuator consists of:
• the gear changing actuator,
• the gear selection actuator.
Part number in wiring diagrams:
• gear changing actuator: 1663,
• gear selection actuator: 1664.
For each actuator, the gearbox ECU uses the two position sensors (15a).
The sensors are of the same type as those on the clutch actuator
electric motor.
The sensors are located opposite a magnetic phonic wheel linked to the
rotor of the electric motor.
The sensors supply the gearbox ECU with a square wave signal when the
electric motor rotates.

44
Section 3
C - GEAR CHANGING LEVER MOVEMENTS
D - Side view
E - Top view
16 - Gear lever on gearbox
b - Gear lever movement axis (selection)
d - Gear lever angle of rotation (changing)
To engage a gear, the gearbox actuator causes:
• the gear lever to rise or fall along the selection axis (c) (gear selection
phase),
• the gear lever to rotate about its axis through an angle (e) (gear
changing phase).
The three gear lever positions on the selection axis are approximately 5 -
7 mm apart.
The three gear lever positions are approximately 17° - 20° apart (d).
The ramp system incorporated into the actuator is used to select and
engage a gear.
The electric motors never operate at the same time.
Each actuator is controlled by the gearbox ECU via a control stage
incorporated into the ECU.
• control the electric motor in both directions of rotation,
• vary the rotational speed of the electric motor,

45
Section 3
gearbox ECU to:
• measure the movement of the gear changing lever (on the gearbox),
• measure the movement speed of the gear changing lever (on the
gearbox).
1 - Gearbox actuator control
f g h j k
F l
G
j k
f g h l
F - Gear changing example: 1st gear to 2nd gear

G - Gear changing example: 3rd gear to 2nd gear
The gear change occurs in several phases.
Depending on the gear changing phase, the gearbox ECU controls
the gearbox actuator in several ways:
• position control,
• force control,
• current control.
GEARBOX ACTUATOR CONTROL

PHASE ACTION
TYPE
f Pre-load Position control
g Gear disengaged (unmeshing) Force and speed control
h Synchronisation Force and speed control
j Gear engaged (meshing) Force and speed control
k Gear engaged (*) Force and speed control
l Retraction (**) Current control
(*) phase k is used to confirm meshing.

(**) phase l is used to prevent wear of the dog teeth.
Once phase j has started, the gearbox ECU continues through to
phase l before starting another gear change.

46
Section 3
2 - Gear lever position for each gear engaged
J - Front view, as seen when facing the bulkhead

K - Top view
N - Neutral
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
R - Reverse

47
Section 4
SYSTEM COMPONENTS
I- DIAGRAM
27
2101
Key:
• single arrow - wire connection,
• triple arrow - multiplex connection,
• dotted arrow - power supply.

48
Section 4
PART NUMBER IN WIRING DIAGRAMS DESCRIPTION
CA00 Ignition switch
C001 Diagnostic socket
BSI1 Built-in Systems Interface
0004 Control panel display
1005 Starter prohibition relay
1320 Injection ECU
1660 Gearbox ECU
1661 Gear selector
1662 Gearbox input speed sensor
1663 Gear changing actuator
1664 Gear selection actuator
1664, 1663 Gearbox actuator
1665 Clutch actuator
1666 Paddles at the steering wheel
1670 Program selector
2100 Stop switch (closing stop switch)
2101 Stop switch (opening stop switch)
4700 Door switch
7800 ABS or ESP ECU

49
Section 4
CONNECTION SIGNAL SIGNAL NATURE

N°
1 Gear engaged information VAN
Selected program information ("automatic" or "sequential")
Gearbox fault information
2 Main brake information (opening stop switch) Wire
3 Driver's door open information Wire
4 Gear engaged information CAN
Selected program information ("automatic" or "sequential")
Gearbox fault information
5 Main brake switch fault information CAN
6 Gearbox ECU wake-up Wire
7 Request to regulate the engine speed information CAN
Engine speed setting information
Torque reduction request information
Maximum torque allowed by gearbox information
Prohibition from changing compressor state information
Gear engaged information
8 Engine torque information CAN
Engine speed information
Coolant temperature information
Throttle position information
Idle speed setting information
Torque requested by driver information
Actual engine torque information
Resistant torque information
9 Gear change in progress information CAN
10 Vehicle speed information CAN
Authorisation to change gear information
ABS or ESP regulation in progress information
ABS or ESP ECU fault information
11 Starting prohibition relay control Wire
12 Supply: +CRANK Wire
13 Supply: + IGNITION ON Wire
14 Supply: + 12V Wire
15 Selection actuator position Wire
16 Selection actuator control Wire
17 Gear changing actuator position Wire
18 Gear changing actuator control Wire
19 Clutch actuator position Wire
20 Clutch actuator control Wire
21 Gear selector position Wire
22 Gearbox input speed - gearbox input speed sensor Wire
23 Sequential/automatic mode Wire
24 Paddle position Wire
25 Braking information (closing stop switch) Wire
26 Read faults Wire (diagnostic line)

50
Section 4
Read parameters
Actuator tests
Downloading
27 Redundant brake information Wire

51
Section 4
II - GEARBOX ECU
A - ROLE
The ECU performs the following functions:
• it changes gear by controlling the actuators electrically (clutch

actuator, gearbox actuator),
• it manages and performs the auto-adaptivity of gear changes and

programs ("automatic" program),
• it stores the characteristics of the actuators (programming),
• it controls the control panel display,
• it communicates with the other ECUs (BSI, ABS, etc) via the CAN,
• it performs auto-diagnostics and implements emergency modes

(priority is given to vehicle mobility).
The gearbox ECU acquires information from the following components:
• program selector,
• gear selector
• paddles at the steering wheel,
• stop switch,
• clutch actuator position sensors,
• selection actuator position sensors,
• gear changing actuator position sensors,
• gearbox input speed sensor.
The gearbox ECU exchanges information with the following ECUs:
• engine ECU,
• ABS or ESP ECU (*),
• BSI.
(*) depending on version.

