Text preview for : en_4j2_5a0.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004



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SECTION : 5A1

ZF 4 HP 16 AUTOMATIC TRANSAXLE
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­3 ZF 4HP 16 Automatic Transaxle . . . . . . . . . . . . 5A1­3 Transaxle Components . . . . . . . . . . . . . . . . . . . . 5A1­4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­5 General Specifications . . . . . . . . . . . . . . . . . . . . 5A1­5 Transaxle Gear Ratio . . . . . . . . . . . . . . . . . . . . . . 5A1­5 Fluid Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­5 Fastener Tightening Specifications . . . . . . . . . . 5A1­5 Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­7 Line Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­8 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­9 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5A1­9 SCHEMATIC AND ROUTING DIAGRAMS . . . 5A1­11 Transaxle Control Module (1 of 2) . . . . . . . . . . 5A1­11 Transaxle Control Module (2 of 2) . . . . . . . . . . 5A1­12 Shift Mode Diagram . . . . . . . . . . . . . . . . . . . . . . 5A1­13 Power Flow Diagram . . . . . . . . . . . . . . . . . . . . . 5A1­17 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . 5A1­33 Transaxle Identification Information . . . . . . . . 5A1­33 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . 5A1­34 Transaxle Housing . . . . . . . . . . . . . . . . . . . . . . . 5A1­35 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­36 Rear Cover & Oil Pan Cover . . . . . . . . . . . . . . 5A1­37 Parking Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­38 Input Shaft & Shift Gear . . . . . . . . . . . . . . . . . . 5A1­39 Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­41 Gear Shift Control . . . . . . . . . . . . . . . . . . . . . . . 5A1­42 DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­43 Basic Knowledge Required . . . . . . . . . . . . . . . . 5A1­43 Functional Check Procedure . . . . . . . . . . . . . . 5A1­43 Line Pressure Check Procedure . . . . . . . . . . . 5A1­43 Clutch Plate Diagnosis . . . . . . . . . . . . . . . . . . . 5A1­45 Cooler Flushing and Flow Test . . . . . . . . . . . . . 5A1­45 Transaxle Fluid Level Service Procedure . . . . 5A1­45 Electrical/Garage Shift Test . . . . . . . . . . . . . . . 5A1­47 Road Test Procedure . . . . . . . . . . . . . . . . . . . . . 5A1­47 Torque Converter Lock­Up Clutch(TCC) Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­48 TCM Initialization Procedure . . . . . . . . . . . . . . 5A1­50 Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . 5A1­51 Internal Wiring Harness Check . . . . . . . . . . . . 5A1­51 Transaxle Wiring Harness Connector . . . . . . . 5A1­54 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5A1­56 DIAGNOSTIC TROUBLE CODE DIAGNOSIS 5A1­60 Diagnostic Trouble Code (DTC) Identification 5A1­60 DTC P0562 ­ System Voltage Low . . . . . . . . . 5A1­68 DTC P0563 ­ System Voltage High . . . . . . . . 5A1­71 DTC P0601 ­ Internal Control Module Memory Checksum Error . . . . . . . . . . . . . . . . . . . . . . . 5A1­74 DTC P0603 ­ Internal Control Module Keep Alive Memory(KAM) Error . . . . . . . . . . . . . . . 5A1­76 DTC P0604 ­ Internal Control Module Random Access Memory(RAM) Error . . . . . . . . . . . . . 5A1­78 DTC P0606 ­ Transaxle Control Module Processor Fault . . . . . . . . . . . . . . . . . . . . . . . . 5A1­80 DTC P0703 ­ Brake Switch Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­83 DTC P0705 ­ Transmission Range Sensor Circuit Malfunction(PRNDL Input) . . . . . . . . 5A1­86 DTC P0710 ­ Transmission Fluid Temperature Sensor Circuit Malfunction . . . . . . . . . . . . . . 5A1­89 DTC P0715 ­ Input Speed Sensor(ISS) Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­92 DTC P0716 ­ Input Speed Sensor(ISS) Circuit Range/Performance . . . . . . . . . . . . . . . . . . . . 5A1­95 DTC P0717 ­ Input Speed Sensor(ISS) Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­98 DTC P0720 ­ Output Speed Sensor(OSS) Circuit Malfunction . . . . . . . . . . . . . . . . . . . . 5A1­101 DTC P0721 ­ Output Speed Sensor(OSS) Circuit Range/Performance . . . . . . . . . . . . . 5A1­104

5A1 ­ 2IZF 4 HP 16 AUTOMATIC TRANSAXLE
DTC P0722 ­ Output Speed Sensor(OSS) Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . 5A1­107 DTC P0725 ­ Engine Speed Input Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­110 DTC P0726 ­ Engine Speed Input Circuit Range/Performance . . . . . . . . . . . . . . . . . . . 5A1­112 DTC P0727 ­ Engine Speed Input Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­114 DTC P0731 ­ Gear 1 Incorrect Ratio . . . . . . 5A1­116 DTC P0732 ­ Gear 2 Incorrect Ratio . . . . . . 5A1­118 DTC P0733 ­ Gear 3 Incorrect Ratio . . . . . . 5A1­120 DTC P0734 ­ Gear 4 Incorrect Ratio . . . . . . 5A1­122 DTC P0781 ­ 1­2 Shift Malfunction . . . . . . . 5A1­124 DTC P0782 ­ 2­3 Shift Malfunction . . . . . . . 5A1­126 DTC P0783 ­ 3­4 Shift Malfunction . . . . . . . 5A1­128 DTC P1604 ­ Data Check of Internal & Extended Ram Failed . . . . . . . . . . . . . . . . . . 5A1­130 DTC P1606 ­ Failure Of External Watchdog 5A1­132 DTC P1671 ­ CAN Transmit Message Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­134 DTC P1672 ­ CAN Bus Off Failure . . . . . . . . 5A1­136 DTC P1673 ­ CAN Receive ECM Message Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­138 DTC P1839 ­ EDS 3 Output Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­140 DTC P1840 ­ EDS 3 Output Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­142 DTC P1841 ­ EDS 3 Output Open . . . . . . . . 5A1­144 DTC P1850 ­ Solenoid 1 Output Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­146 DTC P1851 ­ Solenoid 1 Output Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­148 DTC P1852 ­ Solenoid 1 Output Open . . . . 5A1­150 DTC P1853 ­ Solenoid 2 Output Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­152 DTC P1854 ­ Solenoid 2 Output Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­154 DTC P1855 ­ Solenoid 2 Output Open . . . . 5A1­156 DTC P1861 ­ EDS 4 Output Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­158 DTC P1862 ­ EDS 4 Output Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­160 DTC P1863 ­ EDS 4 Output Open . . . . . . . . 5A1­162 DTC P1864 ­ EDS 5 Output Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­164 DTC P1865 ­ EDS 5 Output Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­166 DTC P1866 ­ EDS 5 Output Open . . . . . . . . 5A1­168 DTC P1867 ­ EDS 6 Output Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­170 DTC P1868 ­ EDS 6 Output Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1869 ­ EDS 6 Output Open . . . . . . . . DTC P1871 ­ EDS Valve Power Supply Circuit Shorted to Power . . . . . . . . . . . . . . . DTC P1874 ­ Solenoid Valve Power Supply Circuit Shorted to Power . . . . . . . . . . . . . . . DTC P1881 ­ 2­1 Shift Malfunction . . . . . . . DTC P1883 ­ 3­2 Shift Malfunction . . . . . . . DTC P1884 ­ 4­3 Shift Malfunction . . . . . . . DTC P1885 ­ 3­1 Shift Malfunction . . . . . . . DTC P1886 ­ 4­2 Shift Malfunction . . . . . . . MAINTENANCE AND REPAIR . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . Transaxle Fluid Level Checking Procedure . Changing the Fluid . . . . . . . . . . . . . . . . . . . . . . Fluid Level Set After Service . . . . . . . . . . . . . Repairing Fluid Leaks . . . . . . . . . . . . . . . . . . . Case Porosity Repair . . . . . . . . . . . . . . . . . . . . Shift Control Lever Assembly . . . . . . . . . . . . . Shift Control Cable . . . . . . . . . . . . . . . . . . . . . . Shift Control Cable Adjustment . . . . . . . . . . . Transaxle Control Module(TCM) . . . . . . . . . . Park/Neutral Start Switch . . . . . . . . . . . . . . . . Oil Cooler Pipes/Hoses . . . . . . . . . . . . . . . . . . Drive Axle Oil Seal . . . . . . . . . . . . . . . . . . . . . . Oil Pan, Oil Pan Gasket . . . . . . . . . . . . . . . . . Control Valve Body Assembly . . . . . . . . . . . . Left Transaxle Mounting Bracket . . . . . . . . . . Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter . . . . . . . . . . . . . . . . . . . . . . . Transaxle Holding Fixture Assembly . . . . . . . Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch B/E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch B/E Measurement Procedure . . . . . . Planetary Gear Set . . . . . . . . . . . . . . . . . . . . . Brake C/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake F, Slotted Nut . . . . . . . . . . . . . . . . . . . . . Torque Converter Housing . . . . . . . . . . . . . . . Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . Parking Lock System . . . . . . . . . . . . . . . . . . . . Bearing Plate(With Spur Gear) Assembly . . Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . Differential/Side Shaft Outer Race, Bearing Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­172 5A1­174 5A1­176 5A1­178 5A1­180 5A1­182 5A1­184 5A1­186 5A1­188 5A1­190 5A1­190 5A1­190 5A1­191 5A1­192 5A1­192 5A1­193 5A1­193 5A1­195 5A1­196 5A1­197 5A1­198 5A1­199 5A1­201 5A1­201 5A1­203 5A1­205 5A1­206 5A1­212 5A1­212 5A1­212 5A1­212 5A1­213 5A1­214 5A1­217 5A1­220 5A1­221 5A1­224 5A1­224 5A1­225 5A1­227 5A1­228 5A1­229 5A1­229 5A1­229 5A1­230
DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 3
Important Measurement/Adjustment . . . . . . . 5A1­230 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­232 Mechanical Components . . . . . . . . . . . . . . . . . 5A1­232 Electronical Components . . . . . . . . . . . . . . . . 5A1­236 TCM Inputs That Affect the 4HP 16 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­241

