2004 DAEWOO LACETTI wheel

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 3
DAEWOO V–121 BL4
Important Measurement/Adjustment 5A1–230. . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5A1–232 . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Components 5A1–232. . . . . . . . . . . . . . . . .
Electronical Components 5A1–236. . . . . . . . . . . . . . . .
TCM Inputs That Affect the 4HP 16
Transaxle 5A1–241. . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION
ZF 4HP 16 AUTOMATIC TRANSAXLE
The ZF 4 HP 16 is a four–speed automatic transaxle de-
signed for cars with front–wheel drive and a transversely
mounted engine.
The transaxle has a hydrodynamic torque converter with
a controlled slip lock–up clutch.
A planetary gear train establishes the mechanical gear ra-
tios. The integral constant ratio can be adapted to the en-
gine’s power output and the vehicle’s weight. The elec-
tronic–hydraulic control makes controlled power shifts and
various shift programs possible. In selector lever position
”P”, the output is locked mechanically.The special feature of this transaxle is that it operates with-
out freewheels. Shifting between individual gears takes
place by means of overlapping clutch engagement and re-
lease.
The advantage of overlap shifting is as follows:
– The transaxle can be of more compact design
and is lighter on account of the absence of free-
wheels and the lower number of shift elements
– Lower drag losses, i.e. higher efficiency
– Lower peak torques acting on the components
and driveline.
However, overlap shifting necessitates high–performance
hardware and software, and precision engine signals.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 5
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFICATIONS
Definition
Transaxle Type4–speed with four–wheel drive and transverse engine
Input Torque240 NSm (177 lb–ft)
Transaxle Weight76kg (168 lb)
Torque Converter Capacity9.72kg (21.4 lb)
Transaxle Fluid Type (manufacture company)ESSO LT 71141 or TOTAL ATF H50235
Transaxle Fluid Capacity7.3qt (6.9L)
TRANSAXLE GEAR RATIO
GearRatio
First2.719
Second1.487
Third1.000
Fourth0.717
Reverse 2.529
Final3.945:1
FLUID CAPACITY
LitresQuarts
Bottom Pan Removal44.2
Complete Overhaul6.97.3
Torque Converter Removal22.1
(Measurements are approximate)
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Bearing Plate Bolts23.517.5–
Slotted Nut220162–
Rear Cover Attachment Bolts23.517.5–
Baffle Plate Attachment Bolts10–89
Park/Neutral Position Switch10–89
Fluid Pump Connecting Bolts10–89
Fluid Filter Housing Cover Attachment Bolts10–89
Input Speed sensor Attachment Bolts8–71
Output Speed Sensor Attachment Bolts8–71
Valve Body Bolts8–71
Valve Body Upper & Lower Fixing Bolts6–53
Fluid Pan Connecting Bolts6–53
Fluid Pan Drain Plug4533–

