ZF4HP16 Automatic Transaxle Guide

15/6/2019 -ZF4HP16-Optra | Valve (7.
1K views)
: 5A1
ZF 4 HP 16 AUTOMATIC TRANSAX
CAUTION : Disconnect the negative battery cable before removing or installing any e
or equipment could easily come in contact with exposed electrical terminals. Discon
prevent personal injury and damage to the vehicle. The ignition must also be in LO
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 –3 Transaxle Fluid Level Servic
ZF 4HP 16 Automatic Transaxle . . . . . . . . . . . . 5A1 –3 Electrical/Garage Shift Test
Transaxle Components . . . . . . . . . . . . . . . . . . . . 5A1 –4 Road Test Procedure . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 –5 Torque Converter Lock–Up
Diagnosis . . . . . . . . . . . . .
General Specifications . . . . . . . . . . . . . . . . . . . . 5A1 –5
TCM Initialization Procedure
Transaxle Gear Ratio . . . . . . . . . . . . . . . . . . . . . . 5A1 –5
Shift Speed Chart . . . . . . . .
Fluid Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 –5
Internal Wiring Harness Che
Fastener Tightening Specifications . . . . . . . . . . 5A1 –5
Transaxle Wiring Harness C
Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 –7
Symptom Diagnosis . . . . . .
Line Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 –8
DIAGNOSTIC TROUBLE CO
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 –9
Diagnostic Trouble Code (D
Special Tools Table ....................... 5A1 –9 DTC P0562 – System Volta
SCHEMATIC AND ROUTING DIAGRAMS . . . 5A1 –11 DTC P0563 – System Volta
Transaxle Control Module (1 of 2) . . . . . . . . . . 5A1 –11 DTC P0601 – Internal Contr
Transaxle Control Module (2 of 2) . . . . . . . . . . 5A1 –12 Checksum Error . . . . . . .
Shift Mode Diagram . . . . . . . . . . . . . . . . . . . . . . 5A1 –13 DTC P0603 – Internal Contr
Alive Memory(KAM) Error
Power Flow Diagram . . . . . . . . . . . . . . . . . . . . . 5A1 –17
DTC P0604 – Internal Contr
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . 5A1–33 Access Memory(RAM) Er
Transaxle Identification Information . . . . . . . . 5A1–33 DTC P0606 – Transaxle Co
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . 5A1–34 Processor Fault . . . . . . . .
Transaxle Housing . . . . . . . . . . . . . . . . . . . . . . . 5A1–35 DTC P0703 – Brake Switch
Malfunction . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–36
DTC P0705 – Transmission
Rear Cover & Oil Pan Cover . . . . . . . . . . . . . . 5A1–37
Circuit Malfunction(PRND
P ki L
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15/6/2019 -ZF4HP16-Optra | Valve (7.1K views)
Parking Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–38
DTC P0710 – Transmission
Input Shaft & Shift Gear . . . . . . . . . . . . . . . . . . 5A1–39 Sensor Circuit Malfunction
Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–41 DTC P0715 – Input Speed S
Gear Shift Control ....................... 5A1–42 Malfunction . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES DTC P0716 – Input Speed S

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–43 Range/Performance . . .
Basic Knowledge Required . . . . . . . . . . . . . . . . 5A1–43 DTC P0717 – Input Speed S
No Signal . . . . . . . . . . . . .
Functional Check Procedure . . . . . . . . . . . . . . 5A1–43
DTC P0720 – Output Speed
Line Pressure Check Procedure . . . . . . . . . . . 5A1–43 Circuit Malfunction . . . .
Clutch Plate Diagnosis . . . . . . . . . . . . . . . . . . . 5A1–45 DTC P0721 – Output Speed
Cooler Flushing and Flow Test . . . . . . . . . . . . . 5A1–45 Circuit Range/Performanc
5A1 – 2 IZF 4 HP 16 AUTOMATIC TRANSAXLE
DTC P0722 – Output Speed Sensor(OSS) DTC P1868 – EDS 6 Outpu

Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . 5A1–107 Power . . . . . . . . . . . . . . . .
DTC P0725 – Engine Speed Input Circuit DTC P1869 – EDS 6 Outpu
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–110 DTC P1871 – EDS Valve Po
DTC P0726 – Engine Speed Input Circuit Circuit Shorted to Power
Range/Performance . . . . . . . . . . . . . . . . . . . 5A1–112 DTC P1874 – Solenoid Valv
DTC P0727 – Engine Speed Input Circuit No Circuit Shorted to Power
Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–114 DTC P1881 – 2–1 Shift Mal
DTC P0731 – Gear 1 Incorrect Ratio . . . . . . 5A1–116 DTC P1883 – 3–2 Shift Mal
DTC P0781 – 1–2 Shift Malfunction . . . . . . . 5A1–124 MAINTENANCE AND REPAI

DTC P0782 – 2–3 Shift Malfunction . . . . . . . 5A1–126 ON–VEHICLE SERVICE . .
DTC P0783 – 3–4 Shift Malfunction . . . . . . . 5A1–128 Transaxle Fluid Level Check
DTC P1604 – Data Check of Internal & Changing the Fluid . . . . . . .
Extended Ram Failed . . . . . . . . . . . . . . . . . . 5A1–130 Fluid Level Set After Service
DTC P1606 – Failure Of External Watchdog 5A1–132 Repairing Fluid Leaks . . .
DTC P1671 – CAN Transmit Message Case Porosity Repair . . . .
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–134 Shift Control Lever Assemb
DTC P1672 – CAN Bus Off Failure . . . . . . . . 5A1–136 Shift Control Cable . . . . . . .
DTC P1673 – CAN Receive ECM Message Shift Control Cable Adjustm
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–138 Transaxle Control Module(T
DTC P1839 – EDS 3 Output Shorted To Park/Neutral Start Switch
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p
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–140 Oil Cooler Pipes/Hoses . .
DTC P1840 – EDS 3 Output Shorted To Drive Axle Oil Seal . . . . . . .
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–142
Oil Pan, Oil Pan Gasket .
DTC P1841 – EDS 3 Output Open . . . . . . . . 5A1–144 Control Valve Body Assemb
DTC P1850 – Solenoid 1 Output Shorted To Left Transaxle Mounting Bra
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–146
Transaxle Assembly . . . . . .
DTC P1851 – Solenoid 1 Output Shorted To
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–148 UNIT REPAIR . . . . . . . . . . . .
Torque Converter . . . . . . . .
DTC P1852 – Solenoid 1 Output Open . . . .5A1–150
Transaxle Holding Fixture A
Valve Body . . . . . . . . . . . . .
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–152
Rear Cover . . . . . . . . . . . . .
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–154 Clutch B/E . . . . . . . . . . . . . .
Clutch B/E Measurement Pr
DTC P1855 – Solenoid 2 Output Open . . . .5A1–156
Planetary Gear Set ......
DTC P1861 – EDS 4 Output Shorted To
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–158 Brake C/D . . . . . . . . . . . . . .
DTC P1862 – EDS 4 Output Shorted To Differential . . . . . . . . . . . . . .

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–160 Side Shaft . . . . . . . . . . . . . .
DTC P1863 – EDS 4 Output Open . . . . . . . . 5A1–162 Brake F, Slotted Nut . . . . . .
DTC P1864 – EDS 5 Output Shorted To Torque Converter Housing
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–164 Shift Mechanism . . . . . . . . .
DTC P1865 – EDS 5 Output Shorted To Parking Lock System . . . .
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–166 Bearing Plate(With Spur Ge
DTC P1866 – EDS 5 Output Open . . . . . . . . 5A1–168 Oil Pump Assembly . . . . . .
DTC P1867 – EDS 6 Output Shorted To Differential/Side Shaft Oute
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–170 Shim . . . . . . . . . . . . . . . . .
ZF 4 HP 16 AUTOMATIC T
Important Measurement/Adjustment . . . . . . . 5A1–230 Mechanical Components .

Electronical Components
GENERAL DESCRIPTION AND SYSTEM TCM Inputs That Affect the
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1–232 Transaxle . . . . . . . . . . . .
INTRODUCTION
The special feature of this trans
ZF 4HP 16 AUTOMATIC TRANSAXLE out freewheels. Shifting betw
The ZF 4 HP 16 is a four–speed automatic transaxle de- place by means of overlapping
The ZF 4 HP 16 is a four speed automatic transaxle de place by means of overlapping
signed for cars with front–wheel drive and a transversely lease.
mounted engine. The advantage of overlap shif
The transaxle has a hydrodynamic torque converter with – The transaxle can be o
a controlled slip lock–up clutch. and is lighter on account
A planetary gear train establishes the mechanical gear ra- wheels and the lower num
tios. The integral constant ratio can be adapted to the en- – Lower drag losses, i.e.
gine’s power output and the vehicle’s weight. The elec- – Lower peak torques ac
tronic–hydraulic control makes controlled power shifts and and driveline.
various shift programs possible. In selector lever position However, overlap shifting nece
”P”, the output is locked mechanically. hardware and software, and p
DAEWOO V–121 BL4
TRANSAXLE COMPONENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Definit
Transaxle Type 4–speed with four–wheel drive
Input Torque 240 N m (1
S
Transaxle Weight 76kg (16

Torque Converter Capacity 9.72kg (21
Transaxle Fluid Type (manufacture company) ESSO LT 71141 or TOTA
Transaxle Fluid Capacity 7.3qt (6.
TRANSAXLE GEAR RATIO

Gear Ratio
First 2.71
Second 1.48
Third 1.00
Fourth 0.71
Reverse 2.52
Final 3.945
FLUID CAPACITY
Litres
Bottom Pan Removal 4
Complete Overhaul 6.9
Torque Converter Removal 2
(Measurements are approximate)
FASTENER TIGHTENING SPECIFICATIONS

Application N m S
Lb
Bearing Plate Bolts 23.5 17
Slotted Nut 220 1
Rear Cover Attachment Bolts 23.5 17
Baffle Plate Attachment Bolts 10 –
Park/Neutral Position Switch 10 –

Fluid Pump Connecting Bolts 10 –
Fluid Filter Housing Cover Attachment Bolts 10 –
Input Speed sensor Attachment Bolts 8 –
Output Speed Sensor Attachment Bolts 8 –
Valve Body Bolts 8
Valve Body Upper & Lower Fixing Bolts 6 –
Fluid Pan Connecting Bolts 6
Fluid Pan Drain Plug 45 3
DAEWOO V–121 BL4
Application N m S
L
Fluid Level Plug 45 3
Line Pleasure Plugs 20 1
Valve Housing 1 Cover Attachment Bolts 6 –
Solenoid Valve Attachment Bolts 6 –
Pressure Control Regulator(EDS) Attachment Bolts 6 –
Oil Cooler Inlet Pipe Bolts 35 2
Oil Cooler Outlet Pipe Bolts 35 2
p
Shift Control Cable Adjuster Pinch Nut 8 –
Shift Control Cable Attachment Nut 8 –
Upper Transaxle–to–Engine Bolts 75 5
Selector Lever(On Transaxle Case) 15 1
Torque Converter Attachment Bolts 45 3
Shift Control Assembly Mounting Bolt, Nut 8 –
Lower Engine–to–Transaxle Bolts(a) 75 5
Lower Engine–to–Transaxle Bolt(b) 21 1
Lower Engine–to–Transaxle Bolts(c) 31 2
Rear Transaxle Mounting Bracket Bolts 62 4
Damping Block Connection Bolt and Nut 68 5
Left Transaxle Mount Bracket Cage Bolt(a) 110 8
Left Transaxle Mount Bracket Cage Bolt(b) 65 48
Left Transaxle Mount Bracket Cage Nut(c) 65 48
Left Transaxle Mounting Bolts 48 3
Range Park/ Rever D 3

Neutr se
al
Gear N R 1st 2nd 3rd 4th 1st 2nd 3rd
Solenoid Valve ON ON/ ON/ ON/ ON/ ON/ ON/ ON/ ON
1 OFF OFF OFF OFF OFF OFF OFF OF
Solenoid Valve ON ON ON OFF OFF OFF ON OFF OFF
2
Line Pressure OFF OFF OFF ON ON/ ON/ OFF ON ON
Control Sole- OFF OFF OF
noid Valve 3
(EDS 3)
Line Pressure ON OFF ON ON ON OFF ON ON ON
Control Sole-
noid Valve 4
(EDS 4)
Line Pressure OFF OFF ON ON OFF OFF ON ON OFF
Control Sole-
noid Valve 5
(EDS 5)
Line Pressure ON OFF ON ON ON OFF ON ON ON
Control Sole-
noid Valve 6
(EDS 6)
Brake B A A A A A A
Brake C H
Brake D H
Clutch E A A A A A
Brake F H H H H
Lock–up A
Clutch
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid

** = Manual is de–energized.
Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
SHIFT SPEED CHART

Up Shift Speed
MODEL First–Second gear ( ± 3.0 Second–Third gear ( ± 4.0 T
mph (4.8km/h)) mph (6.4km/h))
10% 25% 50% 100% 10% 25% 50% 100% 10%

TPS TPS TPS TPS TPS TPS TPS TPS TP
1.8 DOHC 9 11 18 32 18 23 34 62 25
mph (km/h) (15) (18) (29) (52) (29) (37) (55) (99) (45
DAEWOO V–121 BL4
Down Shift Speed

±
MODEL Down Shift ( 4.0 mph (6.4km/h)) Lock Up (Fourth)
Clutch Applied
Fourth–Th Third–Sec Second–Fi 10% 25%

ird ond rst
(Coast) (Coast) (Coast)
1.8 DOHC 25 (41) 13 (21) 7 (11) 48 (77) 48 (77)
mph (km/h)
LINE PRESSURE
Gear Range Solenoid Line Pressure B Port
Park / Neutral ON LOW 90~124.7 psi
(6.2~8.6 bar)
OFF HIGH 221.9~252.3 psi
(15.3~17.4 bar)
Reverse ON LOW 89.9~124.7 psi
(6.2~8.6 bar)
(15.3~17.4 bar)
Drive ON LOW
OFF HIGH
3 ON LOW 90~124.7 psi

(6.2~8.6 bar)
(15.3~17.4 bar)
2 ON LOW
OFF HIGH
1 ON LOW 90~124.7 psi

(6.2~8.6 bar)
(15.3~17.4 bar)
SPECIAL TOOLS
SPECIAL TOOLS TABLE
Scan Tool
DW110–060
Engine Support Fixture
DW260–020
Transaxle Holding
Fixture
DW260–010
Transaxle Support
Fixture
DAEWOO V–121 BL4
DW240–010
Universal Pressure
Gauge Set
DW260–150
Clutch E Stop Ring
Remove/Installer
DW260–140
Clutch B Stop Ring
Remover/Installer
DW260–160
Brake C/D Snap Ring
Remover/Installer
DW260–080
Clutch B/E Shim
Setting Gauge
ZF 4 HP 16 AUTOMATIC TR
SCHEMATIC AND ROUTING DIAGRAM

TRANSAXLE CONTROL MODULE (1 OF 2)
DAEWOO V–121 BL4
TRANSAXLE CONTROL MODULE (2 OF 2)
SHIFT MODE DIAGRAM

Economic Mode (1.8 DOHC)
DAEWOO V–121 BL4
Lock–up Clutch Applied (Economic Mode ; Fourth Gea