INTRODUCTION
ZF 4HP 16 AUTOMATIC TRANSAXLE
The ZF 4 HP 16 is a four­speed automatic transaxle designed for cars with front­wheel drive and a transversely mounted engine. The transaxle has a hydrodynamic torque converter with a controlled slip lock­up clutch. A planetary gear train establishes the mechanical gear ratios. The integral constant ratio can be adapted to the engine's power output and the vehicle's weight. The electronic­hydraulic control makes controlled power shifts and various shift programs possible. In selector lever position "P", the output is locked mechanically. The special feature of this transaxle is that it operates without freewheels. Shifting between individual gears takes place by means of overlapping clutch engagement and release. The advantage of overlap shifting is as follows: ­ The transaxle can be of more compact design and is lighter on account of the absence of freewheels and the lower number of shift elements ­ Lower drag losses, i.e. higher efficiency ­ Lower peak torques acting on the components and driveline. However, overlap shifting necessitates high­performance hardware and software, and precision engine signals.

DAEWOO V­121 BL4

5A1 ­ 4IZF 4 HP 16 AUTOMATIC TRANSAXLE

TRANSAXLE COMPONENTS

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 5

SPECIFICATIONS
GENERAL SPECIFICATIONS
Definition Transaxle Type Input Torque Transaxle Weight Torque Converter Capacity Transaxle Fluid Type (manufacture company) Transaxle Fluid Capacity 4­speed with four­wheel drive and transverse engine 240 NSm (177 lb­ft) 76kg (168 lb) 9.72kg (21.4 lb) ESSO LT 71141 or TOTAL ATF H50235 7.3qt (6.9L)

TRANSAXLE GEAR RATIO
Gear First Second Third Fourth Reverse Final Ratio 2.719 1.487 1.000 0.717 2.529 3.945:1

FLUID CAPACITY
Litres Bottom Pan Removal Complete Overhaul Torque Converter Removal (Measurements are approximate) 4 6.9 2 Quarts 4.2 7.3 2.1

FASTENER TIGHTENING SPECIFICATIONS
Application Bearing Plate Bolts Slotted Nut Rear Cover Attachment Bolts Baffle Plate Attachment Bolts Park/Neutral Position Switch Fluid Pump Connecting Bolts Fluid Filter Housing Cover Attachment Bolts Input Speed sensor Attachment Bolts Output Speed Sensor Attachment Bolts Valve Body Bolts Valve Body Upper & Lower Fixing Bolts Fluid Pan Connecting Bolts Fluid Pan Drain Plug
DAEWOO V­121 BL4

NSm 23.5 220 23.5 10 10 10 10 8 8 8 6 6 45

Lb­Ft 17.5 162 17.5 ­ ­ ­ ­ ­ ­ ­ ­ ­ 33

Lb­In ­ ­ ­ 89 89 89 89 71 71 71 53 53 ­

5A1 ­ 6IZF 4 HP 16 AUTOMATIC TRANSAXLE
Application Fluid Level Plug Line Pleasure Plugs Valve Housing 1 Cover Attachment Bolts Solenoid Valve Attachment Bolts Pressure Control Regulator(EDS) Attachment Bolts Oil Cooler Inlet Pipe Bolts Oil Cooler Outlet Pipe Bolts Shift Control Cable Adjuster Pinch Nut Shift Control Cable Attachment Nut Upper Transaxle­to­Engine Bolts Selector Lever(On Transaxle Case) Torque Converter Attachment Bolts Shift Control Assembly Mounting Bolt, Nut Lower Engine­to­Transaxle Bolts(a) Lower Engine­to­Transaxle Bolt(b) Lower Engine­to­Transaxle Bolts(c) Rear Transaxle Mounting Bracket Bolts Damping Block Connection Bolt and Nut Left Transaxle Mount Bracket Cage Bolt(a) Left Transaxle Mount Bracket Cage Bolt(b) Left Transaxle Mount Bracket Cage Nut(c) Left Transaxle Mounting Bolts NSm 45 20 6 6 6 35 35 8 8 75 15 45 8 75 21 31 62 68 110 65 65 48 Lb­Ft 33 15 ­ ­ ­ 26 26 ­ ­ 55 11 33 ­ 55 15 23 45 50 81 48 48 35 Lb­In ­ ­ 53 53 53 ­ ­ 71 71 ­ ­ ­ 71 ­ ­ ­ ­ ­ ­ ­ ­ ­

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 7
Range Park/ Neutr al N ON ON OFF Rever se R ON/ OFF ON OFF 1st ON/ OFF ON OFF 2nd ON/ OFF OFF ON D 3 2 1

Gear Solenoid Valve 1 Solenoid Valve 2 Line Pressure Control Solenoid Valve 3 (EDS 3) Line Pressure Control Solenoid Valve 4 (EDS 4) Line Pressure Control Solenoid Valve 5 (EDS 5) Line Pressure Control Solenoid Valve 6 (EDS 6) Brake B Brake C Brake D Clutch E Brake F Lock­up Clutch

3rd ON/ OFF OFF ON/ OFF

4th ON/ OFF OFF ON/ OFF

1st ON/ OFF ON OFF

2nd ON/ OFF OFF ON

3rd ON/ OFF OFF ON/ OFF

1st ON/ OFF ON OFF

2nd ON/ OFF OFF ON

1st ON/ OFF ON OFF

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

ON

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

ON

ON

ON

ON

OFF

ON

ON

ON

OFF

ON

ON

ON

ON

ON

ON

A

A H

A

A H A A A

A

A

A

A

A H H

A H

A H H

H

H A

A = Applied H = Holding ON = The solenoid is energized. OFF = The solenoid is de­energized. ** = Manual Second­Third gear is only available above approximately 100 km/h (62 mph). *** = Manual First­Second gear is only available above approximately 60 km/h (37 mph). Note : Manual First­Third gear is also possible at high vehicle speed as a safety feature.