52
Section 4
Advantage of the gearbox ECU and engine ECU communicating with

each other:
• gears can be changed without releasing the accelerator pedal

("automatic" and "sequential" program),
• torque can be reduced during a gear change,
• engine speed can be controlled during a gear change,
• mechanical protection of the gearbox and engine is increased,
• driving pleasure is increased,
• operating safety is increased.
Using this information, the ECU controls:
• the starter prohibition relay,
• the clutch actuator,
• the gearbox actuator.
The actuators are controlled by the gearbox ECU via control stages
The control stages of the gearbox ECU are used to:
• control each electric motor in both directions of rotation,
• vary the rotational speed of the electric motors,
• measure the electric current absorbed by each electric motor.
The software of the injection ECU is updated by downloading (ECU with a

flash EPROM).
B - ELECTRICAL FEATU RES
The gearbox ECU has 2 electrical connectors:
• blue 32-way connector,
• green 48-way connector.

53
Section 4
1 - Allocation of connector channels: (green 48-way)
CHANNEL N° DESCRIPTION
A1-B1 (not used)
C1 Input: signal A1, gear selector
D1-H1 (not used)
J1 Dialogue line: CAN H
K1 (not used)
L1 Permanent +12 Volts
M1 Permanent +12 Volts
A2 Ignition on information
B2 (not used)
C2 Input: signal A2, gear selector
D2-H2 (not used)
J2 Dialogue line: CAN L
K2-L2 (not used)
M2 Permanent +12 Volts
A3 (not used)
B3 Output: starter prohibition relay
C3-D3 (not used)
E3 Input: driver's door open information
F3 Input: stop switch
G3 (not used)
H3 Input: signal A4, gear selector
J3 Input: LH paddle
K3 Input: RH paddle
L3 Power earth
M3 (not used)
A4 Input: program selector information
B4-C4 (not used)
D4 Input: +CRANK
E4 Input: signal A3, gear selector
F4-G4 (not used)
H4 K diagnostic line
J4 Earth: gear selector
K4 Earth: paddle
L4 Power earth
M4 Power earth

54
Section 4
2 - Allocation of connector channels: (blue 32-way)
CHANNEL N° DESCRIPTION
A1 Input: gearbox input speed sensor (+)
B1 Input: gearbox input speed sensor (-)
C1-E1 (not used)
F1 Earth: clutch actuator - gear changing actuator sensor
G1 Output: gear changing actuator motor (-)
H1 Output: gear changing actuator motor (+)
A2-E2 (not used)
F2 Earth: selection actuator sensor
G2 (not used)
H2 Output: clutch motor control (+)
A3 (not used)
B3 Input: gear changing motor position sensor
C3 Input: clutch motor position sensor
D3 (not used)
E3 +5 volts supply - clutch actuator - gear changing actuator
position sensor
F3-G3 (not used)
H3 Output: clutch motor control (-)
A4 Input: clutch actuator position sensor
B4 Input: gear changing actuator position sensor
C4 Input: gear selection actuator position sensor
D4 Input: gear selection actuator position sensor
E4 +5 volts supply - selection actuator position sensor
F4 (not used)
G4 Output: selection actuator motor control (-)
H4 Output: selection actuator motor control (+)
3 - Location
1660 - Gearbox ECU

55
Section 4
The gearbox ECU is located on the clutch actuator support.

56
Section 4
III - COMPONENTS LINKED TO THE ECU
A - BATTERY (BB00)
The battery charge level is important for the operation of the MA type
sequential manual gearbox.
The ECU stores a fault in the following cases:
• battery voltage greater than 16 volts,

• battery voltage below 8 volts.
B - STARTING PROHIBITION RELAY (1005)
1 - Role
The starting prohibition relay allows the gearbox ECU to prevent the
starter motor from operating.
The gearbox ECU controls the starting prohibition relay if the

following conditions are satisfied:
• when the ignition key is in the +CRANK position,

• the position of the actuators allows the engine to start,
• the driver is pressing the brake pedal.
2 - Electrical features
Control: gearbox ECU.
Type: "all or nothing" control by being earthed.
Connector: black 9-way.
Allocation of connector channels:
• channel 2: output: starter motor supply,

• channel 4: +12 volts supply (engine relay unit),
• channel 5: +CRANK supply,
• channel 9: earth (gearbox ECU).
Note: Channels 1, 3, 6, 7 and 8 are not used.
3 - Location

57
Section 4
The starting prohibition relay is located at the front of the front LH

wheel arch (behind the LH headlamp).

58
Section 4
C - GEARBOX INPUT SPEED SENSOR (1662)
1 - Role
This sensor supplies the gearbox ECU with the gearbox input speed.
This information allows the gearbox ECU to:
• determine whether the clutch is slipping (difference between

engine speed and input speed),
• determine the clutch biting point,
• control the clutch actuator,
• control the end of synchronisation of a gear.
2 - Description
The sensor consists of a magnetic core and a winding.
The information supplied to the gearbox ECU is an alternating

voltage which varies as a function of gearbox input shaft rotational
speed.
• channel 1: + signal,
• channel 2: - signal.
Resistance between channels 1 and 2: 800 ohms (approximately).
Features of the signals emitted: alternating voltage with variable

frequency.
Warning: The sensor wire is not shielded. Always ensure that

harnesses are correctly routed.
4 - Location
The gearbox input speed sensor is located opposite the teeth of the
second gear pinion on the primary shaft.

59
Section 4
D - CLUTCH ACTUATOR (1665)
1 - Function
The clutch actuator is used to:
• open and close the clutch,
• adjust the clutch for wear.
The clutch actuator is controlled by the gearbox ECU via a control

stage incorporated into the ECU.
gearbox ECU to:
• measure the movement of the clutch fork,
2 - Description
Refer to the section: operating principle: mechanical components,

MA type sequentially controlled manual gearbox.
• channel 1: sensor earth,
• channel 2: sensor signal 1,
• channel 3: electric motor +,
• channel 5: sensor +5 volt supply,
• channel 6: electric motor.