(1.8 DOHC)
Power Mode (1.8 DOHC)
DAEWOO V–121 BL4
Hold Mode (1.8 DOHC)
POWER FLOW DIAGRAM

Park/Neutral
DAEWOO V–121 BL4

The TCM monitors numerous
Park/Neutral propriate solenoid state comb
In Park or Neutral with the engine running there is no drive for the vehicle operating cond
to the planetary gear set. Line pressure (from the oil pump)
is supplied to the valve body. Only clutch B is supplied and In Park and Neutral solenoid v
the torque converter is released. sure flows to the safety valve a
valve via the solenoid valve.
C t l
Control
Line Pressure Control Valve Clutch B Engaged
The
levelline pressure
in the valve control valve sets
body. When the general
gearshifts pressure
are not taking In Park and Neutral solenoid v
Pressure control solenoids (ED
place, the line pressure varies between two levels, de- ON.
pending on the turbine torque. Line pressure increase lin-
early by time. But it has a limit point. When pressure reach- When EDS 6 is ON, the fluid s
es that point, excess oil pressure drains back into the oil valve flows to the safety valve,
sump. valve B. The oil that is supplied
valve presses on the valve spo
Reduction Valve to the holding valve and check
The reduction valve reduces the line pressure with which
the downstream solenoid valves and pressure control so- Lock–up Clutch (TCC)
lenoid valves (EDS) are supplied. This makes it possible
to use smaller solenoid valves. Solenoid 2 is turned ON and
valves spool will be depressed
The line pressure comes from the oil pump and flows to the the torque converter pressure
reduction valve. The inlet port to the reduction valve will be
blocked and line pressure will be maintained at the ap- As a result, the oil pressure be
propriate level. clutch piston and in the turbine
of flow is through the turbine s
Solenoid Valve 1, 2 behind the piston, to the turbin
Solenoid Valve 1 controls the line pressure (high and low)
to the clutch valves. Solenoid Valve 1 is either ON or OFF. Lubrication/Cooling.
When the solenoid is turned ON the line pressure will be
low [87~116psi (6~8bar)].When the solenoid is turned The lubricating valve ensures
OFF the line pressure will be high [232~261psi plied with cooling oil first if the
(16~18bar)]. cating pressure valve in additio
essary amount of cooling and l
Solenoid 2 controls the fluid flow to clutch valve E or the the bypass duct.
TCC clutch valve. When solenoid 2 is ON fluid is directed
to the TCC pressure valve and if the solenoid is switched The fluid, which is supplied f
OFF fluid will flow to the inlet at clutch valve E. flows to the cooler via the lubr
Reverse
DAEWOO V–121 BL4
In Reverse, solenoid 1 is sw
Reverse switched OFF. This will cause
In Reverse, transaxle drive is via the input shaft and clutch duction valve to flow to clutch
B. The elements of this transaxle function are as follows: The spool of clutch valve D will
S
Clutch B is engaged and drives the reverse sun to pass to holding valve D.
gear in a clock––wise direction.
S
The D band is engaged and holds the planetary Lock–up Clutch (TCC)
gear carrier (front & rear) stationary causing the Solenoid 2 is turned ON and th
differential pinion to rotate clockwise. spool will be depressed. Fluid
S
The differential rotates in a counterclockwise direc- torque converter pressure valv
tion. As a result, the oil pressure be
S
The output shaft is driven in a counterclockwise or clutch piston and in the turbine
reverse direction. of flow is through the turbine s
behind the piston, to the turbin
Control
Lubrication/Cooling
Clutch B Engaged
The lubricating valve ensures
The line pressure, which is supplied by the oil pump, is di-
plied with cooling oil first if the
rected to clutch B via the manual valve. The position of the
cating pressure valve in additio
check ball will change allowing direct pressure to clutch B.
Brake D Engaged the bypass duct.
The line pressure, which engaged clutch B, is also sup- The fluid, which is supplied f
li d t l t h l D
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b
plied to clutch valve D. flows to the cooler via the lubr
Drive Range – First Gear
DAEWOO V–121 BL4
Clutch F Engaged
Drive Range – First Gear EDS 5 will be switched ON.
In Drive 1, transaxle drive is via the input shaft to clutch B. passed through the reduction v
The elements of this transaxle function are as follows: valve and the clutch valve inlet
is depressed.
Clutch B is engaged to drive the rear sun gear.
S
S
The rear sun gear drives the front planetary gear Lock–up Clutch (TCC)
carrier clockwise. Solenoid 2 is turned ON and th
S
The rear planetary gear carrier drives the front ring spool will be depressed. Fluid
gear and front planetary gear carrier clockwise. torque converter pressure valv
As a result, the oil pressure be
Control clutch piston and in the turbine
of flow is through the turbine s
Clutch B Engaged behind the piston, to the turbin
In Park and Neutral solenoid valves 1 and 2 are both ON. Lubrication/Cooling
Pressure
ON. control solenoids (EDS) 4 and 6 are also turned The lubricating valve ensures
When EDS 6 is ON, the fluid supplied from the reduction cating pressure valve in additio
valve flows to the safety valve, clutch valve B and holding essary amount of cooling and l
valve B. The oil that is supplied to the inlet port of the clutch the bypass duct.
valve presses on the valve spool. Line pressure then flows The fluid, which is supplied f
to the holding valve and check ball, engaging clutch B. flows to the cooler via the lubr
Drive Range – Second Gear
DAEWOO V–121 BL4
Clutch F Engaged
Drive Range – Second Gear EDS 5 will be switched ON.
passed through the reduction v
In Drive 2, the transaxle drive is via the input shaft and
valve and the clutch valve inlet
clutch E. The elements of this transaxle function are as fol-
clutch E. The elements of this transaxle function are as fol
is depressed.
lows:
Lock–up Clutch
S
Clutch E is applied to drive the front ring gear. Solenoid valve 2 is turned ON a
S
The front ring gear drives the front planetary gear valve spool will be depressed.
carrier. the torque converter pressure
S
The front planetary gear carrier drives the differen-
tial pinion gear clockwise. As a result, the oil pressure be
S
Brake F is applied holding the front sun gear sta- clutch piston and in the turbine
tionary. of flow is through the turbine s
behind the piston, to the turbin
Lubrication/Cooling
Control
The lubricating valve ensures
Clutch E Engaged cating pressure valve in additio
Solenoid 2 will be switched OFF. Line pressure, which is the bypass duct.
supplied by the reduction valve, flows to the inlet port of
clutch valve E. Fluid will then pass through the clutch valve The fluid, which is supplied f
and clutch E will engage. flows to the cooler via the lubr
Drive Range – Third Gear
DAEWOO V–121 BL4

ON.
Drive Range – Third Gear
In Drive 3, transaxle drive is via the input shaft to clutches When EDS 6 is ON, the fluid s
B and E. The elements of this transaxle function are as fol- valve flows to the safety valve,
lows: valve B. The oil that is supplied
valve presses on the valve spo
S
Clutches B and E are engaged to drive the rear sun to the holding valve and check
gear and rear planetary gear carrier clockwise.
S
The clockwise rotation of the rear sun gear and rear Lock–up Clutch (TCC)
planetary gear carrier will cause the front planetary Solenoid valve 2 is turned ON a
gear to rotate in the same direction. valve spool will be depressed.
the torque converter pressure
Control As a result, the oil pressure be

clutch piston and in the turbine
Clutch B Engaged of flow is through the turbine s
In Park and Neutral solenoid valves 1 and 2 are both ON. behind the piston, to the turbin
Drive Range – Fourth Gear
DAEWOO V–121 BL4
Drive Range – Fourth Gear

Clutch C Engaged
In Drive 4, transaxle drive is via the input shaft and
clutches E and C. The elements of this transaxle function EDS 4 will be switched OFF c
are as follows: high. Line pressure will be di
Clutch E is engaged to drive the rear planetary gear clutch valve

valveDC and holding as
va
S
holding will engage

carrier.
safety valve.
S
The rear planetary gear carrier drives the rear ring
gear.
S
The rear ring gear carrier drives the differential Lock–up Clutch
gear.
Solenoid valve 2 is turned ON a
Control valve spool will be depressed.
the torque converter pressure
Clutch E Engaged
Solenoid 2 will be switched OFF. Line pressure, which is As a result, the oil pressure be
supplied by the reduction valve, flows to the inlet port of clutch piston and in the turbine
clutch valve E. Fluid will then pass through the clutch valve of flow is through the turbine s
and clutch E will engage. behind the piston, to the turbin
Drive Range – Fourth Gear ; Emergency/Substitute Mo
DAEWOO V–121 BL4
Control
Drive Range – Fourth Gear ;
Clutch E Engaged
Emergenc /S bstit te Mode
g g
Emergency/Substitute Mode
Solenoid 2 will be switched O
In Drive 4, transaxle drive is via the input shaft and supplied by the reduction valv
clutches E and C. The elements of this transaxle function clutch valve E. Fluid will then p
are as follows: and clutch E will engage.
S
Clutch E is engaged to drive the rear planetary gear Clutch C Engaged
carrier. EDS 4 will be switched OFF c
S
The rear planetary gear carrier drives the rear ring high. Line pressure will be di
gear. clutch valve D and holding va
S
The rear ring gear carrier drives the differential holding valve C will engage as
gear. safety valve.
Drive Range – Third Gear ; Emergency/Substitute Mod
DAEWOO V–121 BL4
Control
Drive Range – Third Gear ; Clutch B Engaged
Emergency/Substitute Mode In Park and Neutral solenoid v
In Drive 3, transaxle drive is via the input shaft to clutches
ON.
B and E. The elements of this transaxle function are as fol-
lows: When EDS 6 is ON, the fluid s
valve flows to the safety valve,
S
Clutches B and E are engaged to drive the rear sun valve B. The oil that is supplied
gear and rear planetary gear carrier clockwise. valve presses on the valve spo
S
The clockwise rotation of the rear sun gear and rear to the holding valve and chec
planetary gear carrier will cause the front planetary
gear to rotate in the same direction.
COMPONENT LOCATOR
TRANSAXLE IDENTIFICATION INFORMATION
1. Part Number 3. Model Code

2. Serial Number 4. Manufactured Nation and
DAEWOO V–121 BL4
TORQUE CONVERTER
1. Torque Converter Housing 10. Screw

2. Torque Converter 11. Pressure Plug
3. Torque Converter Gasket 12. Pressure Plug
4. Steel Gasket 13. Oil Drain Plug
5. Oil Baffle Plate 14. Oil Level Plug
6. Bolt 15. Screw
7. Magnet 16. Bolt
8. Oil Filter 17. Bolt
9. O–ring
TRANSAXLE HOUSING
1. Transaxle Housing 10. Output Speed Sensor

2. Bushing 11. Washer
3. Shaft Seal 12. Bolt
4. Axle Shaft Seal 13. Shim
5. Sealing Sleeve 14. Shim
6. Breather Pipe 15. Park/Neutral Position Sw
7. Sleeve Protector 16. Bolt
8. Type Plate 17. Sealing sleeve
9. Cable Terminal
DAEWOO V–121 BL4
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OIL PUMP
1. Oil Pump 5. Dowel Pin

2. Oil Pump Seal 6. Bolt
3. Washer 7. Bolt
4. O–ring
REAR COVER & OIL PAN COVER
1. Rear Cover 7. Bolt

2. Piston Ring 8. Oil Pan
3. O–ring 9. Oil Pan Gasket
4. Needle Bearing 10. Oil Pan Bracket
5. Shim 11. Bolt
6. Screw Plug
DAEWOO V–121 BL4
PARKING LEVER
1. Selector Shaft 6. Leg Spring

2. Stop Bushing 7. Pawl
3. Detent Disc 8. Pin
4. Clamping Sleeve 9. Support Bolt
5. Connecting Bar
INPUT SHAFT & SHIFT GEAR
DAEWOO V–121 BL4
1. Inner Disc Carrier F 40. Rear Planetary Gear Set

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

2. Valve Body Wiring Harness 10. Cap Screw
3. O–ring 11. Fixing Plate
4. Plug 12. Fixing Plate
5.
6. Cable Terminal
Retaining Clip 13.
14. Cap Screw
Solenoid Valve
7. Input Speed Sensor 15. Solenoid Valve
8. Cap Screw
DAEWOO V–121 BL4

GEAR SHIFT CONTROL
1. Selector Control Lever 7. Positioning Spring

2. Gear Shift Knob 8. Solenoid
3. Cover 9. Base Plate
4. Step Gate Slider 10. T/A Lever
5. BTSI Button 11. Select Cable
6. Spring 12. Cable Fastener
DIAGNOSTIC INFORMATION AND

PROCEDURES DIAGNOSIS
S
Check all electrical conne
BASIC KNOWLEDGE REQUIRED S
Use on–board diagnostic
You must be familiar with some basic electronics to use if any transaxle trouble co
this section of the Service Manual. They will help you to to the appropriate ”Diagn
follow diagnostic procedures. information and repair the
repairing the vehicle, perf
Notice : Lack of the basic knowledge of this transaxle
verify that the code has n
when performing diagnostic procedures could result in in- S
Perform the Electrical/Ga
correct diagnostic performance or damage to transaxle S
Perform the Road Test Pr
components. S
Inspect the oil and check
Do not, under any circumstances, attempt to diagnose a inants in the oil pan.
transaxle problem without this basic knowledge.
Notice : If a wire is probed with a sharp instrument and not LINE PRESSURE CH
properly sealed afterward, the wire will corrode and an PROCEDURE
open circuit will result.
Diagnostic test probes are now available that allow you to The 4HP 16 A/T uses a trocho
probe individual wires without leaving the wire open to the hydraulic pressure, and a pres
environment. These probe devices are inexpensive and noid 1) to control that pressur
easy to install, and they permanently seal the wire from valve, after it leaves the pum
corrosion. control solenoid is controlled
ranges from 0 to 12 volts cor
Special Tools pressure (approx. 89.9 to 124
0 volt corresponds to a maxim
You should be able to use a Digital Volt Meter (DVM), a cir-
cuit tester, jumper wires or leads and a line pressure gauge 221.9 to 252.4 psi (15.3 to 17
set. Line pressures are calculated
The functional check procedure is designed to verify the – Drive–Park–Neutral and Rev
correct operation of electronic components in the transaxle line pressure to be appro
correct operation of electronic components in the transaxle line pressure to be appro
axle. needs in different gear ranges
This will eliminate the unnecessary removal of transaxle
Gear Solenoid
components.
Range 1
Drive, Off
FUNCTIONAL CHECK
Begin with the Functional CheckPROCEDURE
Procedure which pro-
Reverse
vides a general outline of how to diagnose automatic On
transaxle. The following functional check procedure will in-
dicate the proper path of diagnosing the transaxle by de- Neutral, Off
scribing the basic checks and then referencing the loca- Park
tions of the specific checks.
On
S
Check the fluid level according to the Fluid Level
Service Procedure.
S
Check the transaxle for fluid leaks. Before performing a line pres
S
Check if the transaxle fluid is not burnt by color and pressure control solenoid is rec
smell. signal from the TCM:
S
Ensure that the transaxle is not in Limp Home 1. Install a scan tool.
Mode(LHM). 2. Start the engine and set p
S
Check the battery terminals and the ground con- 3. Check for a stored pressu
nections for corrosion or looseness. nostic trouble code, and o
S
Check that the cooler flow is not restricted. codes.
DAEWOO V–121 BL4
4. Repair vehicle, if necessary. 6. Start engine and allow it t