SHIFT SPEED CHART
Up Shift Speed
MODEL First­Second gear (±3.0 mph (4.8km/h)) 10% TPS 1.8 DOHC mph (km/h) 9 (15) 25% TPS 11 (18) 50% TPS 18 (29) 100% TPS 32 (52) Second­Third gear (±4.0 mph (6.4km/h)) 10% TPS 18 (29) 25% TPS 23 (37) 50% TPS 34 (55) 100% TPS 62 (99) Third­Fourth gear (±5.0 mph (8km/h)) 10% TPS 25 (45) 25% TPS 34 (55) 50% TPS 47 (76) 100% TPS 98 (157)

DAEWOO V­121 BL4

5A1 ­ 8IZF 4 HP 16 AUTOMATIC TRANSAXLE Down Shift Speed
MODEL Down Shift (±4.0 mph (6.4km/h)) Lock Up Clutch Applied (Fourth) 10% 25% Lock Up Clutch Released (Fourth) 10% 25%

Fourth­Th ird (Coast) 1.8 DOHC mph (km/h) 25 (41)

Third­Sec ond (Coast) 13 (21)

Second­Fi rst (Coast) 7 (11)

48 (77)

48 (77)

42 (68)

42 (68)

LINE PRESSURE
Gear Range Park / Neutral Solenoid ON OFF Reverse ON OFF Drive ON OFF 3 ON OFF 2 ON OFF 1 ON OFF Line Pressure LOW HIGH LOW HIGH LOW HIGH LOW HIGH LOW HIGH LOW HIGH 90~124.7 psi (6.2~8.6 bar) 221.9~252.3 psi (15.3~17.4 bar) 90~124.7 psi (6.2~8.6 bar) 221.9~252.3 psi (15.3~17.4 bar) B Port 90~124.7 psi (6.2~8.6 bar) 221.9~252.3 psi (15.3~17.4 bar) 89.9~124.7 psi (6.2~8.6 bar) 221.9~252.3 psi (15.3~17.4 bar) 90~124.7 psi (6.2~8.6 bar) 137.7~162.4 psi (9.5~11.2 bar) 90~124.7 psi (6.2~8.6 bar) 137.7~162.4 psi (9.5~11.2 bar) 90~124.7 psi (6.2~8.6 bar) 137.7~162.4 psi (9.5~11.2 bar) E Port

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 9

SPECIAL TOOLS
SPECIAL TOOLS TABLE

Scan Tool

DW260­030 Axle Seal Installer

DW110­060 Engine Support Fixture

DW260­050 Park/Neutral Position Switch Installer

DW260­020 Transaxle Holding Fixture

DW260­060 Brake F Split Stop Ring Remover/Installer

DW260­010 Transaxle Support Fixture

DW260­070 Transaxle Fluid Plug Remover/Installer

DAEWOO V­121 BL4

5A1 ­ 10IZF 4 HP 16 AUTOMATIC TRANSAXLE

DW240­010 Universal Pressure Gauge Set

DW260­120 Clutch B Adjust Ring

DW260­150 Clutch E Stop Ring Remove/Installer

DW260­130 Clutch E Adjust Ring

DW260­140 Clutch B Stop Ring Remover/Installer

DW260­100 Clutch B/E Disc Thickness Measuring Fixture

DW260­160 Brake C/D Snap Ring Remover/Installer

DW260­090 Clutch B/E (Snap Ring Play, Installation Space) Measuring Fixture

DW260­080 Clutch B/E Shim Setting Gauge

DW260­110 Brake F Disc Clearance Measuring Bar

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 11

SCHEMATIC AND ROUTING DIAGRAMS
TRANSAXLE CONTROL MODULE (1 OF 2)

DAEWOO V­121 BL4

5A1 ­ 12IZF 4 HP 16 AUTOMATIC TRANSAXLE

TRANSAXLE CONTROL MODULE (2 OF 2)

Switch

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 13

SHIFT MODE DIAGRAM
Economic Mode (1.8 DOHC)

DAEWOO V­121 BL4

5A1 ­ 14IZF 4 HP 16 AUTOMATIC TRANSAXLE Lock­up Clutch Applied (Economic Mode ; Fourth Gear) (1.8 DOHC)

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 15 Power Mode (1.8 DOHC)

DAEWOO V­121 BL4

5A1 ­ 16IZF 4 HP 16 AUTOMATIC TRANSAXLE Hold Mode (1.8 DOHC)

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 17

POWER FLOW DIAGRAM
Park/Neutral

DAEWOO V­121 BL4

5A1 ­ 18IZF 4 HP 16 AUTOMATIC TRANSAXLE Park/Neutral
In Park or Neutral with the engine running there is no drive to the planetary gear set. Line pressure (from the oil pump) is supplied to the valve body. Only clutch B is supplied and the torque converter is released. Control Line Pressure Control Valve The line pressure control valve sets the general pressure level in the valve body. When gearshifts are not taking place, the line pressure varies between two levels, depending on the turbine torque. Line pressure increase linearly by time. But it has a limit point. When pressure reaches that point, excess oil pressure drains back into the oil sump. Reduction Valve The reduction valve reduces the line pressure with which the downstream solenoid valves and pressure control solenoid valves (EDS) are supplied. This makes it possible to use smaller solenoid valves. The line pressure comes from the oil pump and flows to the reduction valve. The inlet port to the reduction valve will be blocked and line pressure will be maintained at the appropriate level. Solenoid Valve 1, 2 Solenoid Valve 1 controls the line pressure (high and low) to the clutch valves. Solenoid Valve 1 is either ON or OFF. When the solenoid is turned ON the line pressure will be low [87~116psi (6~8bar)].When the solenoid is turned OFF the line pressure will be high [232~261psi (16~18bar)]. Solenoid 2 controls the fluid flow to clutch valve E or the TCC clutch valve. When solenoid 2 is ON fluid is directed to the TCC pressure valve and if the solenoid is switched OFF fluid will flow to the inlet at clutch valve E. Clutch B Engaged In Park and Neutral solenoid valves 1 and 2 are both ON. Pressure control solenoids (EDS) 4 and 6 are also turned ON. When EDS 6 is ON, the fluid supplied from the reduction valve flows to the safety valve, clutch valve B and holding valve B. The oil that is supplied to the inlet port of the clutch valve presses on the valve spool. Line pressure then flows to the holding valve and check ball, engaging clutch B. Lock­up Clutch (TCC) Solenoid 2 is turned ON and the line pressure control valves spool will be depressed. Fluid will now flow through the torque converter pressure valve. As a result, the oil pressure behind the converter lock­up clutch piston and in the turbine zone is equal. The direction of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber. Lubrication/Cooling. The lubricating valve ensures that the converter is supplied with cooling oil first if the pump rate is low. The lubricating pressure valve in addition guarantees that the necessary amount of cooling and lubricating oil is available via the bypass duct. The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve. The TCM monitors numerous inputs to determine the appropriate solenoid state combination and transaxle gear for the vehicle operating conditions. In Park and Neutral solenoid valve 1 is ON. So line pressure flows to the safety valve and the line pressure control valve via the solenoid valve.

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 19 Reverse

DAEWOO V­121 BL4

5A1 ­ 20IZF 4 HP 16 AUTOMATIC TRANSAXLE Reverse
In Reverse, transaxle drive is via the input shaft and clutch B. The elements of this transaxle function are as follows: S S Clutch B is engaged and drives the reverse sun gear in a clock­­wise direction. The D band is engaged and holds the planetary gear carrier (front & rear) stationary causing the differential pinion to rotate clockwise. The differential rotates in a counterclockwise direction. The output shaft is driven in a counterclockwise or reverse direction. In Reverse, solenoid 1 is switched ON and EDS 4 is switched OFF. This will cause the fluid supplied to the reduction valve to flow to clutch valve D via the EDS 4. The spool of clutch valve D will be depressed allowing fluid to pass to holding valve D. Lock­up Clutch (TCC) Solenoid 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve. As a result, the oil pressure behind the converter lock­up clutch piston and in the turbine zone is equal. The direction of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber. Lubrication/Cooling The lubricating valve ensures that the converter is supplied with cooling oil first if the pump rate is low. The lubricating pressure valve in addition guarantees that the necessary amount of cooling and lubricating oil is available via the bypass duct. The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.

