Manual Caja Citroen Al4

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TECHNICAL
CITROËN
w TRAINING
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PRESENTATION OF THE AL4

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AUTOMATIC TRANSMISSION
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CITROËN UK LTD
221 BATH ROAD
SLOUGH SL1 4BA
_________________
DEALER PERSONNEL
DEVELOPMENT AND
TRAINING
_________________
 CITROËN UK LTD. Reproduction whether partial or in full without
written permission from Citroën UK Ltd is forbidden
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A
DOCUMENT SUMMARY
PRESENTATION OF THE
AL4 AUTOMATIC TRANSMISSION
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The aim of this document is to give a brief description of the design and operation
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of the electronically managed AL4 automatic transmission which offers precise,

adaptive control as well as excellent gear changing quality.
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The following subjects are dealt with in this document:

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- Presentation of the transmission and various pieces of information,
- The selector control,
- Lubrication,
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- The converter,
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- The mechanism,
- The ECU,
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- Auto-diagnostics,
- The electrical circuit,

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- Unit maintenance.
© AUTOMOBILES CITROËN Toute reproduction ou traduction même partielle sans l'autorisation écrite d'AUTOMOBILES CITROËN est interdite et constitue une contrefaçon
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CONTENTS
CHAPTER 1 : PRESENTATION - GENERAL ............................. PAGE 1
I- INTRODUCTION.............................................................................. PAGE 1
II - PRESENTATION ............................................................................. PAGE 2
III - DESCRIPTION OF THE AL4 AUTOMATIC TRANSMISSION .......... PAGE 3
IV - IDENTIFYING THE COMPONENTS OF THE AUTOMATIC

TRANSMISSION.............................................................................. PAGE 5
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V- SPECIFICATIONS - SERVICING ..................................................... PAGE 7
VI - LAYOUT OF THE AL4 AUTOMATIC TRANSMISSION .................... PAGE 8

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VII - MISCELLANEOUS ADVICE............................................................. PAGE 9
CHAPTER 2 : SELECTOR CONTROL........................................

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PAGE 11
I- SELECTOR LEVER ......................................................................... PAGE 11

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II - PROGRAM SELECTOR................................................................... PAGE 13
CHAPTER 3 : CHECKING THE OIL LEVEL ............................... PAGE 15
CHAPTER 4 : THE TORQUE CONVERTER............................... PAGE 17

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I- DESCRIPTION................................................................................. PAGE 17
II - CONVERTER LOCK-UP .................................................................. PAGE 18

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CHAPTER 5 : THE EPICYCLIC GEAR TRAIN ........................... PAGE 21
I- DESCRIPTION................................................................................. PAGE 21
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II - OPERATING PRINCIPLE ................................................................ PAGE 23
CHAPTER 6 : ECU....................................................................... PAGE 27

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I- ECU FUNCTIONS............................................................................ PAGE 27
II - OPERATING SUMMARY ................................................................. PAGE 31
III - ECU CONNECTIONS ...................................................................... PAGE 33
CHAPTER 7 : AUTO-DIAGNOSTIC ............................................ PAGE 35
I- FAULT WARNINGS ......................................................................... PAGE 35
II - MEMORISED FAULTS / DOWNGRADED MODES.......................... PAGE 36
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CONTENTS
CHAPTER 8 : WIRING DIAGRAM - XANTIA.............................. PAGE 37
PETROL ENGINE/WITHOUT CRUISE CONTROL
I- LAYOUT........................................................................................... PAGE 37
PETROL ENGINE/WITH CRUISE CONTROL
I- LAYOUT........................................................................................... PAGE 38
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DIESEL ENGINE/WITHOUT CRUISE CONTROL
I- LAYOUT........................................................................................... PAGE 39
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DIESEL ENGINE/WITH CRUISE CONTROL
I- LAYOUT........................................................................................... PAGE 40
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II - PARTS LIST..................................................................................... PAGE 41

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CHAPTER 9 : AFTER-SALES OPERATIONS ............................ PAGE 43
I- DOWNLOADING.............................................................................. PAGE 43
II - CONFIGURATION ........................................................................... PAGE 43

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III - PEDAL PROGRAMMING ................................................................. PAGE 44
IV - INITIALISING THE "OLD OIL" COUNTER........................................ PAGE 44

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V- UPDATING THE "OLD OIL" COUNTER ........................................... PAGE 44
VI - TEST AFTER REPAIR WORK ......................................................... PAGE 44
VII - CHANGING PARTS, OPERATIONS TO BE PERFORMED ............. PAGE 45

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VIII - AUTHORISED OPERATIONS DURING THE WARRANTY PERIOD

PAGE ........................................................................................... 46
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IX - AUTOMATIC TRANSMISSION REPAIR BY THE CITROËN

AUTOMATIC TRANSMISSION CENTRE, SOUTH WEST PARIS .... PAGE 47
X- SPECIAL TOOLING ......................................................................... PAGE 50
XI - DIAGNOSTIC TOOLING .............................................................. 51
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1
Chapter 1
PRESENTATION - GENERAL
I- INTRODUCTION
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AL4001D
• Electronically operated transverse automatic transmission.

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• Four forward gears and one reverse gear.

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• "Fuzzy logic" auto-adaptive ECU which controls the converter, gear changes
and specific programs.
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• The maximum torque capacity is 210 mN.
• Sealed transmission with reduced maintenance.
• Transmission oil cooled by heat exchanger.
• Current application: CITROËN XANTIA PHASE II vehicles with XU Petrol and

Diesel engines.
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2
Chapter 1
II - PRESENTATION
Transmission layout
• Hydraulic torque converter with lock-up device.
• Primary shaft.
• Two "Simpson 2" type epicyclic gear trains.
• Multiplate clutches.
• Multidisc and band brakes.
• Step down gear in central position.
• Differential with sealed outputs.
Control
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This is performed by:

• the hydraulic unit,
• the ECU,
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• a cable control.
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Features
• Lock-up of 2nd, 3rd and 4th gears.
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• Electronic control of all regulation and gear changing functions.

• Three programs offered to driver:
Auto adaptive - Sport - Snow
• Gears and programs displayed on dashboard.
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• Cannot change up a gear in the no load position.

• User interface performed by a "stepped" selector grid with Shift-Lock safety
function and program push buttons.
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• "1st" imposed position selected using push button.