Inspect: 7. Access the ”Solenoid 1 C
S
Fluid level. ner.
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Manual linkage. 8. Switching solenoid 1 ON/
Install or Connect: gine to 2,500rpm, and the
S
Scan tool (scanner) at the each gear.
S
Oil pressure gauge at line pressure port (clutch B or 9. Compare data to the Driv
E ports on transaxle case) sure chart below.
Notice : Total test running tim
utes, or transaxle damage cou
CAUTION : Brake must be
vent unexpected vehicle m
If pressure readings differ gre
chart, refer to the Diagnosis C
, g
tion.
Notice : Clutch damage may
The scanner is only able to con
lenoid in Park and Neutral with
This protects the clutches from
sures in Drive or Reverse rang
5. Put gear selector in Park and set the parking brake.
Gear Range Solenoid Line B Port
Pressure
Park / Neutral ON LOW 90~124.7 psi (6.2~8.6 bar)
OFF HIGH 221.9~252.3 ps
i (15.3~17.4 bar)
Reverse ON LOW 90~124.7 psi (6.2~8.6 bar)
(15.3~17.4 bar)
Drive ON LOW 90
OFF HIGH
3 ON LOW 90~124.7 psi (6.2~8.6 bar) 90~

(15.3~17.4 bar)
2 ON LOW 90
OFF HIGH
1 ON LOW 90~124.7 psi (6.2~8.6 bar)

(15.3~17.4 bar)
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TR
6. Flush the cooler lines afte

CLUTCH PLATE DIAGNOSIS paired or replaced the tra
Composition Plates COOLER FLUSHING

Dry the plate and inspect the plates for the following condi-
TEST
tions :
Notice : You must flush the co
S
Pitting a transaxle for service. Cool
S
S Flaking
Wear SRTA installation, major overh
a pump or torque converter, or
S
Glazing the fluid has been contaminat
S
Cracking
S
Charring After filling the transaxle with fl
for 30 seconds. This will rem
Chips or metal particles embedded in the lining from the oil cooler. Disconnect
Replace a composition plate which shows any of these axle and observe the flow with
conditions. fluid flow is insufficient, check t
ing the feed line at the cooler.
Steel Plates engine running.
Wipe the plates dry and check the plates for heat discolor- S
If the flow from the cooler
ation. If the surfaces are smooth, even if colorsmear is in- axle is insufficient, check
dicated, you can reuse the plate. If the plate is discolored line to the cooler. BLocka
with hot spots or if the surface is scuffed, replace the plate. or the cooler.
Important : If the clutch shows evidence or extreme heat
S
If the flow from the transa
or burning, replace the springs. is insufficient, the transax
flow problem.
Causes of Burned Clutch Plates S
If the flow the transaxle fe
The following conditions can result in a burned clutch insufficient, but flow from
plate: the transaxle is insufficien
and fittings. Then repeat
S
Incorrect usage of clutch plates. dure. If the flow is still ins
Engine coolant in the transaxle fluid. er.
S
S
A cracked clutch piston.
S
Damaged or missing seals. TRANSAXLE FLUID
S
Low line pressure.
S
Valve problems.
PROCEDURE
This procedure is to be used
– The valve body face is not flat
with the fluid level in a vehicle
– Porosity between channels
in slipping and loss of drive/ re
– The valve bushing clips are improperly installed.
ment of drive/ reverse when th
– The check balls are misplaced.
The vehicle is first checked for
S
The seal rings are worn or damaged
sages on the scan tool. If the o
Engine Coolant in Transaxle to register a vehicle speed sig
Notice : Antifreeze will deteriorate the O–ring seals and The vehicle is to be test driven
the glue used to bond the clutch material to the pressure abnormal delay when selecting
plate. Both conditions may cause transaxle damage. drive. One symptom of low flui
of drive when driving the veh
Perform the following steps if the transaxle oil cooler has when the transaxle fluid level is
developed a leak, allowing engine coolant to enter the cur when the transaxle fluid te
t l
transaxle:
When adding or changing tran
1. Because the coolant will attach to the seal material LT 71141 automatic transaxl
causing leakage, disassemble the transaxle and fluids. The use of incorrect fluid
replace all rubber type seals. and durability of the transaxle
2. Because the facing material may become sepa-
rated from the steel center portion, replace the Fluid Level Diagnosis P
composition faced clutch plate assemblies. 1. If the vehicle is at operati
3. Replace all nylon parts including washers. vehicle to cool down for t
4. Replace the torque converter. than four hours. Or if the
5. Thoroughly clean and rebuild the transaxle, using start the engine and allow
new gaskets and oil filter. approximately 5 minutes
DAEWOO V–121 BL4
sible, drive the vehicle for a few kilometers (N–D, move the gear shift lever
N–R, shift until two gear). This will allow the trans- pausing a few seconds in
axle to be within the correct temperature range. the fluid until gear applica
Transaxle fluid level should be checked at tempera- additional 0.5 liters of flui
ture 20 to 45 ° C (68 to 113 ° F). lever to P(Park). Turn the
CAUTION : Removal of the fluid filler plug when the vehicle. Install the fluid fil
transaxle fluid is hot may cause injury if fluid drains 45N m (34 lb–ft).
S
from the filler hole. 5. Drive the vehicle at 2.2 m

2. Switch off accessories, especially air conditioner, miles(4.5 km) with light th
heater. does not exceed 2500 rp
the transaxle temperature
3. With the brake pedal pressed, move the gear shift
control lever through the gear ranges, pausing a 45 ° C (68 to 11 ° F). With
the shift lever through the
few seconds in each range. Return the gearshift
lever to P(Park). Turn the engine OFF. few seconds in each rang
4. Park the vehicle on a hoist, inspection pit or similar 6. Return the gear shift leve
raised level surface. The vehicle must be level to gine OFF and raise the v
cable, ensuring the vehic
obtain a correct fluid level measurement.
minutes passed after the
5. Place a fluid container below the fluid filler plug.
6. Clean all dirt from around the fluid filler plug. the filler plug. Check if the
Remove the fluid filler plug. Clean the filler plug and the bottom of the filler ho
quantity of fluid to the cor
check that there is no damage to the ”O” ring.
filler plug and tighten it to
S
If fluid drains through the filler hole the transaxle 7. Wipe any fluid around the
may have been overfilled. When the fluid stops shop towel.
draining the fluid level is correct. Install the fluid
filler plug and tighten it to 45N m(34 lb–ft).
S
Fluid Leak Diagnosis a
S
If fluid does
transaxle notlevel
fluid drainmay
through theLower
be low. filler hole, the
the ve- The cause of most external l
cated and repaired with the tra
hicle, and start the vehicle in P(Park) with the
parking brake and the brake applied. With the Methods for Locating L
engine idling, move the gear shift lever through
the gear ranges pausing a few seconds in each General Method
the gear ranges, pausing a few seconds in each
range and adding the fluid until gear application 1. Verify that the leak is tran
is felt. Return the gear shift lever to P(Park). 2. Thoroughly clean the sus
Turn the engine OFF and raise the vehicle. 3. Drive the vehicle for appr
Check if the fluid level is aligned with the bottom miles) or until the transax
of the filler hole. If not, add a small quantity of ing temperature (88 ° C,
fluid to the correct level. Install the fluid filler 4. Park the vehicle over clea
plug and tighten it to 45N m(34 lb–ft).
S
5. Turn the engine OFF and
paper.
7. When the fluid level checking procedure is com- 6. Make the necessary repa
pleted, wipe any fluid around the filler plug with a
rag or shop towel. Powder Method
1. Thoroughly clean the sus
Fluid Level Set After Service 2. Apply an aerosol type pow
1. Depending on the service procedure performed, suspected leak area.
add the following amounts of fluid through the filler 3. Drive the vehicle for appr
plug hole prior to adjusting the fluid level: miles) or until the transax
Oil pan removal – 4 liters (4.23 quarts) ing temperature (88 ° C,
4. Turn the engine OFF.
Converter
Overhaul –removal
6.9liters–(7.3
2 liters ( 2.11 quarts)
quarts) 5. Inspect the suspected lea
Oil drain plug removal – 4 liters (4.23 quarts) path through the powder
leak.
2. Follow steps 1 through 4 of the Fluid Level Diagno-
6. Make the necessary repa
sis Procedure.
3. Clean all dirt from around the fluid filler plug. Dye and Black Light Method
Remove the fluid filler plug. Clean the filler plug and 1. Add dye to the transaxle
check that there is no damage to the ”O” ring. filler plug. Follow the man
4. Lower the vehicle with the filler plug still removed tion for the amount of dye
and start the vehicle in P(Park) with the parking 2. Use the black light to find
brake and the brake applied. With the engine idling, 3. Make the necessary repa
The A/C COMPRESS

S
Repairing the Fluid Leak ON when the A/C swi

Once the leak point is found the source of the leak must OFF when the A/C sw
be determined. The following list describes the potential 7. Monitor the GEAR SHIFT
causes for the leak: and move the gear shift c
S
Fasteners are not torqued to specification. ranges.
S
Fastener threads and fastener holes are dirty or S
Verify that the GEAR
corroded. value matches the ge
S
Gaskets, seals or sleeves are misarranged, dam- instrument panel or co
aged or worn. S
Gear selections shoul
S
Damaged, warped or scratched seal bore or gasket harsh.
surface. 8. Move gear shift control le
S
Loose or worn bearing causing excess seal or the THROTTLE POSITIO
sleeve wears and decreasing engine sp
sleeve wears. and decreasing engine sp
S
Case or component porosity. pedal.
S
Fluid level is too high.
S
Plugged vent or damaged vent tube.
S
THROTTLE POSITIO
S
Water or coolant in fluid. engine speed.
S
Fluid drain back holes plugged.
ROAD TEST PROCE
ELECTRICAL/GARAGE SHIFT TEST
S
Perform the road test usi
S
This test should be perfo
This preliminary test should be performed before a hoist conditions permit.
or road test to make sure electronic control inputs is con- S
Observe all traffic regulat
nected and operating. If the inputs are not checked before
The TCM calculates upshift po
operating the transaxle, a simple electrical condition could
inputs : throttle angle and veh
be misdiagnosed as a major transaxle condition.
wants a shift to occur, an electri
A scan tool provides valuable information and must be solenoids which in turn moves
used on the automatic transaxle for accurate diagnosis. upshift.
1. Move gear selector to P (Park) and set the parking The shift speed charts referen
brake. ”min throttle” or ”wot” to make
2. Connect scan tool to Data Link Connector (DLC) more uniform and accurate. A
terminal. monitor throttle angle. Some
3. Start engine. grammed to record shift poi
4. Turn the scan tool ON. introduction manual to see if t
5. Verify that the appropriate signals are present.
These signals may include: Upshift Procedure
With gear selector in drive(D)
S
ENGINE SPEED
S
VEHICLE SPEED 1. Look at the shift speed ch
S
THROTTLE POSITION tion and choose a percen
S
TRANSAXLE GEAR STATE 25%.
S
GEAR SHIFT LEVER POSITION 2. Set up the scan tool to m
S
TRANSAXLE FLUID TEMPERATURE vehicle speed.
S
CLOSED THROTTLE POSITION LEARN 3. Accelerate to the chosen

throttle steady.
S
OPEN THROTTLE POSITION LEARNT
S
CLOSED ACCEL. PEDAL POSITION LEARNT 4. As the transaxle upshifts,
S
OPEN ACCEL. PEDAL POSITION LEARNT commanded gear change
S
A/C COMPRESSOR STATUS S
Second gear.
S
MODE SWITCH S
Third gear.
S
THROTTLE POSITION VOLTAGE S
Fourth gear.
S
GEAR SHIFT LEVER POSITION VOLTAGE
S
TRANS. FLUID TEMPERATURE VOLTAGE Important : Shift speeds may
S
A/C SWITCH delays responding to electron
S
MODE SWITCH VOLTAGE the original equipment tire size
S
BATTERY VOLTAGE Note

If thewhen
applyTCC applies.
is not This
noticed by
6. Monitor the A/C COMPRESSOR STATUS signal
”Lock–up Clutch Diagnosis” in
while pushing the A/C switch.
section.
DAEWOO V–121 BL4
The Lock up clutch should not apply unless the transaxle

has reached a minimum operating temperature of 8 ° C
Manual Gear Range Se
(46 ° F) TRANS TEMP AND engine coolant temp of 50 ° C Upshifts in the manual gear ra
(122 ° F). shift solenoids. Perform the fol
at 25 percent TP sensor incre
5. Repeat steps 1–4 using several different throttle
angles. Manual Third (3)
S
With vehicle stopped, mo
Part Throttle Detent Downshift Manual third(3) and acce
At vehicle steeds of 55 to 65km/h (34 to 40mph) in Fourth – 1–2 shift.
gear, quickly increase throttle angle to greater than 50%. – 2–3 shift.
Verify that : Manual Second (2)

S
S
TCC apply. Manual second(2) and ac
S
Transaxle downshift to 3rd gear.
– 1–2 shift.
S
Solenoid 1 turns ON to OFF.
S
Solenoid 2 turns OFF.
S
Accelerate to 40km/h(25m
– 2–3 shift does not occu
Full Throttle Detent Downshift – TCC does not apply
At vehicle speeds of 55 to 65km/h (34 to 40mph)in Fourth Manual First (1)
gear, quickly increase throttle angle to its maximum posi- S
tion (100%) al First(1). Accelerate to 3
Verify that : serve :
– No upshifts occur
S
TCC release.
S
Transaxle downshift to Second gear immediately. Reverse (R)
S
Solenoid 1 turns ON to OFF S
S
Solenoid 2 turns OFF. verse) and observe :
Manual Downshifts – Solenoid 1 is OFF

– Solenoid 2 is OFF
1. At vehicle speeds of 60km/h (40mph)in Fourth Use a scan tool to see if any tra
gear, release accelerator pedal while moving gear been set. Refer to ”Diagnostic
selector to Manual Third (3). Observe that : tion and repair the vehicle as d
S
Transaxle downshift to Third gear immediately. vehicle, perform the hoist test a
S
Engine slows vehicle down. not set again.
If the transaxle is not performin
2. Move gear selector back to overdrive(D) and accel-
have been set, there may be
erate to 31mph (50km/h). Release the accelerator
Check all electrical connection
pedal and move the gear selector to Manual
You also have to perform a sn
First(1) and observe that : catch an intermittent condition
S
Transaxle downshift to second gear immediate- enough to set a code.
ly. You may want to read ”Electro
S
Engine slows vehicle down in this section to become famili
caused by transaxle electrical
Notice : A Manual First––Third Gear Ratio will occur at
high speeds as an upshift safety feature Do not attempt If no trouble codes have been s
high speeds as an upshift safety feature. Do not attempt o t oub e codes a e bee s
to perform this shift. pected to be hydraulic, take th
TORQUE CONVERT
Coasting Downshifts
CLUTCH(TCC) DIAG
1. With the gear
to Fourth gearselector
with TCCin applied.
Overdrive(D), accelerate To properly diagnosis the loc
perform all electrical testing f
2. Release the accelerator pedal and lightly apply the
testing.
brakes, and observe that :
The TCC is applied by fluid pre
S
TCC release. a solenoid Located inside the
S
Down shifts occur at speeds shown ON the shift energized by completing an
speed chart. combination of switches and s
1. Place foot on brake.