60
Section 4
a - Electric motor
Features:
• direct current motor,
• control: gearbox ECU,
• variable voltage control (OCR),
• resistance between channels 3 and 6 (electric motor): 2 ohms

(approximately).
Note: OCR: Open Cycle Ratio.
b - Position sensor
The clutch actuator electric motor contains two contact-free

position sensors ("Hall" effect).
Two position sensors incorporated into the electric motor allow

the gearbox ECU to:
• measure the movement of the clutch fork,
Features:
• supply: gearbox ECU (5 volts),
• the sensors supply the gearbox ECU with a square signal.
Features of the signals transmitted:
• the voltage levels are between 0 and 5 volts,
• the sensors supply 60 pulses per rotation of the electric

motor,
• the frequency of the signals varies with the rotational speed of

the electric motor.

61
Section 4
E - GEARBOX ACTUATOR (1663, 1664)
1 - Role
The gearbox actuator engages each gear using translation and

rotational movements of the gear changing lever.
The gear changing and selection actuators are incorporated into the
gearbox actuator (not removable).
Part number in wiring diagrams:
• gear changing actuator: 1663,
• gear selection actuator: 1664.
To perform the required movements, the gearbox actuator

incorporates:
• two electric motors with integrated position sensors,
• a ramp system, used to select and engage a gear simultaneously

(to save time).
Each actuator is controlled by the gearbox ECU via a control stage

gearbox ECU to:
• measure the movement of the gear changing lever (on the

gearbox),
• measure the movement speed of the gear changing lever (on the
gearbox).

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Section 4
2 - Description
Refer to the section: operating principle: mechanical components,

MA type sequentially controlled manual gearbox.
1 - gear changing motor electrical connector

2 - gear selection motor electrical connector
Allocation of connector channels: gear changing motor (1):

• channel 2: sensor +5 volts,
• channel 6: electric motor -.
Allocation of connector channels: gear selection motor (2):

• channel 5: sensor +5 volts,
• channel 6: electric motor -.

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Section 4
a - Electric motor
Features:
• direct current motor,
• control: gearbox ECU,
• variable voltage control (OCR).
Note: OCR: Open Cycle Ratio.
Resistance of electric motors: 2 ohms (approximately).
b - Position sensor
Two position sensors incorporated into the electric motor allow

the gearbox ECU to:
• measure the movement of the gear changing lever (on the

gearbox),
• measure the movement speed of the gear changing lever.
Features:
• supply: gearbox ECU (5 volts),
• the sensors supply the gearbox ECU with a square signal.
Features of the signals transmitted:
• the voltage levels are between 0 and 5 volts,
• the sensors supply 60 pulses per rotation of the electric

motor,
• the frequency of the signals varies with the rotational speed of

the electric motor.

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Section 4
F - GEAR SELECTOR (1661)
1 - Role
The gearbox ECU is informed of the position of the gear selector by
4 wire signals.
1661 - Gear selector

1660 - Gearbox ECU
Supply: gearbox ECU.
• channel 1: signal A1
• channel 2: not connected
• channel 3: electronic earth (different to body earth)
The ECU checks the validity of the information received by verifying
the consistency of the signals (diagnostics).
Each position of the gear selector modifies the status of one or
several signals.
GEAR VOLTAGE VOLTAGE VOLTAGE VOLTAGE

SELECTOR BETWEEN BETWEEN BETWEEN BETWEEN
POSITION CHANNEL 3 & CHANNEL 3 & CHANNEL 3 & CHANNEL 3 &
CHANNEL 1 CHANNEL 4 CHANNEL 6 CHANNEL 5
Max voltage / Max voltage / Max voltage / Max voltage /
min voltage min voltage min voltage min voltage
Central 4.1 V/2.4 V 4.1 V/2.4 V 4.1 V/2.4 V 4.1 V/2.4 V
+ 2.4 V/0.6 V 2.4 V/0.6 V 4.1 V/2.4 V 4.1 V/2.4 V
- 2.4 V/0.6 V 4.1 V/2.4 V 2.4 V/0.6 V 4.1 V/2.4 V
N 2.4 V/0.6 V 4.1 V/2.4 V 4.1 V/2.4 V 2.4 V/0.6 V

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Section 4
R 4.1 V/2.4 V 4.1 V/2.4 V 2.4 V/0.6 V 2.4 V/0.6 V

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Section 4
G - PADDLES AT THE STEERING WHEEL (1666)
1 - Role
The gearbox ECU is informed of the position of the paddles by 2 wire
signals.
2 - Description
3 - Electrical connector, paddles at the steering wheel.
Supply: gearbox ECU.
• channel 1: signal, LH paddle (-),
• channel 2: signal, RH paddle (+),
• channel 4: electronic earth (different to body earth).
The ECU checks the validity of the information received by verifying
the consistency of the signals (diagnostics).
Each action on the paddles modifies the status of one or several
signals.
VOLTAGE VOLTAGE
BETWEEN BETWEEN
EARTH AND EARTH AND
GEAR SELECTOR POSITION
CHANNEL 2 CHANNEL 1
Max voltage / Max voltage /
min voltage min voltage
+ paddle released - paddle released 4.1 V/2.4 V 4.1 V/2.4 V
+ paddle released - paddle activated 2.4 V/0.6 V 4.1 V/2.4 V
+ paddle activated - paddle released 4.1 V/2.4 V 2.4 V/0.6 V
+ paddle activated - paddle activated 2.4 V/0.6 V 2.4 V/0.6 V
4 - Location

67
Section 4
The paddles are incorporated into the switch module at the steering
wheel.

68
Section 4
H - PROGRAM SELECTOR (1670)

1 - Role
This information informs the gearbox ECU of the driver's selection.
Note: When the ignition is switched on, the gearbox switches by default
to "automatic" mode.
The program selector is a one-touch button
2 - Description
1670 - Program selector

a - Auto LED
• channel 1: +12 volt supply: program selector lighting (BSI),
• channel 2: +12 volt supply: "auto" indicator (BSI),
• channel 3: (not used),
• channel 4: signal (to gearbox ECU),
• channel 5: earth,
• channel 6: (not used).
The program is selected by earth information (0 V) on the
corresponding control line (one-touch).
The control line is only earthed whilst the corresponding button is
pressed.
The BSI controls:
• the illumination of the "auto" LED at "a" when the program selector
(1670) is pressed,
• the lighting of the program selector (headlamps).
4 - Location
The program selector is located on the gear selector trim panel.