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 49
DAEWOO V–121 BL4
Functional Check Procedure
Inspect
1. Install a tachometer or scan tool.
2. Operate the vehicle unit proper operating tempera-
ture is reached.
3. Drive the vehicle at 80 to 88km/h (50 to 55 mph)
with light throttle(road load).
4. Maintaining throttle position, lightly touch the brake
pedal and check for release of the TCC and a slight
increase in engine speed(rpm).
5. Release the brake slowly accelerate and check for
a reapply of the Lock up clutch and a slight de-
crease in engine speed(rpm).
Torque Converter Evaluation
Torque Converter Stator
The torque converter stator roller clutch can have one of
two different type malfunctions :
A. Stator assembly freewheels in both directions.
B. Stator assembly remains Locked up at all times.
Condition A – Poor Acceleration Low
Speed
The car tends to have poor acceleration from a stand still.
At speeds above 50 to 55km/h(30 to 35mph), the car may
act normal. If poor acceleration is noted, it should first be
determined that the exhaust system is not blocked, and
the transaxle is in 1st(First) gear when starting out.
If the engine freely accelerates to high rpm in N(Neutral),
it can be assumed that the engine and exhaust system are
normal. Checking for poor performance in ”Drive” and ”Re-
verse” will help determine if the stator is freewheeling at all
times.
Condition B – Poor Acceleration High
Speed
Engine rpm and car speed limited or restricted at high
speeds. Performance when accelerating from a standstill
is normal. Engine may overheat. Visual examination of the
converter may reveal a blue color from overheating.
If the converter has been removed, the stator roller clutch
can be checked by inserting two fingers into the splined in-
ner race of the roller clutch and trying to turn freely clock-
wise, but not turn or be very difficult to turn counter clock-
wise.
Noise
Torque converter whine is usually noticed when the ve-
hicle is stopped and the transaxle is in ”Drive” or ”Re-
verse”. The noise will increase when engine rpm is in-
creased. The noise will stop when the vehicle is moving or
when the torque converter clutch is applied because both
halves of the converter are turning at the same speed.
Perform a stall test to make sure the noise is actually com-
ing from the converter :1. Place foot on brake.
2. Put gear selector in ”Drive”.
3. Depress accelerator to approximately 1200rpm for
no more than six seconds.
Notice : If the accelerator is depressed for more than six
seconds, damage to the transaxle may occur.
A torque converter noise will increase under this load.
Important : This noise should not be confused with pump
whine noise which is usually noticeable in P (Park), N
(Neutral) and all other gear ranges. Pump whine will vary
with pressure ranges.
The torque converter should be replaced under any of the
following conditions:
S External leaks in the hub weld area.
S Converter hub is scored or damaged.
S Converter pilot is broken, damaged or fits poorly
into crankshaft.
S Steel particles are found after flushing the cooler
and cooler lines.
S Pump is damaged or steel particles are found in the
converter.
S Vehicle has TCC shudder and/or no TCC apply.
Replace only after all hydraulic and electrical diag-
noses have been made.(Lock up clutch material
may be glazed.)
S Converter has an imbalance which cannot be cor–
rected. (Refer To Converter Vibration Test Proce-
dure.)
S Converter is contaminated with engine coolant con-
taining antifreeze.
S Internal failure of stator roller clutch.
S Excess end play.
S Heavy clutch debris due to overheating (blue con-
verter).
S Steel particles or clutch lining material found in fluid
filter or on magnet when no internal parts in unit are
worn or damaged(indicates that lining material
came from converter).
The torque converter should not be replace if :
S The oil has an odor, is discolored, and there is no
evidence of metal or clutch facing particles.
S The threads in one or more of the converter bolt
holes are damaged.
–correct with thread insert.
S Transaxle failure did not display evidence of dam-
age or worn internal parts, steel particles or clutch
plate lining material in unit and inside the fluid filter.
S Vehicle has been exposed to high mileage(only).
The exception may be where the Lock up clutch
damper plate lining has seen excess wear by ve-
hicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
Lock–Up Clutch Shudder Diagnosis
The key to diagnosing lock–up clutch(TCC) shudder is to
note when it happens and under what conditions.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 57
DAEWOO V–121 BL4
Symptom ActionPossible Cause
Sealing Ring Selector ShaftS Check sealing ring.
S Replace sealing ring as described in the repair
instruction.
O–ring at Socket OutletS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
O–ring and Speed Sensor ConnectionS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
Oil Leak Incorrectly IdentifiedS No oil leak is possible at this point.
Speed Sensor Itself Is LeakingS Check speed sensor.
S Replace speed sensor as described in the re-
pair instruction.
Hair Line Crack at the Piping in the Con-
nection Area, Sealing Ring Fit in Trans-
axle HousingS Pressurize the line with compressed air and
check it.
S Replace lines as described in the repair in-
struction.
O–ring Defective, IncorrectCheck O–ring.
Replace O–rings as described in the repair instruc-
tion.
Plug LooseCheck the Tightening Torque for the screw plug.
Tighten to torque specified in the repair instruction.
Noise
SymptomPossible CauseAction
NoiseTFT Level Too LowS When the TFT level is too low, the gear wheels
from the transaxle oil pump might generate
noise.
S Check the TFT level as described in the repair
instruction and fill to the proper level.
Monolith in Catalytic Converter Has
BrokenS Check according to the exhaust gas diagnostic
procedure or by shaking the catalytic converter
casing.
S Replace catalytic converter if necessary.
Noise from Auxiliaries (e.g. exhaust
system, alternator, drive shafts.)S Check these components; if necessary, elimi-
nate the faults as described in the repair in-
struction
Noise from Tires or Wheel BearingsS Eliminate fault if necessary
Noise from Planetary GearsS Whistling noise on traction and overrun(in first
gear only)caused by high rotating speeds(func-
tionally unavoidable)
Cumulative Tooth Backlash in the Com-
plete Drive LineS Production status. Customer must be con-
vinced.
Jerky Noise of the Parking Lock (e.g.
when the car is standing on a gradient)S Load–reversal reaction
S Apply the handbrake before selection the park-
ing Lock (position P)