Functional Check Procedure 2. Put gear selector in ”Driv
Inspect 3. Depress accelerator to ap
no more than six seconds
1. Install a tachometer or scan tool.
2. Operate the vehicle unit proper operating tempera- Notice : If the accelerator is d
ture is reached. seconds, damage to the trans
3. Drive the vehicle at 80 to 88km/h (50 to 55 mph) A torque converter noise will i
with light throttle(road load).
4. Maintaining throttle position, lightly touch the brake Important : This noise should
pedal and check for release of the TCC and a slight whine noise which is usually
increase in engine speed(rpm). (Neutral) and all other gear ran
5. Release the brake slowly accelerate and check for with pressure ranges.
a reapply of the Lock up clutch and a slight de- The torque converter should be
crease in engine speed(rpm). following conditions:
Torque Converter Evaluation

S
External leaks in the hub
S
Converter hub is scored o
Torque Converter Stator S
Converter pilot is broken,
The torque converter stator roller clutch can have one of into crankshaft.
two different type malfunctions :
S
Steel particles are found
and cooler lines.
A. Stator assembly freewheels in both directions. S
Pump is damaged or stee
B. Stator assembly remains Locked up at all times. converter.
S
Vehicle has TCC shudde
Condition A – Poor Acceleration Low Replace only after all hyd
Speed noses have been made.(
The car tends to have poor acceleration from a stand still. may be glazed.)
At speeds above 50 to 55km/h(30 to 35mph), the car may
S
Converter has an imbalan
act normal. If poor acceleration is noted, it should first be rected. (Refer To Convert
determined that the exhaust system is not blocked, and dure.)
S
Converter is contaminate
65/324
the transaxle is in 1st(First) gear when starting out.
S
Converter is contaminate
taining antifreeze.
If the engine freely accelerates to high rpm in N(Neutral), S
Internal failure of stator ro
it can be assumed that the engine and exhaust system are S
Excess end play.
normal. Checking for poor performance in ”Drive” and ”Re- S
Heavy clutch debris due t
verse” will help determine if the stator is freewheeling at all
verter).
times. S
Steel particles or clutch li
Condition B – Poor Acceleration High filter or on magnet when
worn or damaged(indicat
Speed came from converter).
Engine rpm and car speed limited or restricted at high
speeds. Performance when accelerating from a standstill The torque converter should n
is normal. Engine may overheat. Visual examination of the S
The oil has an odor, is dis
converter may reveal a blue color from overheating. evidence of metal or clutc
If the converter has been removed, the stator roller clutch
S
The threads in one or mo
can be checked by inserting two fingers into the splined in- holes are damaged.
ner race of the roller clutch and trying to turn freely clock- –correct with thread in
wise, but not turn or be very difficult to turn counter clock- S
Transaxle failure did not d
wise. age or worn internal parts
plate lining material in un
Noise S
Vehicle has been expose
Torque converter whine is usually noticed when the ve- The exception may be wh
hicle is stopped and the transaxle is in ”Drive” or ”Re- damper plate lining has s
verse”. The noise will increase when engine rpm is in- hicles operated in heavy
creased. The noise will stop when the vehicle is moving or such as taxi, delivery or p
when the torque converter clutch is applied because both
halves of the converter are turning at the same speed. Lock–Up Clutch Shudd
Perform a stall test to make sure the noise is actually com- The key to diagnosing lock–up
ing from the converter : note when it happens and und
DAEWOO V–121 BL4
TCC shudder should only occur during the APPLY and/or S

EGR valve – valve may le
RELEASE of the Lock up clutch. exhaust gas and cause e
S
MAP sensor – like vacuu
While TCC Is Applying Or Releasing correct amount of fuel for
If the shudder occurs while TCC is applying, the problem
S
Carbon on intake valves
can be within the transaxle or torque converter. air/fuel mixture into cylind
S
Flat cam – valves don’t o
Something is not allowing the clutch to become fully en-
fuel/air mixture into cylind
gaged, not allowing clutch to release, or is trying to release S
Oxygen sensor – may co
and apply the clutch at the same time. This could be
too lean for too long.
caused by leaking turbine shaft seals, a restricted release S
Fuel pressure – may be t
orifice, a distorted
bolts, or clutch or housing surface on
duethe
to TCC
long Engine mounts – vibratio
S
converter defective friction material

plied by TCC engagemen
plate
plate. S
Axle joints – checks for v
S
TPS – TCC apply and rel
Shudder Occurs After TCC Has Applied :
in many engines. If TPS i
In this case, most of the time there is nothing wrong with may remain applied durin
the transaxle! As mentioned above, once the TCC has S
Cylinder balance – bad p
been applied, it is very unlikely that will slip. Engine prob- ing valves can cause low
lems may go unnoticed under light throttle and load, but S
Fuel contamination – cau
become noticeable after TCC apply when going up a hill mance.
or accelerating, due to the mechanical coupling between
engine and transaxle.

Important : Once TCC is applied there is no torque con-
TCM INITIALIZATION
When one or more operations
verter assistance. Engine or driveline vibrations could be performed, all learned conten
unnoticeable before TCC engagement. memory should be erased afte
Inspect the following components to avoid misdiagnosis of S
When A/T H/W is replace
TCC shudder and possibly disassembling a transaxle and/ S
When a used TCU is inst
or replacing a torque converter unnecessarily : S
When a vehicle condition
S
Spark plugs – Inspect for cracks, high resistance or flare, TPS toggling and s
broken insulator. ble conditions, mis–adap
S
Plug wires – Lock in each end, if there is red dust 1. Connect the Scan 100 wi
(ozone)
the wiresorare
black
bad.substance
Also look(carbon) present,
for a white then
discolor- 2. vehicle.
Turn ignition switch ON.
ation of the wire indicating arcing during hard accel- 3. Turn the power on for the
eration. 4. Follow the ”TCM LEARN
S
Distributor cap and rotor – look for broken or un– on the Scan 100 menu.
crimped parts. Notice : Before pushing ”Yes” B
S
Coil – look for black on bottom indication arcing on the Scan 100 screen, mak
while engine is misfiring. as follows:
S
Fuel injector – filter may be plugged.
S
Vacuum leak – engine won’t get correct amount of Condition :
fuel. May run rich or lean depending on where the 1. Engine idle.
leak is. 2. Select lever set ”P” ran
SHIFT SPEED CHART

Up Shift Speed
MODEL First–Second gear Second–Third gear

(± 3.0 mph (4.8km/h)) (± 4.0 mph (6.4km/h))
10% 25% 50% 100% 10% 25% 50% 100% 10%

TPS TPS TPS TPS TPS TPS TPS TPS TPS
1.8 DOHC 9 (15) 11 18 32 18 23 34 62 25
mph (km/h) (18) (29) (52) (29) (37) (55) (99) (45)
Down Shift Speed
MODEL Down Shift ( ± 4.0 mph (6.4km/h)) Lock Up Clutch

Applied
(Fourth)
Fourth– Third– Second– 10% 25%

Third Second First
(Coast) (Coast) (Coast)
1.8 DOHC 25 (41) 13 (21) 7 (11) 48 (77) 48 (77)
mph (km/h)
INTERNAL WIRING HARNESS CHECK

Step Action Value(s) Y
1 1. Disconnect the transaxle harness. Refer to Com- Go to
2. Measure the resistance between terminals 3 ponent Resist-
and 13 of the transaxle wiring connector. ance Chart
Is the resistance within the values shown?
2 1. Disconnect the internal transaxle harness from Refer to Com- Go to
the first solenoid valve. ponent Resist-
2. Measure the resistance of the first solenoid ance Chart
valve.
3 Measure the resistance between terminals 3 and 13 Refer to Com- Go to
the second solenoid valve. ponent Resist-
Is the resistance within the values shown? ance Chart
the second solenoid valve. ponent Resist-
2. Measure the resistance of the second solenoid ance Chart
valve.

the transaxle wiring connector(EDS 3). ponent Resist-
6 1. Disconnect the internal transaxle harness from Com-

Refer toResist-
ponent Go to
the pressure control valve 3(EDS 3).
2. Measure the resistance of the EDS 3. ance Chart
DAEWOO V–121 BL4

the pressure control valve 4(EDS 4). ponent Resist-
11 Measure the resistance

the transaxle between terminals
wiring connector(EDS 6). 5 and 11 Com-
Refer toResist-
ponent Go to
the transaxle wiring connector(transaxle tempera- ponent Resist-
ture sensor). ance Chart

the transaxle temperature sensor. ponent Resist-
2. Measure the resistance of the transaxle tem- ance Chart
perature sensor.
15 Measure the resistance between terminals 15 and Refer to Com- Go to
16 the transaxle wiring connector(transaxle input ponent Resist-
speed sensor). ance Chart
16 1. Disconnect the internal transaxle harness from Com-

Refer toResist-
ponent Go to
the transaxle input speed sensor.
2. Measure the resistance of the input speed sen- ance Chart
sor.
the transaxle wiring connector(transaxle output ponent Resist-
speed sensor). ance Chart
ponent Resist-
the transaxle
2. Measure output speed
the resistance sensor.
of the transaxle output ance Chart
speed sensor.
19 Measure the resistance between terminals of inter- Refer to Com- No p
nal wiring harness. ponent Resist- foun
Is the resistance within the values shown? ance Chart ta

20 Inspect for resistance: – Verify
S
Ispect the transaxle wiring for poor electrical and Go
connections at the transaxle.
S
Look for possible bent, backed out, deformed
of damaged terminals.
Check for weak terminal tension.
21 Replace the internal wiring harness. – No p
Is the replacement complete. foun
ta
22 Replace the component. – No p
Is the replacement complete. foun

ta
DAEWOO V–121 BL4
TRANSAXLE WIRING HARNESS

CONNECTOR
Wiring Harness Connector
Pin number Description

1 Output Speed Sensor (+)
2 Output Speed Sensor (–)
3 Solenoid Valve (+)
4 Transmission Fluid Temperature Sensor (–)
5 Pressure Control Solenoid Valve (+)
6 Pressure Control Solenoid Valve (EDS3)
7 Pressure Control Solenoid Valve (EDS4)
8 Not Used
9 Transmission Fluid Temperature Sensor (+)
10 Pressure Control Valve Solenoid Valve (EDS5)
11 Pressure Control Valve Solenoid Valve (EDS6)
12 Solenoid Valve 1
13 Solenoid Valve 2
14 Not Used
15 Input Speed Sensor (–)
16 Input Speed Sensor (+)
Component Resistance Chart
Component
Pass Resistance Res
72/324
Component Pass Resistance Res
Through 20° C (68 ° F)
Pins Ohms
Solenoid 1 3, 12 26.5 ± 0.5 Ω 26–345 Ω (n
Solenoid 2 3, 13 26.5 ± 0.5 Ω 26–345 Ω (n
Pressure Control 5, 6 5.7 ± 0.45 Ω 5.3–6.3 Ω (n
Solenoid Valve (EDS3)
Component Pass Resistance Res

Through 20° C (68 ° F)
Pins Ohms
Transaxle Temperature Sensor* 4, 9 980–1,000
Input Speed Sensor 15, 16 830 ± 5 Ω 788–871 Ω
Output Speed Sensor* 1, 2 R
* The resistance of the transaxle is necessarily dependent on the temperature.
DAEWOO V–121 BL4
– Thoroughly clean the tr

SYMPTOM DIAGNOSIS rounding area(using a ste
– To locate leakage, use
Oil Leakage or similar product.
Notice : – Depending on the amo
– Careful localization of leakage points may make it car for a short or a longer
possible to prevent incorrect or cost–intensive re- sufficient to place the car
pairs. engine at idle speed to tra
– If possible, determine e
Test Steps : escaping.
Symptom Possible Cause Ac

Transa le Oil Leak
Oil P mp(Torq e Con erter Sealing) 74/324
Transaxle Oil Leak- Oil Pump(Torque Converter Sealing) S
Visually check torque
age S
Replace the converte
the transaxle repair o
Crankshaft Sealing Ring S
Check whether engin
S
If leak is engine oil, re
described in the engin
Torque Converter S
Visual check.
S
Fit an exchange conv
repair instruction.
Oil Content Too High S
Check oil level(TFT a
in this chapter.
S
Correct oil level, and
Notice : Comply with the
ing procedure) in the repa
level at the overflow plug a
essary.
O–ring at Bolt Head Damaged or Miss- S
Check O–ring.
ing S
Replace O–ring as de
struction.
Shaft Seal S
Visually check the sha
S
Replace the sealing r
repair instruction.
Hose Clamp Loose S
Check to ensure that
S
If necessary, retighten
Oil Pan Gasket Not Installed Properly S
Check to see if the ga
properly.
S
Install gasket properly
pair instruction.
Oil Pan Gasket Damaged S
Check the gasket visu
S
Replace gasket as de
struction.
Bolt at Bracket Loose Check the Tightening Torq
Retighten bolt
Sealing Ring at Oil Dipstick S
Check O–ring.
S
If necessary, replace
Sealing Ring Near End–Cover Connec- S
Check sealing rings.
tion Defective Put in new sealing rin
S
scribed in the repair in

Sealing Ring Selector Shaft S
Check sealing ring.
S
Replace sealing ring a
instruction.
O–ring at Socket Outlet S
Check O–ring.
S
struction.
O–ring and Speed Sensor Connection S
Check O–ring.
S
struction.
Oil Leak Incorrectly Identified S
No oil leak is possible
Speed Sensor Itself Is Leaking S
Check speed sensor.
S
Replace speed senso
pair instruction.
Hair Line Crack at the Piping in the Con- S
nection Area, Sealing Ring Fit in Trans- Pressurize

check it. the line wi
axle Housing S
Replace lines as desc
struction.
O–ring Defective, Incorrect Check O–ring.
Replace O–rings as desc
tion.
Plug Loose Check the Tightening Tor
Tighten to torque specifie
Noise
Noise TFT Level Too Low S
When the TFT level is
from the transaxle oil
noise.
S
Check the TFT level a
instruction and fill to t
Monolith in Catalytic Converter Has S
Check according to th
Broken procedure or by shak
casing.
S
Replace catalytic con
Noise from Auxiliaries (e.g. exhaust S
Check these compon
system, alternator, drive shafts.) nate the faults as des
struction
Noise from Tires or Wheel Bearings S
Eliminate fault if nece
g Eliminate fault if nece
Noise from Planetary Gears S
Whistling noise on tra
gear only)caused by h
tionally unavoidable)
Cumulative Tooth Backlash in the Com- S
plete Drive Line Production

vinced. status. Cu
Jerky Noise of the Parking Lock (e.g. S

Load–reversal reactio
when the car is standing on a gradient) S
Apply the handbrake
ing Lock (position P)
DAEWOO V–121 BL4

Noise The Engine’s Torsional Vibrations are S
At low speeds in fourt
Being Transmitted to the Drive Shafts arise (driving at too lo
S
Noise is functionally u
ances. Convince the
Noise Torque Reaction Strut Loose S
Check mounting and
– Carry out the general c