• Auto adaptive "Flash EEPROM" ECU.
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• Downgraded operation in the event of a fault.

• Closed loop operation.
• On board diagnostics.
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• Selector lever not in position P reminder buzzer.
Important: The automatic transmission ECU is linked to the engine

management ECU so as to obtain:
- good driving pleasure,
- efficient mechanical protection for transmission and engine,
- increased operating safety,
- compliance with antipollution standards.
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3
Chapter 1
III - DESCRIPTION OF THE AL4 AUTOMATIC TRANSMISSION

A - CROSS SECTION
22 21 10 11 12 13
14
1
15
3
16
2
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19 18
8
20
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6
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AL4002P
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4
Chapter 1
B - PARTS LIST
1 - Converter
2 - Input shaft
3 - Fitted oil pump
4 - Secondary pinion of step down gear
5 - Park wheel
6 - Secondary shaft
7 - Drive pinion
8 - Ring
9 - Differential unit
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10 - Cover
11 - Adjustable plate
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12 - Hydraulic distributor (DH)

13 - Manual valve
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14 - Auxiliary hydraulic distributor (DHA)

15 - Clutch E1 (Reverse and 1st)
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16 - Clutch E2 (2nd, 3rd, 4th)

17 - Hub
18- Brake F1 (4th)
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19 - Brake F2 (Reverse)
20 - Brake F3 (1st and 2nd)
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21 - Epicyclic gear train

22 - Primary pinion of step down gear
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5
Chapter 1
IV - IDENTIFYING THE COMPONENTS OF THE AUTOMATIC TRANSMISSION
A - AUTOMATIC TRANSMISSION
The automatic transmission identification is engraved on the rear housing.

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20TP15 A
0000877 B AL4003D
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A - Component reference
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B - Serial number
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6
Chapter 1
B - ECU
SIEMENS M
A 1209263000
S108518006 A D
E
9630386980
0/ 02150 / 270234214 / 97253 N
BVA
F
R
A
N
C 7700103423
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AL4004D
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C G
SIEMENS M
A 1209263000
S108518006 A D
9630386980
D 0/ 02150 / 270234214 / 97253
E
I
N
H
F
R
A
BVA
E N
C
E
7700103423 I
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C - Siemens reference
D - Siemens serial number
E - Siemens number bar code
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F - Serial number
G - Software version
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H - Hardware version
I - Customer number bar code
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7
Chapter 1
V- SPECIFICATIONS - SERVICING
A - FREQUENCY - CAPACITIES
XANTIA
Engine XUD9 BTF/XU10J4R/XU7JP4
Transmission capacity Approximately 6 litres
Draining capacity Approximately 3 litres
Exclusive oil CITROËN 97.36.22
Draining interval Lubricated for life
Top-up interval 60 000 km
Transmission lubrication Pressurised
Final drive lubrication Pressurised
Weight ≈ 70 kg with oil and ECU
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Torque capacity 210 mN from 2000 to 4500 rpm
B - GEARS
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XANTIA
Engine XUD9BTF XU10J4R XU7JP4
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Transmission type 20TP04 20TP05 20TP06

Tyres 205/60R15 - 1.920 m 185/65R15-1.895m
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- circumference
Gear ratios Rd Rdem Vveh Rd Rdem Vveh
1st 0.367 2.72 11.55 0.367 2.72 10.20
2nd 0.667 1.5 21.00 0.667 1.5 18.53
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3rd 1 1 31.48 1 1 27.79

4th 1.407 0.71 44.30 1.407 0.71 39.10
Reverse -0.407 -2.45 12.81 -0.407 -2.45 11.31
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Step down gear 52x67 52x67

Cylindrical torque 25x71 23x73
Tachometric torque 24x20 24x20
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Speeds in km/h are given for 1000 rpm.

Rd = driveshaft ratio / Rdem = demultiplication ratio
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Vveh = Vehicle speed.

Internal gear change safety thresholds:
LEVER POSITION SAFETY THRESHOLD

3 113 km/h 155 km/h
2 73 km/h 103 km/h
2 + press on "1" button of
program selector 35 km/h 48 km/h
R 15 km/h 19 km/h
R + foot on brake 25 km/h 34 km/h
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8
Chapter 1
VI - LAYOUT OF THE AL4 AUTOMATIC TRANSMISSION
Rev
Selector
elec-tor
Prog.
ever
Buzzer
Control panel
Final drive +
ShiftLock
differential
counter
Display
1st
S
MIL illumin
request
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gear train
Epicyclic
Dist.
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Engine management computer

throttle α
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Dist.
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P/N - D - Gear change

Exchanger oil
flow setting
Electro-hydraulic distributor
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AT ECU
Dist.
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transmission
Automatic
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P
u
Oil.
Braking info.
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Electro-hydraulics
potentio-meter
"Kick-down" info
Electr-onics
Mechanics
Throttle
(engine)
AL4005P
Cm = Engine torque Cr = Torque at road wheels

ωm = Engine speed ωe = Gear train input speed
ωs = Gear train output speed ωr = Road wheel speed
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9
Chapter 1
VII - MISCELLANEOUS ADVICE
A - TOWING
The transmission is lubricated when the engine is running since this drives
the transmission oil pump. Thus, when towing, the drive wheels must be
raised off the ground. However, the vehicle may be towed with the drive
wheels on the ground under exceptional circumstances and provided that the
following conditions are complied with:
• the selector lever must be in position N,

• do not add any oil,
• do not exceed 50 km/h over a distance of 50 km.
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B - DRIVING
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Never drive with the ignition switched off.