S S

Control Clutch B Engaged The line pressure, which is supplied by the oil pump, is directed to clutch B via the manual valve. The position of the check ball will change allowing direct pressure to clutch B. Brake D Engaged The line pressure, which engaged clutch B, is also supplied to clutch valve D.

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 21 Drive Range ­ First Gear

DAEWOO V­121 BL4

5A1 ­ 22IZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range ­ First Gear
In Drive 1, transaxle drive is via the input shaft to clutch B. The elements of this transaxle function are as follows: S S S Clutch B is engaged to drive the rear sun gear. The rear sun gear drives the front planetary gear carrier clockwise. The rear planetary gear carrier drives the front ring gear and front planetary gear carrier clockwise. Clutch F Engaged EDS 5 will be switched ON. The line pressure, which passed through the reduction valve, will flow to the holding valve and the clutch valve inlet. As a result the valve spool is depressed. Lock­up Clutch (TCC) Solenoid 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve. As a result, the oil pressure behind the converter lock­up clutch piston and in the turbine zone is equal. The direction of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber. Lubrication/Cooling The lubricating valve ensures that the converter is sup­ plied with cooling oil first if the pump rate is low. The lubricating pressure valve in addition guarantees that the necessary amount of cooling and lubricating oil is available via the bypass duct. The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.

Control Clutch B Engaged In Park and Neutral solenoid valves 1 and 2 are both ON. Pressure control solenoids (EDS) 4 and 6 are also turned ON. When EDS 6 is ON, the fluid supplied from the reduction valve flows to the safety valve, clutch valve B and holding valve B. The oil that is supplied to the inlet port of the clutch valve presses on the valve spool. Line pressure then flows to the holding valve and check ball, engaging clutch B.

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 23 Drive Range ­ Second Gear

DAEWOO V­121 BL4

5A1 ­ 24IZF 4 HP 16 AUTOMATIC TRANSAXLE
Clutch F Engaged EDS 5 will be switched ON. The line pressure, which passed through the reduction valve, will flow to the holding valve and the clutch valve inlet. As a result the valve spool is depressed. Lock­up Clutch Solenoid valve 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve. As a result, the oil pressure behind the converter lock­up clutch piston and in the turbine zone is equal. The direction of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber. Lubrication/Cooling The lubricating valve ensures that the converter is supplied with cooling oil first if the pump rate is low. The lubricating pressure valve in addition guarantees that the necessary amount of cooling and lubricating oil is available via the bypass duct. The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.

Drive Range ­ Second Gear
In Drive 2, the transaxle drive is via the input shaft and clutch E. The elements of this transaxle function are as follows: S S S S Clutch E is applied to drive the front ring gear. The front ring gear drives the front planetary gear carrier. The front planetary gear carrier drives the differential pinion gear clockwise. Brake F is applied holding the front sun gear stationary.

Control Clutch E Engaged Solenoid 2 will be switched OFF. Line pressure, which is supplied by the reduction valve, flows to the inlet port of clutch valve E. Fluid will then pass through the clutch valve and clutch E will engage.

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 25 Drive Range ­ Third Gear

DAEWOO V­121 BL4

5A1 ­ 26IZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range ­ Third Gear
In Drive 3, transaxle drive is via the input shaft to clutches B and E. The elements of this transaxle function are as follows: S S Clutches B and E are engaged to drive the rear sun gear and rear planetary gear carrier clockwise. The clockwise rotation of the rear sun gear and rear planetary gear carrier will cause the front planetary gear to rotate in the same direction. Pressure control solenoids (EDS) 4 and 6 are also turned ON. When EDS 6 is ON, the fluid supplied from the reduction valve flows to the safety valve, clutch valve B and holding valve B. The oil that is supplied to the inlet port of the clutch valve presses on the valve spool. Line pressure then flows to the holding valve and check ball, engaging clutch B. Lock­up Clutch (TCC) Solenoid valve 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve. As a result, the oil pressure behind the converter lock­up clutch piston and in the turbine zone is equal. The direction of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber.

Control Clutch B Engaged In Park and Neutral solenoid valves 1 and 2 are both ON.

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 27 Drive Range ­ Fourth Gear

DAEWOO V­121 BL4

5A1 ­ 28IZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range ­ Fourth Gear
In Drive 4, transaxle drive is via the input shaft and clutches E and C. The elements of this transaxle function are as follows: S S S Clutch E is engaged to drive the rear planetary gear carrier. The rear planetary gear carrier drives the rear ring gear. The rear ring gear carrier drives the differential gear. Clutch C Engaged EDS 4 will be switched OFF causing the fluid level to be high. Line pressure will be directed to the safety valve, clutch valve D and holding valve D. Clutch valve C and holding valve C will engage as pressure flows through the safety valve. Lock­up Clutch Solenoid valve 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve. As a result, the oil pressure behind the converter lock­up clutch piston and in the turbine zone is equal. The direction of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber.

Control Clutch E Engaged Solenoid 2 will be switched OFF. Line pressure, which is supplied by the reduction valve, flows to the inlet port of clutch valve E. Fluid will then pass through the clutch valve and clutch E will engage.

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 29 Drive Range ­ Fourth Gear ; Emergency/Substitute Mode

DAEWOO V­121 BL4

5A1 ­ 30IZF 4 HP 16 AUTOMATIC TRANSAXLE
Control

Drive Range ­ Fourth Gear ; Emergency/Substitute Mode
In Drive 4, transaxle drive is via the input shaft and clutches E and C. The elements of this transaxle function are as follows: S S S Clutch E is engaged to drive the rear planetary gear carrier. The rear planetary gear carrier drives the rear ring gear. The rear ring gear carrier drives the differential gear.

Clutch E Engaged Solenoid 2 will be switched OFF. Line pressure, which is supplied by the reduction valve, flows to the inlet port of clutch valve E. Fluid will then pass through the clutch valve and clutch E will engage. Clutch C Engaged EDS 4 will be switched OFF causing the fluid level to be high. Line pressure will be directed to the safety valve, clutch valve D and holding valve D. Clutch valve C and holding valve C will engage as pressure flows through the safety valve.

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 31 Drive Range ­ Third Gear ; Emergency/Substitute Mode

DAEWOO V­121 BL4

5A1 ­ 32IZF 4 HP 16 AUTOMATIC TRANSAXLE
Control

Drive Range ­ Third Gear ; Emergency/Substitute Mode
In Drive 3, transaxle drive is via the input shaft to clutches B and E. The elements of this transaxle function are as follows: S S Clutches B and E are engaged to drive the rear sun gear and rear planetary gear carrier clockwise. The clockwise rotation of the rear sun gear and rear planetary gear carrier will cause the front planetary gear to rotate in the same direction.

Clutch B Engaged In Park and Neutral solenoid valves 1 and 2 are both ON. Pressure control solenoids (EDS) 4 and 6 are also turned ON. When EDS 6 is ON, the fluid supplied from the reduction valve flows to the safety valve, clutch valve B and holding valve B. The oil that is supplied to the inlet port of the clutch valve presses on the valve spool. Line pressure then flows to the holding valve and check ball, engaging clutch B.

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 33

COMPONENT LOCATOR
TRANSAXLE IDENTIFICATION INFORMATION

1. 2.

Part Number Serial Number

3. 4.