Shift quality automatic transaxle diagn
– Perform a test drive to
Notice :
tions.
– The assessment of shaft quality is, to a large ex-
In which driving situations
tent, an individual, subjective matter. Take careful
complaint arise?
note of how the customer describes the complaint To which shifts does the c
and of the manner in which he or she handles the
Is the complaint reproduc
vehicle and the controls.
or has it only occurred sp
– A sudden deterioration of shift quality may also
occasion?
be caused by the transaxle selecting an emergency
or substitute program – Check the oil level and
– Interrogate the fault me
Test Steps : surement block data.
Shift Quality Rapid Pressure Build–up in the Clutch Operating error (posit
S
in quick succession).
Jerk When Parking Lock Is Released S
Refer to ”Noise” in th
Incorrect Electronic Transaxle Control S

Check the data status
module module ; refer to ”TCM
Emergency/Substitute Program Has S
For checking and rem
Been Activated ”Emergency/Substitut
tion.
Accelerator Pedal in Indefinite Position S
Persuade customer to
Between Full Throttle and Kick Down kick down and full thro
S
Check setting accord
struction ; adjust if ne
Control Overlap Between to Clutches S
Production status
During Shift S
Convince the custome
Temperature Sensor S
Check function accord
(Not Fault Memory) stitute program” in thi
Kick Down Setting Incorrect S
Check
A) Floor mat is obstru

B) The kick down sett
Engine Section.
Test Steps :
Malfunction Perform the general checks a
Notice : transaxle diagnostic procedur
The faults dealt with here concern transaxle functions – Test drive
such as ”traction” (forwards and reverse) and all type of – Check oil level and qua
shifts. Entries will not always be made in the fault memory. – Interrogate fault memo

Malfunction Defective Clutch in Transaxle It There Is S
This is usually due to
Still No Drive With the TCM Discon- or to internal leakage
nected S
Repair is not possible
transaxle.
Kick Down Switch Not Functioning S
Properly ”Emergency/Substitut
tion.
Kick Down Switch Not Operating Prop- S
erly gine Instruction.
Vehicle Is in Emergency Mode S

”Emergency/Substitut
tion.
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE DIAGNO

DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICAT
DTC Description Indication Default Ac
P0562 System Voltage Low MIL ON S
The TCM will record operat
the diagnostic fails. This info
the Failure Records buffer.
S
Adopt Emergency/Substitut
gear by hydraulic control.
S
After ignition OFF/ON: 3rd g
Possible P, R and N also po
S
Power supply cut off to the
P0563 System Voltage High MIL ON S
S
S
S
P0601 Internal Control Module MIL ON S
Memory Checksum Error the diagnostic fails. This info
S
S gear
After by hydraulic
ignition control.
OFF/ON : 3rd
S
P0603 S
Internal Control Module MIL ON S
Keep Alive the diagnostic fails. This info
Memory(KAM)Error the Failure Records buffer.
S
S
S
P0604 Internal Control Module MIL ON S

Random Access Memory the diagnostic fails. This info
(RAM) Error the Failure Records buffer.
S
Adopt Emergency/ Substitu
b h d li t l80/324
S
After ignition OFF/ON : 3rd
S
P0606 S
Transaxle Control Mod- MIL ON S
ule Processor Fault the diagnostic fails. This info
S
S
S
DTC Description Indication Default A

P0703 Brake Switch Circuit No Change S
TCM assume that the brake
Malfunction S
Open lock up clutch.
P0705 Transmission Range Sen- MIL ON S
sor Circuit Malfunction the diagnostic fails. This info
(PRNDL Input) the Failure Records buffer.
S
S
position P, R and N also pos
P0710 S
Transmission Fluid No Change S
TCM assume the transaxle
Temperature Sensor 140 ° F (60 ° C).
S
Circuit Malfunction No influence at vehicle runn

P0715 S
Input Speed Sensor MIL ON S
Circuit Malfunction the diagnostic fails. This info
S
S
S
P0716 S
Circuit Range/Perfor- the diagnostic fails. This info
mance the Failure Records buffer.
S
S
S
P0717 S
S
S
S
P0720 Output Speed Sensor Cir- MIL ON S
cuit Malfunction the diagnostic fails. This info
S
gear.
S
P0721 Output Speed Sensor Cir- MIL ON S
cuit Range/Performance the diagnostic fails. This info
S
gear.
S
DAEWOO V–121 BL4

P0722 S
Output Speed Sensor MIL ON S
Circuit No Signal the diagnostic fails. This info
S
Vehicle running remains act
S
P0725 S
Engine Speed Input No Change S
Circuit Malfunction gear.
S
P0726 S
Engine Speed Input MIL ON S
Ci it R
https://es.scribd.com/doc/157544056/ZF4HP16-Optra /P f th di ti f il Thi 82/324
i f
S
gear.
S
P0727 S
Engine Speed Input MIL ON S
Circuit No Signal the diagnostic fails. This info
S
gear.
S
P0731 S
Gear 1 Incorrect Ratio MIL ON S
S
gear.
S
High line pressure
P0732 S
S
gear.
S
High line pressure.
P0733 S
S
gear.
S
High line pressure
P0734 S
S
S
S
High line pressure.

P0781 S
1–2 Shift Malfunction MIL ON S
S
gear.
S

P0782 S
S
2nd gear.
S
P0783 S
S
gear.
S
P1604 S
Data Check of Internal MIL ON S
& Extended Ram Failed the diagnostic fails. This info
S
S
S
P1606 S
Failure of External MIL ON S
Watchdog the diagnostic fails. This info
S
S
S
Power supply cut OFF to th
P1671 CAN Transmit Message MIL ON S
Failure
the diagnostic
the Failure fails. This
Records info
buffer.
S
S
P1672 CAN Bus OFF Failure MIL ON S

S
S
DAEWOO V–121 BL4

P1673 CAN Receive ECM Mes- MIL ON S
sage Failure the diagnostic fails. This info
S
S
P1839 EDS3 Output Shorted To MIL ON S
Ground the diagnostic fails. This info
S
S

S
P1840 S
EDS3 Output Shorted MIL ON S
To Power the diagnostic fails. This info
S
S
S

P1841 EDS3 Output Open MIL ON S
S
S
S
P1850 Solenoid 1 Output Shorted MIL ON S
To Ground
S
S
P1852 Solenoid 1 Output Open MIL ON S
S
S

To Ground the diagnostic fails. This info
S
S
To Power
S
S
P1855 Solenoid 2 Output Open MIL ON S
S
S
P1861 S
To Ground the diagnostic fails. This info
S
S
S
P1862 S
S
S
S
S
S
S
S
S gear
After by hydraulic
ignition control.
OFF/ON: 3rd g
S
DAEWOO V–121 BL4

Power the diagnostic fails. This info
S
S
After ignition
Possible P, ROFF/ON: 3rdpog
and N also
S
S
S
S
S
S
S
P1868 S
S
S
S
S
S
S
P1871 S
EDS Valve Power Sup- MIL ON S
ply Circuit Shorted To the diagnostic fails This info
ply Circuit Shorted To the diagnostic fails. This info
Power the Failure Records buffer.
S
S
S

P1874 S
Solenoid Valve Power MIL ON S
Supply Circuit Shorted the diagnostic fails. This info
To Power the Failure Records buffer.
S
S
P1881 2–1 Shift Malfunction MIL ON S
S
gear.
S
P1883 S
S
gear.
S
P1884 4–3 Shift Malfunction MIL ON S
S
gear.
S
P1885
MIL ON 89/324
P1885 S
S
gear.
S
P1886 S
S
gear.
S
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE(DTC) P0562

SYSTEM VOLTAGE LOW
S
Adopt Emergency/ Subst
Circuit Description
4th gear by hydraulic con
The transaxle control module(TCM) is an electronic de- S
After ignition OFF/ON : 3
vice which monitors inputs to control various transaxle trol. Possible P, R and N a
functions including shift quality and transaxle sensors, S
Power supply cut off to th
switches, and components to process for use within its’
control program. Based on this input information, the TCM
controls various transaxle output functions and devices. Conditions For Clearing Th
S
The MIL will turn OFF wh
Conditions For Setting The DTC not occurred after three–
System voltage is less than 8.5 volts. A history DTC will clear a
S S
S
Transaxle input voltage is too low. up cycles without a fault.
S
Engine speed is greater than 500 rpm. S
Using a scan tool can cle
S
Immediately after the above condition occurs.
Action Taken When The DTC Sets Diagnostic Aids

S
The Malfunction Indicator Lamp(MIL) will illuminate. S
Inspect the poor wiring ha
S
The TCM will record operating conditions at the connectors and transaxle
time the diagnostic fails. This information will be S
Inspect the improperly fo
stored in the Failure Records buffer. nals.
DTC P0562 – System Voltage Low

1 Perform an On–Board Diagnostic (EOBD) System – Go to
Check.
Is the check completed?
2 1. Install the scan tool. 9–16V Go to

2. Turn the ignition ON and record then clear
DTC(s), then turn ignition OFF.
3. Turn the ignition ON and start the engine.
4. Run the engine to 1,200 rpm.
5. Select system voltage on the scan tool.
6. Drive the vehicle and observe the scan tool for
system voltage.
Is the voltage within the values shown?
3 9–16V Go to
1.
2. Disconnect
Measure thethe negative
voltage battery
of the cable.
battery at the bat-
tery.
4 1. Turn the headlamp ON. 9–16V Go to
2. Turn the air conditioner ON.
3. Run the engine to 1,200rpm.
4. Observe the scan tool for system voltage.
5 1. Turn the ignition OFF. – Syste
2. After testing the charging system, repair the

alternator circuit if necessary.
Is the action completed?
6 The vehicle would not have started if F2 or EF1 were – Go to
blown.
Was a problem found?
7 Replace the fuse. – Syste
Is the replacement complete?
8 1. Turn the ignition ON. 9–16V Go to
2. Measure the voltage of F2, EF1.
9 Repair the fuse voltage supply lines for an open. – Syste
10 1. Turn the ignition OFF. [
0Ω Go to
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and

terminal B3 of the TCM wiring connector.
11 Repair the circuit(between EF1 and terminal B3) for – Syste
short to ground and open.
Is the repair completed?
DAEWOO V–121 BL4

12 1. Disconnect the C105 connector and TCM con- 9–16V Go to
nector.
2. Turn the ignition ON.
3. Measure the voltage of the terminal B3(TCM
wiring connector).
13 Repair the circuit from EF1 to terminal B3 of the TCM – Syste
for a short to power.
Is the repair complete?
0Ω Go to
2. Disconnect the C206 connector.
3. Measure the resistance between F2 fuse and
terminal C15 or C16 of the TCM wiring connec-
tor.
15 Repair the circuit(between F2 and terminal C15 or – Syste
C16) for a short to ground and open.
2. Measure the voltage of the terminal C15 or
C16(TCM wiring connector).
C16) for short to power.
18 1. Inspect the transaxle wiring for poor electrical – Verify

connections at the transaxle connector. and Go
2. Look for possible bent, backed out, deformed,
or damaged terminals.
3. Check for weak terminal tension.
Was a condition found?
19 Replace the TCM. – Go to
20 1. After the repair, use a scan tool ”clear info” – Begin
function and road test the vehicle. sis
2. Review the ”DTC info”.
Has the last test failed or is the current DTC dis-
played?

SYSTEM VOLTAGE HIGH
S
The TCM will record oper
Circuit Description
time the diagnostic fails. T
The transaxle control module(TCM) is an electronic de- stored in the Failure Reco
vice which monitors inputs to control various transaxle S
functions including shift quality and transaxle sensors, 4th gear by hydraulic con
switches, and components to process for use within its’ S
control program. Based on this input information, the TCM trol. Possible P, R and N a
controls various transaxle output functions and devices. S
Conditions For Setting The DTC
System voltage is greater than 16 volts. Conditions For Clearing Th
S
S
Transaxle input voltage is too high.
S
S
Immediately after the above condition occurs. not occurred after three–
S
A history DTC will clear a
Action Taken When The DTC Sets up cycles without a fault.
S
The Malfunction Indicator Lamp(MIL) will illuminate. S
DAEWOO V–121 BL4
DTC P0563 – System Voltage High

Check.

system voltage.
3 1. Disconnect the negative battery cable. 9–16V Go to
2. Measure the voltage of the battery.
6 Inspect the F2, EF1 fuse for an open. – Go to
7 Replace the fuse if necessary. – Syste
0Ω Go to

a short to ground and open.

nector.
wiring connector).

0Ω Go to
tor.

played?
DAEWOO V–121 BL4

INTERNAL CONTROL MODULE MEMORY CHECKS
ERROR
S
The Malfunction Indicator
Circuit Description S
A normal function of the Transmission Control Module time the diagnostic fails. T
(TCM) programming is to perform an internal check that stored in the Failure Reco
verifies the integrity of the RAM memory allocations. S
The DTC P0601 sets when the Random Access 4th gear by hydraulic con
Memory(RAM) is not operating correctly when checked on S
initialization. An area of RAM is failed a read/ write test. trol. Possible P, R and N a
S

S
The EEPROM checksum test is separated in two Conditions For Clearing Th
independent parts, the code checksum test and the S
calibration checksum test. For each area the check-
not occurred after three–
sum is calculated and compared with the corre- S
sponding checksum valve. If the valves are differ-
up cycles without a fault.
ent, the fault will be set.
S
System voltage is too high or too low.
S
S
Transaxle input voltage is too high or too low.
S
Immediately after the above condition occurs. Diagnostic Aids
S
Action Taken When The DTC Sets When DTC

could be P0601 sets, t
TCM.
DTC P0601 – Internal Control Module Memory Checksum

Check.
2 1. Install the scan tool. – Go to

2. Turn the ignition ON, with the engine OFF.
Does the scan tool display P0601?
3 1. Turn the ignition OFF. – Go to
2. Replace the TCM.
Is the action complete?
4 1. Using the scan tool, clear the DTCs. – Go to
2. Road test the vehicle within the conditions for
setting this DTC as specified in the text.
Does the scan tool indicate that this diagnostic has
run and passed?
5 1. Check if any DTCs are set. – Go to
2. Are any DTCs displayed that have not been ble DT
diagnosed?
DAEWOO V–121 BL4

INTERNAL CONTROL MODULE KEEP ALIVE
MEMORY(KAM) ERROR
Circuit Description Action Taken When The DTC
A normal function of the Transmission Control Module
S
(TCM) programming is to perform an internal check that
S
verifies the integrity of the KAM memory allocations time the diagnostic fails. T
verifies the integrity of the KAM memory allocations.
stored in the Failure Reco
The DTC P0603 sets when the keep alive memory (KAM) S
is not operating correctly when checked on initialization. 4th gear by hydraulic con
An area of KAM is failed a read/ write test.
S
trol. Possible P, R and N a
S
S
The checksum of the current regulator data will be Conditions For Clearing Th
tested. If the checksum is not OK, then the error bit S
will be set. not occurred after three–
S
If writing to FLASH during power latch phase failed. S
S
Each of the flash blocks has its own status which is up cycles without a fault.
located at the beginning of the each flash block and S
the status of the FLASH blocks do not fit together.
S
System voltage is too high or too low. Diagnostic Aids
S
Transaxle input voltage is too high or too low. S
When DTC P0603 sets, t
S
Immediately after the above condition occurs. could be TCM.
DTC P0603 – Internal Control Module Keep Alive Memory(

Error
Check.


