WORKSHOP REPORT

CONTINUOSLY VARIABLE TRANSMISSION

MECHANICAL ENGINEER DEPARTMENT

PROGRAMME:

DIPLOMA IN AUTOMOTIVE ENGINEERING

KUMPULAN: 4

MUHAMAD AZAM BIN MOHD AZEMI 04DAD15F1082

MUHAMMAD ZAIM BIN ROMALAN 04DAD15F1092
SITI ZUBAIDAH BINTI KHUZAIMAH 04DAD15F1095
MUHAMMAD ZHARIF ASYRAFF BIN MAKHTAR 04DAD15F1104
ABDULLAH HAKIMI BIN ROSMAWADI 04DAD15F1107
1.0 INTRODUCTION

A continuously variable transmission (CVT) (also known as a single-speed

transmission, stepless transmission, pulley transmission, or, in case of motorcycles, a
twist-and-go) is an automatic transmission that can change seamlessly through a
continuous range of effective gear ratios. This contrasts with other mechanical
transmissions that offer a fixed number of gear ratios. The flexibility of a CVT allows
the input shaft to maintain a constant angular velocity.

A belt-driven design offers approximately 88% efficiency,[1] which, while lower than
that of a manual transmission, can be offset by lower production cost and by enabling
the engine to run at its most efficient speed for a range of output speeds. When power
is more important than economy, the ratio of the CVT can be changed to allow the
engine to turn at the RPM at which it produces greatest power. This is typically higher
than the RPM that achieves peak efficiency. In low-mass low-torque applications
(such as motor scooters) a belt-driven CVT also offers ease of use and mechanical
simplicity.

A CVT does not strictly require the presence of a clutch. Nevertheless, in some
vehicles (e.g. motorcycles), a centrifugal clutch is added[2] to facilitate a "neutral"
stance, which is useful when idling or manually reversing into a parking space.

Figure 1: Variable-diameter pulley (VDP)

2.0 OBJECTIVE
- To learn theory about continuously variable transmission
- To learn how to test hydraulic pressure on CVT.
- To learn how to test stall speed on CVT.

3.0 EQUIPMENT/MATERIAL
1.vehicle with CVT
2. Standard hydraulic pressure table that specific for car to test
3. Oil pressure gauge and its joints and its adapter

4.0 METHODOLOGY/PROCEDURE(HYDRAULIC PRESSURE TEST FOR

MITSUBISHI LANCER X)

1.Start the engine and warm it up until the CVT fluid temperature reaches 70 to
80C.
2.Stop the engine and block the RH and LH rear wheels with the wheel chocks.
3.Install the following special tools at the hydraulic pressure outlet ports shown in
the figure.

Oil pressure gauge <3.0 MPa> (MD998330)

Joint (MD998331)
Joint (MD998900)
 Adapter (MD992127)

4.Restart the engine.

5.Make sure that no CVT fluid leakage is found at the special tool fixing points.
6.Pull the parking brake lever and fully depress the brake pedal. (Maintain this
operation until measurement is completed.)
7.Measure the hydraulic pressure at each measuring point in the conditions
specified in the standard hydraulic pressure table, and check that the
measurements are within the standard value.
8.If not within the standard value, take necessary steps according to the hydraulic
pressure test diagnosis table.
9.Stop the engine.
10.Replace the O-rings on the plugs for each pressure port.
11.Remove the special tools and fit the plugs in the hydraulic pressure ports.
12.Install the plugs. Then, start the engine and check that no CVT fluid leakage is
found around the plugs.

Standard hydraulic pressure table

Measuring Standard hydraulic pressure (MPa)
condition
Selector Engine Forward clutch Reverse brake Primary Line pressure Torque
lever speed pressure pressure pressure [Pressure at converter
position [Pressure at [Pressure at [Pressure at PL] [Pressure at
FWD] REV] PRI] DR]
P Idling 0 0 0.1 - 1.5 0.5 - 1.5 0.1 - 1.0
R 0 0.5 - 1.0 0.1 - 1.5 0.5 - 1.5 0.1 - 1.0
N 0 0 0.1 - 1.5 0.5 - 1.5 0.1 - 1.0
D 0.5 - 1.0 0 0.1 - 1.5 0.5 - 1.5 0.1 - 1.0

Hydraulic pressure test diagnosis table

Symptom Faulty parts
Hydraulic pressure is high at all measuring points. Incorrect measuring method
Hydraulic pressure is low at all measuring points. Malfunction of oil pump
Clogged oil strainer
Clogged oil cooler
Malfunction in valve body assembly
Improper installation of valve body assembly
Only forward clutch pressure is abnormal. Malfunction in valve body assembly
Improper installation of valve body assembly

Only reverse brake pressure is abnormal.
Only primary pressure is abnormal
Only line pressure is abnormal.
Only torque converter output pressure is abnormal Malfunction in valve body assembly
Faulty seal ring A
Malfunction in valve body assembly
Improper installation of valve body assembly
Malfunction in valve body assembly
Improper installation of valve body assembly
Malfunction in valve body assembly
Improper installation of valve body assembly
Improper installation of valve body assembly
Malfunction of torque converter
Faulty seal ring B

(STALL SPEED TEST FOR HONDA THAT USE L12A/L13A ENGINE)

1. Set the parking brake, and block the front wheels.

2. Connect a tachometer to the engine, and start the engine.
3. Make sure the A/C switch is OFF.
4. After the engine has warmed up to normal operating temperature (the radiator fan
comes on), shift to [D] position.
5. Fully press the brake pedal and accelerator for 6 to 8 seconds, and note engine
speed. Do not move the shift lever while raising engine speed.
6. Allow 2 minutes for cooling, then repeat the test in [S], [L], and [R] positions.

NOTE:
Do not test stall speed for more than 10 seconds at a time.
Stall speed tests should be used for diagnostic purposes only.
Stall speed should be the same in [D], [S], [L], and [R] positions.
Do not test stall speed with the A/T pressure gauges installed.
 Stall Speed rpm in [D] and [R] positions:
Specification: 2,500 rpm (min-1)
Service Limit: 2,350-2,650 rpm (min-1)

Stall Speed rpm in [S] and [L] positions:

Specification: 3,000 rpm (min-1)
Service Limit: 2,800-3,100 rpm (min-1)
7. If the measurements are out of the service limit, problems and probable causes are
listed in the table below.

Problem Probable cause

Stall speed rpm high in Low fluid level or ATF pump output low
[D], [S], [L], and [R]
Clogged ATF strainer
positions

PH regulator valve stuck closed

Slipping forward clutch

Faulty start clutch

Stall speed rpm high in Slippage of reverse clutch

[R] position
Problem Probable cause

Faulty start clutch

Stall speed rpm low in Engine output low

[D], [S], [L], and [R]
Faulty start clutch
positions

Stuck pulley control valve