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Never push the vehicle to try and start it (not possible with automatic
transmission).
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Note: The automatic transmission is only lubricated when the engine is

running.
C - OPERATIONS ON ELECTRICAL COMPONENTS

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Never disconnect:
• the battery whilst the engine is running,

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• the ECU whilst the ignition is switched on.
Before reconnecting a connector, check:

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• the condition of the various contacts (bent, rusted...),

• that the mechanical locking device is present and check its condition.
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During electrical inspections:
• the battery must be correctly charged,

• never use a power source greater than 16 V,
• never use a tell-tale light.
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10
Chapter 1
D - OPERATIONS ON MECHANICAL COMPONENTS
Never place the transmission on the ground unprotected.
The converter retaining pin must be inserted when the transmission is

removed.
The centring pin must be used to couple the transmission to the engine.
Remove the centring pin just before coupling the transmission to the engine.
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11
Chapter 2
SELECTOR CONTROL
I- SELECTOR LEVER
The selector lever, through the selector shaft (on the transmission), operates the
multifunction switch and the manual valve on the hydraulic distributor.
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AL4007D
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A - Upper part
B - Lower part
C - Sleeve stop
D - Control lever
E - Locking plunger for the Shift-Lock function
Ri - Initial setting
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12
Chapter 2
The selector lever, located on the central console, has six positions laid out on an
offset or "stepped" grid.
The lever has a mechanical safety device which is unlocked by exerting a radial
action on the lever.
Note: The ignition must be switched on and the brake pedal pressed to unlock
the selector lever from position P. This is the Shift-Lock function.
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G
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AL4028C
C - Sleeve stop
Ri - Initial setting
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G - Control return with ball joint

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13
Chapter 2
II - PROGRAM SELECTOR
This is located on the central console next to the selector lever and has 3 push
buttons.
The driver can therefore inform the ECU of his selection:
• desired program,
• 1st imposed → this is obtained by pressing the "1" button of the selector with
the selector lever in position 2 on the grid.
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P
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R
N N
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3
2
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AL4006C
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Gears change automatically depending on vehicle speed and engine load in

accordance with various gear changing laws. The gear changing laws are chosen
by the ECU as a function of one of the three programs available to the driver.
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The driver can select a program by pressing one of the "S" or "*" program selector
buttons.
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14
Chapter 2
The following three programs are available:
• autoadaptive or "normal" (no buttons pressed):
this is the basic program; the ECU adjusts the operation of the automatic
transmission to the style of driving, the road and engine load; it promotes fuel
economy,
• "Sport" (S button pressed):
this program promotes sporty driving to the detriment of consumption. Gears

are still changed automatically,
• "Snow" (* button pressed):

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this program is suited to driving on low adherence ground. In drive, this means
that either first gear or first and second gears are no longer available and gears
are changed down less frequently using a specific set of changing laws.
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Furthermore, in the imposed positions 1, 2, 3, the "Snow" set of laws are used
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which take into account the restrictions relating to the chosen imposed position.
Note: Every time the ignition is switched off then on again, the ECU
automatically switches to the "normal program" configuration.
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Chapter 3
CHECKING THE OIL LEVEL
Check the oil level every 60 000 kms.

Prerequisites:
• vehicle on horizontal ground,
• check that the transmission is not in downgraded mode,
• remove the filler plug 1 and systematically add 0.5 litres of oil to the transmission,
• press the brake and change through all the gears,
•
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selector lever in position P,

• engine running at idle speed,
• oil temperature 60 °C +- 82 .
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1
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3
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AL4008C AL4009C
4
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1 - Filler plug
2 - Transmission housing
3 - Level plug
4 - Drain plug
2
3
AL4010C
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16
Chapter 3
• Remove the level plug (3).
• If oil streams out then starts to drip → close the level plug and tighten to 2.4 mdaN.
• If oil drips out or does not flow

at all → close the level plug (3),
stop the engine,
add 0.5 litres of oil to the transmission,
repeat the level checking procedure,
the oil level is correct if oil streams out and then starts to drip,
close the level plug (3) and tighten to 2.4 mdaN
close the filler plug (1) and tighten to 2.4 mdaN
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Too much oil may have the following consequences:

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• abnormal heating of the oil,
• oil leaks.
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Too little oil may damage the transmission.

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Note: An oil check is not included in the PDI nor the first service.
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Chapter 4
THE TORQUE CONVERTER
The AL4 automatic transmission is fitted with a standard torque converter which has an
added lock-up device.
I- DESCRIPTION
1- Lock-up piston
2- Double sided friction plate
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3- Vibration damper
4- Impeller
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5- Turbine
6- Stator
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7- Free wheel
8- Oil pump drive
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9 8 9- Automatic transmission input shaft

drive
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Starting
ring
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AL4011P
7
1
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2 Drive
end plate
AL4027C
Converter
3
5 4
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18
Chapter 4
The torque converter consists of:
• an impeller (4), linked to the engine,
• a turbine (5), linked to the transmission,
• a stator (6), fitted on the free wheel (7) and located between the impeller and
the turbine,
• a lock-up device operated by the ECU which consists of a piston (1), a friction
plate (2) and a vibration damper (3).
The converter is secured to the engine drive plate (end plate). Its role is to
provide a flexible and automatic link between the engine and the transmission.
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It has two operating phases:
• the converter phase where it multiplies the engine torque by up to 2.2 times,
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• the coupling phase where it transmits the engine torque with an efficiency of
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0.98 (1 if it is locked up).
II - CONVERTER LOCK-UP
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A - GENERAL
The clutch is hydraulically operated by an electrovalve controlled by the ECU.

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The clutch can be in one of two states:

• open state → normal converter operation,
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• closed state where it connects the impeller and the turbine so as to

transmit all of the engine torque → engine brake available, reduction in
fuel consumption, cooling of automatic transmission oil.
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Lock-up is available on 2nd, 3rd and 4th gears (and 1st gear in rare cases).
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The converter is locked up by inverting the direction of oil flow.
The ECU controls the two possible states of the lock-up using a set of
memorised laws.
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19
Chapter 4
B - OPERATING PRINCIPLE OF THE LOCK-UP

The lock-up piston (1) is used to
connect the impeller (4) to the
turbine (5) via the vibration
damper (3) and the friction plate
(2).
1 - Converter not locked up
a In the unlocked mode, oil

pressure arrives through the
lock-up circuit (a) so as to free
to lock-up piston from the
clutch plate. The oil then
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supplies the converter and the

AL4012D spring through the converter
1 circuit (b).
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5 b
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2
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4
3
2 - Converter locked up
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In the locked mode, the lock-up

circuit (a) is connected to tank.
The oil therefore arrives
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through the converter circuit (b)

into the converter causing the
lock-up piston to move. This
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allows the turbine to connect

with the impeller via the
vibration damper and double
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sided clutch plate.