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Section 4
I - DRIVER'S DOOR OPEN INFORMATION

This information is supplied by the BSI.
This information is used to:
• wake up the gearbox ECU when the doors are unlocked or when the
driver's door is opened,
• engage neutral "N" when the driver's door is opened (safety).
J - IGNITION SWITCH (CA00)

The ignition switch ECU transmits the following information to the
gearbox ECU:
• ignition switch in accessories position (+IGN ON),
• ignition switch in cranking position (+CRANK).
The ignition on information is used to wake up the gearbox ECU.
The +CRANK information is used to inform the gearbox ECU that the
engine is starting.
K - STOP SWITCH (2100)
1 - Role
The stop switch is used to:
• operate the engine starting safety function: the engine is only
authorised to start if the brake pedal is pressed,
• force a change down when the brake pedal is pressed,
• reduce the drive of the transmission when stationary (idle speed).
The closing stop switch is connected directly to the gearbox ECU
(wire connector).
The BSI acquires the information from the second stop switch and
sends the information to the gearbox ECU on the CAN.
The gearbox ECU compares the two items of information.
Closing stop switch. Colour: red.
The stop switch is an "all or nothing" switch (ECU input earthed).
3 - Location
The stop switch is located on the pedal set.

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Section 5
DIAGNOSTICS - REPAIRS
I- RECOMMENDATIONS
A - PRE-DELIVERY INSPECTION
Warning: All fault codes must be erased from all of the vehicle's ECUs
during pre-delivery inspection.
B - RECOMMENDATIONS/PRECAUTIONS
IMPORTANT: For all faults listed on the sequential gearbox, always

check the memories of the injection ECU.
C - SAFETY PRECAUTIONS
IMPORTANT: Follow the safety precautions relating to the sequential

gearbox before and during all repair operations (refer to
the RECOMMENDATIONS - PRECAUTIONS section).
IMPORTANT: The clutch fork and gear changing lever movement areas
must always be clear whilst the actuators are being
controlled (no tools or people).
IMPORTANT: After sales checks with the engine running must always
be performed with gear "N" engaged and the handbrake
applied (except where stated otherwise in the repair
procedures).
IMPORTANT: Disconnect the negative terminal of the battery before

working on the actuators.
Warning: The gearbox ECU initialises the clutch and gearbox actuators
(movement of the clutch fork and gear changing lever) every
time the driver's door is opened and the ignition is switched
on.
Warning: When the ignition is on or off, moving the gear selector causes
the clutch fork and gear changing lever on the gearbox to
move.

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Section 5
D - MAINTENANCE
The MA type Sequential Manual Gearbox is a zero maintenance unit.
E - TOWING
Operations to be performed:
• engage gear "N" using the gear selector,
• check "N" appears on the control panel display,
• if it is impossible to move the vehicle: refer to the Towing Section in

the mechanical repair brochure.
F - RECONNECTING THE BATTERY
When the ignition is switched on, when the brake pedal is pressed (*), the
gearbox ECU:
• initialises the position of the clutch fork (movements of the clutch

fork),
• initialises the position of the gear lever (movements of the gear lever).
(*) the brake pedal must be pressed to start the engine.
Warning: It is impossible to start the engine during the actuator

position initialisation operations.
Note: The time required to initialise the actuator positions varies between
10 seconds and 1 minute.
Note: If the programming operation has not been performed, the

initialisation operations are performed every time an attempt is made
to start the engine.

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Section 5
G - DESCRIPTION OF THE PROGRAMMING OPERATIONS
To operate, the gearbox ECU must store the characteristics of the

gearbox (actuators, clutch, gearbox).
These values are memorised after a programming procedure which is

activated by a diagnostic tool.
The programming operations allow the gearbox ECU to:
• recognise the characteristics of the system components,
• initialise the system.
Programming operations required:
• programming of the clutch actuator,
• programming of the gearbox actuator.
Note: The programming procedures are performed using a diagnostic tool.
Warning: If the programming operation has not been performed, the

initialisation operations are performed every time an attempt
is made to start the engine.
H - DESCRIPTION OF THE CLUTCH ACTUATOR PROGRAMMING

OPERATIONS
The clutch actuator programming operations allow the gearbox ECU to

store:
• the total travel of the clutch fork (end positions),
• the clutch biting point.

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Section 5
1 - Programming the end positions
Programming the clutch actuator end positions enables the gearbox

ECU to store the total travel of the clutch fork.
Conditions required for the programming operations:
• engine off,
• vehicle stationary on level ground,
• ignition on.
Upon an order from the diagnostic tool, the ECU:
• opens the clutch (declutching),

• closes the clutch (clutching).
Programming duration: approximately 2 seconds.

Note: A fault will be recorded in the gearbox ECU memory if a
programming operations fails.
2 - Programming the biting point
The clutch biting point corresponds to the clutch fork position which
causes the gearbox primary shaft to be driven.
• engine running at idle speed,

• gear "N" engaged,
• handbrake on.
Upon an order from the diagnostic tool, the gearbox ECU:
• causes a series of partial clutch opening (declutching) and closing

(clutching) operations,
• detects the rotational speed of the primary shaft from the
gearbox input speed sensor (start of rotation of the primary
shaft).
Programming duration: approximately 10 seconds.