5A1 – 102IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0720 – Output Speed Sensor(OSS) Circuit Malfunction
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn the ignition OFF.
3. Raise and support the drive wheels, then start
the engine.
4. Gear position is D and observe the output
speed on the scan tool.
Is the speed within the values shown?190~9,762rpmGo to ”Diag-
nostic Aids”Go to Step 3
31. Turn the ignition OFF.
2. Disconnect the transaxle wiring connector.
3. Measure the resistance between terminals 1
and 2 of the transaxle wiring connector.
Is the resistance within the values shown?
Go to Step 9Go to Step 4
41. Remove the oil pan.
2. Disconnect the output speed sensor wiring
connector.
3. Measure the resistance between terminal 1 of
the output speed sensor wiring connector and
terminal 1 of the transaxle wiring connector.
4. Measure the resistance between terminal 2 of
the output speed sensor wiring connector and
terminal 2 of the transaxle wiring connector.
Is the resistance within the values shown?0ΩGo to Step 6Go to Step 5
5Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–
61. Turn the ignition ON.
2. Measure the voltage of terminal 1.
3. Measure the voltage of terminal 2.
Is the voltage within the values shown?11–14VGo to Step 7Go to Step 8
7Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–
8Replace the output speed sensor.
Is the action complete?–System OK–
91. Disconnect the transaxle wiring connector and
TCM connector.
2. Measure the resistance between terminal 1 of
the transaxle wiring connector and terminal
B10 of the TCM wiring connector.
3. Measure the resistance between terminal 2 of
the transaxle wiring connector and terminal B5
of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 11Go to Step 10
10Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 105
DAEWOO V–121 BL4
DTC P0721 – Output Speed Sensor(OSS) Circuit
Range/Performance
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn the ignition OFF.
3. Raise and support the drive wheels, then start
the engine.
4. Gear position is D and observe the output
speed on the scan tool.
Is the speed within the values shown?190~9,762rpmGo to ”Diag-
nostic Aids”Go to Step 3
31. Turn the ignition LOCK.
2. Disconnect the transaxle wiring connector.
3. Measure the resistance between terminals 1
and 2 of the transaxle wiring connector.
Is the resistance within the values shown?
Go to Step 9Go to Step 4
41. Remove the oil pan.
2. Disconnect the output speed sensor wiring
connector.
3. Measure the resistance between terminal 1 of
the output speed sensor wiring connector and
terminal 1 of the transaxle wiring connector.
4. Measure the resistance between terminal 2 of
the output speed sensor wiring connector and
terminal 2 of the transaxle wiring connector.
Is the resistance within the values shown?0ΩGo to Step 6Go to Step 5
5Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–
61. Turn the ignition ON.
2. Measure the voltage of terminal 1.
3. Measure the voltage of terminal 2.
Is the voltage within the values shown?11–14VGo to Step 7Go to Step 8
7Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–
8Replace the input speed sensor.
Is the action complete?–System OK–
91. Disconnect the transaxle wiring connector and
TCM connector.
2. Measure the resistance between terminal 1 of
the transaxle wiring connector and terminal
B10 of the TCM wiring connector.
3. Measure the resistance between terminal 2 of
the transaxle wiring connector and terminal B5
of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 11Go to Step 10
10Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–

5A1 – 108IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0722 – Output Speed Sensor(OSS) Circuit No Signal
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn the ignition OFF.
3. Raise and support the drive wheels, then start
the engine.
4. Gear position is D and observe the output
speed on the scan tool.
Is the speed within the values shown?190~9,762rpmGo to ”Diag-
nostic Aids”Go to Step 3
31. Turn the ignition LOCK.
2. Disconnect the transaxle wiring connector.
3. Measure the resistance between terminals 1
and 2 of the transaxle wiring connector.
Is the resistance within the values shown?
Go to Step 9Go to Step 4
41. Remove the oil pan.
2. Disconnect the output speed sensor wiring
connector.
3. Measure the resistance between terminal 1 of
the output speed sensor wiring connector and
terminal 1 of the transaxle wiring connector.
4. Measure the resistance between terminal 2 of
the output speed sensor wiring connector and
terminal 2 of the transaxle wiring connector.
Is the resistance within the values shown?0ΩGo to Step 6Go to Step 5
5Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–
61. Turn the ignition ON.
2. Measure the voltage of terminal 1.
3. Measure the voltage of terminal 2.
Is the voltage within the values shown?11–14VGo to Step 7Go to Step 8
7Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–
8Replace the output speed sensor.
Is the action complete?–System OK–
91. Disconnect the transaxle wiring connector and
TCM connector.
2. Measure the resistance between terminal 1 of
the transaxle wiring connector and terminal
B10 of the TCM wiring connector.
3. Measure the resistance between terminal 2 of
the transaxle wiring connector and terminal B5
of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 11Go to Step 10
10Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–

5A1 – 124IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual 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.
DIAGNOSTIC TROUBLE CODE(DTC) P0781
1–2 SHIFT MALFUNCTION
Circuit Description
The special feature of 4HP 16 Auto Transaxle is that it op-
erates without freewheels. Shifting between individual
gears takes place by means of overlapping clutch engage-
ment and release.
The advantage of overlap shifting are as follows:
–The transaxle can be of more compact design and
is lighter on account of the absence of freewheels
and the lower number of shift elements.–Lower drag losses, i.e. higher efficiency.
–Lower peak torque acting on the components and
driveline.
However, overlap shifting necessitates high–performance
hardware and software, and precision engine signals.
Conditions for Setting The DTC
S Transmission oil temperature is greater than –10°C
(14°F).
S Selector lever is not N(Neutral), P(Park) position.
S System voltage is greater than 9 volts.