Note: The lock-up piston is
joined to the rotating
AL4013D
impeller.
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Chapter 4
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21
Chapter 5
THE EPICYCLIC GEAR TRAIN
I- DESCRIPTION
To provide the four forward gears and one reverse gear, the AL4 automatic
transmission has a SIMPSON type epicyclic gear train.
This consists of two simple epicyclic gear trains connected together.
There are:
• two sunwheels P1 and P2,

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• two sets of planet wheels S1 and S2,

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• two planet wheel carriers PS1 and PS2,

• two rings C1 and C2.
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The two gear trains are connected in the following manner:

• planet wheel carrier PS1 and ring C2 are connected together,
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• planet wheel carrier PS2 and ring C1 are connected together.

Gear train n°1 is located on the rear housing side.
Gear train n°2 is located on the converter side; the movement systematically exits
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through its planet wheel carrier PS2.

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F1 F2 F3
E1 C2
S2
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E2
C1 P2
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S1
P1
PS1
Primary pinion of
the step down gear
Movement input
housing PS2
AL4014D
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22
Chapter 5
Secondary pinion of
the step down gear
P2
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C2
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PS1
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P1
Connection with PS1

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PS2
C1
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AL4015P
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Primary pinion of
the step down gear
Gear train specifications

Sunwheel P1 33 teeth
Sunwheel P2 40 teeth
Planet wheel S1 21 teeth
Planet wheel S2 19 teeth
Ring C1 81 teeth
Ring C2 80 teeth
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23
Chapter 5
II - OPERATING PRINCIPLE
1st gear
F1 F2 F3
E1
C1 C2
E2
PS1 PS2
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PP des Lock-up
P1 P2
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Primary
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AL4016D
PP des = Primary step down pinion
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2nd gear
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F1 F2 F3
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E1
C1 C2
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E2
PS1 PS2
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PP des Lock-up
P1 P2
AL4017D
Primary
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24
Chapter 5
3rd gear
F1 F2 F3
E1
C1 C2
E2
PS1 PS2
PP des Lock-up
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P1 P2
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Primary
AL4018D
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4th gear
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F1 F2 F3
E1
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C1 C2
E2
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PS1 PS2
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PP des Lock-up
P1 P2
AL4019D
Primary
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Chapter 5
Reverse
F1 F2 F3
E1
C1 C2
E2
PS1 PS2
PP des Lock-up
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P1 P2
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Primary
AL4020D
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Table of moving parts

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GEAR DRIVING REACTION RATIO

COMPONENT COMPONENT
1 P1 P2 2.72
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2 PS1 - C2 P2 1.5
3 P1 and PS1 - C2 none 1
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4 PS1 - C2 P1 0.71
Reverse P1 PS1 - C2 2.45
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Chapter 5
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Chapter 6
ECU
The ECU of the AL4 transmission is an autoadaptive and upgradable ECU with a 56
track Flash Eprom.
I- ECU FUNCTIONS
The ECU performs the following functions:

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A - GEAR CHANGING LAWS
The ECU has 10 gear changing laws allowing the operation of the
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transmission to be altered to the driver's style of driving, to the chosen

program and to the internal and external conditions.
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The following laws are therefore obtained:
• 6 laws: for autoadaptivity,

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• 1 law: for the snow program,

• 1 law: "unlocked" for low temperature operation,
• 1 law: for depollution when cold (heating),
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• 1 law: for automatic transmission temperature protection.

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B - PROGRAMS
The ECU manages three programs: autoadaptive, Sport and Snow (upon
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driver's request).
C - AUTO-ADAPTIVENESS
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The ECU has an autoadaptive program which allows it to chose the law which
will be the best suited to the following conditions from the ten laws listed
above:
• driver's style of driving → 3 laws = "economic", Medium", "Sport ",
• road profile and vehicle load → 3 laws = "slight incline" (or "braking 1"),
"sharp incline" (or "braking 2"), "decline",
• temperature,
• selected program.
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Chapter 6
D - GEAR CHANGE UP PREVENTION DUE TO SUDDEN REMOVAL OF FOOT

FROM ACCELERATOR
This function prevents the transmission from changing up to a higher gear

when the foot is suddenly removed from the accelerator pedal; this allows the
engine brake to be maintained whilst decelerating.
E - GEAR LOCKING FOLLOWING A LAW CHANGE
For reasons of safety and comfort, the transmission is prevented from

changing up or down a gear too quickly if the law has just changed.
F - CHANGE DOWN
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The ECU is totally responsible for changing down the gears as a function of
engine load, vehicle speed and driving conditions. The ECU authorises a
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double change down (from 4th to 2nd and 3rd to 1st) or forces a single
change down.
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Furthermore, the ECU provides a change down function in the event of

sustained braking in order to anticipate downward gear changes and so as to
provide the engine brake.
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G - MOMENTARY SWITCH TO SPORT PROGRAM
So as to provide better power take-up in the normal program, the ECU

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temporarily switches to a more sporty law when the accelerator pedal is

suddenly pressed down.
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H - KICKDOWN
The kickdown order is given by the automatic transmission ECU after the
k.
accelerator pedal is pressed down fully and depending on vehicle speed.
I - MANAGEMENT OF IMPOSED GEARS

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The ECU is totally responsible for changing to imposed gears in terms of

operation and safety (changing limits).
J - CONTROLLING THE LINE PRESSURE
The ECU works out the value of line pressure with closed loop feedback. The
reference value is a function of the turbine torque to overcome.
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29
Chapter 6
K - MANAGING GEAR CHANGES
When the ECU decides to change a gear, it must operate the various
electrovalves involved in a precise order and in accordance with timers which
are a function notably of the engine load and vehicle speed. This provides a
good overlap between the receiver which is emptying and the one which is
filling up.
L - OPERATING THE CONVERTER LOCK-UP CLUTCH
This function optimises the converter operation by locking it up to save fuel, to

obtain engine braking, to encourage cooling of the transmission oil and to
prevent slip. A law which depends on vehicle speed, throttle position and gear
engaged is used to decide whether to lock the converter up or not.
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M - TORQUE REDUCTION
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This function is used to increase driving pleasure by reducing the engine

torque when changing gear. This action consists of momentarily reducing the
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ignition advance in accordance with a pre-programmed table provided by the

engine management computer.
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N - IDLE SPEED COMPENSATION
This function is used to attenuate the dragging effect of the transmission when
it is being driven through the engine management computer (idle reference
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speed).
O - AUTOMATIC TRANSMISSION PROTECTION