Note: After replacing the clutch, the clutch actuator must be
reprogrammed following the road test.

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Section 5
I - DESCRIPTION OF THE GEARBOX ACTUATOR PROGRAMMING

OPERATION
Programming the gearbox actuator allows the gearbox to store:
• the characteristics of the internal gearbox control (gearbox grid)
• the position of the gearbox actuator on the gearbox
• the internal characteristics of the gearbox actuator
Warning: Always program the clutch actuator before programming the
gearbox actuator.
Note: It is impossible to control the gearbox actuator using the diagnostic
tool if the programming operations have not been performed
(commands to operate the actuators using the diagnostic tool are
ignored).
• engine off,
• handbrake off,
• battery voltage greater than or equal to 12.5 volts.
Warning: The programming operation will fail if the battery voltage falls
below 10.5 V during the programming procedure.
Note: The battery voltage must remain stable during the programming
operation. Connect a battery charger in parallel to the vehicle's
battery if necessary.
The gearbox ECU causes a series of juddering movements to ascertain:
• the position of each gear,
• the shape of the gearbox grid.
Programming duration: 8 minutes maximum.
The following operations must be performed to store the programming
values:
• switch off the ignition,
• wait for the control panel to switch off,
• wait for 4 minutes before switching the ignit ion back on again.
Note: A fault will be recorded in the gearbox ECU memory if a programming
operations fails.
Note: If the programming operation fails, the gearbox actuator
programming operation can be repeated, regardless of its position.

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Section 5
II - DIAGNOSTIC TOOL FUNCTIONS
A - PRESENTATION ORDER
• Identification.
• Read faults.
• Erase faults.
• Parameter measurements.
• Actuator test.
• Remove gearbox actuator.
• Set gearbox actuator to assembly position.
• Programming.
• Counters.
• Exchange sheet.
• Downloading.
B - IDENTIFICATION
• Supplier.
• PSA RPO no.
• Software version.
• Diag update version.
C - STORED FAULTS
1 - Remote faults
List of faults displayed by the diagnostic tool:
• information sent by the engine ECU fault,

• information sent by the ABS ECU fault,
• CAN communications fault (absence/interference),
• information sent by the BSI ECU fault.

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Section 5
2 - Local faults
List of faults displayed by the diagnostic tool:

• ECU supply fault,
• position sensor supply fault - clutch actuator / gear changing
actuator,
• brake signal fault (switch/CAN),
• position sensor supply fault - selection actuator,
• position signal fault - clutch actuator,
• position signal fault - gear changing actuator,
• position signal fault - selection actuator,
• input speed signal fault,
• ECU fault - powerlatch,
• ECU fault - output stage,
• ECU fault - RAM,
• ECU fault - ROM,
• gear selector signal fault,
• gear selector counter information fault,
• paddle signal fault,
• paddles counter information fault,
• clutch actuator motor signal fault,
• clutch actuator motor signal fault - incorrect current,
• gear changing actuator motor signal fault,
• selection actuator motor signal fault,
• clutch fault,
• clutch actuator counter information fault,
• gearbox fault,
• gearbox counter information,
• starting prohibition relay signal fault
• incomplete programming fault,
• EOBD codes transmission fault,
• clutch worn fault.

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Section 5
3 - Contexts associated to the faults

The gearbox ECU stores the following information when a fault is
recorded.
INFORMATION COMMENTS
Battery voltage Battery voltage (Volt)
Clutch status Possible clutch status:

slipping/clutched/declutched/synchronised
Gear engaged Possible gear: neutral/1st gear/2nd gear/3rd gear/4th

gear/5th gear/reverse
Gearbox input speed Rotational speed of the gearbox primary shaft (rpm)
Vehicle speed Information from the ABS ECU (kph)
Ignition key position Possible position of the ignition key: + ignition on /

cranking
Gear change in progress Gear change in progress: yes/no
Engine speed Engine speed information, supplied by the engine ECU

(rpm)
Coolant temperature Engine coolant temperature
D - PARAMETER MEASUREMENTS
1 - The diagnostic tool can display the following parameters
PARAMETER PARAMETER STATUS COMMENTS
Battery voltage Measurement of battery

voltage in Volts
Clutch status Slipping/clutched/declutche Gives the current state of

d/synchronised the clutch
Gear selector position Central Current gear selector

position/reverse/neutral/plu position
s/minus/invalid
Kickdown Yes/no Variable giving the full load

state
Gear engaged Neutral/1st gear/2nd Current gear engaged

gear/3rd gear/4th gear/5th
gear/reverse
RH steering wheel paddle (+) Yes/no Indicates whether a higher

gear has been requested
(with the paddles)
LH steering wheel paddle (-) Yes/no Indicates whether a lower

gear has been requested

78
Section 5
(with the paddles)

79
Section 5
PARAMETER PARAMETER STATUS COMMENTS

Gearbox input speed 0 - 7000 rpm Rotational speed of the
gearbox input shaft (rpm)
Vehicle speed 0 - 200 kph (0 - 125 mph) Information from the ABS ECU
Engine speed 0 - 7000 rpm Information from the engine
ECU
Actual engine torque 10 - 40.8 m.daN Information from the engine
ECU
Calculated engine torque 10 - 40.8 m.daN MA type sequential manual
gearbox ECU
Accelerator pedal position 0% - 100% Accelerator pedal position
Coolant temperature - 48°C to 142.5°C Engine coolant temperature
Door open information Yes/no Information giving the door
status (open or closed)
Program status Automatic mode Status of the program selector
Sequential mode (automatic mode/manual
mode)
Brake information (main) Yes/no Information about whether the
brake pedal is pressed (main
information)
Brake information Yes/no Information about whether the
(secondary) brake pedal is pressed
(secondary information)

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Section 5
2 - Other parameters stored by the gearbox ECU

The gearbox ECU stores the number of times the following
components are manoeuvred:
a - Gearbox counters
PARAMETERS PARAMETER DEFINITION
Gear 1 counter Number of gear 1 changes (for information)
Reverse counter Number of reverse gear changes (for information)
b - Gear selector and paddle counter
PARAMETERS PARAMETER DEFINITION
Paddle counter Number of manoeuvres performed with the paddles (for

information)
Gear selector counter Number of manoeuvres performed with the gear
selector (for information)
E - ACTUATOR TEST
The diagnostic tools are used to test:
• the gearbox actuator,
• the clutch actuator.

