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Thread: 1,2 TDI clutch/ gearbox problems

  1. #201
    Join Date
    Aug 2007
    Location
    East Sussex
    Posts
    1,265
    Here for RTFM12:

    http://wiki.ross-tech.com/wiki/index...smission_(085)

    Ensure that the actuator is connected to the change rod at the correct point - there is a depression in the rod for the securing screw. Also, were the correct instructions followed for replacement of the gasket; the actuator lever should not be dis-assembled because it is on a spline and there is only one way to re-assemble? Any play in the ball joints? Was the actuator screw loosened during the basic setting?

    RAB
    2013 E-Up! Dark Blue (Wifey's new car!)
    2001 A2 1.2Tdi Silver, bought in 2007
    2001 Lupo 3L Red, bought new, the first registered in the UK
    1999 Lupo 3L Silver (Wifey's car)
    1946 MG TC owned since 1971 (my first car!)



  2. #202
    Join Date
    Aug 2007
    Location
    East Sussex
    Posts
    1,265
    If the actuator was dis-assembled so that the spline was removed, look earlier on this thread (around #177) for info on correct assembly. Otherwise it might just be that the linkage just needs loosening and then re-tightening, taking care not to disturb adjustment when tightening.

    RAB
    2013 E-Up! Dark Blue (Wifey's new car!)
    2001 A2 1.2Tdi Silver, bought in 2007
    2001 Lupo 3L Red, bought new, the first registered in the UK
    1999 Lupo 3L Silver (Wifey's car)
    1946 MG TC owned since 1971 (my first car!)



  3. #203
    Quote Originally Posted by RAB View Post
    If the actuator was dis-assembled so that the spline was removed, look earlier on this thread (around #177) for info on correct assembly. Otherwise it might just be that the linkage just needs loosening and then re-tightening, taking care not to disturb adjustment when tightening.

    RAB
    Ok, only the bottom of the actuator was have been disassembled. But it looks as it is on your picture, the spline points as yours. The linkage was loosen and retighten like in ross tech site. The ball joint has only 1mm or even less move when tightened.
    The basic settings rules were followed by letter to letter. In the past we made some basic settings for different reasons so I guess we have a problem somewhere but not in the process.

  4. #204
    Join Date
    Aug 2007
    Location
    East Sussex
    Posts
    1,265
    How many times have you carried out the basic setting? It does not always work first time. I assume that there is movement and you haven't reversed the hoses (one is for pressure and one is return). Otherwise it points to wear in the actuator, whereby the correct readings cannot be reached.

    The correct values are here:

    Value 3 (G239):
    Selector lever in R, 1,3,5 setpoint 3,8V + -0,4V
    Selector lever in 2.4 setpoint value 1.6V + -0.4V
    Value 4 (G240):
    Selector lever in R: 3.8V + -0.4V
    Selector lever in 1.2: 3.0V + -0.4V
    Selector lever in 3.4: 2.0V + -0.4V
    Selector lever in 5: 1.2V + -0.4V

    RAB
    2013 E-Up! Dark Blue (Wifey's new car!)
    2001 A2 1.2Tdi Silver, bought in 2007
    2001 Lupo 3L Red, bought new, the first registered in the UK
    1999 Lupo 3L Silver (Wifey's car)
    1946 MG TC owned since 1971 (my first car!)



  5. #205
    Join Date
    Jun 2015
    Location
    Rīga, Latvija
    Posts
    13
    Hello,
    What could be the problem, when basic setting stops at he moment, when I need to start engine? It simply wont start. Starter motor is working, tested it. Did everything like in the manual. Problems started after changing leaking oring on one of the pipes.

  6. #206
    Join Date
    Aug 2007
    Location
    East Sussex
    Posts
    1,265
    There's no requirement for a basic setting if you are only changing an O ring. RTFM? Gear Actuator adjusted?

    RAB
    2013 E-Up! Dark Blue (Wifey's new car!)
    2001 A2 1.2Tdi Silver, bought in 2007
    2001 Lupo 3L Red, bought new, the first registered in the UK
    1999 Lupo 3L Silver (Wifey's car)
    1946 MG TC owned since 1971 (my first car!)



  7. #207
    Join Date
    Jun 2015
    Location
    Rīga, Latvija
    Posts
    13
    Cleared errors due to pump disconnection, car didnt start. Thougt basic setting could help. Clutch = 1.98V, actuator was adjusted. Everything runs fine in basic setting until "StartMot". Its like something is blocking signal to starter. VCDS just waits for me to start the engine, there is no RTFM. If I quit VCDS there is no error due to interrupted basic setting.

  8. #208
    Join Date
    Aug 2007
    Location
    East Sussex
    Posts
    1,265
    So you had a starter problem before the basic setting? The starter motor has a device to prevent the motor from operating when it overheats (from start/stop). This is a square 'box' on top of the rear of the starter, near the electrical connection. These often fail but cannot be replaced. Just bypass it with a simple spade connection. Before doing so, make sure there is 12v at the connection when you try to start. If not, then it is likely to be a faulty relay.

    RAB
    2013 E-Up! Dark Blue (Wifey's new car!)
    2001 A2 1.2Tdi Silver, bought in 2007
    2001 Lupo 3L Red, bought new, the first registered in the UK
    1999 Lupo 3L Silver (Wifey's car)
    1946 MG TC owned since 1971 (my first car!)



  9. #209
    Join Date
    Jun 2015
    Location
    Rīga, Latvija
    Posts
    13
    Thanks fot the tips. Finaly had some time to work on the car. I had no starter problems before. Relay and that box on starter are working. I managed to start the car by putting 12V to the box. But engine runs ~5 seconds and stops. I was able to finish basic setting this way, but not able to start engine after it. At least I got 2 fault codes:
    00263 Transmission 27-10 Implausible Signal Intermittent
    01122 Clutch 17-10 Control Difference - Intermittent.
    Retried doing full basic setting, got the same results.

  10. #210
    Join Date
    Aug 2007
    Location
    East Sussex
    Posts
    1,265
    The engine won't start because the system is fail-safe. Are you sure about the 01122 code - elsewhere it is shown as a camshaft sensor issue. Do you have sufficient hydraulic oil in the reservoir? How many gear changes can you make before the pump re-starts? If all that is OK, you probably have a problem with the clutch or the clutch actuator.

    RAB
    2013 E-Up! Dark Blue (Wifey's new car!)
    2001 A2 1.2Tdi Silver, bought in 2007
    2001 Lupo 3L Red, bought new, the first registered in the UK
    1999 Lupo 3L Silver (Wifey's car)
    1946 MG TC owned since 1971 (my first car!)



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