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• Reverse gear safety: for vehicle speed > Threshold.
• Incorrect operations:
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− on the automatic transmission: change from N → D or N → R prohibited

if N > threshold. The change is authorised if N < threshold or after a
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timer.
P - SHIFT-LOCK FUNCTION
This function locks the selector lever in position P when the ignition is
switched on. The lever is unlocked by pressing the brake pedal.
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30
Chapter 6
Q - CONTROL PANEL DISPLAY

The ECU informs the driver of the position of the selector lever and the choice
of program using the liquid crystal display on the control panel.
The ECU may also warn the driver of a transmission problem by flashing the
sport and snow display.
R - "OLD OIL" FUNCTION
Using the parameters of automatic transmission oil temperature and the time
for which the oil is subject to a high temperature, the ECU increments an "old
oil" counter. When this reaches the calibrated maximum valve, the ECU
orders the "Sport" and "Snow" warning lights to flash on the control panel to
warn the driver that the automatic transmission oil needs changing.
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S - SAFETY - DIAGNOSTIC
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The ECU:
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• permanently checks its supplies and that its sensors and actuators are
operating correctly,
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• validates and stores operating faults,

• talks with after-sales tools through line K,
• provides a downgraded mode,
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• asks the engine management computer to illuminate the engine

management light in the event of a fault leading to a deterioration in the
level of vehicle pollution (only on fiscal level L4).
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T - CONFIGURATION - DOWNLOADING
The ECU can be upgraded; its program can be updated by downloading.

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The configuring operation is used to configure the automatic transmission

ECU depending on the options which are not fitted to the vehicle.
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U - OTHER FUNCTIONS
The following three functions, inherent to automatic transmission, are

performed by the multifunction switch:
1 - Buzzer
This tells the driver that he is leaving his vehicle without having put the
selector lever in position P.
2 - Illumination of reversing lights in position R.
3 - Prevention from starting engine when not in positions P or N.
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Chapter 6
II - OPERATING SUMMARY
3 4 5 7 4 5 9 4 11
1 2
12
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33 6 8 10
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A B C
36 17 13
13 16
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14
14 15 EOBD
15 14
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16 13 16
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32
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19 18
31 34
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30 35
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28
29 27 26 25 24 23 22 21 20
AL4021P
Load information
A - Petrol engine with double track potentiometer
B - Petrol engine with single track potentiometer
C - Diesel engine
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32
Chapter 6
Parts list
REF. DESCRIPTION
1 Accelerator pedal
2 Kickdown function on accelerator cable
3 Double track throttle potentiometer
4 TDC sensor
5 Engine coolant temperature probe
6 Petrol injection ECU
7 Single track throttle potentiometer
8 Petrol injection ECU
9 Potentiometer on injection pump load lever
10 Diesel injection ECU
11 Torque reduction electrovalve
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12 Kickdown information
13 Engine load information
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14 Engine speed + engine coolant temperature information

15 Engine torque information (provided by injection ECU)
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16 Torque reduction request information + idle speed compensation request

information
17 Illumination of EOBD light request information (only on versions with L4
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depollution)
18 LED display (control panel)
19 Diagnostic socket
20 Sequence electrovalve
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21 Pressure modulating electrovalve

22 Oil flow modulating electrovalve
23 Transmission oil temperature probe
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24 Transmission oil pressure sensor

25 Transmission input speed sensor
26 Transmission output speed sensor
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27 Multifunction switch
28 Reversing lights
29 Starter motor prevention relay
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30 Shift lock actuator

31 Gear lever
32 Program selector (Sport, Snow, Normal, 1st imposed)
33 Brake pedal (braking information)
33 Stop switch
34 Automatic transmission ECU
35 Not in position P reminder buzzer
36 Throttle position information (throttle potentiometer)
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33
Chapter 6
III - ECU CONNECTIONS
PIN DESCRIPTION COMMENTS

N°
1 Output: supply (+) for sequence electrovalves (EVS1 to
EVS6)
2 Output: supply to electrovalve controlling flow in heat
exchanger
3 Output: air conditioning compressor cut-off command not used
4 Output: display (on instrument panel)
5 Output: torque reduction request /idle speed compensation
6 / depending on
version
6 Output: illumination of EOBD light request information (*) L4 version
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(to engine management computer)

7 Output: sequence electrovalve EVS3 (earth)
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11 Output: shift lock actuator control

12 Output: heat exchanger oil flow electrovalve control
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(EPDE)
15 Input: kickdown control
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16 Input: brake redundant contact (brake opening contact)

17 L diagnostic line
18 K diagnostic line
19 Output: lock-up electrovalve
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20 Output: main pressure electrovalve

21 /
22 /
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22 Input: engine torque information

23 /
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23 Throttle position information input (driver's wishes

information)
24 Supply (+) to oil pressure sensor
25 Supply (-) to oil pressure sensor
26 Supply (+) to modulating electrovalves (pressure EVM,
lock-up EVM)
27 Supply (+) to ECU
28 Supply to ECU (common earth with engine management
ECU)
29 - /
30
31 Input: multifunction switch position S2 contact
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Chapter 6
PIN DESCRIPTION COMMENTS

N°
32 Input: multifunction switch S3 contact
34 Input: multifunction switch Parking/Neutral contact
35 /
36 Input: program selector, "1" button
38 - /
39
40 Input: program selector: snow button
41 Input: program selector, normal/sport button
42 Electronic earth for multifunction switch
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43 Input: stop lights contact (brake closing contact)

44 /
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45 Input: signal (+) from turbine speed sensor

46 Input: signal (-) from turbine speed sensor
47 Signal (-) from automatic transmission output speed sensor
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48 Signal (+) from automatic transmission output speed

sensor
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49 Input: engine speed information (TDC)

50 /
51 Supply (-) for throttle potentiometer double track
potentiometer
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51 /
52 Supply (+) for throttle potentiometer double track
potentiometer
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52 /
53 Signal (-) from oil temperature probe
54 Signal (+) from oil temperature probe
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55 Input: signal from line pressure sensor