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Section 5
1 - Recommendations / precautions
Warning: High forces must be created at high speeds to control
the gearbox.
IMPORTANT: Never test the actuators when they are removed

(the actuator will be damaged) (with the exception of
the operation to set the actuator to the assembly
position).
During these operations:

• never move the clutch fork by hand or using a tool,
• never move the gear lever by hand or using a tool,
• always leave the clutch fork or gear lever movement area clear.
2 - Clutch actuator
Clutch actuator tests:
• opening of the clutch (declutching),
• closing of the clutch (clutching),
• movement of the clutch fork in the intermediate position (between
the clutched and declutched position).
The actuator remains in the requested position only whilst the
diagnostic tool is communicating with the gearbox ECU.
Warning: The actuator must be fitted on the gearbox for this test.
When the diagnostic tool and the gearbox ECU finish
communicating, the actuator returns to the position it
was in prior to the test.
The following tests can be performed with the diagnostic tool:
• engaging of each gear upon the operator's request,
• engaging of gear "N".
The actuator remains in the requested position only whilst the
diagnostic tool is communicating with the gearbox ECU.
Warning: The actuator must be fitted on the gearbox for this test.
When the diagnostic tool and the gearbox ECU finish
communicating, the actuator returns to the position it
was in prior to the test (with the exception of gear "N").

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Section 5
4 - Removing the gearbox actuator
The gearbox ECU causes the gear lever to move to the removal
position (see corresponding operation).
This action must be used when the actuator is on the gearbox.
Note: When the diagnostic tool and the gearbox ECU finish
communicating, the actuator remains in the removal position.
Warning: Check the position of the gear lever before removing (see
corresponding operation).
Note: If the actuator is removed without having been set to the removal
position beforehand, set it to the assembly position using the "Set
gearbox actuator to the assembly position" function.
5 - Setting the gearbox actuator to the assembly position
Warning: This function should only be used when the actuator is

removed.
This function is used to set the actuator to the assembly position.
To perform the operation to set the actuator to the assembly

position:
• the actuator must be removed,
• the actuator must be turned upside down, with the mounting

brackets upwards.
See corresponding operation.

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Section 5
F - PERFORMING THE PROGRAMMING OPERATIONS USING THE

DIAGNOSTIC TOOL
A: programming of the clutch actuator

B: programming of the gearbox actuator.
C: programming sequences
The diagnostic tool can perform three programming sequences:
• programming of the gearbox actuator,
• programming sequences.
Faults will be recorded in the gearbox ECU memory if a

programming operations fails.
Note: The programming procedures can be repeated if they fail.

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Section 5
1 - Programming the clutch actuator

This programming sequence performs the following programming
operations automatically:
• programming of the end positions of the clutch fork,
• programming of the clutch biting point.
This programming operation has to be performed:
• every time the clutch actuator is removed/refitted,
• every time a new clutch is fitted, following the road test,
• every time the gearbox ECU is replaced.
• engine off,
• battery voltage greater than 12 volts,
• connect the diagnostic tool to the vehicle's diagnostic socket,
• switch on the ignition.
Using the menus on the diagnostic tool, select:
• "DIAGNOSTIC",
• select the vehicle,
• enter the vehicle's RPO no.,
• after the global test, select "MA TYPE SEQUENTIAL MANUAL
GEARBOX".
• "PROGRAMMING",
• "PROGRAM CLUTCH ACTUATOR".
Warning: The instructions given by the diagnostic tool must be
followed carefully.
The diagnostic tool programs:
- the end positions,
- the clutch biting point (engine running).
If a programming operation fails, note down the information provided
by the diagnostic tool (report screen).
The following operations must be performed to store the
programming values:

85
Section 5
• wait for 4 minutes before switching the ignition back on again.

86
Section 5
2 - Programming the gearbox actuator

This programming operation has to be performed:
• every time the gearbox actuator is removed/refitted,
• every time the gearbox is replaced,
• every time the gearbox ECU is replaced.
• engine off,
• ignition on,
• clutch open (declutched position),
• handbrake off,
• battery voltage greater than or equal to 12.5 volts.
• "DIAGNOSTIC",
GEARBOX".
• "PROGRAMMING",
• "PROGRAM GEARBOX ACTUATOR".
followed carefully.
The diagnostic tool programs:
• the opening of the clutch (declutching),
programming values:
If the programming operation fails:
• note down the information provided by the diagnostic tool (report
screen),
• a fault will be recorded in the gearbox ECU,
• deal with the fault,
• repeat the procedure.

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Section 5
3 - Programming sequence (clutch and gearbox actuators)

This programming sequence automatically performs the clutch
actuator programming operation followed by the gearbox actuator
programming operation.
• engine off,
• battery voltage greater than 12.5 volts,
• connect the diagnostic tool to the vehicle's diagnostic socket,
• switch on the ignition.
• "DIAGNOSTIC",
GEARBOX".
• "PROGRAMMING",
• "PROGRAMMING SEQUENCE (GEARBOX AND CLUTCH
ACTUATORS)".
followed carefully.
The diagnostic tool automatically programs in turn:
• the end positions of the clutch actuator,
• the biting point,
• the opening of the clutch (declutching),
programming values:
If a programming operation fails, note down the information provided
by the diagnostic tool (report screen).
The gearbox ECU records a fault if the programming operation fails.