2. Replace the TCM.
run and passed?
diagnosed?
DAEWOO V–121 BL4

INTERNAL CONTROL MODULE RANDOM ACCE
MEMORY(RAM) ERROR
S
Circuit Description time the diagnostic fails. T
A normal function of the Transmission Control Module stored in the Failure Reco
(TCM) programming is to perform an internal check that S
verifies the integrity of the RAM memory allocations. S 4th

Aftergear by hydraulic
ignition OFF/ONcon
:3
The DTC P0604 sets when the Random Access
trol. Possible P, R and N a
Memory(RAM) is not operating correctly when checked on S
initialization. An area of RAM is failed a read/ write test.
Conditions For Clearing Th
Conditions For Setting The DTC S
S
An area of RAM is failed a read/ write test. not occurred after three–
S
System voltage is too high or too low. S
S
Transaxle input voltage is too high or too low. up cycles without a fault.
S
Immediately after the above condition occurs. S
Action Taken When The DTC Sets Diagnostic Aids

The Malfunction Indicator Lamp(MIL) will illuminate.
S
recommended.
DTC P0604 – Internal Control Module Random Acces

Memory(RAM) Error
Check.

2. Replace the TCM.

run and passed?
diagnosed?
DAEWOO V–121 BL4

TRANSAXLE CONTROL MODULE PROCESSOR FA
S
In case that TCM reset has occurred by software (warm time the diagnostic fails. T
reset) not by ignition key ON, TCM increments software stored in the Failure Reco
reset counter. If the counter exceeds the permissible max- S
imum value for the software count then the fault will be de- 4th gear.
tected. S
Conditions For Setting The DTC Conditions For Clearing Th
S
System voltage is too high or too low. S
S
Transaxle input voltage is too high or too low. not occurred after three–
S
Immediately after the above condition occurs. S
Action Taken When The DTC Sets S
DTC P0606 – Transaxle Control Module Processor Fau

Check.

system voltage.
3 9–16V Go to
1.
2. Disconnect
Measure thethe negative
voltage battery
of the cable.
battery at the bat-
tery.

6 The vehicle would not have started if F2 or EF1 were – Go to
blown.
7 Replace the fuse if necessary. – Syste
0Ω Go to

short to ground and open.
DAEWOO V–121 BL4

nector.
wiring connector).
0Ω Go to
tor.

played?

BRAKE SWITCH CIRCUIT MALFUNCTION
S
Immediately after the abo
Circuit Description
The brake switch is used to indicate brake pedal status to Action Taken When The DTC
the transaxle control module(TCM). The brake switch is a S
No lamp control required
normally open switch. Applying the brake pedal closes the should be stored immedia
switch, supplying voltage to the TCM. Releasing the brake detected.
pedal interrupts voltage to the TCM. S
TCM assume that the bra
This DTC is stored at start–up. If the TCM receives a brake
switch signal after start–up, the DTC will be stored in Conditions For Clearing Th
S
memory.
Conditions for Setting The DTC Diagnostic Aids
S
Brake switch stuck to closed. S
Inspect the poor wiring ha
S
Brake switch wiring harness shortage to ground. connectors and transaxle
S
Brake switch wiring harness shortage to power. S
Inspect the improperly fo
DAEWOO V–121 BL4
DTC P0703 – Brake Switch Circuit Malfunction

Check.

2. Turn the ignition ON. With the engine OFF.
3. Record then clear DTC(s)
4. Select scan tool stransmission data display.
5. Disconnect the brake switch connector.
6. Did the brake switch status change from” on” to
”off”?
3 1. Replace the brake switch. – Go to
2. Refer to Brake Replacement.
3. After the ignition OFF, turn ignition ON.
Is the DTC reset?
4 Inspect the EF13. – Go to
Is the fuse blown?
5 Replace the fuse. – Syste
0Ω Go to
2. Disconnect the C102 wiring connector and the
brake switch wiring connector.
3. Measure the resistance between the terminal
D5 of the C102 connector and the terminal 3 of
the brake switch wiring connector.
7 Repair the open circuit between the C102 connector – Syste
and the brake switch connector.
8 1. Turn the ignition ON. 11–14v Go to
2. Measure the voltage of the C102 connector, 6
terminal.
9 Repair the short to power between the C102 con- – Syste
nector and the brake switch connector.
0Ω Syste
2. Disconnect the brake switch wiring connector
g
and TCM wiring connector.
3. Measure between the brake switch connector,
terminal 4 and TCM connector, terminal A5.
11 Repair the open or

switch connector andshort
TCM.to ground between brake – Syste
12 1. Turn the ignition ON. 11–14v Go to
2. Measure the voltage of the brake switch wiring
connector, terminal 4.

13 Repair the short to power between the brake switch – Syste
wiring connector and TCM.
played?
DAEWOO V–121 BL4

TRANSMISSION RANGE SENSOR CIRCUIT
MALFUNCTION (PRNDL INPUT)
Circuit Description Action Taken When The DTC
The Transmission range switch is located on the selector S
shaft and informs the TCM of the current selector lever S
position P–R–N–D–3–2–1. time the diagnostic fails. T
The selector lever position is transmitted to the TCM in en- stored in the Failure Reco
coded form along 4 lines. The encoding is such that mal- S
functions in the connecting lead are identified. 4th gear.
The TR switch is located on the selector shaft, which is
Conditions for Clearing the
connected to the selector lever via a pull cable. In addition,
the TR switch controls the starter interlock, the reverse
S
lights and the selector lever position indicator on the in- not occurred after three–
strument panel.
S
Conditions for Setting The DTC S
S
TR switch stuck to closed.
S
TR switch wiring harness shortage to ground. Diagnostic Aids
S
TR switch wiring harness shortage to power. S
S
Immediately after the above condition occurs. switch.
Gear Position And Range Signal Chart.
L1 L2 L3
P 0 0 12
R 0 0 0
N 0 12 0
D 12 12 12
3 12 12 0
2 12 0 12
1 0 12 12
DTC P0705 – Transmission Range Sensor Circuit Malfunc

(PRNDL Input)

Check.

3. Record then clear DTC(s) and turn the ignition
OFF, then turn the ignition ON.
4. Applying the brakes and select each transaxle
range (P, R,N,D,3,2,1), while monitoring scan
tool.
Refer to Gear Position And Range Signal Chart.
Does each selected transaxle range match scan tool
and signal range chart?
3 Inspect the F2 for open? – Go to
4 Replace the fuse as necessary. – Syste
5 Inspect the TR switch. Refer to ”Diagnostic Aids”. – Go to
Was the problem found?
6 Replace the TR switch. – Syste
7 1. Disconnect the TR switch connector and TCM [
0Ω Go to
connector.
2. Measure the resistance between terminal 3 of
the TR switch and terminal C1 of the TCM con-

nector.
the TR switch and terminal B15 of the TCM
connector.
the TR switch and terminal B6 of the TCM con-
nector.
the TR switch and terminal B11 of the TCM
connector.
DAEWOO V–121 BL4

8 Repair the malfunctioning terminals as necessary. – Syste
2. Measure the voltage of terminal 3.
Is The action complete?
played?

TRANSMISSION FLUID TEMPERATURE SENSO
CIRCUIT MALFUNCTION
Conditions for Setting The
Circuit Description
S
The calculated temperatu
The TFT sensor is a positive temperature coefficient predetermined min. and m
thermistor (temperature sensitive resistor) that provides S
If the temperature is less
information to the TCM regarding transaxle fluid tempera- than max value then the
ture. The temperature sensor is located in valve body. Cal- garded as of range and th
culated temperature is a factor used to determine the shift will be set.
time and shift delay time. S
Transmission
–40 fluid
° C (–40 ° F) andtempe
150
The internal electrical resistance of the sensor varies in
relation to the operating temperature of the transaxle fluid.
Action Taken When The DTC
The TCM sends a 5 volt–reference signal to the tempera- S
No lamp control required
ture sensor and measures the voltage rise in the electrical should be stored immedia
circuit. A higher fluid temperature creates a higher resist- defected.
ance in the temperature sensor, thereby measuring a S
TCM assumes the transa
higher voltage signal. 60 ° C.
S
No influence on drivability
The TCM measures this voltage as another input to help
control line pressure, shift schedules and TCC apply. Conditions for Clearing the
When transaxle fluid temperature reaches 120 ° C (248 ° F) Using a scan tool can cle
S
the TCM enters ”hot mode.” Above this temperature the

TCM modifies transaxle shift schedules and TCC apply in Diagnostic Aids
an attempt to reduce fluid temperature by reducing trans- S
axle heat generation. could be Transmission Te
DAEWOO V–121 BL4
DTC P0710 – Transmission Fluid Temperature Sensor Cir

Malfunction

Check.

3. Record then clear DTC(s) and turn the ignition
OFF, then turn the ignition ON.
4. Select TFT on the scan tool.
either of the flowing conditions:
6. The TFT does not change more than 1.5 ° C
(34.7 ° F) in 80 seconds since start–up.
7. The TFT changes more than 20 ° C (68 ° F) with-
in 7 seconds (unrealistic change).
Did either of the fail conditions occur?
3 1. Turn the ignition OFF. TFT 25 ° C Go to
2. Disconnect the transaxle wiring connector. 990 Ω
3. Measure the resistance between terminals 9
and 4 of the transaxle wiring connector.
4 1. Remove the oil pan. – Go to
2. Disconnect the wiring connector of the trans-
axle fluid temperature sensor.
3. Inspect the automatic transaxle wiring harness
for an intermittent short or open.
5 Replace the automatic transaxle wiring harness. – Syste
6 Replace the TFT sensor. – Syste
7 [
0Ω Go to
1. Disconnect the automatic
nector and disconnect the transaxle wiring con-
wiring connector of
the TCM(transaxle control module).
the transaxle wiring connector and terminal B1
of the TCM wiring connector.
3 Measure the resistance between terminal 9 of
the transaxle wiring connector and terminal A4
8 1. Inspect the automatic transaxle wiring harness – Syste
for an intermittent short to ground or open con-
dition.
2. Inspect the automatic TFT sensor wiring har-
ness for an intermittent short to ground or open
condition.
3. Repair the circuits if necessary.

2. Measure the voltage of terminal A4 of the TCM
wiring connector.
3. Measure the voltage of terminal B1 of the TCM
wiring connector.
10 1. Inspect the automatic transaxle wiring harness – Syste
for an intermittent short to power.
2. Inspect the automatic TFT sensor wiring har-
ness for an intermittent short to power.
3. Repair the circuits if necessary.
played?
DAEWOO V–121 BL4

INPUT SPEED SENSOR(ISS) CIRCUIT MALFUNCT
S
TCM or ECM is defective
Immediately after the abo
Information relative to transaxle input speed to the TCM.
The TCM uses transaxle input speed information to con- Action Taken When The DTC
trol line pressure, TCC apply and release and transaxle S
shift patterns. This information is also uses to calculate the S
appropriate operating gear ratios and TCC slippage. time the diagnostic fails. T
The input speed sensor mounts onto piston B that is inside stored in the Failure Reco
of valve body. S
An air gap of 1.8~2.2mm(0.07~0.086inch) is maintained 4th gear by hydraulic con
between the sensor and the piston B.
S
trol, position P, R and N a
The sensor consists of a permanent magnet surrounded S
by a coil of wire. As the piston B is driven by the turbine
shaft, an AC signal is induced by the input speed sensor. Conditions for Clearing The
Higher vehicle speeds induce a higher frequency and volt- S
age measurement at the sensor. not occurred after three–
Sensor resistance should measure between 825~835 S
ohms at 20 ° C(68 ° F). Sensor can measure from up cycles without a fault.
1,000~8,000HZ. S
Conditions for Setting The DTC Diagnostic Aids

S
Input speed is more than 7,000 rpm. S
S
System voltage is too high or too low. could be ISS(input speed
DTC P0715 – Input Speed Sensor(ISS) Circuit Malfunct

Check.
2 1. Install the scan tool. Input speed : Go to

2. Turn the ignition ON and record then clear 0–7,000rpm nosti
DTC(s).
3. Turn the ignition OFF, then turn the ignition
ON.
4. Observe the input speed on the scan tool.
Is the speed within the values shown?
3 1. Turn the ignition OFF. 830 ± 5Ω Go to
2. Disconnect the transaxle wiring connector.
3. Measure
and 16 ofthe
theresistance between
transaxle wiring terminals 15
connector.
4 1. Remove the oil pan. [
0Ω Go to
2. Disconnect the input speed sensor wiring con-
nector.
the input speed sensor wiring connector and
terminal 15 of the transaxle wiring connector.
7 Repair the short to battery power. – Syste
8 Replace the input speed sensor. – Syste
9 1. Disconnect the transaxle wiring connector and [
0Ω Go to
TCM connector.
DAEWOO V–121 BL4

Is the voltage within the values shown?.

played?
ZF 4 HP 16 AUTOMATIC TRANSAXL

INPUT SPEED SENSOR(ISS) CIRCUIT
RANGE/PERFORMANCE
S
No engine speed error DTCs P0727,
Gear position is D.
Information relative to transaxle input speed to the TCM. S
TCM or ECM is defective.
The TCM uses transaxle input speed information to con- S
Immediately after the above conditio
trol line pressure, TCC apply and release and transaxle
shift patterns. This information is also uses to calculate the Action Taken When The DTC Sets
appropriate operating gear ratios and TCC slippage. S
The Malfunction Indicator Lamp(MIL
The input speed sensor mounts onto piston B that is inside S
The TCM will record operating condi
of valve body. time the diagnostic fails. This informa
An air gap of 1.8~2.2mm(0.07~0.086inch) is maintained stored in the Failure Records buffer.
between the sensor and the piston B.
S
Adopt Emergency/ Substitute mode
4th gear by hydraulic control.
The sensor consists of a permanent magnet surrounded S
After ignition OFF/ON : 3rd gear by h
by a coil of wire. As the piston B is driven by the turbine trol, position P, R and N also possible
shaft, an AC signal is induced by the input speed sensor. S
Higher vehicle speeds induce a higher frequency and volt-
age measurement at the sensor. Conditions for Clearing The MIL/DTC
Sensor resistance should measure between 825~835 S
The MIL will turn OFF when the malf
ohms at 20 ° C(68 ° F). Sensor can measure from 1,000~ not occurred after three–ignition cycl
S
8,000HZ. A
uphistory
cyclesDTC willaclear
without fault.after 40 cons
Conditions for Setting The DTC S
Using a scan tool can clear history D
S
The increasing rate of the turbine speed is more
than 45,000 rpm/sec. Diagnostic Aids
S
System voltage is greater than 8.5 volts. S
When DTC P0716 sets, the possible
S
Engine is running. could be ISS(input speed sensor).
DAEWOO V–121 BL4
DTC P0716 – Input Speed Sensor(ISS) Circuit Range/Performance

Step Action Value(s) Yes
1 Perform an On–Board Diagnostic (EOBD) System – Go to Step 2
Check.
2 1. Install the scan tool. Input speed : Go to ”Diag-

2. Turn the ignition ON and record then clear 0–7,000rpm nostic Aids”
DTC(s).
3. Turn the ignition OFF, then turn the ignition
ON.
4. Observe the input speed on the scan tool.
Is the speed within the values shown?
3 1. Turn the ignition OFF. 830 ± 5Ω Go to Step 9
2. Disconnect the transaxle wiring connector.
3. Measure
and 16 ofthe
theresistance between
transaxle wiring terminals 15
connector.
4 1. Remove the oil pan. [
0Ω Go to Step 6
2. Disconnect the input speed sensor wiring con-
nector.
5 Repair the malfunctioning terminals as necessary. – System OK
6 1. Turn the ignition ON. 11–14V Go to Step 7
7 Repair the short to battery power. – System OK
8 Replace the input speed sensor. – System OK
9 1. Disconnect the transaxle wiring connector and [
0Ω Go to Step 11
TCM connector.