56 Input: signal from throttle potentiometer
56 /
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EMC: engine management ECU - EOBD: European On Board Diagnosis
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35
Chapter 7
AUTO-DIAGNOSTIC
I- FAULT WARNINGS
The appearance of certain faults in the system causes the SPORT and SNOW
warning lights to flash.
The sport and snow warning lights flash in the following cases:
• when the transmission oil is too hot (extinguish when oil has cooled),
• when the transmission oil is old (oil counter value at calibrated maximum
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value),
• when there is a break in the serial link between the transmission ECU and the
control panel.
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The "SPORT" and "SNOW" warning lights flash if there is a fault on the following
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components or information:
• transmission ECU,
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• ECU supply,
• oil pressure sensor,
• supply to sequence electrovalves (EVS1 to EV6),
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• regulation fault in main hydraulic pressure,

• multifunction switch,
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• sequence electrovalves (EVS1 to EV6),

• main pressure modulating electrovalve (pressure EVM),
• converter lock-up modulating electrovalve (lock-up EVM),
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• oil flow electrovalve in heat exchanger,

• main hydraulic pressure electrovalve,
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• accelerator pedal not programmed,

• input speed and output speed,
• input speed and engine speed,
• output speed and engine speed,
• engine speed information,
• pedal position,
• supply to analogue sensors.
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Chapter 7
II - MEMORISED FAULTS / DOWNGRADED MODES

There are 6 levels of downgraded mode depending on the fault detected.
FAULT FOUND EFFECT
Level 1 - kick down input no effect on operation of
transmission
Level 2 - transmission oil temperature slight degradation in
- engine torque information operation, impact on driving
- display control comfort
- shift lock actuator
Level 3 - vehicle speed large degradation in
- lock-up modulating electrovalve operation of the
- torque reduction output transmission (reduced gear
- pressure sensor changing quality, loss of
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- supply to sensors functions)

- brake switch input
- heat exchanger flow modulating electrovalve
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(EPDE)
- throttle position information supplied by the
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injection ECU and torque information missing

Level 4 - engine speed large degradation in
- transmission input speed sensor operation of the
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transmission (loss of
functions, or downgraded
functions)
Level 5 - throttle potentiometer information Switches to 3rd hydraulic
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- engine torque information the next time the ignition is

- multifunction switch (loss of reverse gear switched on.
safety when driving) If the vehicle is in 4th gear,
- supply to analogue sensors this gear is maintained and
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- pressure modulating electrovalve 3rd gear is automatically

- main pressure regulation engaged the next time the
- heat exchanger oil flow modulating ignition is switched on.
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electrovalve control This downgraded mode is

- input speed and output speed called differed stopping
- input speed and engine speed mode
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- output speed and engine speed

Level 6 - ECU not working Switches to 3rd hydraulic.
- sequence electrovalves This downgraded mode is
- supply to sequence electrovalves called stopping mode
- accelerator pedal position not programmed
Warning: Transmission in stopping mode: a loud bang may be felt when moving
the lever from P ⇒ R or N ⇒ R.
Warning: In hydraulic emergency mode, gear changing safety limits are no
longer provided.
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Chapter 8
WIRING DIAGRAM - XANTIA
PETROL ENGINE/WITHOUT CRUISE CONTROL
I- LAYOUT
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AL4022P
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Chapter 8
PETROL ENGINE/WITH CRUISE CONTROL
I- LAYOUT
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AL4023P
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39
Chapter 8
DIESEL ENGINE/WITHOUT CRUISE CONTROL
I- LAYOUT
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AL4024P
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Chapter 8
DIESEL ENGINE/WITH CRUISE CONTROL
I- LAYOUT
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AL4025P
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41
Chapter 8
II - PARTS LIST
BB00 - Battery
BF00 - Passenger compartment fuse box
BMF1 - Maxi fuse box
C001 - Diagnostic socket
CA00 - Ignition switch
M000 - 

MC10 -
 Earths
MC16 - 
MM07 - 
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0004 - Control panel

1005 - Starting prohibition relay
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1316 - Throttle position sensor

1621 - Automatic transmission vehicle speed sensor
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1630 - Automatic transmission ECU

1631 - Torque reduction electrovalve
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1635 - Automatic transmission electro-hydraulic unit

1637 - Automatic transmission kickdown switch
1638 - Automatic transmission shift-lock actuator
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1640 - Automatic transmission program selector

1642 - Shift lock control relay
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2100 - Stop switch

7307 - Cruise control safety relay
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10 - - - Starting function, current generation

12 - - - Injection supply function
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21 - - - Stop lights function

22 - - - Reversing lights function
30 - - - Passenger compartment lighting function
73 - - - Cruise control function
80 - - - Air conditioning function
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Chapter 8
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43
Chapter 9
AFTER-SALES OPERATIONS
I- DOWNLOADING
This operation is to be performed in the following cases:

• when the automatic transmission ECU is updated,
• to adapt the automatic transmission ECU to an upgraded engine management
computer,
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The downloading operation must be followed by:

• a pedal programming operation,
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• configuration,
• a road test.
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IMPORTANT: The engine management computer must be upgraded every time

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the automatic transmission ECU is upgraded.
Following the procedure on the ELIT or PROXIA/LEXIA diagnostic tool to perform

a downloading operation.
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II - CONFIGURATION
ee

• replacement of ECU,
• downloading to ECU.
k.
A new or newly downloaded ECU is always configured with the following three
options:
ir
• with or without shift lock,

• with or without air conditioning,
• with or without EOBD (L4 depollution standard).
The ECU configuration operation consists of preventing the options not fitted to
the vehicle from being subject to the diagnostic procedure.
Follow the procedure on the ELIT or PROXIA/LEXIA diagnostic tool to perform a
configuration operation.
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Chapter 9
III - PEDAL PROGRAMMING

• replacement of ECU,
• replacement of automatic transmission,
• updating by downloading,
• replacement or adjustment of accelerator cable,
• replacement of or downloading to engine management computer
(XUD9BTF/XU7JP4/L4),
• replacement of throttle potentiometer,
• replacement of diesel injection pump.
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Follow the procedure on the ELIT or PROXIA/LEXIA diagnostic tool to perform a

pedal programming operation.
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IV - INITIALISING THE "OLD OIL" COUNTER

This procedure will be active from update n°13 of the diagnostic tools. The aim of
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this operation is to tell the automatic transmission ECU that the transmission oil
has just been changed.
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V- UPDATING THE "OLD OIL" COUNTER

This procedure will be active from update n° 13 of the diagnostic tools. It consists
of making the transmission ECU memorise the "old oil" counter should the ECU
rg
be replaced without changing the oil.
Note: If the oil counter cannot be read from an old ECU, change the transmission
ee
oil.
VI - TEST AFTER REPAIR WORK

k.
The ECU permanently adapts itself to the transmission. Thus, when replacing the
transmission, the ECU or another transmission component, a road test must be
performed choosing a route which allows frequent gear changes and the use of all
ir
gears. All the programs should also be selected.