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Section 5
4 - Initialising the gearbox actuator
This service is used to start the gearbox actuator initialisation

process. This command can therefore be used to release the
gearbox actuator when it is in a configuration not recognised by the
system.
G - COUNTERS
The main menu is used to read and write the counters.
The counters should be reset when replacing parts
Example: When changing the controls at the steering wheel (COM

2002), the paddle counters should be reset.
1 - Clutch counter
Energy counter - level 1
Energy counter - total
The counters are used to ascertain the energy dissipated into the
clutch.
2 - Gearbox counters
Gear 1 counter
Gear 2 counter
Gear 3 counter
Gear 4 counter
Gear 5 counter
Reverse counter
The counters are used to ascertain the number of times that the
gears have been engaged.

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Section 5
3 - Gear selector and steering wheel paddle counters
Gear selector counters.
Paddle counters.
These counters are used to ascertain the number of commands

performed by the paddles or the gear selector.
4 - Exchange sheet
Information sheet relating to the system containing the following

details:
Information sheet
VIN:_ _ _ _ _ _ _ _ _ _ _
Mileage: _ _ _ _ _ _ _ miles
Fault codes in the Sensodrive gearbox:
P _ _ _ _, P _ _ _ _, U _ _ _ _, P _ _ _ _, etc.
Clutch counter total: _ _ _ _ _ _
Gear counters:
1st: _ _ _ _
2nd: _ _ _ _
3rd: _ _ _ _
4th: _ _ _ _
5th: _ _ _ _
Reverse: _ _ _ _
To print the sheet, press *

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Section 5
III - REMOVING / REFITTING PARTS
REMOVAL/REFITTING - ITEM OPERATIONS TO BE COMMENTS

PERFORMED
Removal - refitting; gearbox ECU Switch off the ignition -
Wait for the control panel to
switch off
Disconnect the negative
terminal from the battery
Removal; clutch actuator Remove the clutch actuator
Refitting; clutch actuator After refitting the actuator,
perform the "PROGRAM
CLUTCH ACTUATOR" operation
Removal; gearbox actuator Before removing the actuator,
perform the "REMOVE
GEARBOX ACTUATOR"
operation
Refitting; gearbox actuator After refitting the actuator, Programming duration:
perform the "PROGRAM 12 minutes maximum.
GEARBOX ACTUATOR"
operation
Refitting; gearbox actuator Before refitting the actuator Time taken to set to
incorrectly fitted (actuator removed) removal position:
=> perform "SET ACTUATOR
TO ASSEMBLY POSITION"
operation
After refitting actuator Programming duration:
=> perform 12 minutes maximum.
"PROGRAM GEARBOX
ACTUATOR".
Removal; gearbox This operation requires the
gearbox actuator, the clutch
actuator and the gearbox ECU
to be removed beforehand
Remove:
- the clutch actuator
- the gearbox actuator

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Section 5
REMOVAL/REFITTING - ITEM OPERATIONS TO BE COMMENTS

PERFORMED
Refitting; gearbox The actuators must be refitted The clutch actuator must
on the gearbox be programmed before
the gearbox actuator
=> refit the clutch actuator
=> refit the gearbox actuator Programming duration:
13 minutes maximum.
=> perform the
"PROGRAMMING SEQUENCE"
(automatic sequencing of the
"PROGRAM CLUTCH
ACTUATOR" and "PROGRAM
GEARBOX ACTUATOR"
operations)
Removal - refitting; paddles at the None
steering wheel
Removal - refitting; gear selector None
The following procedures require the use of the diagnostic tools:
• reading and writing of the operating count ers,
• removal of the gearbox actuator,
• setting of the gearbox actuator to the assembly position.

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Section 5
IV - EXCHANGING PARTS
A - PRELIMINARY OR ADDITIONAL OPERATIONS TO BE PERFORMED

WHEN EXCHANGING PARTS
COMPONENT OPERATIONS TO BE COMMENTS

REPLACED PERFORMED
Input speed sensor --- ---
Clutch After refitting the gearbox and Programming duration: 13

actuators minutes maximum.
=> perform the "PROGRAMMING

SEQUENCE" (automatic
sequencing of the "PROGRAM
CLUTCH ACTUATOR" and
"PROGRAM GEARBOX
ACTUATOR" operations)
=> reset the clutch counters using

the diagnostic tool
=> perform a road test
=> perform the "PROGRAM

CLUTCH ACTUATOR" operations
Clutch actuator After refitting actuator Programming duration: 1

minute maximum
=> reset the operating counter

Gearbox actuator After refitting actuator Programming duration: 12

minutes maximum.
GEARBOX ACTUATOR" operations.
=> reset the operating counters

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Section 5
REMOVAL/REFITTING -
OPERATIONS TO BE PERFORMED COMMENTS
ITEM
Gearbox ECU => read the counters in the old ECU

(and note them down)
=> fit the new ECU
=> write the previously noted values

into the counters
=> perform the "PROGRAMMING

SEQUENCE" (automatic sequencing of
the "PROGRAM CLUTCH ACTUATOR"
and "PROGRAM GEARBOX ACTUATOR"
operations)
Gearbox Refer to the gearbox removal/refitting

operations
=> reset the operating counters
Gear selector => reset the gear selector operating

counters
Paddles at the steering => reset the paddle operating counters

wheel
The following procedures require the use of the diagnostic tools:

• reading and writing of the operating counters,
• removal of the gearbox actuator,
• setting of the gearbox actuator to the assembly position.
B - CLUTCH - CLUTCH MECHANISM

The sequential gearbox is designed to use the original clutch.
Fitting a clutch from another make or with different characteristics may
cause the system to malfunction.
Warning: Always fit a clutch with the same specifications as the original
one.
Warning: Never fit a clutch mechanism which has been dropped.