Model Code Manufactured Nation and Company

DAEWOO V­121 BL4

5A1 ­ 34IZF 4 HP 16 AUTOMATIC TRANSAXLE

TORQUE CONVERTER

1. 2. 3. 4. 5. 6. 7. 8. 9.

Torque Converter Housing Torque Converter Torque Converter Gasket Steel Gasket Oil Baffle Plate Bolt Magnet Oil Filter O­ring

10. 11. 12. 13. 14. 15. 16. 17.

Screw Pressure Plug Pressure Plug Oil Drain Plug Oil Level Plug Screw Bolt Bolt

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 35

TRANSAXLE HOUSING

1. 2. 3. 4. 5. 6. 7. 8. 9.

Transaxle Housing Bushing Shaft Seal Axle Shaft Seal Sealing Sleeve Breather Pipe Sleeve Protector Type Plate Cable Terminal

10. 11. 12. 13. 14. 15. 16. 17.

Output Speed Sensor Washer Bolt Shim Shim Park/Neutral Position Switch Bolt Sealing sleeve

DAEWOO V­121 BL4

5A1 ­ 36IZF 4 HP 16 AUTOMATIC TRANSAXLE

OIL PUMP

1. 2. 3. 4.

Oil Pump Oil Pump Seal Washer O­ring

5. 6. 7.

Dowel Pin Bolt Bolt

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 37

REAR COVER & OIL PAN COVER

1. 2. 3. 4. 5. 6.

Rear Cover Piston Ring O­ring Needle Bearing Shim Screw Plug

7. 8. 9. 10. 11.

Bolt Oil Pan Oil Pan Gasket Oil Pan Bracket Bolt

DAEWOO V­121 BL4

5A1 ­ 38IZF 4 HP 16 AUTOMATIC TRANSAXLE

PARKING LEVER

1. 2. 3. 4. 5.

Selector Shaft Stop Bushing Detent Disc Clamping Sleeve Connecting Bar

6. 7. 8. 9.

Leg Spring Pawl Pin Support Bolt

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 39

INPUT SHAFT & SHIFT GEAR

DAEWOO V­121 BL4

5A1 ­ 40IZF 4 HP 16 AUTOMATIC TRANSAXLE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. Inner Disc Carrier F Clutch Plate F Line Clutch Disc F Clutch Outer Disc F Spring Disc Stop Ring Cup Spring O­ring O­ring Piston D Slotted Nut Roller Bearing Adjust Ring Bearing Plate Roller Bearing Spur Gear Piston D Spring Disc Snap Ring Clutch Plate D Cup Spring Line Clutch Disc D Spring Disc Disc Carrier C/D Pitting Key Line Clutch Disc C Clutch Outer Disc C Cup Spring Line Clutch Disc C Snap Ring Piston C Cylinder C Snap Ring Front Ring Gear Oil Tray Front Planetary Gear Front Sun Gear Snap Ring Needle Bearing 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. Rear Planetary Gear Set Snap Ring Rear Sun Gear Needle Bearing Snap Ring Piston B Clutch Plate B Clutch Outer Disc B Line Clutch Disc B Spring Disc Piston Ring Inner Disc Carrier E Needle Bearing Snap Ring Clutch Plate Disc E Line Clutch Disc E Clutch Outer Disc E Spring Disc Retainer Ring O­ring Oil Dam Cup Spring O­ring Piston E O­ring Input Shaft O­ring O­ring Piston Oil Dam O­ring Cup Spring Stop Ring Shim Needle Bearing O­ring Piston Ring Rear Cover

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 41

VALVE BODY

1. 2. 3. 4. 5. 6. 7. 8.

Control Valve Body Valve Body Wiring Harness O­ring Plug Cable Terminal Retaining Clip Input Speed Sensor Cap Screw

9. 10. 11. 12. 13. 14. 15.

Solenoid Valve Cap Screw Fixing Plate Fixing Plate Cap Screw Solenoid Valve Solenoid Valve

DAEWOO V­121 BL4

5A1 ­ 42IZF 4 HP 16 AUTOMATIC TRANSAXLE

GEAR SHIFT CONTROL

1. 2. 3. 4. 5. 6.

Selector Control Lever Gear Shift Knob Cover Step Gate Slider BTSI Button Spring

7. 8. 9. 10. 11. 12.

Positioning Spring Solenoid Base Plate T/A Lever Select Cable Cable Fastener

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 43

DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSIS
BASIC KNOWLEDGE REQUIRED
You must be familiar with some basic electronics to use this section of the Service Manual. They will help you to follow diagnostic procedures. Notice : Lack of the basic knowledge of this transaxle when performing diagnostic procedures could result in incorrect diagnostic performance or damage to transaxle components. Do not, under any circumstances, attempt to diagnose a transaxle problem without this basic knowledge. Notice : If a wire is probed with a sharp instrument and not properly sealed afterward, the wire will corrode and an open circuit will result. Diagnostic test probes are now available that allow you to probe individual wires without leaving the wire open to the environment. These probe devices are inexpensive and easy to install, and they permanently seal the wire from corrosion. S S Check all electrical connections for tightness. Use on­board diagnostic tool or a scan tool to see if any transaxle trouble codes have been set. Refer to the appropriate "Diagnostic Trouble Code (DTC)" information and repair the vehicle as directed. After repairing the vehicle, perform the road test and verify that the code has not set again. Perform the Electrical/Garage Shift Tests. Perform the Road Test Procedure in this section. Inspect the oil and check for metal or other contaminants in the oil pan.

S S S

LINE PRESSURE CHECK PROCEDURE
The 4HP 16 A/T uses a trochoid type oil pump to produce hydraulic pressure, and a pressure control solenoid (solenoid 1) to control that pressure at the pressure regulator valve, after it leaves the pump. The transaxle pressure control solenoid is controlled by an electrical signal that ranges from 0 to 12 volts corresponds to minimum line pressure (approx. 89.9 to 124.7 psi (6.2 to 8.6 bar)) and 0 volt corresponds to a maximum line pressure (approx. 221.9 to 252.4 psi (15.3 to 17.4 bar)) in all range. Line pressures are calculated for two sets of gear ranges ­ Drive­Park­Neutral and Reverse. This allow the transaxle line pressure to be appropriate for different pressure needs in different gear ranges: Gear Range Drive, Reverse Solenoid 1 Off On Neutral, Park Off On RPM 2,500 2,500 2,500 2,500 Pressure 221.9~252.4psi (15.3~17.4 bar) 17.4~269.8psi (1.2~18.6 bar) 221.9~252.4psi (15.3~17.4 bar) 89.9~269.8 psi (6.2~18.6 bar)

Special Tools
You should be able to use a Digital Volt Meter (DVM), a circuit tester, jumper wires or leads and a line pressure gauge set. The functional check procedure is designed to verify the correct operation of electronic components in the transaxle. This will eliminate the unnecessary removal of transaxle components.

FUNCTIONAL CHECK PROCEDURE
Begin with the Functional Check Procedure which provides a general outline of how to diagnose automatic transaxle. The following functional check procedure will indicate the proper path of diagnosing the transaxle by describing the basic checks and then referencing the locations of the specific checks. S S S S S S Check the fluid level according to the Fluid Level Service Procedure. Check the transaxle for fluid leaks. Check if the transaxle fluid is not burnt by color and smell. Ensure that the transaxle is not in Limp Home Mode(LHM). Check the battery terminals and the ground connections for corrosion or looseness. Check that the cooler flow is not restricted.

Before performing a line pressure check, verify that the pressure control solenoid is receiving the correct electrical signal from the TCM: 1. Install a scan tool. 2. Start the engine and set parking brake. 3. Check for a stored pressure control solenoid diagnostic trouble code, and other diagnostic trouble codes.