This test is absolutely essential so that the ECU can adapt itself to the
transmission by comparing reference values with actual values. The difference
recorded is then memorised to allow optimum gear changing quality.
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Chapter 9
VII - CHANGING PARTS, OPERATIONS TO BE PERFORMED
COMPONENT OPERATION TO BE PERFORMED COMMENTS

REPLACED
Transmission (1) Adjust multifunction switch requires diagnostic tool +
+ multimeter
Initialise old oil counter (2)
+
Road test
Transmission oil Initialise old oil counter (2) requires diagnostic tool
Replace hydraulic distributor Adjust control inside transmission special tool
components (hydraulic +
distributor, electrovalves) Road test
Heat exchanger oil flow
modulating electrovalve
Transmission input speed Do not drain transmission
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sensor Check oil level

Transmission output speed
sensor
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Main pressure sensor

Oil temperature probe Remove hydraulic distributor Requires transmission to be
drained. Requires electrical
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harness inside transmission to

be removed. Requires control
inside transmission to be
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adjusted. Check oil level

Replace or adjust accelerator Program accelerator pedal Check operation of kickdown
cable switch
Replace throttle Program pedal requires diagnostic tool
potentiometer
rg
Replace diesel injection Program pedal

pump (with potentiometer on
load lever)
Replace injection ECU Program pedal download automatic
ee
transmission ECU
Multifunction switch Adjust switch multimeter
Replace transmission ECU Read old oil counter in old ECU (2), note download engine management
the value computer
k.
+
Configure new ECU
+
Update oil counter in new ECU from value
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stored in old one (2) (3)

+
Program accelerator pedal
+
Road test
(1) New transmissions are supplied filled with oil

(2) Possible from update n° 13 of diagnostic tools
(3) If the oil counter cannot be read from an old ECU, replace the
transmission oil.
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Chapter 9
VIII - AUTHORISED OPERATIONS DURING THE WARRANTY PERIOD
Transmission fitted
Authorised replacements:
• drain and fill oil,
• download/configure ECU,
• program pedal,
• initialise/update "old oil" counter,
• hydraulic distributor cover seal,
• selector shaft seal,
• driveshaft seals,
• seal between closing plate and transmission housing,
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• gear selector control,

• heat exchanger and its seals,
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• accessible plugs, support brackets and control pins,

• complete hydraulic distributor,
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• electrovalves and pressure regulators on hydraulic distributor,

• speed sensors (turbine speed, engine speed, vehicle speed),
.ca
• transmission oil temperature probe,

• electrical harness inside transmission,
• TDC sensor,
rg
• selector lever position switch,

• oil pressure sensor,
• relays,
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• transmission ECU (*).

Note: If the oil in the transmission is burnt, always replace the heat exchanger.
k.
(*) only after approval.

Transmission removed
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Authorised replacements (depending on transmission architecture):

• torque converter,
• inter housing gasket,
• whole transmission (*).
IMPORTANT: When returning a transmission under warranty, return it with its

heat exchanger.
(*) only after approval.
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Chapter 9
The operating procedures for the various authorised operations are given in the
corresponding after-sales document.
Replacing the whole AL4 transmission or its ECU must be subject to prior
approval.
This approval is given by the Regional Headquarters for France. The point of sale
fills in the "request for replacement approval" (copy enclosed) and sends this duly
completed request to the Regional Headquarters. After being analysed, additional
technical assistance will be proposed in order to complete the diagnostic or
replacement approval will be faxed back to the point of sale on the approval
request.
For UK, contact warranty department at Citroën UK or follow After Sales

procedure for UK RHD vehicles.
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IX - AUTOMATIC TRANSMISSION REPAIR BY THE CITROËN AUTOMATIC

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TRANSMISSION CENTRE, SOUTH WEST PARIS
Conditions
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• The vehicle is not under contractual warranty (1 year).

.ca
• Preliminary checks (level and quality of oil, adjustments relating to

transmission, etc…) and any repairs (repairs with or without removing
transmission) must have been performed.
rg
Procedure
• Send the centre the duly completed approval sheet by fax.

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• Upon receiving the work request, the centre will specify its provisional repair
time by telephone or fax.
• The centre will send the point of sale special packaging for transport purposes
k.
with blanks and the converter lock corresponding to the AL4 automatic
transmission.
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• Remove the transmission from the vehicle.

• Package the transmission (leave oil / water exchanger fitted) and attach the
photocopy of the workshop customer work order, the approval request sheet
and the works order.
• Send the transmission to the centre using GEFCO transport (specific
procedure).
• Transmission will be returned by GEFCO after repair.
• Return empty special packaging to GEFCO with blanks and converter lock.
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Chapter 9
REQUEST FOR REPLACEMENT APPROVAL OR ASSISTANCE FOR

MB3/4HP20/AL4 AUTOMATIC TRANSMISSION
Warranty start Stamp

Vehicle type
Engine type
Transmission type
ECU type
V.I.N or DAM N°
Transmission N°
Mileage
Date
1) VEHICLE Form completed Telephone Fax
IMMOBILISED YES NO by:
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2) CUSTOMER complaint ................................................................................................................