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Section 5
V- DOWNLOADING THE ECU PROGRAM
The ECU software is updated by downloading (ECU with FLASH EPROM).
This operation is performed using a diagnostic tool.
IMPORTANT: The injection ECU must be updated every time the sequential
manual gearbox ECU is updated (and vice versa).
Operations to be performed:
• before downloading, read the operating counters and the clutch counters,
• note down the values of the counters,
• perform the downloading operation.
At the end of this procedure:
• write the operating counters,
• program the clutch actuator (*),
• program the gearbox actuator (*),
• perform a road test.
(*) Note: These programming operations can be replaced by the

"PROGRAMMING SEQUENCE" operation (automatic sequencing of the
"PROGRAM CLUTCH ACTUATOR" and "PROGRAM GEARBOX
ACTUATOR" operations).

95
Section 5
VI - EXCHANGING A SENSODRIVE ECU
Warning: Never swap two SensoDrive gearbox ECUs between two vehicles.
Where necessary, perform all programming operations for each
ECU (programming of the clutch actuator and programming of
the gearbox actuator) for each vehicle.
Note: failure to follow this instruction will lead to incorrect gearbox

operation and may even damage the actuators.
VII - CONFIGURING A NEW ECU
No configuration operations are required.
VIII - ROAD TEST
Perform a road test to confirm the repair is correct and if necessary, adjust
the parameters of the gearbox ECU.
During the road test:
• use all gears,
• test all programs ("automatic" and "sequential").
IX - WARRANTY RETURN PROCEDURE
Before being returned to the assessment centre, the following components

must be placed in a plastic bag and packaged in their original packaging:
• clutch actuator,
• gearbox actuator,
• gearbox ECU.
All incidents relating to the Sensodrive sequential gearbox must be included

immediately within an incident report (CRI) within Techfile.

96
Section 6
WIRING DIAGRAM
I- LAYOUT DIAGRAM
Sensodrive sequential gearbox with air conditioning and ESP.

97
Section 6
II - WIRING DIAGRAM
With air conditioning and ESP.

98
Section 6
III - LOCATION DIAGRAM

99
Section 6
IV - PARTS LIST
B00 : Battery
BSI1 : Built-in Systems Interface
BMF1 : Maxi-fuse box
CA00 : Ignition switch
CV00 : Switch module at the steering wheel (COM2002)
C001 : Diagnostic socket
PSF1 : Engine relay unit
0004 : Control panel
MC10 :
MC11 :
MC30 :
Earth
MC32 :
MC35 :
M000 :
1005 : Starting safety relay
1660 : Sensodrive gearbox ECU
1661 : Gear selector
1662 : Sequential gearbox input speed sensor
1663 : Gear changing actuator
1664 : Gear selection actuator
1665 : Clutch actuator
1670 : Program selector
10 - - : Starting circuit
12 - - : Injection
21 - - : Braking circuit
78 - - : E.S.P

100
Section 6
84 - - : Multifunction screen

Sensodrive Gearbox

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TECHNICAL TRAINING

DOCUMENT REF N°: 2.4.404 November

QUALITY DEVELOPMENT DIVISION

SENSODRIVE ELECTRONICALLY CONTROLLED

The aim of this brochure is to present the electronically controlled manual

The following subjects will be dealt with in this document:

- Presentation of the gearbox,

- Presentation and operation of the actuators,

- Presentation of the various modes:

- Presentation of the auto-diagnostic function,

- Maintenance, repair and programming of the sequential manual

ELECTRONICALLY CONTROLLED "SENSODRIVE" GEARBOX

SECTION 1: PRESENTATION ........................................................ 1

SECTION 2: OPERATING PRINCIPLE .......................................... 21

II - OPERATION IN "SEQUENTIAL" MODE ..............................................................28

III - GEAR CHANGE................................................................................................28

IV - DISPLAY OF FAULTS - OPERATION IN DOWNGRA DED MODES ........................32

SECTION 3: MECHANICAL COMPONENTS .................................. 36

II - CLUTCH ACTUATOR (1665) ............................................................................37

III - GEARBOX ACTUATOR (1664, 1663)...............................................................43

SECTION 4: SYSTEM COMPONENTS .......................................... 47

II - GEARBOX ECU ...............................................................................................51

III - COMPONENTS LINKED TO THE ECU................................................................56

ELECTRONICALLY CONTROLLED "SENSODRIVE" GEARBOX

SECTION 5: DIAGNOSTICS - REPAIRS........................................ 70

II - DIAGNOSTIC TOOL FUNCTIONS ......................................................................75

III - REMOVING / REFITTING PARTS .......................................................................90

IV - EXCHANGING PARTS ......................................................................................92

V- DOWNLOADING THE ECU PROGRAM ..............................................................94

VI - EXCHANGING A SENSODRIVE ECU .................................................................95

VII - CONFIGURING A NEW ECU .............................................................................95

VIII - ROAD TEST.....................................................................................................95

IX - WARRANTY RETURN PROCEDURE...................................................................95

SECTION 6: WIRING DIAGRAM ................................................... 96

III - LOCATION DIAGRAM ......................................................................................98

ELECTRONICALLY CONTROLLED "SENSODRIVE" GEARBOX

ELECTRONICALLY CONTROLLED "SENSODRIVE" GEARBOX

The MA type sequential gearbox is a manual gearbox in which the following

• gear selection and changing,

The driver changes gear effortlessly - there is no clutch pedal.

The MA type sequential gearbox has 2 operating programs:

• a "sequential" program: the driver decides when to change gear,

Features of the "sequential" program:

ELECTRONICALLY CONTROLLED "SENSODRIVE" GEARBOX

Features of the "automatic" program:

• snow mode is selected automatically as soon as wheel slip is detected

• if the accelerator pedal is pressed to the floor, the ECU automatically

When changing gear:

• the accelerator pedal does not have to be released,

• the clutch pedal,

• the manual gear lever (no cable, no linkage).

The MA type Sequential Manual Gearbox is a zero maintenance unit.

The gearbox is lubricated for life.

ELECTRONICALLY CONTROLLED "SENSODRIVE" GEARBOX

The following components are used to control the gearbox:

• a specific MA type gearbox,

• a specific ECU with "Flash" memory (software can be updated by

• a clutch actuator (electric),

• a gearbox actuator (electric),