DAEWOO V­121 BL4

5A1 ­ 44IZF 4 HP 16 AUTOMATIC TRANSAXLE
4. S S S S Repair vehicle, if necessary. Inspect: Fluid level. Manual linkage. Install or Connect: Scan tool (scanner) Oil pressure gauge at line pressure port (clutch B or E ports on transaxle case) 6. 7. 8. Start engine and allow it to warm up at idle. Access the "Solenoid 1 Control Mode" on the scanner. Switching solenoid 1 ON/OFF, accelerating the engine to 2,500rpm, and then read the line pressure at the each gear. Compare data to the Drive­Park­Neutral line pressure chart below.

9.

Notice : Total test running time should not exceed 2 minutes, or transaxle damage could occur. CAUTION : Brake must be applied at all times to prevent unexpected vehicle motion. If pressure readings differ greatly from the line pressure chart, refer to the Diagnosis Charts contained in this section. Notice : Clutch damage may occur. The scanner is only able to control the pressure control solenoid in Park and Neutral with the vehicle stopped. This protects the clutches from extremely high or low pressures in Drive or Reverse rang. B Port 90~124.7 psi (6.2~8.6 bar) 221.9~252.3 ps i (15.3~17.4 bar) 90~124.7 psi (6.2~8.6 bar) 221.9~252.3 psi (15.3~17.4 bar) 90~124.7 psi (6.2~8.6 bar) 137.7~162.4 psi (9.5~11.2 bar) 90~124.7 psi (6.2~8.6 bar) 221.9~252.3 psi (15.3~17.4 bar) 90~124.7 psi (6.2~8.6 bar) 137.7~162.4 psi (9.5~11.2 bar) 90~124.7 psi (6.2~8.6 bar) 137.7~162.4 psi (9.5~11.2 bar) 90~124.7 psi (6.2~8.6 bar) 221.9~252.3 psi (15.3~17.4 bar) E Port

5.

Put gear selector in Park and set the parking brake. Gear Range Park / Neutral Solenoid ON OFF Reverse ON OFF Drive ON OFF 3 ON OFF 2 ON OFF 1 ON OFF Line Pressure LOW HIGH LOW HIGH LOW HIGH LOW HIGH LOW HIGH LOW HIGH

DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 45

CLUTCH PLATE DIAGNOSIS
Composition Plates
Dry the plate and inspect the plates for the following conditions : S S S S S S Pitting Flaking Wear Glazing Cracking Charring

6.

Flush the cooler lines after you have properly repaired or replaced the transaxle.

COOLER FLUSHING AND FLOW TEST
Notice : You must flush the cooler whenever you receive a transaxle for service. Cooler flushing is essential for SRTA installation, major overhaul, whenever you replace a pump or torque converter, or whenever you suspect that the fluid has been contaminated. After filling the transaxle with fluid, start the engine and run for 30 seconds. This will remove any residual moisture from the oil cooler. Disconnect the return line at the transaxle and observe the flow with the engine running. If the fluid flow is insufficient, check the fluid flow by disconnecting the feed line at the cooler. Observe the flow with the engine running. S If the flow from the cooler return line at the transaxle is insufficient, check the flow rate from the feed line to the cooler. BLockage exists in the transaxle or the cooler. If the flow from the transaxle feed line to the cooler is insufficient, the transaxle is the cause of the fluid flow problem. If the flow the transaxle feed line to the cooler is insufficient, but flow from the cooler return line to the transaxle is insufficient, inspect the cooler pipes and fittings. Then repeat the cooler flushing procedure. If the flow is still insufficient, replace the cooler.

Chips or metal particles embedded in the lining Replace a composition plate which shows any of these conditions.

Steel Plates
Wipe the plates dry and check the plates for heat discoloration. If the surfaces are smooth, even if colorsmear is indicated, you can reuse the plate. If the plate is discolored with hot spots or if the surface is scuffed, replace the plate. Important : If the clutch shows evidence or extreme heat or burning, replace the springs.

S

Causes of Burned Clutch Plates
The following conditions can result in a burned clutch plate: S S S S S S Incorrect usage of clutch plates. Engine coolant in the transaxle fluid. A cracked clutch piston. Damaged or missing seals. Low line pressure. Valve problems. ­ The valve body face is not flat ­ Porosity between channels ­ The valve bushing clips are improperly installed. ­ The check balls are misplaced. S The seal rings are worn or damaged

S

TRANSAXLE FLUID LEVEL SERVICE PROCEDURE
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in slipping and loss of drive/ reverse or delay on engagement of drive/ reverse when the vehicle is cold. The vehicle is first checked for transaxle diagnostic messages on the scan tool. If the oil level is low, it is possible to register a vehicle speed signal fault. The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of drive. One symptom of low fluid level is a momentary loss of drive when driving the vehicle around a corner. Also when the transaxle fluid level is low, a loss of drive may occur when the transaxle fluid temperature is low. When adding or changing transaxle fluid use only ESSO LT 71141 automatic transaxle fluid or other approved fluids. The use of incorrect fluid will cause the performance and durability of the transaxle to be severely degraded.

Engine Coolant in Transaxle
Notice : Antifreeze will deteriorate the O­ring seals and the glue used to bond the clutch material to the pressure plate. Both conditions may cause transaxle damage. Perform the following steps if the transaxle oil cooler has developed a leak, allowing engine coolant to enter the transaxle: 1. Because the coolant will attach to the seal material causing leakage, disassemble the transaxle and replace all rubber type seals. Because the facing material may become separated from the steel center portion, replace the composition faced clutch plate assemblies. Replace all nylon parts including washers. Replace the torque converter. Thoroughly clean and rebuild the transaxle, using new gaskets and oil filter.

2.

Fluid Level Diagnosis Procedure
1. If the vehicle is at operating temperature allow the vehicle to cool down for two hours, but no greater than four hours. Or if the vehicle is at cool status, start the engine and allow the engine to idle for approximately 5 minutes (825~875 rpm), if pos-

3. 4. 5.

DAEWOO V­121 BL4

5A1 ­ 46IZF 4 HP 16 AUTOMATIC TRANSAXLE
sible, drive the vehicle for a few kilometers (N­D, N­R, shift until two gear). This will allow the transaxle to be within the correct temperature range. Transaxle fluid level should be checked at temperature 20 to 45°C (68 to 113°F). CAUTION : Removal of the fluid filler plug when the transaxle fluid is hot may cause injury if fluid drains from the filler hole. 2. Switch off accessories, especially air conditioner, heater. 3. With the brake pedal pressed, move the gear shift control lever through the gear ranges, pausing a few seconds in each range. Return the gearshift lever to P(Park). Turn the engine OFF. 4. Park the vehicle on a hoist, inspection pit or similar raised level surface. The vehicle must be level to obtain a correct fluid level measurement. 5. Place a fluid container below the fluid filler plug. 6. Clean all dirt from around the fluid filler plug. Remove the fluid filler plug. Clean the filler plug and check that there is no damage to the "O" ring. S If fluid drains through the filler hole the transaxle may have been overfilled. When the fluid stops draining the fluid level is correct. Install the fluid filler plug and tighten it to 45NSm(34 lb­ft). If fluid does not drain through the filler hole, the transaxle fluid level may be low. Lower the vehicle, and start the vehicle in P(Park) with the parking brake and the brake applied. With the engine idling, move the gear shift lever through the gear ranges, pausing a few seconds in each range and adding the fluid until gear application is felt. Return the gear shift lever to P(Park). Turn the engine OFF and raise the vehicle. Check if the fluid level is aligned with the bottom of the filler hole. If not, add a small quantity of fluid to the correct level. Install the fluid filler plug and tighten it to 45NSm(34 lb­ft). move the gear shift lever through the gear ranges, pausing a few seconds in each range and adding the fluid until gear application is felt. Then add an additional 0.5 liters of fluid. Return the gear shift lever to P(Park). Turn the engine OFF and raise the vehicle. Install the fluid filler plug and tighten it to 45NSm (34 lb­ft). Drive the vehicle at 2.2 miles(3.5km) to 2.8 miles(4.5 km) with light throttle so that the engine does not exceed 2500 rpm. This should result in the transaxle temperature being in the range 20 to 45°C (68 to 11°F). With the brake applied, move the shift lever through the gear ranges, pausing a few seconds in each range at the engine idling. Return the gear shift lever to P(Park). Turn the engine OFF and raise the vehicle on the hoist, if applicable, ensuring the vehicle is level. When the three minutes passed after the engine stopped, remove the filler plug. Check if the fluid level is aligned with the bottom of the filler hole. If not, add a small quantity of fluid to the correct level. Install the fluid filler plug and tighten it to 45NSm (34 lb­ft). Wipe any fluid around the filler plug with a rag or shop towel.