...............................................................................................................................................................
3) OIL appearance coloured oil burnt normal

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Check at 80°C level level insufficient level normal too much oil
Check at 60°C (AL4)
Leak Location ............................................... dripping flowing
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For the next section, only complete relevant sections:

Accelerator pedal programmed (MB3 or AL4) YES NO
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4) OPERATING FAULT
gears do not change slipping
random changes slipping then knocking
delay engaging N-D or N-R knocking
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problem in imposed gears no drive

other .................................................................
when changing up sudden fault when driving stationary
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when changing down engine cold engine warm

progressive degradation occasionally
when changing gears which ones ? ........................................................................
k.
when changing lever position, state positions..............................................................................

coherence between lever position/control panel display of P→ 1 YES NO
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5) NOISE
conditions when driving when accelerating when decelerating stationary
type of noise metallic friction whining cyclic
6) MEMORISED FAULTS
Warning light flashing (if fitted): YES NO
Transmission ECU identification ............. Engine ECU identification ........................
Transmission: Engine:
7) POINT OF SALE COMMENTS: 8) RESPONSE TO APPROVAL REQUEST

e.g. associated variables ................................... (Approval n°) .....................................................
.............................................................................. .............................................................................
.............................................................................. .............................................................................
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Chapter 9
Note: Above for France. For UK contact warranty department, Citroën UK Ltd.
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Chapter 9
X- SPECIAL TOOLING
Box - ( ) 0338
A B C D E F
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G H1 H2 J1 J2 K
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L M1 M2 N1 N2 P
AL4026D
A - Drift
B - 2 sockets for removing-refitting converter
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C - Right hand driveshaft seal extractor

D - Tool for holding converter
E - Ball joint extractor
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F - Tool for fitting converter lip seal

G - Hook for removing lip seal from converter
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H1 - Tool for fitting left hand driveshaft seal

H2 - Guide for fitting left hand driveshaft seal
J1 - Tool for fitting right hand differential output seal
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J2 - Guide for fitting right hand differential output seal

K - Tool for fitting selector shaft seal
L - Interface harness for checking AL4 automatic transmission
M1 - Screw for setting internal selector control
M2 - Shim for adjusting internal selector control
N1 - Gear changing shaft seal extractor
N2 - Gear changing shaft seal extractor
P - Socket for removing transmission mounting
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Chapter 9
XI - DIAGNOSTIC TOOLING
ELIT unit: 4125-T
This tool is used for:
• identifying ECUs,
• reading faults,
• erasing faults,
• measuring parameters,
• activating actuators,
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• programming accelerator pedal,

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• configuring ECUs,
• updating the ECU by downloading.

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PROXIA station: 4165-T

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• reading faults,
• erasing faults,
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• updating the ECU by downloading,
• consulting wiring diagrams.
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Chapter 9
LEXIA station: 4171-T
• reading faults,
• erasing faults,

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• updating the ECU by downloading,
• consulting wiring diagrams.

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Terminal box and harness: 4187-T

.ca
Using a voltmeter and an ohmmeter, this tool is used to check:
• sensors and actuators,

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• automatic transmission harness.

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Chapter 9
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Manual Caja Citroen Al4

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www.CarGeek.

PRESENTATION OF THE AL4

of the electronically managed AL4 automatic transmission which offers precise,

The following subjects are dealt with in this document:

- Presentation of the transmission and various pieces of information,

- The selector control,

- The electrical circuit,

AL4 AUTOMATIC TRANSMISSION

CHAPTER 1 : PRESENTATION - GENERAL ............................. PAGE 1

II - PRESENTATION ............................................................................. PAGE 2

III - DESCRIPTION OF THE AL4 AUTOMATIC TRANSMISSION .......... PAGE 3

IV - IDENTIFYING THE COMPONENTS OF THE AUTOMATIC

V- SPECIFICATIONS - SERVICING ..................................................... PAGE 7

VI - LAYOUT OF THE AL4 AUTOMATIC TRANSMISSION .................... PAGE 8

VII - MISCELLANEOUS ADVICE............................................................. PAGE 9

CHAPTER 2 : SELECTOR CONTROL........................................

I- SELECTOR LEVER ......................................................................... PAGE 11

II - PROGRAM SELECTOR................................................................... PAGE 13

CHAPTER 3 : CHECKING THE OIL LEVEL ............................... PAGE 15

CHAPTER 4 : THE TORQUE CONVERTER............................... PAGE 17

II - CONVERTER LOCK-UP .................................................................. PAGE 18

CHAPTER 5 : THE EPICYCLIC GEAR TRAIN ........................... PAGE 21

II - OPERATING PRINCIPLE ................................................................ PAGE 23

CHAPTER 6 : ECU....................................................................... PAGE 27

I- ECU FUNCTIONS............................................................................ PAGE 27

II - OPERATING SUMMARY ................................................................. PAGE 31

III - ECU CONNECTIONS ...................................................................... PAGE 33

CHAPTER 7 : AUTO-DIAGNOSTIC ............................................ PAGE 35

I- FAULT WARNINGS ......................................................................... PAGE 35

II - MEMORISED FAULTS / DOWNGRADED MODES.......................... PAGE 36

AL4 AUTOMATIC TRANSMISSION

CHAPTER 8 : WIRING DIAGRAM - XANTIA.............................. PAGE 37

PETROL ENGINE/WITHOUT CRUISE CONTROL

PETROL ENGINE/WITH CRUISE CONTROL

DIESEL ENGINE/WITHOUT CRUISE CONTROL

DIESEL ENGINE/WITH CRUISE CONTROL

II - PARTS LIST..................................................................................... PAGE 41

CHAPTER 9 : AFTER-SALES OPERATIONS ............................ PAGE 43

II - CONFIGURATION ........................................................................... PAGE 43

III - PEDAL PROGRAMMING ................................................................. PAGE 44

IV - INITIALISING THE "OLD OIL" COUNTER........................................ PAGE 44

V- UPDATING THE "OLD OIL" COUNTER ........................................... PAGE 44

VI - TEST AFTER REPAIR WORK ......................................................... PAGE 44

VII - CHANGING PARTS, OPERATIONS TO BE PERFORMED ............. PAGE 45

VIII - AUTHORISED OPERATIONS DURING THE WARRANTY PERIOD

IX - AUTOMATIC TRANSMISSION REPAIR BY THE CITROËN

X- SPECIAL TOOLING ......................................................................... PAGE 50

XI - DIAGNOSTIC TOOLING .............................................................. 51

AL4 AUTOMATIC TRANSMISSION

AL4 AUTOMATIC TRANSMISSION

• Electronically operated transverse automatic transmission.

• Four forward gears and one reverse gear.

• The maximum torque capacity is 210 mN.

• Sealed transmission with reduced maintenance.

• Transmission oil cooled by heat exchanger.

• Current application: CITROËN XANTIA PHASE II vehicles with XU Petrol and

AL4 AUTOMATIC TRANSMISSION

This is performed by:

• Electronic control of all regulation and gear changing functions.