Page 298 of 2492

FUEL TANK
Filler neck
19
ROLE OF THE VALVES
A) Over-filling valve
When the fuel filler cap is removed, the valve
is closed, locking a volume of air in the brea-
ther chamber. This prevents fuel from ente-
ring this chamber.
When the filler cap is replaced, the valve
opens and the fuel tank breather is again
connected to the canister.
B) Excess - insufficient pressure safety valve
If the fuel vapour recirculation circuit is
blocked, this valve prevents the fuel tank from
excess pressure (the fuel tank would other-
wise inflate) or insufficient pressure (as fuel is
used, the fuel tank would be crushed).
C) Restriction valve
This valve prevents leaded fuel from entering
the fuel tank.
D) Valve preventing leaks if the vehicle is turned
over
If the vehicle is turned over, this valve pre-
vents the fuel tank from emptying, either
through the pipe to the canister or the brea-
ther pipe (Diesel).
The fuel tank has a sealed filler cap and a ventila-
tion circuit.
The filler neck for unleaded fuel has:
- an opening which is narrower and incompati-
ble with a leaded fuel pump nozzle (lead would
pollute the depollution system: the oxygen
sensor and catalytic converter),
- a valve blocking the filling opening (C) (to pre-
vent fuel vapour evaporating or fuel coming
out of the tank).
Refitting the fuel filler cap releases the over-filling
valve (A), allowing the tank to breathe through
the breather.
99212R
19-24
Page 359 of 2492

Oil pressure
Before starting:
- if the gearbox has been drained, fill it with 3.5
litres of oil,
- if you are simply checking the level, you must
add 0.5 litre of the recommended type of oil.
1-Vehicle on a 4 post lift, transmission at am-
bient temperature.
2-Start the engine with the selector lever in the
Park position.
3-Connect the
XR25 test kit and enter:
D14then
#0 4
4-Raise the vehicle and allow the engine to run
until it reaches a temperature of 60 °C.
5-When the desired temperature has been rea-
ched, open the top-up plug; allow the excess
oil to overflow (must be more than 0.1 litre)
for approximately 20 seconds. Replace the
plug
6-If the volume of oil which flowed out is less
than 0.1 litre, the level is not correct. Repeat
the operation.
In this case, add 1 litre of the recommended oil
and allow the transmission to cool down between
successive operations.
AUTOMATIC TRANSMISSION
Filling - Levels
23
FILLING - TOPPING UP
Filling is performed though tube (D).
Use a funnel fitted with a 15/100 filter so as to
prevent any impurities entering.
The level
MUST be checked in accordance with the
following method:
94845R1
The transmission is fitted with an oil pressure
take-off. Connect the B.Vi. 1215 to check the
automatic transmission pressure sensor only.
The oil pressure cannot be altered.
Its value is determined by the electronic compu-
ter.
94845-1R
23-8
Page 367 of 2492

- the heat shield from the exhaust manifold,
- the catalytic converter (disconnect the oxygen
sensor) and secure the exhaust pipe to the
body,
- the horn,
- the acoustic tie-rod between the shock
absorber turrets,
- the air filter,
- the earth strap,
- the absolute pressure sensor,
- the expansion bottle and secure it to the
engine.
Disconnect:
- the accelerator cable as well as the kickdown
switch connector,
- the brake servo pipe,
- the relay plate and the electrical connectors
from the engine connection unit,
AUTOMATIC TRANSMISSION
Automatic transmission (Removal - Refitting)
23
K7M
ENGINE
- the connector from the automatic transmission
computer,
- the canister pipe.
Remove the battery mounting bracket.
- the heating pipes on the thermostat.
Unclip the radiator and move it away by securing
it to the engine.
98756R
Disconnect:
- the injection supply wire located in the scuttle
panel as well as the starter motor supply,
- the fuel inlet and outlet hoses using Mot. 1311-
06, unclip them from their support,
99461R
23-16
Page 374 of 2492
AUTOMATIC TRANSMISSION
Wiring
23
The new generation of A4.2 automatic transmission is fitted with monoblock wiring which means that many
of the intermediate connectors are no longer required. As a result, the method for repairing sensors or
switches is different.
PRG23.5
1 - 55 track connector on the automatic transmission computer
2 - Oil pressure sensor
3 - Electro-hydraulic interface (sealed connector)
4 - Inter engine unit connection
5 - Injection/diagnostic connector
6 - Pressure sensor connector
7 - Speed sensor
8 - Multifunction switch
23-23
Page 375 of 2492