5.

6.

7.

Fluid Leak Diagnosis and Repair
The cause of most external leaks can generally be Located and repaired with the transaxle in the vehicle.

S

Methods for Locating Leaks
General Method 1. Verify that the leak is transaxle fluid. 2. Thoroughly clean the suspected leak area. 3. Drive the vehicle for approximately 25 km (15 miles) or until the transaxle reaches normal operating temperature (88°C, 190°F). 4. Park the vehicle over clean paper or cardboard. 5. Turn the engine OFF and look for fluid spots on the paper. 6. Make the necessary repairs to correct the leak. Powder Method 1. Thoroughly clean the suspected leak area. 2. Apply an aerosol type powder (foot powder) to the suspected leak area. 3. Drive the vehicle for approximately 25 km (15 miles) or until the transaxle reaches normal operating temperature (88°C, 190°F). 4. Turn the engine OFF. 5. Inspect the suspected leak area and trace the leak path through the powder to find the source of the leak. 6. Make the necessary repairs. Dye and Black Light Method 1. Add dye to the transaxle though the transaxle fluid filler plug. Follow the manufacturer's recommendation for the amount of dye to be used. 2. Use the black light to find the fluid leak. 3. Make the necessary repairs.
DAEWOO V­121 BL4

7.

When the fluid level checking procedure is completed, wipe any fluid around the filler plug with a rag or shop towel. Depending on the service procedure performed, add the following amounts of fluid through the filler plug hole prior to adjusting the fluid level: Oil pan removal ­ 4 liters (4.23 quarts) Converter removal ­ 2 liters ( 2.11 quarts) Overhaul ­ 6.9liters (7.3 quarts) Oil drain plug removal ­ 4 liters (4.23 quarts)

Fluid Level Set After Service
1.

2. 3.

4.

Follow steps 1 through 4 of the Fluid Level Diagnosis Procedure. Clean all dirt from around the fluid filler plug. Remove the fluid filler plug. Clean the filler plug and check that there is no damage to the "O" ring. Lower the vehicle with the filler plug still removed and start the vehicle in P(Park) with the parking brake and the brake applied. With the engine idling,

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 47
Repairing the Fluid Leak Once the leak point is found the source of the leak must be determined. The following list describes the potential causes for the leak: S S S S S S S S S S Fasteners are not torqued to specification. Fastener threads and fastener holes are dirty or corroded. Gaskets, seals or sleeves are misarranged, damaged or worn. Damaged, warped or scratched seal bore or gasket surface. Loose or worn bearing causing excess seal or sleeve wears. Case or component porosity. Fluid level is too high. Plugged vent or damaged vent tube. Water or coolant in fluid. Fluid drain back holes plugged. 7. The A/C COMPRESSOR STATUS should come ON when the A/C switch is pressed, and turns OFF when the A/C switch is repushed. Monitor the GEAR SHIFT LEVER POSITION signal and move the gear shift control lever through all the ranges. S Verify that the GEAR SHIFT LEVER POSITION value matches the gear range indicated on the instrument panel or console. S Gear selections should be immediate and not harsh. Move gear shift control lever to neutral and monitor the THROTTLE POSITION signal while increasing and decreasing engine speed with the accelerator pedal. S S THROTTLE POSITION should increase with engine speed.

8.

ROAD TEST PROCEDURE
S S S Perform the road test using a scan tool. This test should be performed when traffic and road conditions permit. Observe all traffic regulations.

ELECTRICAL/GARAGE SHIFT TEST
This preliminary test should be performed before a hoist or road test to make sure electronic control inputs is connected and operating. If the inputs are not checked before operating the transaxle, a simple electrical condition could be misdiagnosed as a major transaxle condition. A scan tool provides valuable information and must be used on the automatic transaxle for accurate diagnosis. 1. 2. 3. 4. 5. Move gear selector to P (Park) and set the parking brake. Connect scan tool to Data Link Connector (DLC) terminal. Start engine. Turn the scan tool ON. Verify that the appropriate signals are present. These signals may include: S S S S S S S S S S S S S S S S S S 6. ENGINE SPEED VEHICLE SPEED THROTTLE POSITION TRANSAXLE GEAR STATE GEAR SHIFT LEVER POSITION TRANSAXLE FLUID TEMPERATURE CLOSED THROTTLE POSITION LEARN OPEN THROTTLE POSITION LEARNT CLOSED ACCEL. PEDAL POSITION LEARNT OPEN ACCEL. PEDAL POSITION LEARNT A/C COMPRESSOR STATUS MODE SWITCH THROTTLE POSITION VOLTAGE GEAR SHIFT LEVER POSITION VOLTAGE TRANS. FLUID TEMPERATURE VOLTAGE A/C SWITCH MODE SWITCH VOLTAGE BATTERY VOLTAGE

The TCM calculates upshift points based primarily on two inputs : throttle angle and vehicle speed. When the TCM wants a shift to occur, an electrical signal is sent to the shift solenoids which in turn moves the valves to perform the upshift. The shift speed charts reference throttle angle instead of "min throttle" or "wot" to make shift speed measurement more uniform and accurate. A scan tool should be used to monitor throttle angle. Some scan tools have been programmed to record shift point information. Check the introduction manual to see if this test is available.

Upshift Procedure
With gear selector in drive(D) 1. Look at the shift speed chart contained in this section and choose a percent throttle angle of 10 or 25%. Set up the scan tool to monitor throttle angle and vehicle speed. Accelerate to the chosen throttle angle and hold the throttle steady. As the transaxle upshifts, note the shift speed and commanded gear changes for : S S S Second gear. Third gear. Fourth gear.

2. 3. 4.

Important : Shift speeds may vary due to slight hydraulic delays responding to electronic controls. A change from the original equipment tire size affects shift speeds. Note when TCC applies. This should occur in fourth gear. If the apply is not noticed by an rpm drop, refer to the "Lock­up Clutch Diagnosis" information contained in this section.

Monitor the A/C COMPRESSOR STATUS signal while pushing the A/C switch.

DAEWOO V­121 BL4

5A1 ­ 48IZF 4 HP 16 AUTOMATIC TRANSAXLE
The Lock up clutch should not apply unless the transaxle has reached a minimum operating temperature of 8°C (46°F) TRANS TEMP AND engine coolant temp of 50°C (122°F). 5. Repeat steps 1­4 using several different throttle angles.

Manual Gear Range Selection
Upshifts in the manual gear ranges are controlled by the shift solenoids. Perform the following tests by accelerating at 25 percent TP sensor increments. Manual Third (3) S With vehicle stopped, move the gear selector to Manual third(3) and accelerate to observe : ­ 1­2 shift. ­ 2­3 shift. Manual Second (2) S With vehicle stopped, move the gear selector to Manual second(2) and accelerate to observe : ­ 1­2 shift. S Accelerate to 40km/h(25mph) and observe : ­ 2­3 shift does not occur ­ TCC does not apply Manual First (1) S With vehicle stopped, move gear selector to Manual First(1). Accelerate to 30km/h(19mph) and observe : ­ No upshifts occur Reverse (R) S With vehicle stopped, move gear selector to R(Reverse) and observe : ­ Solenoid 1 is OFF ­ Solenoid 2 is OFF Use a scan tool to see if any transaxle trouble codes have been set. Refer to "Diagnostic Trouble Codes"in this section and repair the vehicle as directed. After repairing the vehicle, perform the hoist test and verify that the code has not set again. If the transaxle is not performing well and no trouble codes have been set, there may be an intermittent condition. Check all electrical connections for damage or a loose fit. You also have to perform a snapshot test which can help catch an intermittent condition that dose not occur long enough to set a code. You may want to read "Electronic Component Diagnosis" in this section to become familiar with transaxle conditions caused by transaxle electrical malfunction. If no trouble codes have been set and the condition is suspected to be hydraulic, take the vehicle on a road test.