10 Repair the malfunctioning terminals as necessary. – System OK
ZF 4 HP 16 AUTOMATIC TRANSAXLE
12. Install the upper transaxle–to–engine

Tighten
Tighten the upper transaxle–to–eng
N m (55 lb–ft).
S
13. Install the clips to the shift control ca

nect the shift cable.
14. Install the park/neutral position switc

connector.
15. Connect the transaxle wiring harness
15. Connect the transaxle wiring harness
axle.
16. Remove the engine support fixture D

17. Install the battery. Refer to Section
Electrical.
18. Add the transaxle fluid. Refer to ”Tra
Level Checking Procedure” in this s
19. Connect the negative battery cable.
DAEWOO V–121 BL4
UNIT REPAIR
TORQUE CONVERTER
Disassembly and Assembly Pro
1. Remove the transaxle assembly. Re
axle Assembly” in this section.
2. Remove the torque converter assem
3. Installation should follow the remova
the reverse order.
TRANSAXLE HOLDING FIXT

ASSEMBLY
Tools Required
DW260–020 Transaxle Support Fixture
CAUTION : To reduce the possibility
ry or transaxle damage, make sure
next step, that all of the bolts for th
are installed as shown, and that th
ened to 11 N m (98 lb–in).
S

1. Install the transaxle support fixture D
onto the transaxle.
2. Torque the support fixture bolts to 11
3. in).
Position the transaxle with the rear c
VALVE BODY
1. Remove the oil pan bolts and oil pan

2. Remove the oil pan gasket.
Installation Notice
Tighten the oil pan bolts to 6 N S
m (53 lb
ZF 4 HP 16 AUTOMATIC TRA
3. Remove valve body fixing

speed sensor bolt on the
4. Remove the holder for the
sensor.
Installation Notice
Tighten the bolts to 8 N m (7
S
5. Tilt the valve body.

6. Remove the fastening sc
sensor under the valve bo
7. Lever the cable

the output speedout of the
sensor.
8. Installation should follow
the reverse order.
Installation Notice
Tighten the screw to 6 N m ( S
REAR COVER
Disassembly and Asse
1. Removal the valve body a

Body Removal” in this se
2. Pull out sealing sleeve (b
3. Turn transaxle by 90 ° .
4. Remove the rear cover b

5. Hit the rear cover rightly.
g y
6. Remove the cover.
the reverse order.
Installation Notice
Tighten the rear cover bolts to
DAEWOO V–121 BL4
CLUTCH B/E
Tools Required
DW260–140 Clutch B Stop Ri

DW260–150 Clutch B Stop Ri
1. Remove the rear cover. R

moval” in this section.
2. Remove the two sealing
3. Take out input shaft with
4. Remove needle bearing a

5. Remove shim.
6. Take out the retaining sna
7. Take out the piston B.
8. Remove disc set B.
9. Take out the piston rings.

Removal Notice
S
Remove the rectangu
put shaft and the retai
10. Remove inner disc carrie

bearing.
DAEWOO V–121 BL4
11. Take out the snap ring.
12. Remove disc set E.
13. Press down cup spring(cl

press fixture.
14. Remove the split stop ring
15. Remove the oil dam and

16. Pull the o–ring off the oil
g
17. Press down cup spring(c

press fixture.
18. Remove the split stop ring
19. Remove the cup spring.

the reverse order.
Adjustment Notice
Before assembling clutch B/E
have to measured by below m
CLUTCH B/E MEASU
289/324
CLUTCH B/E MEASU
PROCEDURE
Tools Required
DW260–090 Clutch B/E(snap
Measuring Fixture
Determine Snap Ring P
1. Put the dial gauge senso

ring.
2. Feed compressed air to c
3. Set dial gauge to zero.
4. Pressurize clutch E via th
measurement value.
5. Repeat measurement twi
120 ° .
6. Average measurement va
surement value is S)
S
CALCULATION
S = (M1+M2+M3)/3
S
EXAMPLE
– M1 = 0.27mm, M2 =
– S = 0.25mm
DAEWOO V–121 BL4
Tools Required
DW260–090 Clutch B/E (sn
space) Measuring Fixture
Measuring Installation
(EB)
1. Put the dial gauge’s sens

ing ring.
4. Lift measurement ring B b
cup and read the measur
cup and read the measur
120 ° .
surement value is MB)
S
The minimum installat
the height of the ring R
11.99mm) plus measu
S
CALCULATION
MB = (M4+M5+M6)/3
EB = RB + MB
S
EXAMPLE
M4 = 2.36mm
M5 = 2.40mm
M6 = 2.38mm
So,MB = (2.36+2.40+
EB = 11.99+2.38 =14.
Tools Required
DW260–090 Clutch B/E(snap
Measuring Fixture
Measuring Installation
1. Put the dial gauge’s sens

ing ring.
4. Read off the measured va
120 ° .
surement value is ME)
S
The minimum installat
ring height RE (specif
plus ME – minus snap
S
CALCULATION
ME = (M7+M8+M9)/3
EE = RE + ME–S
S
EXAMPLE
M7 = 2.6mm
M8 = 2.55mm
M9 = 2.54mm
So,ME = (2.6+2.55+2
EE = 20.98+2.56–0.2
Tools Required
DW260–100 Brake B/E Disc T
Determining Adjusting
1. Using disc thickness gau

ME for the disc set for clu
disc, which located in sec
2. Calculate the test dimens
EB = installation spac
MB = disc set thickne
S
EXAMPLE
EB = 14.37mm
MB = 11.3mm
PB = 3.07mm
3. Find the disc set’s thickne
table.
PB
2.83~3.39mm
3.40~3.68mm
3.69~4.08mm
4.09~4.54mm
PB is 3.08mm so, the
1.8mm.
4. Replace clutch B’s setting
Tools Required
DW 260–100 Brake B/E Disc
ture
1. Using disc thickness gau
MB for the disc set for clu
disc, which located in the
EE = installation spac
MB = disc set thickne
S
EXAMPLE
EE = 23.29mm
ME = 16.70mm
PE = 6.59mm
table.
https://es.scribd.com/doc/157544056/ZF4HP16-Optra PE 292/324
PE
5.41~6.00mm
6.01~6.48mm
6.49~6.98mm
PB is 3.08mm so, the
5.0mm.
DAEWOO V–121 BL4
PLANETARY GEAR
1. Remove the clutch B/E. R

this section.
2. Remove the rear sun gea
3. Remove the planetary ge
4. Remove snap ring from fr
5. Take out rear planetary g
6. Remove the axial needle
7. Take out front gear set w

gear and oil trays.
8. Take oil trays and front su

gear set.
the reverse order.
BRAKE C/D
Tools Required
DW260–160 Brake C/D Snap
1. Take snap ring out of tran
DAEWOO V–121 BL4
2. Release cylinder with pis

pressed air to the feed bo
3. Remove cylinder with pis
4. Take disc carrier C/D and

axle housing.
5. Release cylinder with pis

pressed air to the feed bo
p
6. Remove cylinder with pis
7. Separate between piston
8. Take snap ring out of bra
9. Remove the disc set C.

Installation Notice
S
Transaxle has two line
steel clutch disc. The
installed in such a wa
steel disc.
S
Insert the fitting keys i
grooves.
DAEWOO V–121 BL4
10. Turn the disc carrier C/D

11. Using assembly bracket P
take out the snap ring.
12. Remove the disc set D.

the reverse order.
DIFFERENTIAL

1. Remove the torque conve
”Torque Converter” in thi
2. Lift out the differential.
the reverse order.
Removal Notice
S
Don’t disassemble the dif
operation.
SIDE SHAFT

1. Remove the differential. R
this section.
2. Tilt and remove the side s
the reverse order.
Removal Notice
S
Don’t disassemble the dif
operation.
BRAKE F, SLOTTED
Tools Required
DW260–060 Brake F Split Sto
1. Remove
section. the side shaft. R
2. Take OFF the disc set an
carrier.
3. Mount fixture and remove

ring.
4. Remove the fixture and ta
DAEWOO V–121 BL4
5. Release the piston F by a

the bore.
6. Remove piston F and bea

the reverse order.
Removal Notice
Since the bearing set is tight,
ward from underneath to remo
Tools Required
q
DW 260–110 Brake F Disc Cle
+/ – Measuring Installation
– 12.54
ORIGIN ON/OFF
1. Using a depth gauge, me
housing sealing surfaces
port surface at two oppos
2. Average the measuremen
S
CALCULATION
BF = (M1+M2)/2
S
CALCULATION
M1 = 18.6mm
M2 = 18.8mm
BF = 18.7mm

BF = installation spac
MF = disc set thickne
S
EXAMPLE
BF = 18.70mm
MF = 14.50mm
PE = 4.2mm

table.
PF
3.01~3.19mm
3.20~3.48mm
3.49~3.88mm
3.89~4.08mm
4.09~4.30mm
PE is 4.20mm so, the

3.0mm.
TORQUE CONVERT
2. Hit the torque converter h
Installation Notice
First pre–tighten
der.(7,20) the bolts
(12,23)
³
(16
³
Tighten
Tighten the bolts to 15 N
S
Then, tighten the bolts in
³
(16,4) (14,5) (13,2
³ ³
³
(10,20) (9,19) (8,
³ ³
S
Last, in numerical order, t
way.(1 23)
³
Tighten
Tighten the bolts to 23 N
4. Take out the metal gaske

5. Take out the paper gaske
6. Remove the oil filter bolt
Installation Notice
Tighten
Tighten the oil filter bolt to
DAEWOO V–121 BL4
7. Remove the baffle plate b

Installation Notice
Tighten
Tighten the baffle plate bo
8. Remove the line pressure

the reverse order.
Installation Notice
Tighten
Tighten the line pressure
N m (15 lb–ft).
S
SHIFT MECHANISM
1. Take out the select shaft
2. Remove the shift mechan

S
Shift mechanism is co
S
Shift mechanism is co
ent disc, connecting b
the reverse order.
PARKING LOCK SYS

1. Remove the parking lock
S
Parking lock system is
leg spring, support bo
the reverse order.
BEARING PLATE(W
ASSEMBLY
1. Remove the piston F. Ref
section.
2. Remove the bearing plate
the reverse order.
Installation Notice
Tighten
Tighten the bearing plate
OIL PUMP ASSEMB
1. Remove the oil pump hou

2. Using the plastic hammer
housing.
Installation Notice
Tighten
Tighten the oil pump hous
3. Remove the stator shaft b
DAEWOO V–121 BL4
4. Dismantle the oil pump g

the reverse order.
DIFFERENTIAL/SIDE
RACE, BEARING SH
1. Take out the outer race o
side.
2.
3. Remove
Take out the
the bearing shim
outer race o
housing side.
Installation Notice
S
Heat the bearing seats w
rings with shim for differe
the transaxle housing.
IMPORTANT
MEASUREMENT/AD
Tools Required
DW260–080 Clutch B/E Shim
Adjusting Axial Play, In
Important : After assembling

measure the axial play specific
is not satisfied the specificatio
shim.
Incorrect axial play may cause
specification of the axial play
1. Clamp fixture on the inpu

ing base rests on the stat
3. Measure axial play by pu
handle.(repeat measurem
4. Calculate the measureme

S
EXAMPLE
M1 = 0.51mm
M2 = 0.49mm
M = (0.51+0.49)/2 = 0
S (specification) = 0.1
D (adjustment value)
So, D is 0.08 to 0.32m
Calculate the average
5. Replace shim.
S
Disc thickness must b
0.32mm thicker. It is s
a disc that average 0.
that was installed.
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
The ZF 4HP 16 automatic transaxle consists primarily of
the following components.
Mechanical
S
Torque converter with TCC
S
Drive link assembly
S
Two multiple disk clutch assemblies : Clutch B,E
S
Three multiple brake assemblies : Brake C,D,F
S
Lock–up clutch valve
S
Two planetary gear sets
S
One oil pump The stator, which bears again
S
Final drive and differential assembly wheel, is then rotating freely i
wheel is over–come. From th
Electronic verter acts as a straightforwar
S
Two shift solenoid valve(sol.1,2)
S
Four pressure control solenoid valve(EDS) Space Behind Lock–up
S
Two speed sensors : A/T ISS and A/T OSS 1. Friction lining
S
Fluid temperature sensor 2. Lock–up clutch piston
S
Automatic transaxle control module(TCM) 3. Converter cover
S
Wiring harness assembly 4. Turbine wheel
5. Impeller
MECHANICAL COMPONENTS 6. Stator
7. Turbine hub
Torque Converter
8 Torque converter impeller
8. Torque converter impeller
The converter consists of the impeller, the turbine wheel,
the reaction member (stator) and the oil to transmit torque.
Torque Converter Lock
The impeller, which is driven by the engine, causes the oil
in the converter to flow in a circular pattern. This oil flow The converter lock–up clutch is
meets the turbine wheel, where is direction of flow is de- converter slip and thus helps to
flected. At the hub, the oil leaves the turbine and reaches The previous control principle f
the reaction member (stator), where it is once again de- operation has been replaced b
flected so that it reaches the impeller at the correct angle the 4 HP 16. The converter loc
of flow. released in a controlled man
The reversal effect generates movement in the stator, the phase, a slight speed differenc
reaction torque then amplifies the turbine torque. turbine wheel is established.
The ratio between turbine torque and torque is referred to gine ’ s rotating vibration is not
as torque multiplication. The result is optimum shift qu
The greater the difference is speed between the pump and An electronic pressure–regula
turbine, the greater the torque multiplication; it is at its sure regulation of the lock–up
highest when the turbine is at a standstill. The higher the When open (conversion rang
speed of the turbine, the lower the torque multiplication. the converter lock–up clutch pi
When the turbine speed reaches about 85%of the pump is equal. The direction of flow
speed, torque multiplication=1, i.e. the turbine torque and through the space behind
equivalent to pump torque. chamber.
S
Lubricates the transaxle w
To engage the lock–up clutch, the direction of flow is modi-

fied (reversed) via a valve in the hydraulic selector unit. At
the same time, the space behind the lock–up clutch piston Pump Housing
is vented. The oil pressure passes from the turbine cham- 1. Disc
ber to the lock–up clutch piston and presses it against the 2. Shaft seal
converter ’ s cover. The turbine is thus blocked by way of 3. Stator shaft
the linings between the piston and cover, and permits rigid 4. Pump wheel
through drive with no slip (or reduced slip if controlled) to 5. Pump ring gear
the mechanical stage of the transaxle. 6. Dowel pin
Planetary Gears
The ZF 4HP 16 automatic trans
sun gear, 4 planetary gears, p
Each gear is located one direc
linked together. In other words
nently linked to rear planet ca
linked to rear ring gear.
The individual gear ratios are o
the gear set elements in dif
clutches and brakes.
On the 4HP 16, the power flow
tary gear set via rear planet ca
both simultaneously, dependin
Fluid Pump The output is always via the fr
The fluid pump is located between the torque converter
and the transaxle case and is driven directly by the torque
converter. The pump sucks the fluid through a filter and de-
livers it to the main pressure regulator valve of the control
system. Excess fluid flows back to the pump. The fluid
pump fulfills the following functions:
S
Generates line pressure.
S
Delivers fluid under pressure to the torque convert-
er, thus preventing air bubbles in the fluid.
S
Induces a flow of fluid through the torque converter
in order to eliminate heat.
S
Supplies fluid pressure to the hydraulic control sys-
tem.
S
Supplies fluid pressure to the shift components.
DAEWOO V–121 BL4
The dynamic pressure at clutc