AUTOMATIC TRANSMISSION
Wiring
23
REPAIRING COMPONENTS
Most of the components comprising the mono-
block wiring are not directly interchangeable.
Only the pressure sensor can be replaced without
having to cut the cable.
REPAIRING THE MULTIFUNCTION SWITCH
Initially, this is checked with the 55 track connec-
tor using the bornier Sus. 1228 and the table be-
low.
If this checking procedure highlights a fault, sec-
tion the cable 15 cm from the switch and check
between the section and the 55 track connector.
See the wiring diagram and table below. If one of the insulations or one of the continuities
is not assured, replace the multifunction switch
and refer to note 8074 for the repair procedure.
Refer to notes 8074 and 8075 for repairing the
speed sensor and using the locally made lifting
plate.
99613S4
NOTE: remember to distribute the connection
joints.
LEVER POSITION ASSURED CONTINUITIES ASSURED INSULATIONS
P/N Terminal 44 / EarthTerminals 51 and 52 / Earth
Terminal 27 / Terminal 46
R Terminal 27 / Terminal 46Terminals 44, 51 and 52 /
Earth
D NoneTerminals 44, 51 and 52 /
Earth
Terminal 27 / Terminal 46
3 Terminal 51 / EarthTerminals 44 and 52 / Earth
Terminal 27 / Terminal 46
2 Terminals 51 and 52 / EarthTerminal 44 / Earth
Terminal 27 / Terminal 46
1 Terminal 52 / EarthTerminals 44 and 51 / Earth
Terminal 27 / Terminal 46
99585S
23-24
Page 376 of 2492
AUTOMATIC TRANSMISSION
Wiring
23
Removing the wiring assembly is specific to the
AD4 A4.2.
REMOVAL
Put the vehicle on a two post lift.
Disconnect the battery.
Remove the front left hand wheel.
From the wheel arch:
Remove:
- the earth wire from the multifunction sensor,
- the multifunction sensor mounting bolt (A).
On the vehicle:
- position the lifting plate (tool made locally as
described on the next page).
99586R1
99182S
99613S
98750R1
Remove the engine torque traction link on the
gearbox side.
Remove the speed sensor (mounting bolt (B)).
Remove gear selector control ball joint (C).
Remove all the wiring assembly, taking note of its
position and mountings so that is refitted
correctly.
Disconnect the 52 track connector and the
connector in the inter engine unit. Fit the engine support tool with the support
bracket on the left hand side.
23-25
Page 377 of 2492
AUTOMATIC TRANSMISSION
Wiring
23
There are two possible solutions for manufactu-
ring this plate.
1)By modifying the existing plate on the E7J en-
gine (air filter support plate mounted onto the
cylinder head).
2)By having it manufactured locally
Parts list: - 1 plate of thickness 4 or
5 mm in semi-hard steel,
-
2 HEX M8 × 20 bolts (collar
bolts).
99613S1
99585R
Disconnect the connectors from the pressure sen-
sor and the diagnostic/injection socket.
Disconnect the sealed connector switch.
Remove the wiring.
99613S2
REFITTING
Replace the wiring without securing it.
Refit:
- the speed sensor,
- the multifunction sensor.
Refit the mounting on the gearbox side.
Remove the engine support tool.
Reconnect all the components.
Secure the wiring using its clips.
LIFTING PLATE
23-26
Page 378 of 2492
AUTOMATIC TRANSMISSION
Wiring diagram
23
104 - Ignition switch
119 - Automatic transmission computer
120 - Injection computer
129 - ECO/PERF selector switch
160 - Stop switch
163 - Starter motor
225 - Diagnostic socket
247 - Double headlight relay
250 - Speed sensor
303 - Automatic transmission selector lighting
319 - Air conditioning control panel
535 - ECO/PERF selector switch warning light
569 - 4 speed automatic transmission kickdown
597 - Engine fuse box
645 - Passenger compartment connection unit
754 - Electrical/hydraulic interface
779 - Automatic transmission multifunction switch
780 - Automatic transmission turbine or vehicle speed sensor
781 - Line pressure sensor
R22 - Engine/automatic transmission
R34 - Engine/dashboard
MH - Engine electric earth
MJ - Front right pillar electric earth
23-27