Part Throttle Detent Downshift
At vehicle steeds of 55 to 65km/h (34 to 40mph) in Fourth gear, quickly increase throttle angle to greater than 50%. Verify that : S S S S TCC apply. Transaxle downshift to 3rd gear. Solenoid 1 turns ON to OFF. Solenoid 2 turns OFF.

Full Throttle Detent Downshift
At vehicle speeds of 55 to 65km/h (34 to 40mph)in Fourth gear, quickly increase throttle angle to its maximum position (100%) Verify that : S S S S TCC release. Transaxle downshift to Second gear immediately. Solenoid 1 turns ON to OFF Solenoid 2 turns OFF.

Manual Downshifts
1. At vehicle speeds of 60km/h (40mph)in Fourth gear, release accelerator pedal while moving gear selector to Manual Third (3). Observe that : S S 2. Transaxle downshift to Third gear immediately. Engine slows vehicle down.

Move gear selector back to overdrive(D) and accelerate to 31mph (50km/h). Release the accelerator pedal and move the gear selector to Manual First(1) and observe that : S S Transaxle downshift to second gear immediately. Engine slows vehicle down

Notice : A Manual First­­Third Gear Ratio will occur at high speeds as an upshift safety feature. Do not attempt to perform this shift.

Coasting Downshifts
1. 2. With the gear selector in Overdrive(D), accelerate to Fourth gear with TCC applied. Release the accelerator pedal and lightly apply the brakes, and observe that : S S TCC release. Down shifts occur at speeds shown ON the shift speed chart.

TORQUE CONVERTER LOCK­UP CLUTCH(TCC) DIAGNOSIS
To properly diagnosis the lock­up clutch(TCC) system, perform all electrical testing first and then the hydraulic testing. The TCC is applied by fluid pressure which is controlled by a solenoid Located inside the valve body. The solenoid is energized by completing an electrical circuit through a combination of switches and sensors.
DAEWOO V­121 BL4

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ­ 49 Functional Check Procedure
Inspect 1. Install a tachometer or scan tool. 2. Operate the vehicle unit proper operating temperature is reached. 3. Drive the vehicle at 80 to 88km/h (50 to 55 mph) with light throttle(road load). 4. Maintaining throttle position, lightly touch the brake pedal and check for release of the TCC and a slight increase in engine speed(rpm). 5. Release the brake slowly accelerate and check for a reapply of the Lock up clutch and a slight decrease in engine speed(rpm). 1. 2. 3. Place foot on brake. Put gear selector in "Drive". Depress accelerator to approximately 1200rpm for no more than six seconds.

Notice : If the accelerator is depressed for more than six seconds, damage to the transaxle may occur. A torque converter noise will increase under this load. Important : This noise should not be confused with pump whine noise which is usually noticeable in P (Park), N (Neutral) and all other gear ranges. Pump whine will vary with pressure ranges. The torque converter should be replaced under any of the following conditions: S S S S S S External leaks in the hub weld area. Converter hub is scored or damaged. Converter pilot is broken, damaged or fits poorly into crankshaft. Steel particles are found after flushing the cooler and cooler lines. Pump is damaged or steel particles are found in the converter. Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses have been made.(Lock up clutch material may be glazed.) Converter has an imbalance which cannot be cor­ rected. (Refer To Converter Vibration Test Procedure.) Converter is contaminated with engine coolant containing antifreeze. Internal failure of stator roller clutch. Excess end play. Heavy clutch debris due to overheating (blue converter). Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are worn or damaged(indicates that lining material came from converter). The oil has an odor, is discolored, and there is no evidence of metal or clutch facing particles. The threads in one or more of the converter bolt holes are damaged. ­correct with thread insert. S Transaxle failure did not display evidence of damage or worn internal parts, steel particles or clutch plate lining material in unit and inside the fluid filter. Vehicle has been exposed to high mileage(only). The exception may be where the Lock up clutch damper plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic, such as taxi, delivery or police use.

Torque Converter Evaluation Torque Converter Stator
The torque converter stator roller clutch can have one of two different type malfunctions : A. Stator assembly freewheels in both directions. B. Stator assembly remains Locked up at all times.

Condition A ­ Poor Acceleration Low Speed
The car tends to have poor acceleration from a stand still. At speeds above 50 to 55km/h(30 to 35mph), the car may act normal. If poor acceleration is noted, it should first be determined that the exhaust system is not blocked, and the transaxle is in 1st(First) gear when starting out. If the engine freely accelerates to high rpm in N(Neutral), it can be assumed that the engine and exhaust system are normal. Checking for poor performance in "Drive" and "Reverse" will help determine if the stator is freewheeling at all times.

S

S S S S S

Condition B ­ Poor Acceleration High Speed
Engine rpm and car speed limited or restricted at high speeds. Performance when accelerating from a standstill is normal. Engine may overheat. Visual examination of the converter may reveal a blue color from overheating. If the converter has been removed, the stator roller clutch can be checked by inserting two fingers into the splined inner race of the roller clutch and trying to turn freely clockwise, but not turn or be very difficult to turn counter clockwise.

The torque converter should not be replace if : S S

Noise
Torque converter whine is usually noticed when the vehicle is stopped and the transaxle is in "Drive" or "Reverse". The noise will increase when engine rpm is increased. The noise will stop when the vehicle is moving or when the torque converter clutch is applied because both halves of the converter are turning at the same speed. Perform a stall test to make sure the noise is actually coming from the converter :
DAEWOO V­121 BL4

S

Lock­Up Clutch Shudder Diagnosis
The key to diagnosing lock­up clutch(TCC) shudder is to note when it happens and under what conditions.

5A1 ­ 50IZF 4 HP 16 AUTOMATIC TRANSAXLE
TCC shudder should only occur during the APPLY and/or RELEASE of the Lock up clutch. S S S S S S S S S EGR valve ­ valve may let it too much unburnable exhaust gas and cause engine to run lean. MAP sensor ­ like vacuum leak, engine won't get correct amount of fuel for proper engine operation. Carbon on intake valves ­ restricts proper flow or air/fuel mixture into cylinders. Flat cam ­ valves don't open enough to let proper fuel/air mixture into cylinders. Oxygen sensor ­ may command engine too rich or too lean for too long. Fuel pressure ­ may be too low. Engine mounts ­ vibration of mounts can be multiplied by TCC engagement. Axle joints ­ checks for vibration. TPS ­ TCC apply and release depends on the TPS in many engines. If TPS is out of specification, TCC may remain applied during initial engine starting. Cylinder balance ­ bad piston rings or poorly sealing valves can cause low power in a cylinder. Fuel contamination ­ causes poor engine performance.

While TCC Is Applying Or Releasing
If the shudder occurs while TCC is applying, the problem can be within the transaxle or torque converter. Something is not allowing the clutch to become fully engaged, not allowing clutch to release, or is trying to release and apply the clutch at the same time. This could be caused by leaking turbine shaft seals, a restricted release orifice, a distorted clutch or housing surface due to long converter bolts, or defective friction material on the TCC plate.

Shudder Occurs After TCC Has Applied :
In this case, most of the time there is nothing wrong with the transaxle! As mentioned above, once the TCC has been applied, it is very unlikely that will slip. Engine problems may go unnoticed under light throttle and load, but become noticeable after TCC apply when going up a hill or accelerating, due to the mechanical coupling between engine and transaxle. Important : Once TCC is applied there is no torque converter assistance. Engine or driveline vibrations could be unnoticeable before TCC engagement. Inspect the following components to avo