Shift Elements: Multi–disc Clutches and the dynamic pressure in front
Brakes equal. This equalizing effect i
The purpose of the shift elements is to perform shifts un- way.
der load without the tractive flow being interrupted. The space between the baffle p
unpressurized oil. A dynamic p
The shift elements consist of the following.
engine speed builds up. The sp
builds up. However, there is si
sure, which causes the clutch t
sure is relieved, the cup spring
back into its original position.
The advantages of this dyna
are:
S
Reliable clutch opening in
S
Smoother shifts.
Parking Lock
The parking
position P. It lock is actuated
protects vi
the vehicl
ing away.
The stop plate is actuated by
1. Snap Ring permanently connected to th
2. Steel Disc cable. The parking lock pawl
3. Lined Disc welded onto the lateral shaft of
4. Cup Spring vents the drive wheels from tu
5. Baffle Plate
This blocks the driven wheels
6. Disc Carrier
7. Input Shaft
8. Oil Supply to Dynamic Pressure Equalizer
9. Oil Supply to Clutch
10. Cylinder
11. Piston
12. Spring Disc
The shift elements are engaged hydraulically. The pres-
surized oil reaches the space between the cylinder and
piston, as a result the discs are compressed. The clutch/
brake is engaged when the oil pressure drops, the cup
spring acting on the piston presses the piston back into its
initial position. The clutch/brake is now released again.
Depending on the gear, the multi–disc clutches B and E
supply the engine torque to the planetary gear train, with 1. Pawl
multi–disc brakes C, D and F directing the torque into the 2. Supporting Bolt
housing. 3. Leg Spring
valves.
Valve Body S
Assures limited operation
Valve body performs the following tasks: axle in the event of the el
S
Generates the line pressure needed for actuating Actuating the lock–up clu
S
the shift elements.

S
Generating the lubricating
S
Actuates the individual shift elements via the clutch axle
DAEWOO V–121 BL4
ELECTRONICAL COMPONENTS Automatic Transaxle O

(A/T OSS)
Selector Lever/Program Switch The vehicle A/T OSS is a mag
The driver engages the travel position via the selector le- relays information relative to v
ver: Vehicle speed information is u
shift timing, line pressure, and
P : Park Position
and release.
R : Reverse
N : Neutral The output speed sensor moun
D : Forward Speeds sensor rotor, which is pressed
gap
tweenofthe
0.1mm~1.3mm(0.004~
sensor and the teeth
Park/Neutral Position Switch
https://es.scribd.com/doc/157544056/ZF4HP16-Optra f 314/324
sensor consists of a permane
The Park/Neutral Position Switch is located on the selec-
coil of wire.
tor shaft and informs the TCM of the current selector lever
position P–R–N–D–3–2–1. As the differential rotates, an AC
output speed sensor (OSS).
The selector lever position is transmitted to the TCM in en-
coded form along 4 lines. The encoding is such that mal-
functions in the connecting lead are identified.
The Park/Neutral Position Switch is located on the selec-
tor shaft, which is connected to the selector lever via a pull
cable. In addition, the Park/Neutral Position Switch con-
trols the starter interlock, the reversing light and the selec-
tor lever position indicator on the instrument panel.
Signal Combination
L1 L2 L3 L4
P 0 0 12 0
R 0 0 0 12
N 0 12 0 0 Automatic Transaxle In
(A/T ISS)
D 12 12 12 0 The A/T ISS is a magnetic ind
3 12 12 0 12
formation relative to transaxle
2 12 0 12 12 The TCM uses transaxle inpu
1 0 12 12 12 trol line pressure, TCC apply
shift patterns. This information
appropriate operating gear rat
The input speed sensor mount
of valve body.
An air gap of 1.8~2.2mm(0.07
between the sensor and the p
The sensor consists of a perm
by a coil of wire. As the piston
shaft, an AC signal induced in
Higher vehicle speeds induce a
age measurement at the sens
Sensor resistance should m
ohms at 20 ° C (68 ° F). S
1,000~8,000HZ.
Line Pres
Solenoid ON(low)
valve 1/Sole- 89.9~9
noid valve 2 (6.2~6.
OFF(high)
S
221.9~
psi
S
(15.3~1
bar)
Shift Solenoid Valve: Solenoid 1,2

The shift solenoids are two identical, normally open elec-
tronic exhaust work that control upshifts and downshifts in
all forward gear ranges. These shift solenoids valves to-
gether in a combination of ON and OFF sequences to con-
trol the line pressure and shift mechanisms (clutches,
brakes).
Pressure Control Solen
Solenoid 1 controls the high or low of the line pressure
VALVE 3,4,5,6)
(flow to each clutch valve) by the operation type (ON/
OFF), i.e. solenoid 1is ON, line pressure will be low The pressure control valve (ED
(87~116 psi (6~8bar)), solenoid 1 is OFF, line pressure will sion electronic
tion of pressure
the clutches, regula
brakes an
be high (232~261 psi (16~18bar)).
The valve reduces the system
Solenoid 2 controls the oil flow to clutch valve E or lockup downstream solenoid valves a
clutch valve by the ON/OFF signal. lating valves are supplied. It is
lenoid valves as a result. The E
The TCM monitors numerous inputs to determine the ap- pressure.
propriate solenoid state combination and transaxle gear
for the vehicle operating conditions.
Gear Solenoid 1 Solenoid 2

Park, Neutral ON ON
First ON/OFF ON
Second ON/OFF OFF
Third ON/OFF OFF
Fourth ON/OFF OFF

Reverse ON/OFF ON
DAEWOO V–121 BL4
Transaxle Fluid Temperature (TFT) Sensor

The TFT sensor is a positive temperature coefficient
thermistor (temperature
information sensitivetransaxle
to the TCM regarding resistor) fluid
that tempera-
provides
ture. The temperature sensor is located in valve body. Cal-
culated temperature is a factor used to determine the shift
time and shift delay time.
The internal electrical resistance of the sensor varies in
relation to the operating temperature of the transaxle fluid
(see chart).
The TCM measures this volta

control line pressure, shift sch
When transaxle fluid temperatu

the TCM enters ”hot mode.” A
TCM modifies transaxle shift s
an attempt to reduce fluid tem
axle heat generation. During
The TCM sends a 5 volt–reference signal to the tempera- the TCC at all times in fourth g
ture sensor and measures the voltage rise in the electrical Also, the TCM commands the
circuit. A higher fluid temperature creates a higher resist- to help reduce fluid heat genera
i th t t
th b i l 317/324
ance in the temperature sensor, thereby measuring a low- available on some application
er voltage signal.
Transaxle Sensor – Temperature To

Resistance To Voltage (approximate)
° C ( ° F) R high (ohms) R low (ohms) ° C ( ° F) R high (o
–40 (–40) 586 556 50 (122) 1,206
–30 (–22) 641 611 60 (146) 1,295
–20 (–4) 699 670 70 (158) 1,388
–10 (14) 760 732 80 (176) 1,485
0 (32) 825 799 90 (194) 1,585
10 (50) 893 868 100 (212) 1,690
20 (68) 963 942 110 (230) 1,798
25 (77) 1,000 980 120 (248) 1,910
30 (86) 1,039 1,017 130 (266) 2,025
140 (284) 2,145
S
Bent pins in the connecto
Transaxle Electrical Connector ing connection and disco
The transaxle electrical connector is a very important part S
Wires backing away from
of the transaxle operating system. Any interference with clamped (in either interna
the electrical connection can cause the transaxle to set ness).
Diagnostic Trouble Codes (DTCs) and/or affect proper op- S
Dirt contamination enterin
eration. connected.
S
Pins in the internal wiring
The following items can affect the electrical connections:
the connector or pushed
S
Excessive transaxle fluid leaking into the connector, Carefully limit twisting or wiggli
wicking up into the external wiring harness, and moval. Bent pins can occur.
degrading the wire insulation. DO NOT pry the connector off
S
Water/moisture intrusion in the connector. tool.
S
Low pin retention in the external connector from
excessive connection and disconnection of the wir- To reinstall the external wiring
ing connector assembly. pins by lining up arrows on ea
S
Pin corrosion from contamination. Push the connector straight do
S
Broken/cracked connector assembly. out twisting or angling the ma
S
Points to remember when working with transaxle The connector should click int
wiring connector assembly.
S
To remove the connector, squeeze the two tabs and/or noise.
towards each other and pull straight up (refer to Transaxle Control Mod
towards each other and pull straight up (refer to Transaxle Control Mod
illustration). The transaxle control module
vice which monitors inputs to
functions including shift qual
switches, and components to
control program. Based on this
controls various transaxle out
Data Link Connector (D

The data link connector (DLC)
tor. The DLC provides the me
from the TCM to aid in powertr
lows the technician to use a s
systems and display diagnos
The DLC connector is located
ment, directly below the steeri
DAEWOO V–121 BL4
Data Link Connector (CAN TYPE) 1.8L DOHC (Delphi 32
A Connector (Blue) B Connector (Green) C

1 Solenoid 2 Fluid Temperature Ground Selecto
2 Not Used Input Speed Sensor (+) Not Use
3 Pressure Control Solenoid Valve BAT + Not Us
(EDS 4)
4 TFT Sensor Input Speed Sensor (–) Hold Mo
5 Stoplamp Switch Output Speed Sensor (–) Not Use
6 Hold Mode Indicator Selector Lever Line L3 EDS Su
7 DLC Input Speed Sensor Ground EDS Su
8 CAN High Speedometer Soleno
9 Solenoid 1 Not Used Not Us
10 Pressure Control Solenoid Valve Output Speed Sensor (+) Not Use
(EDS 5)
11 Pressure Control Solenoid Valve Selector Lever Line L4 Not Use
(EDS 3)
12 Pressure Control Solenoid Valve Ground Not Us
(EDS 6)
13 Not Used Ground Not Us
14 Not Used Not Used Not Us
15 Not Used Selector Lever Line L2 IG ON

16 CAN Low Not Used IG ON
Engine Coolant Tempe

TCM INPUTS THAT AFFECT THE 4HP S
Provides coolant tempera
16 TRANSAXLE determining initial TCC e
S
An incorrect engine coola
Throttle Position Sensor input could causes an inc
S
Provides throttle position data to the TCM for deter- Engine Speed
mining shift patterns and TCC apply/release. S
The ignition module prov
S
An incorrect throttle position sensor input could TCM.
causes erratic or shift pattern, poor shift quality or S
The TCM uses engine sp
TCC function trolling wide open throttle
solenoid duty cycle.
Automatic Transaxle Output (Shaft) Speed Stoplamp Switch
Sensor S
Provides brake apply info
S
Provides vehicle speed data to the TCM for deter- controlling TCC apply and
mining shift patterns and TCC apply/release, and S
An incorrect TCC stoplam
gear ratio calculations. causes an incorrect TCC
S
An incorrect throttle position sensor input could
causes erratic or shift pattern, poor shift quality or Transaxle Fluid Temper
TCC function S
Provides transaxle fluid te
the TCM for determining
TCC apply during high te
Automatic Transaxle Input (Shaft) Speed
mode operation).
Sensor S
An incorrect transaxle tem
S
Provides transaxle input speed data to the TCM for could causes altered shif
determining shift patterns and TCC apply/release, ty and incorrect TCC app
and gear ratio.
DAEWOO V–121 BL4
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ZF4HP16 Automatic Transaxle Guide

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ZF4HP16 Automatic Transaxle Guide

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15/6/2019 -ZF4HP16-Optra | Valve (7.

DIAGNOSTIC INFORMATION AND PROCEDURES DTC P0716 – Input Speed S

5A1 – 2 IZF 4 HP 16 AUTOMATIC TRANSAXLE

DTC P0722 – Output Speed Sensor(OSS) DTC P1868 – EDS 6 Outpu

DTC P0781 – 1–2 Shift Malfunction . . . . . . . 5A1–124 MAINTENANCE AND REPAI

DTC P1862 – EDS 4 Output Shorted To Differential . . . . . . . . . . . . . .

Important Measurement/Adjustment . . . . . . . 5A1–230 Mechanical Components .

DAEWOO V–121 BL4

5A1 – 4 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Transaxle Weight 76kg (16

Transaxle Fluid Capacity 7.3qt (6.

TRANSAXLE GEAR RATIO

(Measurements are approximate)

FASTENER TIGHTENING SPECIFICATIONS

Park/Neutral Position Switch 10 –

DAEWOO V–121 BL4

5A1 – 6 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Range Park/ Rever D 3

OFF = The solenoid

SHIFT SPEED CHART

10% 25% 50% 100% 10% 25% 50% 100% 10%

DAEWOO V–121 BL4

5A1 – 8 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Down Shift Speed

Fourth–Th Third–Sec Second–Fi 10% 25%

3 ON LOW 90~124.7 psi

1 ON LOW 90~124.7 psi

DAEWOO V–121 BL4

5A1 – 10 IZF 4 HP 16 AUTOMATIC TRANSAXLE

SCHEMATIC AND ROUTING DIAGRAM

DAEWOO V–121 BL4

5A1 – 12 IZF 4 HP 16 AUTOMATIC TRANSAXLE

TRANSAXLE CONTROL MODULE (2 OF 2)

SHIFT MODE DIAGRAM

DAEWOO V–121 BL4

5A1 – 14 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Lock–up Clutch Applied (Economic Mode ; Fourth Gea

Power Mode (1.8 DOHC)

DAEWOO V–121 BL4

5A1 – 16 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Hold Mode (1.8 DOHC)

POWER FLOW DIAGRAM

DAEWOO V–121 BL4

5A1 – 18 IZF 4 HP 16 AUTOMATIC TRANSAXLE

DAEWOO V–121 BL4

5A1 – 20 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Drive Range – First Gear

DAEWOO V–121 BL4

5A1 – 22 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Drive Range – Second Gear

DAEWOO V–121 BL4

5A1 – 24 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Drive Range – Third Gear

DAEWOO V–121 BL4

5A1 – 26 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Pressure control solenoids (ED

Control As a result, the oil pressure be

Drive Range – Fourth Gear

DAEWOO V–121 BL4

5A1 – 28 IZF 4 HP 16 AUTOMATIC TRANSAXLE

Drive Range – Fourth Gear

Clutch E is engaged to drive the rear planetary gear clutch valve

holding will engage